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Komatsu 930E-2 Dump Truck Shop Manual SN A30224-A30245 – PDF DOWNLOAD
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Komatsu 930E-2 Dump Truck Shop Manual
Book Code: CEBM006602
SERIAL NUMBERS : A30224 thru A30245
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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: A30224-A30245
Book Code: CEBM006602
Language: English
Pages: 944
File Format: Portable Document Format (PDF)
KOMATSU 930E-2 DUMP TRUCK SHOP MANUAL SN A30224-A30245 – 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 - TRUCK COMPONENTS AND SPECIFICATIONS...................................... 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 PREPARATION - 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 SECTION C - ENGINE - INDEX................................................................103 SECTION C2 - POWER MODULE - INDEX.....................................................105 POWER MODULE......................................................................107 Preparation...................................................................107 Preparation for Removal.......................................................108 Removal - Power Module........................................................111 Installation - Power Module...................................................113 Hookup - Power Module.........................................................113 SECTION C3 - COOLING SYSTEM - INDEX...................................................115 COOLING SYSTEM....................................................................117 RADIATOR......................................................................117 Removal - Radiator........................................................117 RADIATOR REPAIR...............................................................119 Internal Inspection.......................................................119 External Cleaning.........................................................119 Disassembly...............................................................120 Cleaning and Inspection...................................................121 Assembly..................................................................121 Pressure Testing..........................................................122 Additional Service Information............................................122 Installation - Radiator...................................................123 RADIATOR FILLING PROCEDURE....................................................124 COOLANT SYSTEM TROUBLESHOOTING................................................124 SECTION C4 - POWERTRAIN - INDEX.......................................................125 POWER TRAIN.......................................................................127 ALTERNATOR....................................................................127 Removal - Alternator......................................................127 ENGINE/ALTERNATOR MATING......................................................129 General Instructions......................................................129 Measuring Procedure.......................................................129 Joining The Alternator and Engine.........................................131 ENGINE........................................................................132 Removal...................................................................132 Service...................................................................132 Installation..............................................................132 SECTION C5 - AIR CLEANERS - INDEX.....................................................133 AIR CLEANERS......................................................................135 AIR CLEANERS..................................................................135 Operation.................................................................135 General Service Information...............................................135 FILTER ELEMENT REPLACEMENT....................................................136 Main Filter Element Cleaning..............................................137 Precleaner Section........................................................138 Cleaning Precleaner Tubes.................................................138 AIR INTAKE TROUBLESHOOTING....................................................139 SECTION C7 - FAN CLUTCH - INDEX.......................................................141 FAN CLUTCH........................................................................143 REMOVAL & INSTALLATION TOOLING................................................143 FAN CLUTCH - DISASSEMBLY......................................................146 CLEANING AND INSPECTION.......................................................156 ASSEMBLY - FAN CLUTCH.........................................................160 TEST PROCEDURE................................................................174 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..............................175 SECTION D2 - 24 VDC ELECTRIC SUPPLY SYSTEM - INDEX....................................177 24VDC ELECTRIC SUPPLY SYSTEM......................................................179 ELECTRICAL SYSTEM DESCRIPTION.................................................179 BATTERIES.....................................................................179 Maintenance and Service...................................................179 Troubleshooting...........................................................179 BATTERY SUPPLY SYSTEM.........................................................181 24VDC Battery Charging Alternator.........................................181 Battery Box...............................................................181 Battery Control Box.......................................................181 System Battery Starter Disconnect Relay...................................181 Battery Disconnect Switches...............................................182 24VDC Auxiliary Battery Connectors........................................182 Battery Equalizer.........................................................183 Troubleshooting...........................................................183 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX...............................185 24 VDC ELECTRICAL SYSTEM COMPONENTS...............................................187 PASSENGER SEAT BASE COMPARTMENT...............................................187 TRUCK SHUTDOWN PROCEDURE......................................................187 COMPONENTS....................................................................187 Tail Light Resistor Diode Assemblies......................................187 5 Minute Idle Timer Components............................................187 5 Minute Idle Timer.......................................................189 5 Minute Idle Relay.......................................................189 5 Minute Idle Contactor...................................................189 5 Minute Idle Circuit Test................................................189 Inclinometer..............................................................189 Brake Warning Buzzer (BWB)................................................189 Alarm Indicating Device (AID) System......................................189 Coolant Level/Flasher.....................................................189 Temperature and Latch Card................................................190 Hot Switch Inverter Card..................................................190 Hot Switch Inverter Card (Slot 4) (Not Used)..............................191 Oil Level Card............................................................191 Temperature Card..........................................................191 Diode Matrix (Without Sound) Card.........................................191 Diode Matrix (With Sound) Card............................................191 Lamp Test Switch..........................................................191 Electrical Interface Cabinet..............................................192 Lubrication System Timer..................................................192 Lincoln Lube Delay Timer..................................................192 Barometric Pressure Transducer............................................192 Pulse Voltage Modulator...................................................192 Power Distribution Terminals..............................................192 Truck Control Interface Panel.............................................192 Kontrol Power Relay.......................................................192 Circuit Breaker Panel.....................................................192 Diode Board - DB1.........................................................194 Diode Testing.............................................................194 Relay Boards..............................................................195 Relay Boards: RB1, RB2, RB3, RB4, RB5.....................................195 Service...................................................................195 Relay Board Identification................................................196 Relay Board Functions.....................................................197 Installing Additional Circuits............................................198 Body Up Switch............................................................199 Operation.................................................................199 Adjustment................................................................199 Service...................................................................199 Hoist Limit Switch........................................................200 Operation.................................................................200 Adjustment................................................................200 Service...................................................................200 CIRCUIT BREAKER CHART.........................................................201 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX.....................................203 BATTERY CHARGING ALTERNATOR.......................................................205 ELECTRICAL SYSTEM DESCRIPTION.................................................205 BATTERY.......................................................................205 Maintenance and Service...................................................205 Troubleshooting...........................................................205 BATTERY CHARGING SYSTEM (Niehoff).............................................207 General Description.......................................................207 TROUBLESHOOTING PROCEDURES (On-Truck).........................................207 Equipment Required:.......................................................207 Preliminary Checks........................................................208 Test Setup................................................................208 Test Procedure............................................................208 Regulator Bypass Test.....................................................209 ON VEHICLE TROUBLESHOOTING GUIDE..................................................211 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage....211 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................211 CHARGE VOLT AND AMP VALUES....................................................212 DEFINITIONS...................................................................212 ADVANCED SYSTEM TROUBLESHOOTING...................................................213 Static Test - Engine OFF, Key ON, Battery Switch ON...........................213 Go To Alternator..............................................................213 Go To Regulator (If Required).................................................214 Go To Regulator Connector On The Alternator...................................214 ALTERNATOR OVERHAUL...............................................................215 ALTERNATOR DIMENSIONS.........................................................215 ALTERNATOR SPECIFICATIONS.....................................................216 SERVICE PARTS.................................................................217 ON-VEHICLE TEST...............................................................219 Equipment:................................................................219 Preliminary Checks:.......................................................219 Test Set-up...............................................................219 Test Procedure............................................................219 ON-VEHICLE TEST...............................................................220 Bypass Test:..............................................................220 BENCH TEST....................................................................221 STATIC TESTS..................................................................222 Regulator Tests...........................................................222 Control Box Tests.........................................................223 ALTERNATOR DISASSEMBLY........................................................225 ASSEMBLY- ALTERNATOR..........................................................230 BF4822 STATOR SERVICE TOOL INSTRUCTIONS...........................................239 Stator Removal And Replacement................................................239 Stator Installation...........................................................240 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX..........................................243 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX..........................245 ELECTRICAL PROPULSION SYSTEM COMPONENTS...........................................247 GENERAL SYSTEM DESCRIPTION....................................................247 SYSTEM COMPONENTS.............................................................249 Auxiliary Blower System...................................................249 Propulsion System Controller (PSC)........................................249 TRUCK CONTROL INTERFACE PANEL (TCI)...........................................250 Diagnostic Information Display............................................251 DID PANEL EVENT CODES.........................................................251 PSC SOFTWARE FUNCTIONS........................................................276 Input Processing..........................................................276 STATE MANAGEMENT..............................................................276 State Machine.............................................................276 Transitions Between States................................................277 DC Link State.............................................................279 Powering the Link.........................................................279 De-Powering the Link......................................................279 Control Functions.........................................................279 Engine Control............................................................279 ALTERNATOR FIELD CONTROL......................................................280 Desired Three-Phase Voltage...............................................280 Desired DC Link Voltage...................................................280 Self-load.................................................................280 Propel Torque Control.....................................................281 Retard Torque Control.....................................................281 Wheel Slide Control.......................................................281 Resistor Grid Control.....................................................282 Chopper Voltage Control...................................................282 AUXILIARY BLOWER CONTROL......................................................282 EVENT PROCESSING..............................................................282 Event Detection...........................................................282 Power On Tests............................................................282 Initiated Tests...........................................................283 Periodic Tests............................................................283 EVENT RESTRICTIONS............................................................283 EVENT LOGGING AND STORAGE.....................................................283 Event History Buffer......................................................284 Data Packs................................................................284 To Record and Save a Data Pack to a Floppy Disk...........................284 Event Reset...............................................................285 SERIAL DATA COMMUNICATIONS....................................................286 PSC - TCI Communications processing.......................................286 PSC - PTU Communications Processing.......................................286 Inverter Communications Processing........................................286 OUTPUT PROCESSING.............................................................287 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS......................................287 Fast Start................................................................287 Engine Shutdown/Engine Not Running........................................287 Limp Home Mode............................................................287 Entering/Exiting Limp Home Mode...........................................287 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.....................................288 ELECTRONIC ACCELERATOR AND RETARD PEDALS......................................298 Removal...................................................................298 Installation..............................................................298 Disassembly...............................................................298 Assembly..................................................................298 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX....................299 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.....................................301 AC DRIVE SYSTEM MAINTENANCE...................................................301 TRUCK SHUTDOWN PROCEDURES.....................................................301 NORMAL TRUCK SHUTDOWN PROCEDURE...............................................302 SHUTDOWN AFTER SYSTEM FAILURE.................................................303 SYSTEM CHECKOUT...............................................................304 Battery and Control Checks of System WITH Battery Power OFF...............304 Battery and Control Circuit Checks of System With Battery Power ON........307 Checks with Key Switch OFF................................................308 CPU Battery Checks........................................................310 MEMORY BACKUP BATTERY REPLACEMENT.............................................310 TCI PROGRAMMING...............................................................311 PSC PROGRAMMING...............................................................311 INVERTER PROGRAMMING..........................................................312 TCI CHECKOUT..................................................................312 Modular Mining Communication Port.........................................313 TCI Input Checks..........................................................314 TCI Digital Output Tests..................................................316 TCI Digital Input Tests...................................................318 PSC Checkout Procedure....................................................320 PSC Digital Input Checks..................................................324 Miscellaneous Checks......................................................325 A3PV Panel................................................................325 LINKV Panel...............................................................325 Thermistor Checks.........................................................325 17FM384 Panel Check.......................................................325 Pedal Percentages and Meter Calibration...................................326 Meter Calibration Procedure...............................................326 Reprogram With Serial Numbers and Pedal Percentages.......................328 LOAD TESTING..................................................................330 Preload Checks............................................................330 ADDITIONAL TRUCK CHECKS.......................................................332 On-Board Load Testing.....................................................334 Preparation...............................................................334 Initiate Loadbox Test.....................................................337 Manual Offset HP Output Adjustment........................................339 TROUBLESHOOTING...................................................................341 PVM Optimum Load Curve Handshaking Troubleshooting............................341 MISCELLANEOUS COMPONENT REPAIR................................................342 Troubleshooting Phase Modules and Chopper Modules.........................342 Phase Module Removal and Snubber Resistor Replacement.....................342 Snubber Resistor Installation.............................................343 Phase Module Installation.................................................343 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING..............................344 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING..............................347 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING......................................348 IGBT TROUBLESHOOTING..........................................................349 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX........................................351 SECTION G2 - TIRES AND RIMS - INDEX...................................................353 TIRES AND RIMS....................................................................355 WHEEL STUD MAINTENANCE........................................................356 FRONT TIRES AND RIMS..........................................................357 Removal...................................................................357 Installation..............................................................358 REAR TIRES AND RIMS...........................................................359 Removal...................................................................359 Installation..............................................................360 RIM...........................................................................361 Tire Removal..............................................................361 Tire Installation.........................................................362 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX......................................365 FRONT WHEEL HUB AND SPINDLE.......................................................367 WHEEL HUB AND SPINDLE ASSEMBLY................................................367 Preparation...............................................................367 Removal...................................................................367 Installation - Wheel Hub and Spindle Assembly.............................370 Disassembly - Wheel Hub and Spindle Assembly..............................371 Cleaning and Inspection - Wheel Hub and Spindle Assembly..................371 Assembly - Wheel Hub and Spindle Assembly.................................373 Wheel Bearing Adjustment:.................................................373 Brake Installation........................................................374 Seal Assembly Gap Check...................................................375 STEERING CYLINDERS AND TIE ROD................................................376 Spherical Bearing Wear Limits.............................................376 Removal - Steering Cylinder and Tie Rod...................................377 Installation - Steering Cylinder and Tie Rod..............................378 Bearing Replacement.......................................................378 TOE-IN ADJUSTMENT.............................................................379 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX.....................................381 REAR AXLE HOUSING ATTACHMENT......................................................383 PIVOT PIN.....................................................................383 Removal...................................................................383 Installation..............................................................383 PIVOT EYE BEARING.............................................................384 Disassembly...............................................................384 Assembly..................................................................384 PIVOT EYE REPAIR..............................................................385 Removal...................................................................385 Disassembly...............................................................385 Assembly..................................................................385 Installation..............................................................385 ANTI-SWAY BAR.................................................................386 Removal...................................................................386 Installation..............................................................386 Disassembly...............................................................386 Cleaning and Inspection...................................................386 Assembly..................................................................386 SECTION G5 - REAR AXLE HOUSING - INDEX................................................387 REAR AXLE HOUSING.................................................................389 REAR AXLE HOUSING.............................................................389 Preparation...............................................................389 Removal...................................................................389 Cleaning and Inspection - Rear Axle Housing...............................391 Installation - Rear Axle Housing..........................................391 WHEEL MOTOR...................................................................392 Preparation...............................................................392 Removal...................................................................392 Cleaning and Inspection - Wheel Motor.....................................393 Installation - Wheel Motor................................................394 WHEEL MOTOR GEAR OIL..........................................................397 Filtering Requirements....................................................397 Particle Size Analysis....................................................397 Flushing..................................................................397 Oil Sample Analysis.......................................................398 ELEMENT SPECIFICATION CHARTS..................................................399 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................403 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................405 FRONT SUSPENSION..................................................................407 Removal.......................................................................407 Installation - Front Suspension...............................................408 "Turn-Of-The-Nut" Tightening Procedure........................................411 MINOR REPAIRS (LOWER BEARING & SEALS).........................................412 Removal - Bearing Retainer................................................412 Installation - Bearing Retainer...........................................412 MAJOR SUSPENSION REBUILD......................................................414 Disassembly...............................................................414 Assembly..................................................................414 SECTION H3 - REAR SUSPENSIONS - INDEX.................................................417 REAR SUSPENSIONS..................................................................419 Removal.......................................................................419 Installation - Rear Suspension................................................421 Disassembly - Rear Suspension.................................................422 Cleaning and Inspection - Rear Suspension.....................................422 Assembly - Rear Suspension....................................................422 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX.........................425 SUSPENSION OILING AND CHARGING PROCEDURE..........................................427 GENERAL.......................................................................427 EQUIPMENT LIST................................................................427 Hydrair® Charging Kit.....................................................427 Installation of Charging Kit..............................................427 Removal of Charging Kit...................................................428 Support Blocks For Oiling And Charging Dimensions.........................428 FRONT SUSPENSION..............................................................429 Front Suspension Oiling...................................................429 Front Suspension Nitrogen Charging........................................430 REAR SUSPENSION...............................................................431 Rear Suspension Oiling....................................................431 Rear Suspension Nitrogen Charging.........................................432 OIL AND NITROGEN SPECIFICATIONS CHART.............................................434 SECTION J - BRAKE CIRCUIT - INDEX.........................................................435 SECTION J2 - BRAKE CIRCUIT - INDEX....................................................437 BRAKE CIRCUIT.....................................................................439 SERVICE BRAKE CIRCUIT.........................................................439 SECONDARY BRAKING AND AUTOMATIC APPLY.........................................441 PARKING BRAKE CIRCUIT.........................................................441 BRAKE LOCK CIRCUIT............................................................442 WARNING CIRCUIT...............................................................442 Rear Axle Brake Lines.....................................................444 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX..................................445 BRAKE CIRCUIT COMPONENT SERVICE...................................................447 BRAKE VALVE...................................................................447 Rebuild Criteria..........................................................447 Removal...................................................................448 Installation..............................................................448 DISASSEMBLY...................................................................449 Cleaning and Inspection...................................................452 ASSEMBLY......................................................................452 Actuator Base Threaded Inserts............................................452 Boot and Cap..............................................................452 Valve Body Seal Installation..............................................452 Regulator Sleeve O-ring Installation......................................453 Actuator Plunger O-ring Installation......................................453 Assembly of Valve.........................................................453 DIFFERENTIAL PRESSURE SWITCH..................................................455 Disassembly...............................................................455 Cleaning and Inspection...................................................455 Assembly..................................................................455 VALVE BENCH TEST AND ADJUSTMENT...............................................456 Test Set Up Procedure.....................................................457 Brake Valve Output Pressure Adjustment....................................457 Differential Pressure Switch Adjustment...................................457 Final Test and Adjustment.................................................458 Installation Of Brake Pedal Actuator Assembly to Brake Valve..............459 Installation of Retard Pedal To Brake Pedal...............................459 DUAL RELAY VALVE..............................................................461 Removal...................................................................461 Installation..............................................................461 Disassembly...............................................................463 Cleaning and Inspection...................................................463 Assembly..................................................................463 DIFFERENTIAL PRESSURE SWITCH..................................................464 Disassembly...............................................................464 Cleaning and Inspection...................................................464 Assembly..................................................................464 VALVE TEST AND ADJUSTMENT.....................................................465 Test Set Up Procedure.....................................................466 Brake Valve Output Pressure Adjustment....................................466 Differential Pressure Switch Adjustment...................................467 BRAKE MANIFOLD................................................................468 Removal...................................................................468 Installation..............................................................469 Disassembly...............................................................469 Cleaning and Inspection...................................................469 Assembly..................................................................469 HYDRAULIC BRAKE ACCUMULATORS..................................................470 Brake Accumulator Bleed Down Procedure....................................470 ACCUMULATORS - HYDRAULIC COMPONENT CABINET....................................470 Removal...................................................................470 Installation..............................................................470 Disassembly...............................................................470 Cleaning and Inspection...................................................472 Assembly..................................................................472 BLADDER ACCUMULATOR CHARGING PROCEDURE........................................474 Temperature During Precharge..............................................475 Precharge Maintenance.....................................................475 Accumulator Storage Procedures............................................476 Bladder Storage Procedures................................................477 ACCUMULATORS - FRAME MOUNTED..................................................477 Removal...................................................................477 Installation..............................................................477 Disassembly...............................................................479 Cleaning and Inspection...................................................479 Assembly - Accumulator....................................................480 Accumulator Testing.......................................................480 ACCUMULATOR CHARGING PROCEDURE................................................481 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)..................................482 Removal.......................................................................482 Installation..................................................................482 Disassembly and Adjustment....................................................482 Potentiometer Check...........................................................484 Assembly......................................................................484 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................485 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................487 EQUIPMENT REQUIRED............................................................489 INITIAL SYSTEM SET-UP.........................................................490 BRAKE SYSTEM CHECKOUT.........................................................491 Failure Modes Check-Out...................................................492 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.....................................495 CHECK-OUT PROCEDURE...............................................................499 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX..........................................501 WET DISC BRAKE ASSEMBLY...........................................................503 OPERATION.....................................................................503 MAINTENANCE...................................................................504 Brake Disc Wear Indicator.................................................504 Removal/Installation - Wet Disc Brake Assembly............................504 BRAKE REBUILD.................................................................506 Disassembly...............................................................506 Cleaning and Inspection...................................................509 Assembly..................................................................510 Floating Ring Seal Assembly/Installation..................................513 WET DISC BRAKE BLEEDING PROCEDURE.............................................516 SECTION J7 - PARKING BRAKE - INDEX....................................................517 PARKING BRAKE.....................................................................519 OPERATION.....................................................................519 MAINTENANCE...................................................................520 Inspection - Parking Brake................................................520 Removal - Parking Brake...................................................520 Installation - Parking Brake..............................................521 Disassembly - Parking Brake...............................................522 Cleaning and Inspection - Parking Brake...................................522 Assembly - Parking Brake..................................................522 PARKING BRAKE BLEEDING PROCEDURE..............................................524 SECTION L - HYDRAULIC SYSTEM - INDEX......................................................525 SECTION L2 - HYDRAULIC SYSTEM - INDEX.................................................527 HYDRAULIC SYSTEM..................................................................529 Hoist Circuit Operation.......................................................530 Steering Circuit Operation....................................................532 Disc Brake Cooling System.....................................................534 SECTION L3 - HYDRAULIC SYSTEM COMPONENTS REPAIR - INDEX...............................537 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................539 HOIST PUMP....................................................................539 Removal...................................................................539 Installation..............................................................541 Disassembly...............................................................542 Inspection of Parts.......................................................546 Assembly..................................................................546 TROUBLESHOOTING GUIDE (HOIST PUMP)................................................551 HYDRAULIC TANK................................................................552 Filling Instructions......................................................552 Removal - Hydraulic Tank..................................................552 Installation - Hydraulic Tank.............................................553 HYDRAULIC TANK STRAINERS......................................................553 Removal...................................................................553 Inspect and Clean.........................................................553 Installation..............................................................553 HYDRAULIC TANK BREATHERS......................................................554 SECTION L4 - STEERING CIRCUIT - INDEX.................................................555 STEERING CIRCUIT..................................................................557 STEERING CIRCUIT OPERATION....................................................557 COMPONENT DESCRIPTION.........................................................558 Steering Control Unit.....................................................558 Bleeddown Manifold Valve..................................................559 Bleeddown Solenoid........................................................559 Relief Valves.............................................................561 Hoist Limit Solenoid......................................................561 Accumulators..............................................................561 Low Precharge Warning Switch..............................................561 High Pressure Filters.....................................................561 Quick Disconnect Ports....................................................561 Flow Amplifier............................................................562 FLOW AMPLIFIER SYSTEM OPERATION...............................................564 No Steer..................................................................564 Steering Left.............................................................566 Steering Right............................................................568 No Steer, External Shock Load.............................................570 STEERING PUMP.................................................................572 Operation.................................................................572 High Altitude Operation...................................................572 PRINCIPLE OF OPERATION........................................................574 Full Pump Volume..........................................................574 Half Pump Volume..........................................................574 Neutral Position..........................................................574 ADDITIONAL STEERING PUMP INFORMATION..........................................575 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................577 STEERING CONTROL UNIT.............................................................579 Removal.......................................................................579 Installation..................................................................579 STEERING CONTROL UNIT REBUILD.................................................580 Disassembly...............................................................580 Cleaning and Inspection - Steering Control Unit...........................581 Assembly - Steering Control Unit..........................................583 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................587 STEERING CIRCUIT COMPONENT REPAIR.................................................589 BLEEDDOWN MANIFOLD VALVE......................................................589 Removal...................................................................589 Installation..............................................................589 ACCUMULATORS..................................................................590 Removal...................................................................590 Installation..............................................................590 Disassembly - Accumulators................................................591 Cleaning and Inspection - Accumulators....................................591 Assembly - Accumulators...................................................592 Testing - Accumulators....................................................592 STEERING ACCUMULATOR CHARGING PROCEDURE.......................................593 FLOW AMPLIFIER................................................................594 Removal...................................................................594 Installation..............................................................594 FLOW AMPLIFIER REBUILD........................................................594 Disassembly - Flow Amplifier..............................................596 Assembly - Flow Amplifier.................................................597 STEERING CYLINDERS............................................................598 Disassembly - Steering Cylinder...........................................599 Piston Seal & Bearing Installation........................................599 Assembly - Steering Cylinder..............................................599 Test - Steering Cylinder..................................................599 STEERING AND BRAKE PUMP.......................................................600 Removal...................................................................600 Installation..............................................................600 Disassembly - Steering and Brake Pump.....................................602 Control Piston Group......................................................602 Valve Plate Group.........................................................602 Rotating Group............................................................605 Swashblock Group..........................................................605 Driveshaft Group..........................................................605 Inspection - Steering and Brake Pump......................................605 Control Piston Group......................................................605 Valve Plate Group.........................................................605 Rotating Group............................................................605 Swashblock Group..........................................................607 Driveshaft Group..........................................................608 Compensator Block and Unloader Module.....................................608 Stroke Adjuster Assembly..................................................608 Assembly - Steering and Brake Pump........................................608 Swashblock Group..........................................................608 Driveshaft Group..........................................................609 Rotating Group............................................................609 Control Piston Group......................................................609 Valve Plate Group.........................................................610 TROUBLESHOOTING CHART.............................................................611 SECTION L7 - HOIST CIRCUIT - INDEX....................................................617 HOIST CIRCUIT.....................................................................619 HOIST CIRCUIT OPERATION.......................................................619 COMPONENT DESCRIPTION.........................................................620 Hydraulic Tank............................................................620 Hydraulic Pump............................................................620 High Pressure Filters.....................................................620 Hoist Valve...............................................................620 Inlet Sections - Hoist Valve..............................................620 Spool Sections - Hoist Valve..............................................621 Hoist Pilot Valve.........................................................621 Bleeddown Manifold........................................................622 Hoist-up Limit Solenoid...................................................622 Pilot Operated Check Valve................................................622 Overcenter Manifold.......................................................622 HOIST CIRCUIT OPERATION...........................................................623 Float Position Of Pilot Valve With Truck Body On Frame........................624 Power Up Operation............................................................626 Hold Operation................................................................628 Power Down Operation..........................................................630 Float Operation...............................................................632 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...................................635 HOIST CIRCUIT COMPONENT REPAIR....................................................637 HOIST VALVE...................................................................637 Removal - Hoist Valve.....................................................637 Installation - Hoist Valve................................................638 O-Ring Replacement........................................................638 INLET SECTION.................................................................639 Disassembly - Inlet Section...............................................639 Cleaning and Inspection - Inlet Section...................................640 Assembly - Inlet Section..................................................640 REAR SPOOL SECTION (Work Ports)...............................................640 Disassembly - Rear Spool Section..........................................640 Cleaning and Inspection - Rear Spool Section..............................642 Assembly - Rear Spool Section.............................................642 FRONT SPOOL SECTION (Tank Ports)..............................................643 Disassembly...............................................................643 Cleaning and Inspection...................................................643 Assembly..................................................................643 HOIST PILOT VALVE.............................................................645 Removal - Hoist Pilot Valve...............................................645 Installation - Hoist Pilot Valve..........................................645 Disassembly - Hoist Pilot Valve...........................................646 Cleaning and Inspection - Hoist Pilot Valve...............................647 Assembly - Hoist Pilot Valve..............................................647 HOIST CYLINDERS...............................................................648 Removal - Hoist Cylinder..................................................648 Installation - Hoist Cylinder.............................................649 Disassembly - Hoist Cylinder..............................................651 Cleaning and Inspection - Hoist Cylinder..................................652 Assembly - Quill And Cylinder.............................................653 Installation - Quill......................................................653 Installation - Check Balls And Plugs In Quill.............................654 Assembly - Hoist Cylinder.................................................655 DISABLED TRUCK DUMPING PROCEDURE..............................................656 Hookup....................................................................656 DUMPING PROCEDURE.........................................................656 Raising the Body..........................................................656 Lowering the Body.........................................................656 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.........................................657 HYDRAULIC SYSTEM FILTERS..........................................................659 HOIST CIRCUIT FILTER..........................................................659 Filter Element Replacement................................................659 Removal - Hoist Circuit Filter............................................660 Installation - Hoist Circuit Filter.......................................660 Indicator Switch - Hoist Circuit Filter...................................660 STEERING CIRCUIT FILTER.......................................................661 Filter Element Replacement................................................661 Removal - Steering Circuit Filter.........................................662 Installation - Steering Circuit Filter....................................662 Indicator Switch - Steering Circuit Filter................................662 INDICATOR SWITCH..............................................................662 Test Procedure............................................................662 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...................................665 HYDRAULIC CHECK-OUT PROCEDURE.....................................................667 GENERAL INFORMATION...........................................................667 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.............................667 Equipment Requirements....................................................668 Pump Pressure Control Adjustments.........................................668 Steering Control Unit and Flow Amplifier Leakage Test.....................669 Bleeddown Manifold Leakage Test...........................................669 Steering/Brake Pump Stroke Adjustment.....................................670 Shock And Suction Valves..................................................671 Equipment Requirements....................................................671 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.................672 Equipment Requirements....................................................672 Pressure Checks...........................................................672 Brake Cooling Circuit Test................................................672 Power Up Relief Pressure Test.............................................673 Adjustment................................................................673 Power Down Relief Pressure Test...........................................674 Adjustment................................................................674 Hoist Counterbalance Valve Adjustment Preparation.........................675 Counterbalance Valve Pressure Check.......................................675 Counterbalance Valve Adjustment...........................................676 HYDRAULIC SYSTEM FLUSHING PROCEDURE...............................................677 Preparation...................................................................677 Flushing Procedure............................................................677 Filter Element Replacement....................................................678 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.............................679 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................680 SECTION M - OPTIONS AND SPECIAL TOOLS - INDE..............................................681 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX.............................................683 FIRE CONTROL SYSTEM (MANUAL)......................................................685 Operation.....................................................................685 Inspection and Maintenance....................................................685 Recharging Procedures.........................................................686 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1......................687 Control Module................................................................687 Actuator......................................................................688 Linear Detection Wire.........................................................688 Power Wire....................................................................688 Test Kit......................................................................688 Squib.........................................................................688 Securing the Detection Wire...................................................689 Preliminary Test Before Final Hook-Up.........................................689 Installation Procedure for Squib..............................................691 Placing the Electric Detection & Actuation System Into Service................691 INSPECTION AND MAINTENANCE SCHEDULES..........................................692 Daily.....................................................................692 Normal Maintenance Based On Actual Operating Hours........................692 IN CASE OF FIRE...............................................................693 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.....................................695 SECTION M8 - SPECIAL TOOLS............................................................697 SECTION M20 - PAYLOAD METER II - ON BOARD WEIGHING INDEX..............................703 GENERAL INFORMATION...............................................................705 Haul Cycles...................................................................705 LIGHTS, SWITCHES AND COMPONENTS...................................................706 TIPS FOR OPERATION................................................................707 EXTERNAL DISPLAY LIGHTS...........................................................707 THEORY OF OPERATION...............................................................708 Basic Description.............................................................708 Inclinometer..................................................................708 Linkage Factor................................................................708 Gain Factor...................................................................709 Brake Lock....................................................................709 Sources of Error..............................................................709 Typical Data From Service Check Mode..........................................709 Example Calculation of Payload................................................710 Viewing Payload Calculation Inputs............................................710 Checking the Gain.............................................................711 Adjusting the Gain............................................................711 TYPES OF DATA STORED..............................................................712 Cycle Data....................................................................712 Engine ON/OFF Data............................................................713 Fault Codes and Warning Data..................................................713 Engine Operation..............................................................714 Total Payload and Total Number of Cycles......................................714 Other Data....................................................................714 OPERATOR FUNCTIONS................................................................715 Using the Operator Load Counter...............................................715 Viewing the Operator Load Counter.............................................715 Clearing the Operator Load Counter............................................715 Dimming the Lights on the Display.............................................715 INITIAL SETUP OF PAYLOAD METER....................................................716 Switch Settings...............................................................716 Checking the Operator Check Mode..............................................717 Checking the Service Check Mode...............................................717 Checking the Gt setting:......................................................718 Checking the Inclinometer Settings............................................718 Calibrating a Truck...........................................................718 DISPLAYS AT START-UP..............................................................719 Normal Operation..............................................................719 SETUP AND MAINTENANCE.............................................................720 Setting The Speed Limit.......................................................720 Setting the Option Code.......................................................720 Setting The Machine I.D. Code.................................................721 Setting The Operator I.D. Code................................................721 Setting The Time and Date.....................................................721 DOWNLOAD OF INFORMATION...........................................................722 DISPLAY OF FAULT CODES............................................................722 Monitoring Input Signals......................................................726 Service Check Mode............................................................726 UP FACTOR - PAYLOAD CALCULATION GAIN..............................................727 PL MODE -LOAD CALCULATION TIMING..................................................727 FINAL GEAR RATIO SELECTION........................................................728 BATTERY REPLACEMENT PROCEDURE.....................................................729 Replacing the Battery.........................................................729 After Replacing the Battery...................................................730 SUSPENSION PRESSURE SENSOR........................................................730 Removal.......................................................................730 Installation..................................................................731 INCLINOMETER......................................................................731 Removal.......................................................................731 Installation..................................................................731 Adjustment....................................................................731 PAYLOAD METER BACK PANEL..........................................................732 CONNECTIONS.......................................................................733 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.....................................734 PAYLOAD CIRCUIT NUMBERS...........................................................735 TROUBLESHOOTING...................................................................736 COMMON PROBLEMS...............................................................736 Suspension Charging.......................................................736 Symptom Table.............................................................737 Missing Body-Up Signal....................................................737 Missing Speed Signal......................................................738 F-18: Alternator R-Terminal, Oil Pressure Signals.........................738 Shorted 18v Sensor Power Supply (930E)....................................738 FAULT TREE DIAGNOSIS..........................................................739 Payload Lights Won't Illuminate...........................................739 Red, Amber or Green Payload Light Does Not Illuminate.....................740 Cannot Download - PC Communications.......................................741 PC Communications Configuration...........................................742 F.CAL: Payload Meter Won't Calibrate......................................743 F-20: Sensor Power Fault..................................................744 F-21, F-25: Left Front Pressure Sensor....................................746 F-22, F-26: Right Front Pressure Sensor...................................746 F-23, F-27: Left Rear Pressure Sensor.....................................746 F-24, F-28: Right Rear Pressure Sensor....................................746 F-31, F-32: Inclinometer..................................................748 Body Up Input.............................................................750 Brake Lock Input..........................................................751 Speed Signal..............................................................752 Adjusting the Speed Sensor................................................752 CONNECTORS AND PRESSURE SENSORS...............................................754 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.......................................757 Menu Functions................................................................760 Using Scope...................................................................760 Log File Information..........................................................760 Connections to Payload Meter II™..............................................761 USING SCOPE.......................................................................762 Monitoring Inputs Using Scope.................................................762 Monitoring Suspension Charging Using Scope....................................762 Pressure Sensor Dummy Loads...................................................765 GAIN ADJUSTMENT WORKSHEET.........................................................766 SECTION N - CAB COMPONENTS - INDEX........................................................767 SECTION N2 - TRUCK CAB - INDEX........................................................769 TRUCK CAB.........................................................................771 Description...................................................................771 Preparation...................................................................772 Removal - Cab.................................................................772 Installation - Cab............................................................774 CAB DOOR......................................................................774 Removal...................................................................774 Installation..............................................................774 Door Adjustment...........................................................775 Door Jamb Bolt Adjustment.................................................775 Door Handle Plunger Adjustment............................................776 Door Glass Replacement....................................................777 Door Window Regulator Replacement.........................................781 Door Handle or Latch Assembly Replacement.................................781 Door and Door Hinge Seal Replacement......................................782 Door Opening Seal Removal.................................................782 Installation..............................................................782 GLASS REPLACEMENT.............................................................783 Adhesive Bonded Windows...................................................783 Replacement Procedure.....................................................783 Windshield And Rear Glass.................................................784 Removal...................................................................784 Installation..............................................................785 SECTION N3 - CAB COMPONENTS - INDEX...................................................787 CAB COMPONENTS....................................................................789 WINDSHIELD WIPERS.............................................................789 Wiper Motor Replacement...................................................789 Removal...................................................................789 Installation..............................................................789 Wiper Arm Replacement.....................................................789 Removal...................................................................789 Installation..............................................................790 Wiper Linkage Replacement.................................................790 Removal...................................................................790 Installation..............................................................790 WINDSHIELD WASHER.............................................................791 Operation.................................................................791 Service...................................................................791 OPERATOR SEAT.................................................................792 Adjustment................................................................792 Removal...................................................................792 Installation..............................................................792 SECTION N4 - OPERATOR COMFORT - INDEX.................................................793 OPERATOR COMFORT..................................................................795 HEATER/AIR CONDITIONER........................................................795 Operation.................................................................795 HEATER COMPONENTS.............................................................796 Circuit Breakers..........................................................796 Heater Control Components.................................................796 Heater Coil...............................................................796 Fan Motor And Speed Control...............................................797 Actuators.................................................................797 Filter Service............................................................797 AIR CONDITIONING SYSTEM...........................................................799 Environmental Impact..........................................................799 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................800 PRINCIPLES OF REFRIGERATION...................................................800 Air Conditioning..........................................................800 Refrigeration - The Act Of Cooling........................................801 The Refrigeration Cycle...................................................801 AIR CONDITIONER SYSTEM COMPONENTS.............................................802 Compressor (Refrigerant Pump).............................................802 Service Valves............................................................802 Condenser.................................................................802 Receiver-Drier............................................................802 Expansion Block Valve.....................................................803 Accumulator...............................................................803 Evaporator................................................................803 ELECTRICAL CIRCUIT............................................................804 Thermostat................................................................804 Compressor Clutch.........................................................804 Trinary™ Switch...........................................................805 SYSTEM SERVICING..............................................................806 SERVICE TOOLS AND EQUIPMENT...................................................807 Recovery/Recycle Station..................................................807 Leak Detector.............................................................807 Service Valves............................................................808 Vacuum Pump...............................................................808 Manifold Gauge Set........................................................809 Installing Manifold Gauge Set.............................................810 Purging Air From Service Hoses............................................810 SYSTEM PERFORMANCE TEST.......................................................811 SYSTEM OIL....................................................................812 Handling and Reusing PAG Oil..............................................812 Oil Quantity..............................................................812 Checking System Oil.......................................................812 REFRIGERANT...................................................................813 Recycled Refrigerant......................................................813 Reclaimed Refrigerant.....................................................813 Refrigerant Quantity......................................................813 R-134a Refrigerant Containers.............................................813 SYSTEM LEAK TESTING...........................................................814 Electronic Leak Detector..................................................814 Tracer Dyes...............................................................814 Soap and Water............................................................814 RECOVERING AND RECYCLING THE REFRIGERANT......................................815 Performing the Recovery Cycle.............................................815 Performing the Recycling Procedure........................................815 Evacuating and Charging the A/C System....................................815 SYSTEM REPAIR.................................................................816 System Flushing...........................................................816 COMPONENT REPLACEMENT.........................................................816 Hoses and Fittings........................................................816 Lines.....................................................................816 Expansion Valve...........................................................817 Receiver-Drier............................................................817 Thermostat................................................................817 Compressor................................................................817 Accumulator...............................................................817 Clutch....................................................................818 Servicing the Compressor Clutch...........................................818 Pulley Removal............................................................820 Clutch Coil Check.........................................................821 Pulley Installation.......................................................821 Clutch Assembly Installation..............................................821 EVACUATING THE SYSTEM.........................................................823 CHARGING THE A/C SYSTEM.......................................................825 TROUBLESHOOTING...................................................................826 Preliminary Checks............................................................826 Diagnosis Of Gauge Readings And System Performance............................826 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................827 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................833 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................835 OPERATOR CAB CONTROLS.............................................................837 STEERING COLUMN...............................................................837 Removal...................................................................837 Installation..............................................................837 STEERING WHEEL AND CONTROLS...................................................839 Horn Button...............................................................839 Telescope Lock Ring.......................................................839 Tilt Wheel Lever..........................................................839 Turn Signal / Headlight Dimmer............................................839 DYNAMIC RETARDING.............................................................839 Retarder Control Lever....................................................840 Dynamic Retarder /Service Brake Pedal.....................................840 Accelerator (Throttle) Pedal..............................................840 Starting on a Grade With a Loaded Truck...................................840 GRADE/SPEED RETARD CHART......................................................841 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.............................842 Defroster Control Switch..................................................842 Outside/Inside Air Control Switch.........................................842 Heat Vent Control Switch..................................................842 Temperature Control Knob..................................................842 Fan Control Knob..........................................................842 Heater/Air Conditioner Selector Switch....................................842 Heater/Air Conditioner Vents..............................................842 INSTRUMENT PANEL..............................................................843 OVERHEAD PANEL AND DISPLAYS...................................................843 CENTER CONSOLE................................................................844 F-N-R Selector Switch.....................................................844 Hoist Control Lever.......................................................845 To Raise dump body:.......................................................845 To lower body:............................................................845 Ash Tray..................................................................845 Lighter...................................................................845 L.H. Window Control Switch................................................845 R.H. Window Control Switch................................................845 Engine Shutdown Switch....................................................845 Override/Fault Reset Switch...............................................846 Retard Speed Control (RSC) "Off/On" Switch................................846 Retard Speed Control (RSC) Adjust Dial....................................846 PSC Download Port.........................................................847 Engine Diagnostics Download Port..........................................847 Engine Control System.....................................................847 TCI Download Port.........................................................847 Passenger Seat............................................................847 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................849 Control Symbols...............................................................849 INSTRUMENT PANEL (Figure 5-6).................................................849 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)...............................851 Key Switch....................................................................851 Starting......................................................................851 Cold Weather Starting.........................................................851 Normal Engine Shutdown........................................................851 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................852 Operation.....................................................................852 Fog Lights (Optional).........................................................852 Ladder Light Switch...........................................................852 Manual Backup Switch..........................................................852 Panel Illumination Lights.....................................................853 Cab Air Conditioner/Heater Vents..............................................853 Rotating Beacon Light Switch (Optional).......................................853 Heated Mirror Switch (Optional)...............................................853 Wheel Brake Lock Control......................................................853 Parking Brake Control.........................................................853 Tachometer....................................................................854 Right Turn Signal Indicator...................................................854 High Beam Indicator...........................................................854 Left Turn Signal Indicator....................................................854 Speedometer...................................................................854 Voltmeter.....................................................................854 Engine Oil Pressure Gauge.....................................................854 Water Temperature Gauge.......................................................854 Fuel Gauge....................................................................854 AC Drive System Temperature Gauge.............................................855 Hydraulic Oil Temperature Gauge...............................................855 Hourmeter.....................................................................855 Rest Switch...................................................................855 Light Switch..................................................................856 Windshield Wiper and Washer...................................................856 Panel Light Dimmer............................................................856 STATUS / WARNING INDICATOR LIGHT SYMBOLS..........................................858 Hazard Warning Lights.........................................................863 Lamp Test Switch..............................................................863 Link-On Warning Light.........................................................863 SECTION P - LUBRICATION AND SERVICE -INDEX................................................865 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................867 LUBRICATION AND SERVICE...........................................................869 930E SERVICE CAPACITIES.......................................................869 HYDRAULIC TANK SERVICE........................................................869 Adding Oil................................................................869 WHEEL MOTOR SERVICE...........................................................869 COOLANT LEVEL CHECK...........................................................870 RADIATOR FILLING PROCEDURE....................................................870 RESERVE ENGINE OIL SYSTEM (Optional)..........................................870 Reserve Oil Tank Filling Procedure (Remote fill)..........................870 LUBRICATION CHART.............................................................871 10 HOUR (DAILY) INSPECTION....................................................872 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................875 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................876 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................877 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................880 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................881 5000 HOUR MAINTENANCE CHECKS..................................................882 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.....................................883 AUTOMATIC LUBRICATION SYSTEM......................................................885 GENERAL DESCRIPTION...........................................................885 SYSTEM COMPONENTS.............................................................887 SYSTEM OPERATION..............................................................888 Normal Operation..........................................................888 Pressure Failure Detection Circuits.......................................889 INJECTOR OPERATION............................................................890 GENERAL INSTRUCTIONS..............................................................891 LUBRICANT REQUIREMENTS........................................................891 System Priming................................................................891 LUBRICANT PUMP................................................................891 Pump Housing Oil Level....................................................891 Pump Pressure Control.....................................................891 Pressure Control Valve Adjustment.........................................891 INJECTORS (SL-1 Series “H”))..................................................892 Injector Specifications...................................................892 Injector Adjustment.......................................................892 SYSTEM CHECKOUT...............................................................892 Lubrication Cycle Timer Check.............................................893 Lubrication Cycle Timer Adjustment........................................893 FILTER ASSEMBLY...............................................................893 PUMP REBUILD..................................................................894 Disassembly...............................................................894 Cleaning and Inspection...................................................894 Assembly..................................................................896 SYSTEM TROUBLESHOOTING CHART......................................................897 PREVENTATIVE MAINTENANCE PROCEDURES...............................................900 Daily Lubrication System Inspection...........................................900 250 Hour Inspection...........................................................900 1000 Hour Inspection..........................................................900 SECTION Q ALPHABETICAL INDEX..............................................................901 SECTION R.................................................................................905 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH351..............................................907 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH352..............................................908 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH347..................................909 LIGHTING AND CONTROL WIRING - EJ2145..................................................910 ELECTRICAL WIRING SCHEMATIC - EJ2146..................................................926
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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