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Komatsu 930E-2 Dump Truck Shop Manual SN A30181-A30223 – PDF DOWNLOAD
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Komatsu 930E-2 Dump Truck Shop Manual
Book Code: CEBM006902
SERIAL NUMBERS A30181 thru A30223
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Description
Komatsu 930E-2 Dump Truck Shop Manual
FILE DETAILS:
Komatsu 930E-2 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 930E-2
Serial Number: A30181-A30223
Book Code: CEBM006902
Language: English
Pages: 938
File Format: Portable Document Format (PDF)
KOMATSU 930E-2 DUMP TRUCK SHOP MANUAL SN A30181-A30223 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 930E-2 Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, wamings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general infom’ration. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of US. and metric (SI) units throughout and all references to “Right”, “Left”.
- ‘Front‘, or “Rear” are made with respect to the operator’s nomtal seated position, unless specifically stated otherwise- Standard torque requirements are shown in torque charts in the general infomiation section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 Mm) torque- All torque specifications have i 10% tolerance unless otherwise specified.
- A Product identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter ‘M’ designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains infomiation which will identify the original manufacturing bill of material forthis unit. This complete number will be necessary for proper ordering of many service parts andlor warranty consideration.
TABLE OF CONTENTS:
Komatsu 930E-2 Dump Truck Shop Manual
MAIN MENU...................................................................................... 0 COVER.......................................................................................... 1 FOREWORD....................................................................................... 5 TABLE OF CONTENTS.............................................................................. 7 SECTION A - GENERAL INFORMATION - INDEX........................................................ 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION................................................... 11 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX............................. 15 GENERAL SAFETY......................................................................... 17 Safety Rules....................................................................... 17 Truck Safety Features.............................................................. 17 Clothing And Personal Items........................................................ 17 Unauthorized Modification.......................................................... 17 Leaving The Operator’s Seat........................................................ 17 Mounting And Dismounting........................................................... 17 Fire Extinguishers And First Aid Kits.............................................. 18 Precautions For High Temperature Fluids............................................ 18 Asbestos Dust Hazard Prevention.................................................... 18 Fire Prevention For Fuel And Oil................................................... 18 ROPS Precautions................................................................... 19 Preventing Injury From Work Equipment.............................................. 19 Precautions For Optional Attachments............................................... 19 Precautions When Starting The Machine.............................................. 19 PRECAUTIONS FOR TRUCK OPERATION.................................................... 20 Safety Is Thinking Ahead....................................................... 20 Safety At The Worksite......................................................... 20 Fire Prevention................................................................ 20 Preparing For Operation........................................................ 20 Ventilation For Enclosed Areas................................................. 20 Mirrors, Windows, And Lights................................................... 20 In The Operator’s Cab - Before Starting The Engine............................. 21 OPERATING THE MACHINE.............................................................. 21 Starting The Engine............................................................ 21 Truck Operation - General...................................................... 21 Traveling In The Truck......................................................... 22 Precautions When Traveling In Reverse.......................................... 22 Traveling On Slopes............................................................ 22 Ensuring Good Visibility....................................................... 23 Operating On Snow.............................................................. 23 Avoid Damage To The Dump Body.................................................. 23 Driving Near High Voltage Cables............................................... 23 When Loading The Truck......................................................... 23 When Dumping................................................................... 23 Working On Loose Ground........................................................ 23 Parking The Machine............................................................ 24 TOWING............................................................................. 24 WORKING NEAR BATTERIES............................................................. 24 Jump Starting With Booster Cables.............................................. 24 PRECAUTIONS FOR MAINTENANCE............................................................ 25 BEFORE PERFORMING MAINTENANCE...................................................... 25 Stopping The Engine Before Service............................................. 25 Warning Tag.................................................................... 25 Proper Tools................................................................... 25 Securing The Dump Body......................................................... 25 DURING MAINTENANCE................................................................. 26 Personnel...................................................................... 26 Attachments.................................................................... 26 Working Under The Machine...................................................... 26 Keeping The Machine Clean...................................................... 26 Rules To Follow When Adding Fuel Or Oil........................................ 26 Radiator Coolant Level......................................................... 26 Use Of Lighting................................................................ 26 Precautions With The Battery................................................... 27 Handling High Pressure Hoses................................................... 27 Precautions With High Pressure Oil............................................. 27 Maintenance Near High Temperatures And High Pressures.......................... 27 Rotating Fan And Belts......................................................... 27 Waste Materials................................................................ 27 TIRES.............................................................................. 28 Handling Tires................................................................. 28 Storing Tires After Removal.................................................... 28 ADDITIONAL JOB SITE RULES.............................................................. 29 WHEN REPAIRS ARE NECESSARY............................................................. 30 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................................ 31 Preliminary Procedures before Welding or Performing Maintenance.................... 31 Normal Engine Shutdown Procedure................................................... 31 Engine Shutdown Procedure before Welding or Performing Maintenance................. 31 TRUCK OPERATION........................................................................ 34 PREPARING FOR OPERATION............................................................ 34 Safety Is Thinking Ahead....................................................... 34 WALK AROUND INSPECTION............................................................. 34 ENGINE START-UP SAFETY PRACTICES................................................... 38 AFTER STARTING THE ENGINE.......................................................... 39 Additional Guidelines.......................................................... 39 MACHINE OPERATION SAFETY PRECAUTIONS............................................... 39 MACHINE OPERATION ON THE HAUL ROAD................................................. 40 DYNAMIC RETARDING OPERATION........................................................ 41 Dynamic Retarder Control Lever................................................. 41 Dynamic Retarder/Service Brake Pedal........................................... 41 STARTING ON A GRADE WITH A LOADED TRUCK............................................ 42 PASSING............................................................................ 42 LOADING............................................................................ 42 DUMPING............................................................................ 42 Raising The Dump Body.......................................................... 42 Lowering The Dump Body......................................................... 43 TOWING............................................................................. 44 SAFE PARKING PROCEDURES............................................................ 45 NORMAL ENGINE SHUTDOWN PROCEDURE................................................... 45 DELAYED ENGINE SHUTDOWN PROCEDURE.................................................. 45 SUDDEN LOSS OF ENGINE POWER........................................................ 46 SECTION A4 - WARNINGS AND CAUTIONS......................................................... 47 SECTION A5 - STANDARD CHARTS AND TABLES.................................................... 55 SECTION A7 - STORAGE AND IDLE MACHINE PREPARTATION - INDEX................................. 61 STORAGE AND IDLE MACHINE PREPARATION................................................... 63 Short Term Idle Periods............................................................ 63 PREPARATION FOR STORAGE............................................................ 64 REMOVAL FROM STORAGE............................................................... 65 RECONDITIONING AN IDLE VEHICLE..................................................... 67 ENGINE OPERATION................................................................... 70 After The Engine Has Started................................................... 71 ENGINE STORAGE..................................................................... 72 Preparing Engine For Storage................................................... 72 Temporary Storage (30 Days Or Less)............................................ 72 Extended Storage (more Than 30 Days)........................................... 72 RESTORING AN ENGINE AFTER EXTENDED STORAGE......................................... 74 ELECTRIC DRIVE TRUCKS.............................................................. 75 Storage Instructions and Procedures............................................ 75 Placing Equipment Into Storage................................................. 75 Storing A Truck That Is Operational............................................ 75 Storing A Truck That Is Not Operational........................................ 76 Storing A Major Component...................................................... 76 Periodic Inspections........................................................... 77 Placing Equipment Into Service After Storage................................... 77 When A Truck Is Operational.................................................... 77 When A Truck Is Not Operational................................................ 77 For The First Hour............................................................. 78 SECTION B - STRUCTURES - INDEX................................................................. 79 SECTION B2 - STRUCTURAL COMPONENTS - INDEX................................................. 81 STRUCTURAL COMPONENTS.................................................................. 83 Preparation........................................................................ 83 GRILLE, HOOD AND LADDER............................................................ 84 Removal........................................................................ 84 Installation................................................................... 84 DECKS.............................................................................. 85 RIGHT DECK AND COMPONENTS.......................................................... 85 Removal........................................................................ 85 Installation................................................................... 86 LEFT DECK.......................................................................... 86 Removal........................................................................ 86 Installation................................................................... 86 CENTER DECK........................................................................ 86 SECTION B3 - DUMP BODY - INDEX............................................................. 87 DUMP BODY.............................................................................. 89 Removal............................................................................ 89 Installation....................................................................... 90 BODY PADS.......................................................................... 91 Adjustment..................................................................... 91 BODY GUIDE......................................................................... 92 HOIST LIMIT SWITCH................................................................. 92 BODY UP SWITCH..................................................................... 92 BODY-UP RETENTION CABLE............................................................ 92 ROCK EJECTORS...................................................................... 93 Rock Ejectors (Type I)............................................................. 93 Inspection..................................................................... 93 Rock Ejectors (Type II)............................................................ 94 Inspection..................................................................... 94 SECTION B4 - FUEL TANK - INDEX............................................................. 95 FUEL TANK.............................................................................. 97 Removal............................................................................ 98 Installation....................................................................... 98 Repair............................................................................. 98 Cleaning........................................................................... 98 FUEL GAUGE SENDER.................................................................. 99 Removal........................................................................ 99 Installation................................................................... 99 LOW FUEL SWITCH.................................................................... 99 WIGGINS QUICK FILL FUEL SYSTEM.........................................................100 FUEL RECEIVER......................................................................100 TANK BREATHER VALVE................................................................100 Removal........................................................................100 Installation...................................................................100 Disassembly....................................................................100 Assembly.......................................................................100 LEFT SIDE FILL.....................................................................101 FUEL - WATER SEPARATOR.............................................................102 Installation...................................................................102 Filter Service.................................................................103 Backflushing Procedure.........................................................103 Filter Element Replacement.....................................................103 SECTION C - ENGINE - INDEX.....................................................................105 SECTION C2 - POWER MODULE - INDEX..........................................................107 Preparation............................................................................109 Preparation for Removal................................................................110 Power Module Removal...................................................................113 Power Module Installation..............................................................115 Power Module Hookup....................................................................115 Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)....117 SECTION C3 - COOLING SYSTEM - INDEX........................................................119 COOLING SYSTEM.........................................................................121 COOLING SYSTEM DESCRIPTION.........................................................121 Coolant Flow...................................................................121 RADIATOR...........................................................................122 Removal........................................................................122 RADIATOR REPAIR....................................................................124 Internal Inspection............................................................124 External Cleaning..............................................................124 Disassembly....................................................................125 Cleaning and Inspection........................................................126 Assembly.......................................................................126 Pressure Testing...............................................................127 Additional Service Information.................................................127 Installation...................................................................128 RADIATOR FILL PROCEDURE............................................................128 Radiator Pressure Regulator Valve..............................................129 COOLING SYSTEM TROUBLESHOOTING.....................................................129 SECTION C4 - POWERTRAIN - INDEX............................................................131 POWER TRAIN............................................................................133 ALTERNATOR REMOVAL PROCEDURE.......................................................133 Removal (MTU/DDC 4000 Engine)..................................................133 ENGINE/ALTERNATOR MATING...........................................................135 General Instructions...........................................................135 MEASURING PROCEDURE................................................................135 Joining Alternator and MTU/DDC Engine..........................................137 ENGINE.............................................................................138 Removal........................................................................138 Service........................................................................138 Installation...................................................................138 SECTION C5 - AIR CLEANERS - INDEX..........................................................139 AIR CLEANERS...........................................................................141 AIR CLEANERS.......................................................................141 Operation......................................................................141 General Service Information....................................................141 FILTER ELEMENT REPLACEMENT.........................................................142 Main Filter Element Cleaning...................................................143 Precleaner Section.............................................................144 Cleaning Precleaner Tubes......................................................144 AIR INTAKE TROUBLESHOOTING.........................................................145 SECTION C7 - FAN CLUTCH - INDEX............................................................147 FAN CLUTCH.............................................................................149 REMOVAL & INSTALLATION TOOLING.....................................................149 FAN CLUTCH - DISASSEMBLY...........................................................152 CLEANING AND INSPECTION............................................................162 ASSEMBLY - FAN CLUTCH..............................................................166 TEST PROCEDURE.....................................................................180 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX...................................181 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX..........................................183 24VDC ELECTRIC SUPPLY SYSTEM...........................................................185 ELECTRICAL SYSTEM DESCRIPTION......................................................185 BATTERIES..........................................................................185 Maintenance and Service........................................................185 Troubleshooting................................................................185 BATTERY SUPPLY SYSTEM..............................................................187 24VDC Battery Charging Alternator..............................................187 Battery Box....................................................................187 Battery Control Box............................................................187 System Battery Starter Disconnect Relay........................................187 Battery Disconnect Switches....................................................188 24VDC Auxiliary Battery Connectors.............................................188 Battery Equalizer..............................................................189 Troubleshooting................................................................189 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX....................................191 24 VDC ELECTRICAL SYSTEM COMPONENTS....................................................193 PASSENGER SEAT BASE COMPARTMENT....................................................193 TRUCK SHUTDOWN PROCEDURE...........................................................193 COMPONENTS.........................................................................193 Tail Light Resistor Diode Assemblies...........................................193 5 Minute Idle Timer Components.................................................193 5 Minute Idle Timer............................................................195 5 Minute Idle Relay............................................................195 5 Minute Idle Contactor........................................................195 5 Minute Idle Circuit Test.....................................................195 Inclinometer...................................................................195 Brake Warning Buzzer (BWB).....................................................195 Alarm Indicating Device (AID) System...........................................195 Coolant Level/Flasher..........................................................195 Temperature and Latch Card.....................................................196 Hot Switch Inverter Card.......................................................196 Hot Switch Inverter Card (Slot 4) (Not Used)...................................197 Oil Level Card.................................................................197 Temperature Card...............................................................197 Diode Matrix (Without Sound) Card..............................................197 Diode Matrix (With Sound) Card.................................................197 Lamp Test Switch...............................................................197 Electrical Interface Cabinet...................................................198 Lubrication System Timer.......................................................198 Lincoln Lube Delay Timer.......................................................198 Barometric Pressure Transducer.................................................198 Pulse Voltage Modulator........................................................198 Power Distribution Terminals...................................................198 Truck Control Interface Panel..................................................198 Kontrol Power Relay............................................................198 Circuit Breaker Panel..........................................................198 Diode Board - DB1..............................................................200 Diode Testing..................................................................200 Relay Boards...................................................................201 Relay Boards: RB1, RB2, RB3, RB4, RB5..........................................201 Service........................................................................201 Relay Board Identification.....................................................202 Relay Board Functions..........................................................203 Installing Additional Circuits.................................................204 Body Up Switch.................................................................205 Operation......................................................................205 Adjustment.....................................................................205 Service........................................................................205 Hoist Limit Switch.............................................................206 Operation......................................................................206 Adjustment.....................................................................206 Service........................................................................206 CIRCUIT BREAKER CHART..............................................................207 SECTION D5 - DDEC ELECTRONIC ENGINE CONTROL - INDEX........................................209 DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE..........................211 COMPONENT DESCRIPTION..............................................................212 Electronic Control Module......................................................212 Electronic Unit Nozzles........................................................214 System Sensors and Operator Inputs.............................................214 ENGINE PROTECTION SYSTEM...........................................................215 DIAGNOSTICS........................................................................216 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX..........................................217 BATTERY CHARGING ALTERNATOR............................................................219 ELECTRICAL SYSTEM DESCRIPTION......................................................219 BATTERY............................................................................219 Maintenance and Service........................................................219 Troubleshooting................................................................219 BATTERY CHARGING SYSTEM (Niehoff)..................................................221 General Description............................................................221 TROUBLESHOOTING PROCEDURES (On-Truck)..............................................221 Equipment Required:............................................................221 Preliminary Checks.............................................................222 Test Setup.....................................................................222 Test Procedure.................................................................222 Regulator Bypass Test..........................................................223 ON VEHICLE TROUBLESHOOTING GUIDE.......................................................225 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage.........225 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:...................................225 CHARGE VOLT AND AMP VALUES.........................................................226 DEFINITIONS........................................................................226 ADVANCED SYSTEM TROUBLESHOOTING........................................................227 Static Test - Engine OFF, Key ON, Battery Switch ON................................227 Go To Alternator...................................................................227 Go To Regulator (If Required)......................................................228 Go To Regulator Connector On The Alternator........................................228 ALTERNATOR OVERHAUL....................................................................229 ALTERNATOR DIMENSIONS..............................................................229 ALTERNATOR SPECIFICATIONS..........................................................230 SERVICE PARTS......................................................................231 ON-VEHICLE TEST....................................................................233 Equipment:.....................................................................233 Preliminary Checks:............................................................233 Test Set-up....................................................................233 Test Procedure.................................................................233 ON-VEHICLE TEST....................................................................234 Bypass Test:...................................................................234 BENCH TEST.........................................................................235 STATIC TESTS.......................................................................236 Regulator Tests................................................................236 Control Box Tests..............................................................237 ALTERNATOR DISASSEMBLY.............................................................239 ASSEMBLY- ALTERNATOR...............................................................244 BF4822 STATOR SERVICE TOOL INSTRUCTIONS................................................253 Stator Removal And Replacement.....................................................253 Stator Installation................................................................254 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX...............................................257 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX...............................259 ELECTRICAL PROPULSION SYSTEM COMPONENTS................................................261 GENERAL SYSTEM DESCRIPTION.........................................................261 SYSTEM COMPONENTS..................................................................263 Auxiliary Blower System........................................................263 Propulsion System Controller (PSC).............................................263 TRUCK CONTROL INTERFACE PANEL (TCI)................................................264 Diagnostic Information Display.................................................265 DID PANEL EVENT CODES..............................................................265 PSC SOFTWARE FUNCTIONS.............................................................290 Input Processing...............................................................290 STATE MANAGEMENT...................................................................290 State Machine..................................................................290 Transitions Between States.....................................................291 DC Link State..................................................................293 Powering the Link..............................................................293 De-Powering the Link...........................................................293 Control Functions..............................................................293 Engine Control.................................................................293 ALTERNATOR FIELD CONTROL...........................................................294 Desired Three-Phase Voltage....................................................294 Desired DC Link Voltage........................................................294 Self-load......................................................................294 Propel Torque Control..........................................................295 Retard Torque Control..........................................................295 Wheel Slide Control............................................................295 Resistor Grid Control..........................................................296 Chopper Voltage Control........................................................296 AUXILIARY BLOWER CONTROL...........................................................296 EVENT PROCESSING...................................................................296 Event Detection................................................................296 Power On Tests.................................................................296 Initiated Tests................................................................297 Periodic Tests.................................................................297 EVENT RESTRICTIONS.................................................................297 EVENT LOGGING AND STORAGE..........................................................297 Event History Buffer...........................................................298 Data Packs.....................................................................298 To Record and Save a Data Pack to a Floppy Disk................................298 Event Reset....................................................................299 SERIAL DATA COMMUNICATIONS.........................................................300 PSC - TCI Communications processing............................................300 PSC - PTU Communications Processing............................................300 Inverter Communications Processing.............................................300 OUTPUT PROCESSING..................................................................301 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS...........................................301 Fast Start.....................................................................301 Engine Shutdown/Engine Not Running.............................................301 Limp Home Mode.................................................................301 Entering/Exiting Limp Home Mode................................................301 PROPULSION SYSTEM COMPONENT ABBREVIATIONS..........................................302 ELECTRONIC ACCELERATOR AND RETARD PEDALS...........................................312 Removal........................................................................312 Installation...................................................................312 Disassembly....................................................................312 Assembly.......................................................................312 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX.........................313 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE..........................................315 AC DRIVE SYSTEM MAINTENANCE........................................................315 TRUCK SHUTDOWN PROCEDURES..........................................................315 NORMAL TRUCK SHUTDOWN PROCEDURE....................................................316 SHUTDOWN AFTER SYSTEM FAILURE......................................................317 SYSTEM CHECKOUT....................................................................318 Battery and Control Checks of System WITH Battery Power OFF....................318 Battery and Control Circuit Checks of System With Battery Power ON.............321 Checks with Key Switch OFF.....................................................322 CPU Battery Checks.............................................................324 MEMORY BACKUP BATTERY REPLACEMENT..................................................324 TCI PROGRAMMING....................................................................325 PSC PROGRAMMING....................................................................325 INVERTER PROGRAMMING...............................................................326 TCI CHECKOUT.......................................................................326 Modular Mining Communication Port..............................................327 TCI Input Checks...............................................................328 TCI Digital Output Tests.......................................................330 TCI Digital Input Tests........................................................332 PSC Checkout Procedure.........................................................334 PSC Digital Input Checks.......................................................338 Miscellaneous Checks...........................................................339 A3PV Panel.....................................................................339 LINKV Panel....................................................................339 Thermistor Checks..............................................................339 17FM384 Panel Check............................................................339 Pedal Percentages and Meter Calibration........................................340 Meter Calibration Procedure....................................................340 Reprogram With Serial Numbers and Pedal Percentages............................342 LOAD TESTING.......................................................................344 Preload Checks.................................................................344 ADDITIONAL TRUCK CHECKS............................................................346 On-Board Load Testing..........................................................348 Preparation....................................................................348 Initiate Loadbox Test..........................................................351 Manual Offset HP Output Adjustment.............................................353 TROUBLESHOOTING........................................................................355 PVM Optimum Load Curve Handshaking Troubleshooting.................................355 MISCELLANEOUS COMPONENT REPAIR.....................................................356 Troubleshooting Phase Modules and Chopper Modules..............................356 Phase Module Removal and Snubber Resistor Replacement..........................356 Snubber Resistor Installation..................................................357 Phase Module Installation......................................................357 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING...................................358 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING...................................361 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING...........................................362 IGBT TROUBLESHOOTING...............................................................363 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX.............................................365 SECTION G2 - TIRES AND RIMS - INDEX........................................................367 TIRES AND RIMS.........................................................................369 WHEEL STUD MAINTENANCE.............................................................370 FRONT TIRES AND RIMS...............................................................371 Removal........................................................................371 Installation...................................................................372 REAR TIRES AND RIMS................................................................373 Removal........................................................................373 Installation...................................................................374 RIM................................................................................375 Tire Removal...................................................................375 Tire Installation..............................................................376 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...........................................379 FRONT WHEEL HUB AND SPINDLE............................................................381 WHEEL HUB AND SPINDLE ASSEMBLY.....................................................381 Preparation....................................................................381 Removal........................................................................381 Installation - Wheel Hub and Spindle Assembly..................................384 Disassembly - Wheel Hub and Spindle Assembly...................................385 Cleaning and Inspection - Wheel Hub and Spindle Assembly.......................385 Assembly - Wheel Hub and Spindle Assembly......................................387 Wheel Bearing Adjustment:......................................................387 Brake Installation.............................................................388 Seal Assembly Gap Check........................................................389 STEERING CYLINDERS AND TIE ROD.....................................................390 Spherical Bearing Wear Limits..................................................390 Removal - Steering Cylinder and Tie Rod........................................391 Installation - Steering Cylinder and Tie Rod...................................392 Bearing Replacement............................................................392 TOE-IN ADJUSTMENT..................................................................393 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX..........................................395 REAR AXLE HOUSING ATTACHMENT...........................................................397 PIVOT PIN..........................................................................397 Removal........................................................................397 Installation...................................................................397 PIVOT EYE BEARING..................................................................398 Disassembly....................................................................398 Assembly.......................................................................398 PIVOT EYE REPAIR...................................................................399 Removal........................................................................399 Disassembly....................................................................399 Assembly.......................................................................399 Installation...................................................................399 ANTI-SWAY BAR......................................................................400 Removal........................................................................400 Installation...................................................................400 Disassembly....................................................................400 Cleaning and Inspection........................................................400 Assembly.......................................................................400 SECTION G5 - REAR AXLE HOUSING - INDEX.....................................................401 REAR AXLE HOUSING......................................................................403 REAR AXLE HOUSING..................................................................403 Preparation....................................................................403 Removal........................................................................403 Cleaning and Inspection - Rear Axle Housing....................................405 Installation - Rear Axle Housing...............................................405 WHEEL MOTOR........................................................................406 Preparation....................................................................406 Removal........................................................................406 Cleaning and Inspection - Wheel Motor..........................................407 Installation - Wheel Motor.....................................................408 WHEEL MOTOR GEAR OIL...............................................................411 Filtering Requirements.........................................................411 Particle Size Analysis.........................................................411 Flushing.......................................................................411 Oil Sample Analysis............................................................412 ELEMENT SPECIFICATION CHARTS.......................................................413 SECTION H - HYDRAIR II SUSPENSIONS - INDEX.....................................................417 SECTION H2 - FRONT SUSPENSIONS - INDEX.....................................................419 FRONT SUSPENSION.......................................................................421 Removal............................................................................421 Installation - Front Suspension....................................................422 "Turn-Of-The-Nut" Tightening Procedure.............................................425 MINOR REPAIRS (LOWER BEARING & SEALS)..............................................426 Removal - Bearing Retainer.....................................................426 Installation - Bearing Retainer................................................426 MAJOR SUSPENSION REBUILD...........................................................428 Disassembly....................................................................428 Assembly.......................................................................428 SECTION H3 - REAR SUSPENSIONS - INDEX......................................................431 REAR SUSPENSIONS.......................................................................433 Removal............................................................................433 Installation - Rear Suspension.....................................................435 Disassembly - Rear Suspension......................................................436 Cleaning and Inspection - Rear Suspension..........................................436 Assembly - Rear Suspension.........................................................436 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX..............................439 SUSPENSION OILING AND CHARGING PROCEDURE...............................................441 GENERAL............................................................................441 EQUIPMENT LIST.....................................................................441 Hydrair® Charging Kit..........................................................441 Installation of Charging Kit...................................................441 Removal of Charging Kit........................................................442 Support Blocks For Oiling And Charging Dimensions..............................442 FRONT SUSPENSION...................................................................443 Front Suspension Oiling........................................................443 Front Suspension Nitrogen Charging.............................................444 REAR SUSPENSION....................................................................445 Rear Suspension Oiling.........................................................445 Rear Suspension Nitrogen Charging..............................................446 OIL AND NITROGEN SPECIFICATIONS CHART..................................................448 SECTION J - BRAKE CIRCUIT - INDEX..............................................................449 SECTION J2 - BRAKE CIRCUIT - INDEX.........................................................451 BRAKE CIRCUIT..........................................................................453 SERVICE BRAKE CIRCUIT..............................................................453 SECONDARY BRAKING AND AUTOMATIC APPLY..............................................455 PARKING BRAKE CIRCUIT..............................................................455 BRAKE LOCK CIRCUIT.................................................................456 WARNING CIRCUIT....................................................................456 Rear Axle Brake Lines..........................................................458 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.......................................459 BRAKE CIRCUIT COMPONENT SERVICE........................................................461 BRAKE VALVE........................................................................461 Rebuild Criteria...............................................................461 Removal........................................................................462 Installation...................................................................462 DISASSEMBLY........................................................................463 Cleaning and Inspection........................................................466 ASSEMBLY...........................................................................466 Actuator Base Threaded Inserts.................................................466 Boot and Cap...................................................................466 Valve Body Seal Installation...................................................466 Regulator Sleeve O-ring Installation...........................................467 Actuator Plunger O-ring Installation...........................................467 Assembly of Valve..............................................................467 DIFFERENTIAL PRESSURE SWITCH.......................................................469 Disassembly....................................................................469 Cleaning and Inspection........................................................469 Assembly.......................................................................469 VALVE BENCH TEST AND ADJUSTMENT....................................................470 Test Set Up Procedure..........................................................471 Brake Valve Output Pressure Adjustment.........................................471 Differential Pressure Switch Adjustment........................................471 Final Test and Adjustment......................................................472 Installation Of Brake Pedal Actuator Assembly to Brake Valve...................473 Installation of Retard Pedal To Brake Pedal....................................473 DUAL RELAY VALVE...................................................................475 Removal........................................................................475 Installation...................................................................475 Disassembly....................................................................477 Cleaning and Inspection........................................................477 Assembly.......................................................................477 DIFFERENTIAL PRESSURE SWITCH.......................................................478 Disassembly....................................................................478 Cleaning and Inspection........................................................478 Assembly.......................................................................478 VALVE TEST AND ADJUSTMENT..........................................................479 Test Set Up Procedure..........................................................480 Brake Valve Output Pressure Adjustment.........................................480 Differential Pressure Switch Adjustment........................................481 BRAKE MANIFOLD.....................................................................482 Removal........................................................................482 Installation...................................................................483 Disassembly....................................................................483 Cleaning and Inspection........................................................483 Assembly.......................................................................483 HYDRAULIC BRAKE ACCUMULATORS.......................................................484 Brake Accumulator Bleed Down Procedure.........................................484 ACCUMULATORS - HYDRAULIC COMPONENT CABINET.........................................484 Removal........................................................................484 Installation...................................................................484 Disassembly....................................................................484 Cleaning and Inspection........................................................486 Assembly.......................................................................486 BLADDER ACCUMULATOR CHARGING PROCEDURE.............................................488 Temperature During Precharge...................................................489 Precharge Maintenance..........................................................489 Accumulator Storage Procedures.................................................490 Bladder Storage Procedures.....................................................491 ACCUMULATORS - FRAME MOUNTED.......................................................491 Removal........................................................................491 Installation...................................................................491 Disassembly....................................................................493 Cleaning and Inspection........................................................493 Assembly - Accumulator.........................................................494 Accumulator Testing............................................................494 ACCUMULATOR CHARGING PROCEDURE.....................................................495 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................496 Removal............................................................................496 Installation.......................................................................496 Disassembly and Adjustment.........................................................496 Potentiometer Check................................................................498 Assembly...........................................................................498 SECTION J4 - BRAKE CIRCUIT CHECKOUT PROCEDURE - INDEX......................................499 BRAKE CIRCUIT CHECK-OUT PROCEDURE......................................................501 EQUIPMENT REQUIRED.................................................................503 INITIAL SYSTEM SET-UP..............................................................504 BRAKE SYSTEM CHECKOUT..............................................................505 Failure Modes Check-Out........................................................506 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING..........................................509 CHECK-OUT PROCEDURE....................................................................513 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX...............................................515 WET DISC BRAKE ASSEMBLY................................................................517 OPERATION..........................................................................517 MAINTENANCE........................................................................518 Brake Disc Wear Indicator......................................................518 Removal/Installation - Wet Disc Brake Assembly.................................518 BRAKE REBUILD......................................................................520 Disassembly....................................................................520 Cleaning and Inspection........................................................523 Assembly.......................................................................524 Floating Ring Seal Assembly/Installation.......................................527 WET DISC BRAKE BLEEDING PROCEDURE..................................................530 SECTION J7 - PARKING BRAKE - INDEX.........................................................531 PARKING BRAKE..........................................................................533 OPERATION..........................................................................533 MAINTENANCE........................................................................534 Inspection - Parking Brake.....................................................534 Removal - Parking Brake........................................................534 Installation - Parking Brake...................................................535 Disassembly - Parking Brake....................................................536 Cleaning and Inspection - Parking Brake........................................536 Assembly - Parking Brake.......................................................536 PARKING BRAKE BLEEDING PROCEDURE...................................................538 SECTION L - HYDRAULIC SYSTEM - INDEX...........................................................539 SECTION L2 - HYDRAULIC SYSTEM - INDEX......................................................541 HYDRAULIC SYSTEM.......................................................................543 Hoist Circuit Operation............................................................544 Steering Circuit Operation.........................................................546 Disc Brake Cooling System..........................................................548 SECTION L3 - HYDRAULIC SYSTEM COMPONENTS REPAIR - INDEX....................................551 HYDRAULIC SYSTEM COMPONENT REPAIR......................................................553 HOIST PUMP.........................................................................553 Removal........................................................................553 Installation...................................................................555 Disassembly....................................................................556 Inspection of Parts............................................................560 Assembly.......................................................................560 TROUBLESHOOTING GUIDE (HOIST PUMP).....................................................565 HYDRAULIC TANK.....................................................................566 Filling Instructions...........................................................566 Removal - Hydraulic Tank.......................................................566 Installation - Hydraulic Tank..................................................567 HYDRAULIC TANK STRAINERS...........................................................567 Removal........................................................................567 Inspect and Clean..............................................................567 Installation...................................................................567 HYDRAULIC TANK BREATHERS...........................................................568 SECTION L4 - STEERING CIRCUIT - INDEX......................................................569 STEERING CIRCUIT.......................................................................571 STEERING CIRCUIT OPERATION.........................................................571 COMPONENT DESCRIPTION..............................................................572 Steering Control Unit..........................................................572 Bleeddown Manifold Valve.......................................................573 Bleeddown Solenoid.............................................................573 Relief Valves..................................................................575 Hoist Limit Solenoid...........................................................575 Accumulators...................................................................575 Low Precharge Warning Switch...................................................575 High Pressure Filters..........................................................575 Quick Disconnect Ports.........................................................575 Flow Amplifier.................................................................576 FLOW AMPLIFIER SYSTEM OPERATION....................................................578 No Steer.......................................................................578 Steering Left..................................................................580 Steering Right.................................................................582 No Steer, External Shock Load..................................................584 STEERING PUMP......................................................................586 Operation......................................................................586 High Altitude Operation........................................................586 PRINCIPLE OF OPERATION.............................................................588 Full Pump Volume...............................................................588 Half Pump Volume...............................................................588 Neutral Position...............................................................588 ADDITIONAL STEERING PUMP INFORMATION...............................................589 SECTION L5 - STEERING CONTROL UNIT - INDEX.................................................591 STEERING CONTROL UNIT..................................................................593 Removal............................................................................593 Installation.......................................................................593 STEERING CONTROL UNIT REBUILD......................................................594 Disassembly....................................................................594 Cleaning and Inspection - Steering Control Unit................................595 Assembly - Steering Control Unit...............................................597 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX.....................................601 STEERING CIRCUIT COMPONENT REPAIR......................................................603 BLEEDDOWN MANIFOLD VALVE...........................................................603 Removal........................................................................603 Installation...................................................................603 ACCUMULATORS.......................................................................604 Removal........................................................................604 Installation...................................................................604 Disassembly - Accumulators.....................................................605 Cleaning and Inspection - Accumulators.........................................605 Assembly - Accumulators........................................................606 Testing - Accumulators.........................................................606 STEERING ACCUMULATOR CHARGING PROCEDURE............................................607 FLOW AMPLIFIER.....................................................................608 Removal........................................................................608 Installation...................................................................608 FLOW AMPLIFIER REBUILD.............................................................608 Disassembly - Flow Amplifier...................................................610 Assembly - Flow Amplifier......................................................611 STEERING CYLINDERS.................................................................612 Disassembly - Steering Cylinder................................................613 Piston Seal & Bearing Installation.............................................613 Assembly - Steering Cylinder...................................................613 Test - Steering Cylinder.......................................................613 STEERING AND BRAKE PUMP............................................................614 Removal........................................................................614 Installation...................................................................614 Disassembly - Steering and Brake Pump..........................................616 Control Piston Group...........................................................616 Valve Plate Group..............................................................616 Rotating Group.................................................................619 Swashblock Group...............................................................619 Driveshaft Group...............................................................619 Inspection - Steering and Brake Pump...........................................619 Control Piston Group...........................................................619 Valve Plate Group..............................................................619 Rotating Group.................................................................619 Swashblock Group...............................................................621 Driveshaft Group...............................................................622 Compensator Block and Unloader Module..........................................622 Stroke Adjuster Assembly.......................................................622 Assembly - Steering and Brake Pump.............................................622 Swashblock Group...............................................................622 Driveshaft Group...............................................................623 Rotating Group.................................................................623 Control Piston Group...........................................................623 Valve Plate Group..............................................................624 TROUBLESHOOTING CHART..................................................................625 SECTION L7 - HOIST CIRCUIT - INDEX.........................................................631 HOIST CIRCUIT..........................................................................633 HOIST CIRCUIT OPERATION............................................................633 COMPONENT DESCRIPTION..............................................................634 Hydraulic Tank.................................................................634 Hydraulic Pump.................................................................634 High Pressure Filters..........................................................634 Hoist Valve....................................................................634 Inlet Sections - Hoist Valve...................................................634 Spool Sections - Hoist Valve...................................................635 Hoist Pilot Valve..............................................................635 Bleeddown Manifold.............................................................636 Hoist-up Limit Solenoid........................................................636 Pilot Operated Check Valve.....................................................636 Overcenter Manifold............................................................636 HOIST CIRCUIT OPERATION................................................................637 Float Position Of Pilot Valve With Truck Body On Frame.............................638 Power Up Operation.................................................................640 Hold Operation.....................................................................642 Power Down Operation...............................................................644 Float Operation....................................................................646 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX........................................649 HOIST CIRCUIT COMPONENT REPAIR.........................................................651 HOIST VALVE........................................................................651 Removal - Hoist Valve..........................................................651 Installation - Hoist Valve.....................................................652 O-Ring Replacement.............................................................652 INLET SECTION......................................................................653 Disassembly - Inlet Section....................................................653 Cleaning and Inspection - Inlet Section........................................654 Assembly - Inlet Section.......................................................654 REAR SPOOL SECTION (Work Ports)....................................................654 Disassembly - Rear Spool Section...............................................654 Cleaning and Inspection - Rear Spool Section...................................656 Assembly - Rear Spool Section..................................................656 FRONT SPOOL SECTION (Tank Ports)...................................................657 Disassembly....................................................................657 Cleaning and Inspection........................................................657 Assembly.......................................................................657 HOIST PILOT VALVE..................................................................659 Removal - Hoist Pilot Valve....................................................659 Installation - Hoist Pilot Valve...............................................659 Disassembly - Hoist Pilot Valve................................................660 Cleaning and Inspection - Hoist Pilot Valve....................................661 Assembly - Hoist Pilot Valve...................................................661 HOIST CYLINDERS....................................................................662 Removal - Hoist Cylinder.......................................................662 Installation - Hoist Cylinder..................................................663 Disassembly - Hoist Cylinder...................................................665 Cleaning and Inspection - Hoist Cylinder.......................................666 Assembly - Quill And Cylinder..................................................667 Installation - Quill...........................................................667 Installation - Check Balls And Plugs In Quill..................................668 Assembly - Hoist Cylinder......................................................669 DISABLED TRUCK DUMPING PROCEDURE...................................................670 Hookup.........................................................................670 DUMPING PROCEDURE..............................................................670 Raising the Body...............................................................670 Lowering the Body..............................................................670 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX..............................................671 HYDRAULIC SYSTEM FILTERS...............................................................673 HOIST CIRCUIT FILTER...............................................................673 Filter Element Replacement.....................................................673 Removal - Hoist Circuit Filter.................................................674 Installation - Hoist Circuit Filter............................................674 Indicator Switch - Hoist Circuit Filter........................................674 STEERING CIRCUIT FILTER............................................................675 Filter Element Replacement.....................................................675 Removal - Steering Circuit Filter..............................................676 Installation - Steering Circuit Filter.........................................676 Indicator Switch - Steering Circuit Filter.....................................676 INDICATOR SWITCH...................................................................676 Test Procedure.................................................................676 SECTION L10 - HYDRAULIC CHECKOUT PROCEDURE - INDEX.........................................679 HYDRAULIC CHECK-OUT PROCEDURE..........................................................681 GENERAL INFORMATION................................................................681 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE..................................681 Equipment Requirements.........................................................682 Pump Pressure Control Adjustments..............................................682 Steering Control Unit and Flow Amplifier Leakage Test..........................683 Bleeddown Manifold Leakage Test................................................683 Steering/Brake Pump Stroke Adjustment..........................................684 Shock And Suction Valves.......................................................685 Equipment Requirements.........................................................685 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES......................686 Equipment Requirements.........................................................686 Pressure Checks................................................................686 Brake Cooling Circuit Test.....................................................686 Power Up Relief Pressure Test..................................................687 Adjustment.....................................................................687 Power Down Relief Pressure Test................................................688 Adjustment.....................................................................688 Hoist Counterbalance Valve Adjustment Preparation..............................689 Counterbalance Valve Pressure Check............................................689 Counterbalance Valve Adjustment................................................690 HYDRAULIC SYSTEM FLUSHING PROCEDURE....................................................691 Preparation........................................................................691 Flushing Procedure.................................................................691 Filter Element Replacement.........................................................692 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET..................................693 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET.....................694 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX..................................................695 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX..................................................697 FIRE CONTROL SYSTEM (MANUAL)...........................................................699 Operation..........................................................................699 Inspection and Maintenance.........................................................699 Recharging Procedures..............................................................700 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1...........................701 Control Module.....................................................................701 Actuator...........................................................................702 Linear Detection Wire..............................................................702 Power Wire.........................................................................702 Test Kit...........................................................................702 Squib..............................................................................702 Securing the Detection Wire........................................................703 Preliminary Test Before Final Hook-Up..............................................703 Installation Procedure for Squib...................................................705 Placing the Electric Detection & Actuation System Into Service.....................705 INSPECTION AND MAINTENANCE SCHEDULES...............................................706 Daily..........................................................................706 Normal Maintenance Based On Actual Operating Hours.............................706 IN CASE OF FIRE....................................................................707 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM..........................................709 SECTION M8 - SPECIAL TOOLS.................................................................711 SECTION M20 - PAYLOAD METER II - ON BOARD WEIGHING SYSTEM - INDEX..........................717 GENERAL INFORMATION....................................................................719 Haul Cycles........................................................................719 LIGHTS, SWITCHES AND COMPONENTS........................................................720 TIPS FOR OPERATION.....................................................................721 EXTERNAL DISPLAY LIGHTS................................................................721 THEORY OF OPERATION....................................................................722 Basic Description..................................................................722 Inclinometer.......................................................................722 Linkage Factor.....................................................................722 Gain Factor........................................................................723 Brake Lock.........................................................................723 Sources of Error...................................................................723 Typical Data From Service Check Mode...............................................723 Example Calculation of Payload.....................................................724 Viewing Payload Calculation Inputs.................................................724 Checking the Gain..................................................................725 Adjusting the Gain.................................................................725 TYPES OF DATA STORED...................................................................726 Cycle Data.........................................................................726 Engine ON/OFF Data.................................................................727 Fault Codes and Warning Data.......................................................727 Engine Operation...................................................................728 Total Payload and Total Number of Cycles...........................................728 Other Data.........................................................................728 OPERATOR FUNCTIONS.....................................................................729 Using the Operator Load Counter....................................................729 Viewing the Operator Load Counter..................................................729 Clearing the Operator Load Counter.................................................729 Dimming the Lights on the Display..................................................729 INITIAL SETUP OF PAYLOAD METER.........................................................730 Switch Settings....................................................................730 Checking the Operator Check Mode...................................................731 Checking the Service Check Mode....................................................731 Checking the Gt setting:...........................................................732 Checking the Inclinometer Settings.................................................732 Calibrating a Truck................................................................732 DISPLAYS AT START-UP...................................................................733 Normal Operation...................................................................733 SETUP AND MAINTENANCE..................................................................734 Setting The Speed Limit............................................................734 Setting the Option Code............................................................734 Setting The Machine I.D. Code......................................................735 Setting The Operator I.D. Code.....................................................735 Setting The Time and Date..........................................................735 DOWNLOAD OF INFORMATION................................................................736 DISPLAY OF FAULT CODES.................................................................736 Monitoring Input Signals...........................................................740 Service Check Mode.................................................................740 UP FACTOR - PAYLOAD CALCULATION GAIN...................................................741 PL MODE -LOAD CALCULATION TIMING.......................................................741 FINAL GEAR RATIO SELECTION.............................................................742 BATTERY REPLACEMENT PROCEDURE..........................................................743 Replacing the Battery..............................................................743 After Replacing the Battery........................................................744 SUSPENSION PRESSURE SENSOR.............................................................744 Removal............................................................................744 Installation.......................................................................745 INCLINOMETER...........................................................................745 Removal............................................................................745 Installation.......................................................................745 Adjustment.........................................................................745 PAYLOAD METER BACK PANEL...............................................................746 CONNECTIONS............................................................................747 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE..........................................748 PAYLOAD CIRCUIT NUMBERS................................................................749 TROUBLESHOOTING........................................................................750 COMMON PROBLEMS....................................................................750 Suspension Charging............................................................750 Symptom Table..................................................................751 Missing Body-Up Signal.........................................................751 Missing Speed Signal...........................................................752 F-18: Alternator R-Terminal, Oil Pressure Signals..............................752 Shorted 18v Sensor Power Supply (930E).........................................752 FAULT TREE DIAGNOSIS...............................................................753 Payload Lights Won't Illuminate................................................753 Red, Amber or Green Payload Light Does Not Illuminate..........................754 Cannot Download - PC Communications............................................755 PC Communications Configuration................................................756 F.CAL: Payload Meter Won't Calibrate...........................................757 F-20: Sensor Power Fault.......................................................758 F-21, F-25: Left Front Pressure Sensor.........................................760 F-22, F-26: Right Front Pressure Sensor........................................760 F-23, F-27: Left Rear Pressure Sensor..........................................760 F-24, F-28: Right Rear Pressure Sensor.........................................760 F-31, F-32: Inclinometer.......................................................762 Body Up Input..................................................................764 Brake Lock Input...............................................................765 Speed Signal...................................................................766 Adjusting the Speed Sensor.....................................................766 CONNECTORS AND PRESSURE SENSORS....................................................768 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM............................................771 Menu Functions.....................................................................774 Using Scope........................................................................774 Log File Information...............................................................774 Connections to Payload Meter II™...................................................775 USING SCOPE............................................................................776 Monitoring Inputs Using Scope......................................................776 Monitoring Suspension Charging Using Scope.........................................776 Pressure Sensor Dummy Loads........................................................779 GAIN ADJUSTMENT WORKSHEET..............................................................780 SECTION N - CAB COMPONENTS - INDEX.............................................................781 SECTION N2 - TRUCK CAB - INDEX.............................................................783 TRUCK CAB..............................................................................785 Description........................................................................785 Preparation........................................................................786 Removal - Cab......................................................................786 Installation - Cab.................................................................788 CAB DOOR...........................................................................788 Removal........................................................................788 Installation...................................................................788 Door Adjustment................................................................789 Door Jamb Bolt Adjustment......................................................789 Door Handle Plunger Adjustment.................................................790 Door Glass Replacement.........................................................791 Door Window Regulator Replacement..............................................795 Door Handle or Latch Assembly Replacement......................................795 Door and Door Hinge Seal Replacement...........................................796 Door Opening Seal Removal......................................................796 Installation...................................................................796 GLASS REPLACEMENT..................................................................797 Adhesive Bonded Windows........................................................797 Replacement Procedure..........................................................797 Windshield And Rear Glass......................................................798 Removal........................................................................798 Installation...................................................................799 SECTION N3 - CAB COMPONENTS - INDEX........................................................801 CAB COMPONENTS.........................................................................803 WINDSHIELD WIPERS..................................................................803 Wiper Motor Replacement........................................................803 Removal........................................................................803 Installation...................................................................803 Wiper Arm Replacement..........................................................803 Removal........................................................................803 Installation...................................................................804 Wiper Linkage Replacement......................................................804 Removal........................................................................804 Installation...................................................................804 WINDSHIELD WASHER..................................................................805 Operation......................................................................805 Service........................................................................805 OPERATOR SEAT......................................................................806 Adjustment.....................................................................806 Removal........................................................................806 Installation...................................................................806 SECTION N4 - OPERATOR COMFORT - INDEX......................................................807 OPERATOR COMFORT.......................................................................809 HEATER/AIR CONDITIONER.............................................................809 Operation......................................................................809 HEATER COMPONENTS..................................................................810 Circuit Breakers...............................................................810 Heater Control Components......................................................810 Heater Coil....................................................................810 Fan Motor And Speed Control....................................................811 Actuators......................................................................811 Filter Service.................................................................811 AIR CONDITIONING SYSTEM................................................................813 Environmental Impact...............................................................813 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES..........................................814 PRINCIPLES OF REFRIGERATION........................................................814 Air Conditioning...............................................................814 Refrigeration - The Act Of Cooling.............................................815 The Refrigeration Cycle........................................................815 AIR CONDITIONER SYSTEM COMPONENTS..................................................816 Compressor (Refrigerant Pump)..................................................816 Service Valves.................................................................816 Condenser......................................................................816 Receiver-Drier.................................................................816 Expansion Block Valve..........................................................817 Accumulator....................................................................817 Evaporator.....................................................................817 ELECTRICAL CIRCUIT.................................................................818 Thermostat.....................................................................818 Compressor Clutch..............................................................818 Trinary™ Switch................................................................819 SYSTEM SERVICING...................................................................820 SERVICE TOOLS AND EQUIPMENT........................................................821 Recovery/Recycle Station.......................................................821 Leak Detector..................................................................821 Service Valves.................................................................822 Vacuum Pump....................................................................822 Manifold Gauge Set.............................................................823 Installing Manifold Gauge Set..................................................824 Purging Air From Service Hoses.................................................824 SYSTEM PERFORMANCE TEST............................................................825 SYSTEM OIL.........................................................................826 Handling and Reusing PAG Oil...................................................826 Oil Quantity...................................................................826 Checking System Oil............................................................826 REFRIGERANT........................................................................827 Recycled Refrigerant...........................................................827 Reclaimed Refrigerant..........................................................827 Refrigerant Quantity...........................................................827 R-134a Refrigerant Containers..................................................827 SYSTEM LEAK TESTING................................................................828 Electronic Leak Detector.......................................................828 Tracer Dyes....................................................................828 Soap and Water.................................................................828 RECOVERING AND RECYCLING THE REFRIGERANT...........................................829 Performing the Recovery Cycle..................................................829 Performing the Recycling Procedure.............................................829 Evacuating and Charging the A/C System.........................................829 SYSTEM REPAIR......................................................................830 System Flushing................................................................830 COMPONENT REPLACEMENT..............................................................830 Hoses and Fittings.............................................................830 Lines..........................................................................830 Expansion Valve................................................................831 Receiver-Drier.................................................................831 Thermostat.....................................................................831 Compressor.....................................................................831 Accumulator....................................................................831 Clutch.........................................................................832 Servicing the Compressor Clutch................................................832 Pulley Removal.................................................................834 Clutch Coil Check..............................................................835 Pulley Installation............................................................835 Clutch Assembly Installation...................................................835 EVACUATING THE SYSTEM..............................................................837 CHARGING THE A/C SYSTEM............................................................839 TROUBLESHOOTING........................................................................840 Preliminary Checks.................................................................840 Diagnosis Of Gauge Readings And System Performance.................................840 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.........................................841 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.......................................847 SECTION N5 - OPERATOR CAB CONTROLS - INDEX.................................................849 OPERATOR CAB CONTROLS..................................................................851 STEERING COLUMN....................................................................851 Removal........................................................................851 Installation...................................................................851 STEERING WHEEL AND CONTROLS........................................................853 Horn Button....................................................................853 Telescope Lock Ring............................................................853 Tilt Wheel Lever...............................................................853 Turn Signal Headlight Dimmer...................................................853 DYNAMIC RETARDING..................................................................853 Retarder Control Lever.........................................................854 Dynamic Retarder/Service Brake Pedal...........................................854 Accelerator (Throttle) Pedal...................................................854 Starting on a Grade With a Loaded Truck........................................854 GRADE/SPEED RETARD CHART...........................................................855 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..................................856 Defroster Control Switch.......................................................856 Outside/Inside Air Control Switch..............................................856 Heat Vent Control Switch.......................................................856 Temperature Control Knob.......................................................856 Fan Control Knob...............................................................856 Heater/Air Conditioner Selector Switch.........................................856 Heater/Air Conditioner Vents...................................................856 INSTRUMENT PANEL...................................................................857 OVERHEAD PANEL AND DISPLAYS........................................................857 CENTER CONSOLE.....................................................................858 F-N-R Selector Switch..........................................................858 HOIST CONTROL LEVER................................................................859 To Raise dump body:............................................................859 To lower body:.................................................................859 Ash Tray.......................................................................859 Lighter........................................................................859 L.H. Window Control Switch.....................................................859 R.H. Window Control Switch.....................................................859 Engine Shutdown Switch.........................................................859 Override/Fault Reset Switch....................................................860 Retard Speed Control (RSC) "Off/On" Switch.....................................860 Retard Speed Control (RSC) Adjust Dial.........................................860 PSC Download Port..............................................................861 Engine Diagnostics Download Port...............................................861 TCI Download Port..............................................................861 Passenger Seat.................................................................861 INSTRUMENT PANEL AND INDICATOR LIGHTS..................................................863 Control Symbols....................................................................863 INSTRUMENT PANEL (Figure 5-6)......................................................863 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)....................................865 Key Switch.........................................................................865 Starting...........................................................................865 Cold Weather Starting..............................................................865 Normal Engine Shutdown.............................................................865 Engine Shutdown Switch with 5 Minute Idle Timer Delay..............................866 Operation..........................................................................866 Fog Lights (Optional)..............................................................866 Ladder Light Switch................................................................866 Manual Backup Switch...............................................................866 Panel Illumination Lights..........................................................867 Cab Air Conditioner/Heater Vents...................................................867 Rotating Beacon Light Switch (Optional)............................................867 Heated Mirror Switch (Optional)....................................................867 Wheel Brake Lock Control...........................................................867 Parking Brake Control..............................................................867 Tachometer.........................................................................868 Right Turn Signal Indicator........................................................868 High Beam Indicator................................................................868 Left Turn Signal Indicator.........................................................868 Speedometer........................................................................868 Voltmeter..........................................................................868 Engine Oil Pressure Gauge..........................................................868 Water Temperature Gauge............................................................868 Fuel Gauge.........................................................................868 AC Drive System Temperature Gauge..................................................869 Hydraulic Oil Temperature Gauge....................................................869 Hourmeter..........................................................................869 Rest Switch........................................................................869 Light Switch.......................................................................870 Windshield Wiper and Washer........................................................870 Panel Light Dimmer.................................................................870 STATUS / WARNING INDICATOR LIGHT SYMBOLS...............................................872 SECTION P - LUBRICATION AND SERVICE - INDEX....................................................879 SECTION P2 - LUBRICATION AND SERVICE - INDEX...............................................881 LUBRICATION AND SERVICE................................................................883 930E SERVICE CAPACITIES............................................................883 HYDRAULIC TANK SERVICE.............................................................883 Adding Oil.....................................................................883 WHEEL MOTOR SERVICE................................................................883 COOLANT LEVEL CHECK................................................................884 RADIATOR FILLING PROCEDURE.........................................................884 LUBRICATION CHART..................................................................885 10 HOUR (DAILY) INSPECTION.........................................................886 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................889 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................890 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................891 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................894 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS......................................895 5000 HOUR MAINTENANCE CHECKS.......................................................896 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX..........................................897 AUTOMATIC LUBRICATION SYSTEM...........................................................899 GENERAL DESCRIPTION................................................................899 SYSTEM COMPONENTS..................................................................901 SYSTEM OPERATION...................................................................902 Normal Operation...............................................................902 Pressure Failure Detection Circuits............................................903 INJECTOR OPERATION.................................................................904 GENERAL INSTRUCTIONS...................................................................905 LUBRICANT REQUIREMENTS.............................................................905 System Priming.....................................................................905 LUBRICANT PUMP.....................................................................905 Pump Housing Oil Level.........................................................905 Pump Pressure Control..........................................................905 Pressure Control Valve Adjustment..............................................905 INJECTORS (SL-1 Series “H”)).......................................................906 Injector Specifications........................................................906 Injector Adjustment............................................................906 SYSTEM CHECKOUT....................................................................906 Lubrication Cycle Timer Check..................................................907 Lubrication Cycle Timer Adjustment.............................................907 FILTER ASSEMBLY....................................................................907 PUMP REBUILD.......................................................................908 Disassembly....................................................................908 Cleaning and Inspection........................................................908 Assembly.......................................................................910 SYSTEM TROUBLESHOOTING CHART...........................................................911 PREVENTATIVE MAINTENANCE PROCEDURES....................................................914 Daily Lubrication System Inspection................................................914 250 Hour Inspection................................................................914 1000 Hour Inspection...............................................................914 SECTION Q ALPHABETICAL INDEX...................................................................915 SECTION R - SYSTEM SCHEMATICS - INDEX .........................................................919 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH351...................................................921 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH347.......................................922 ENGINE RUN AND START ELECTRICAL SCHEMATIC - HE460..........................................923 ELECTRICAL WIRING SCHEMATIC - EJ4230.......................................................924
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