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Komatsu 930E-2 Dump Truck Shop Manual SN A30246-A30254 – PDF DOWNLOAD
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Komatsu 930E-2 Dump Truck Shop Manual
Book Code: CEBM008003
SERIAL NUMBERS A30246 – A30254
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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: A30246-A30254
Language: English
Book Code: CEBM008003
Pages: 934
File Format: Portable Document Format (PDF)
KOMATSU 930E-2 DUMP TRUCK SHOP MANUAL SN A30246-A30254 – 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, warnings 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 information. 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 U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% 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 Truck Model designation consists of three numbers and one letter (i.e. 930E). 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 information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or 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 - 24VDC 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 Isolation Diodes..........................................................181 Battery Disconnect Switches...............................................182 24VDC Auxiliary Battery Connectors........................................182 Battery Equalizer.........................................................182 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 - INDEX.............................................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 TROUBLE: Detonated Squib......................................................695 SECTION M8 - SPECIAL TOOLS............................................................697 SECTION M20 - PAYLOAD METER III - INDEX...............................................703 OPERATION SECTION.................................................................707 Introduction..................................................................707 Data Summary..............................................................707 Data Gathering............................................................707 COMPONENT DESCRIPTION.........................................................708 System Diagram............................................................708 Suspension Pressure Sensors...............................................708 Inclinometer..............................................................708 Operator Display..........................................................708 Operator Switch...........................................................709 Speed Input...............................................................709 Body-Up Switch............................................................709 Brake Lock Switch.........................................................709 Payload Meter.............................................................709 Communications Ports......................................................709 Keyswitch Input...........................................................710 Payload Meter Power.......................................................710 Load Lights...............................................................710 Wiring and Termination....................................................711 TCI Outputs...............................................................711 OPERATOR’S DISPLAY AND SWITCH.................................................712 Reading the Speedometer...................................................712 Reading the Load Display..................................................712 Using the Operator ID.....................................................712 Using the Load and Ton Counter............................................712 Total Ton Counter.........................................................712 Total Load Counter........................................................713 Clearing the Counters.....................................................713 Viewing Live Sensor Data..................................................713 Other Display Messages....................................................713 PAYLOAD OPERATION & CALCULATION...............................................714 Description of Haul Cycle States..........................................714 Haul Cycle Description....................................................714 Load Calculation..........................................................715 Carry Back................................................................715 Measurement Accuracy......................................................715 SOURCES FOR PAYLOAD ERROR.....................................................715 Payload Error.............................................................715 Loading Conditions........................................................716 Pressure Sensors..........................................................716 Swingloads................................................................716 Speed and Distance........................................................716 HAUL CYCLE DATA...............................................................716 Haul Cycle Data...........................................................717 Haul Cycle Warning Flags..................................................718 M: Haul Cycle Too Long....................................................719 N: Sensor Input Error.....................................................719 Frame Torque Data.........................................................719 Sprung Weight Data........................................................719 Maximum Speed Data........................................................719 Alarm Records.............................................................719 Fault Code Data...........................................................720 PC SOFTWARE OVERVIEW..........................................................721 PC Overview...............................................................721 System Configuration......................................................721 Installing the PLMIII Software............................................721 DOWNLOADING DATA..............................................................722 PLM III SYSTEM CONFIGURATION..................................................723 Starting Communications...................................................723 Displayed Payload Units...................................................723 Time Units................................................................723 Connection Menu...........................................................723 Connecting to the Payload Meter...........................................724 Configure the Payload Meter...............................................724 Setting the Date and Time.................................................724 Setting the Truck Type....................................................725 Setting the Gauge Display Units...........................................725 Setting the Frame Serial Number...........................................725 Setting the Truck Number..................................................725 Setting the Komatsu Distributor...........................................725 Setting the Komatsu Customer..............................................725 Clean Truck Tare..........................................................726 Inclinometer Calibration..................................................726 DATA ANALYSIS.................................................................727 Creating a Query..........................................................727 Sorting on Truck Unit Number..............................................727 Sorting on Truck Type.....................................................727 Sorting on Date Range.....................................................728 Sorting on Time Range.....................................................728 Payload Detail Screen.....................................................729 Creating Reports..........................................................729 Summary - one page report.................................................730 Detailed - multi-page report..............................................730 Creating Graphs...........................................................731 Exporting Data............................................................731 CSV Export................................................................731 Compressed................................................................732 Importing Data............................................................733 Deleting Haul Cycle Records...............................................733 Viewing Alarms............................................................734 Deleting Alarm Records....................................................734 TROUBLESHOOTING SECTION...........................................................735 TROUBLESHOOTING...............................................................735 Viewing Active Alarms.....................................................735 Real-Time Data Display....................................................735 Testing the Payload Lights................................................735 Creating Log Files of Inputs..............................................736 Daily Inspections.........................................................736 Periodic Maintenance......................................................736 Abnormal Displays at Power-Up.............................................737 No Payload Display When Keyswitch is Turned ON............................738 No Display on Speedometer.................................................739 No Display on Operator Display............................................739 No Communications With PC.................................................740 Load Lights Don’t Light During Loading....................................741 Load Lights Remain ON.....................................................742 Load Lights Remain ON During Dumping......................................742 Display Doesn't Clear When The Load Is Dumped.............................742 Calibration Problems......................................................743 Alarm 1 - Left Front Pressure High........................................744 Alarm 2 - Left Front Pressure Low.........................................744 Troubleshoot Wiring to Left Front Suspension..............................744 Alarm 3 - Right Front Pressure High.......................................745 Alarm 4 - Right Front Pressure Low........................................745 Troubleshoot Wiring to Right Front Suspension.............................745 Alarm 5 -Left Rear Pressure High..........................................746 Alarm 6 - Left Rear Pressure Low..........................................746 Troubleshoot Wiring to Left Rear Suspension...............................746 Alarm 7 - Right Rear Pressure High........................................747 Alarm 8 - Right Rear Pressure Low.........................................747 Troubleshoot Wiring to Right Rear Suspension..............................747 Alarm 9 - Inclinometer High...............................................748 Alarm 10 - Inclinometer Low...............................................748 Troubleshoot Inclinometer Wiring..........................................748 Alarm 13 - Body Up Input Failure..........................................749 Alarm 16 - Memory Write Failure...........................................750 Alarm 17 - Memory Read Failure............................................750 Alarm 18..................................................................751 Alarm 19..................................................................751 Alarm 22..................................................................751 Operator Switch Doesn't Work..............................................752 Alarm 26 - User Switch Fault - SELECT.....................................752 Alarm 27 - User Switch Fault - SET........................................752 Connector Map.............................................................753 Connectors................................................................754 PLMIII CHECK OUT PROCEDURE........................................................755 General Description...........................................................755 Tools Required................................................................755 Checkout Procedure............................................................755 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................759 Flashburn Programming.....................................................759 Confirmation Checklist....................................................761 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX.......................................763 RESERVE ENGINE OIL SYSTEM.........................................................765 Operation.....................................................................766 LED Monitor Light.............................................................766 Tank Fill Control (Optional)..................................................767 Filling Procedure (Remote fill feature).......................................767 SERVICE.......................................................................768 Every 10 Hours, or once each shift:.......................................768 Every 500 Hours:..........................................................768 Changing Oil..............................................................768 TROUBLESHOOTING...............................................................769 Circuit Breaker or Fuse...................................................769 SYSTEM ELECTRICAL SCHEMATICS..................................................770 SECTION N - CAB COMPONENTS - INDEX........................................................771 SECTION N2 - TRUCK CAB - INDEX........................................................773 TRUCK CAB.........................................................................775 Description...................................................................775 Preparation...................................................................776 Removal - Cab.................................................................776 Installation - Cab............................................................778 CAB DOOR......................................................................778 Removal...................................................................778 Installation..............................................................778 Door Adjustment...........................................................779 Door Jamb Bolt Adjustment.................................................779 Door Handle Plunger Adjustment............................................780 Door Glass Replacement....................................................781 Door Window Regulator Replacement.........................................785 Door Handle or Latch Assembly Replacement.................................785 Door and Door Hinge Seal Replacement......................................786 Door Opening Seal Removal.................................................786 Installation..............................................................786 GLASS REPLACEMENT.............................................................787 Adhesive Bonded Windows...................................................787 Replacement Procedure.....................................................787 Windshield And Rear Glass.................................................788 Removal...................................................................788 Installation..............................................................789 SECTION N3 - CAB COMPONENTS - INDEX...................................................791 CAB COMPONENTS....................................................................793 WINDSHIELD WIPERS.............................................................793 Wiper Motor Replacement...................................................793 Removal...................................................................793 Installation..............................................................793 Wiper Arm Replacement.....................................................793 Removal...................................................................793 Installation..............................................................794 Wiper Linkage Replacement.................................................794 Removal...................................................................794 Installation..............................................................794 WINDSHIELD WASHER.............................................................795 Operation.................................................................795 Service...................................................................795 OPERATOR SEAT.................................................................796 Adjustment................................................................796 Removal...................................................................796 Installation..............................................................796 SECTION N4 - OPERATOR COMFORT - INDEX.................................................797 OPERATOR COMFORT..................................................................799 HEATER/AIR CONDITIONER........................................................799 Operation.................................................................799 HEATER COMPONENTS.............................................................800 Circuit Breakers..........................................................800 Heater Control Components.................................................800 Heater Coil...............................................................800 Fan Motor And Speed Control...............................................801 Actuators.................................................................801 Filter Service............................................................801 AIR CONDITIONING SYSTEM...........................................................803 Environmental Impact..........................................................803 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................804 PRINCIPLES OF REFRIGERATION...................................................804 Air Conditioning..........................................................804 Refrigeration - The Act Of Cooling........................................805 The Refrigeration Cycle...................................................805 AIR CONDITIONER SYSTEM COMPONENTS.............................................806 Compressor (Refrigerant Pump).............................................806 Service Valves............................................................806 Condenser.................................................................806 Receiver-Drier............................................................806 Expansion Block Valve.....................................................807 Accumulator...............................................................807 Evaporator................................................................807 ELECTRICAL CIRCUIT............................................................808 Thermostat................................................................808 Compressor Clutch.........................................................808 Trinary™ Switch...........................................................809 SYSTEM SERVICING..............................................................810 SERVICE TOOLS AND EQUIPMENT...................................................811 Recovery/Recycle Station..................................................811 Leak Detector.............................................................811 Service Valves............................................................812 Vacuum Pump...............................................................812 Manifold Gauge Set........................................................813 Installing Manifold Gauge Set.............................................814 Purging Air From Service Hoses............................................814 SYSTEM PERFORMANCE TEST.......................................................815 SYSTEM OIL....................................................................816 Handling and Reusing PAG Oil..............................................816 Oil Quantity..............................................................816 Checking System Oil.......................................................816 REFRIGERANT...................................................................817 Recycled Refrigerant......................................................817 Reclaimed Refrigerant.....................................................817 Refrigerant Quantity......................................................817 R-134a Refrigerant Containers.............................................817 SYSTEM LEAK TESTING...........................................................818 Electronic Leak Detector..................................................818 Tracer Dyes...............................................................818 Soap and Water............................................................818 RECOVERING AND RECYCLING THE REFRIGERANT......................................819 Performing the Recovery Cycle.............................................819 Performing the Recycling Procedure........................................819 Evacuating and Charging the A/C System....................................819 SYSTEM REPAIR.................................................................820 System Flushing...........................................................820 COMPONENT REPLACEMENT.........................................................820 Hoses and Fittings........................................................820 Lines.....................................................................820 Expansion Valve...........................................................821 Receiver-Drier............................................................821 Thermostat................................................................821 Compressor................................................................821 Accumulator...............................................................821 Clutch....................................................................822 Servicing the Compressor Clutch...........................................822 Pulley Removal............................................................824 Clutch Coil Check.........................................................825 Pulley Installation.......................................................825 Clutch Assembly Installation..............................................825 EVACUATING THE SYSTEM.........................................................827 CHARGING THE A/C SYSTEM.......................................................829 TROUBLESHOOTING...................................................................830 Preliminary Checks............................................................830 Diagnosis Of Gauge Readings And System Performance............................830 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................831 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................837 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................839 OPERATOR CAB CONTROLS.............................................................841 STEERING COLUMN...............................................................841 Removal...................................................................841 Installation..............................................................841 STEERING WHEEL AND CONTROLS...................................................843 Horn Button...............................................................843 Telescope Lock Ring.......................................................843 Tilt Wheel Lever..........................................................843 Turn Signal/Headlight Dimmer..............................................843 DYNAMIC RETARDING.............................................................843 Retarder Control Lever....................................................844 Dynamic Retarder/Service Brake Pedal......................................844 Accelerator (Throttle) Pedal..............................................844 Starting on a Grade With a Loaded Truck...................................844 GRADE/SPEED RETARD CHART......................................................845 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.............................846 Heater/Air Conditioner Vents..............................................846 INSTRUMENT PANEL..............................................................847 OVERHEAD PANEL AND DISPLAYS...................................................847 CENTER CONSOLE................................................................848 F-N-R Selector Switch.....................................................848 Hoist Control Lever.......................................................849 Raising The Dump Body.....................................................849 Lowering The Dump Body:...................................................849 Ash Tray..................................................................849 Lighter...................................................................849 L.H. Window Control Switch................................................849 R.H. Window Control Switch................................................849 Engine Shutdown Switch....................................................849 Override/Fault Reset Switch...............................................850 Retard Speed Control (RSC) Switch.........................................850 Retard Speed Control (RSC) Adjust Dial....................................850 PSC Download Port.........................................................851 Engine Diagnostics Download Port..........................................851 Engine Control System.....................................................851 TCI Download Port.........................................................851 Passenger Seat............................................................851 PAYLOAD METER.................................................................851 Payload Meter Download Connector..........................................851 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................853 CONTROL SYMBOLS...............................................................853 INSTRUMENT PANEL..............................................................853 PANEL GAUGES, INDICATORS, AND CONTROLS............................................855 Key Switch....................................................................855 Starting......................................................................855 Cold Weather Starting.........................................................855 Normal Engine Shutdown........................................................855 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................856 Fog Lights (Optional).........................................................856 Ladder Light Switch...........................................................856 Manual Backup Switch..........................................................856 Panel Illumination Lights.....................................................857 Cab/Air Conditioner Vents.....................................................857 Rotating Beacon Light Switch (Optional).......................................857 Heated Mirror Switch (Optional)...............................................857 Wheel Brake Lock Control......................................................857 Parking Brake Control.........................................................857 Tachometer....................................................................858 Right Turn Signal Indicator...................................................858 High Beam Indicator...........................................................858 Left Turn Signal Indicator....................................................858 Speedometer...................................................................858 Voltmeter.....................................................................858 Engine Oil Pressure Gauge.....................................................858 Water Temperature Gauge.......................................................858 Fuel Gauge....................................................................858 AC Drive System Temperature Gauge.............................................859 Hydraulic Oil Temperature Gauge...............................................859 Hourmeter.....................................................................859 Rest Switch...................................................................859 Light Switch..................................................................860 Windshield Wiper and Washer...................................................860 Panel Light Dimmer............................................................860 OVERHEAD STATUS / WARNING INDICATORS..........................................861 STATUS / WARNING INDICATOR LIGHT SYMBOLS......................................862 Hazard Warning Lights.....................................................867 Lamp Test Switch..........................................................867 Link-On Warning Light.....................................................867 SECTION P - LUBRICATION AND SERVICE - INDEX...............................................869 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................871 LUBRICATION AND SERVICE...........................................................873 930E SERVICE CAPACITIES.......................................................873 HYDRAULIC TANK SERVICE........................................................873 Adding Oil................................................................873 WHEEL MOTOR SERVICE...........................................................873 COOLANT LEVEL CHECK...........................................................874 RADIATOR FILLING PROCEDURE....................................................874 RESERVE ENGINE OIL SYSTEM (Optional)..........................................874 Reserve Oil Tank Filling Procedure (Remote fill)..........................874 LUBRICATION CHART.............................................................875 10 HOUR (DAILY) INSPECTION....................................................876 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................879 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................880 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................881 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................884 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................885 5000 HOUR MAINTENANCE CHECKS..................................................886 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.....................................887 AUTOMATIC LUBRICATION SYSTEM......................................................889 GENERAL DESCRIPTION...........................................................889 SYSTEM COMPONENTS.............................................................891 SYSTEM OPERATION..............................................................892 Normal Operation..........................................................892 Pressure Failure Detection Circuits.......................................893 INJECTOR OPERATION............................................................894 GENERAL INSTRUCTIONS..............................................................895 LUBRICANT REQUIREMENTS........................................................895 System Priming................................................................895 LUBRICANT PUMP................................................................895 Pump Housing Oil Level....................................................895 Pump Pressure Control.....................................................895 Pressure Control Valve Adjustment.........................................895 INJECTORS (SL-1 Series “H”))..................................................896 Injector Specifications...................................................896 Injector Adjustment.......................................................896 SYSTEM CHECKOUT...............................................................896 Lubrication Cycle Timer Check.............................................897 Lubrication Cycle Timer Adjustment........................................897 FILTER ASSEMBLY...............................................................897 PUMP REBUILD..................................................................898 Disassembly...............................................................898 Cleaning and Inspection...................................................898 Assembly..................................................................900 SYSTEM TROUBLESHOOTING CHART......................................................901 PREVENTATIVE MAINTENANCE PROCEDURES...............................................904 Daily Lubrication System Inspection...........................................904 250 Hour Inspection...........................................................904 1000 Hour Inspection..........................................................904 SECTION Q ALPHABETICAL INDEX..............................................................905 SECTION R - SYSTEM SCHEMATICS.............................................................909 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH347..................................911 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH352..............................................912 PLM III ELECTRICAL SYSTEM SCHEMATIC - HE479 ..........................................913 PLM III HOOK-UP WIRING - HE483........................................................914 ELECTRICAL SCHEMATIC - XS0400.........................................................915
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