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Komatsu 930E-2 Dump Truck Shop Manual SN A30301-A30303 – PDF DOWNLOAD
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Komatsu 930E-2 Dump Truck Shop Manual
Book Code: CEBM012401
SERIAL NUMBERS A30301 thru A30303
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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: A30301-A30303
Book Code: CEBM012401
Language: English
Pages: 937
File Format: Portable Document Format (PDF)
KOMATSU 930E-2 DUMP TRUCK SHOP MANUAL SN A30301-A30303 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 930E-2 Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, wamings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general infom’ration. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of US. and metric (SI) units throughout and all references to “Right”, “Left”.
- ‘Front‘, or “Rear” are made with respect to the operator’s nomtal seated position, unless specifically stated otherwise- Standard torque requirements are shown in torque charts in the general infomiation section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 Mm) torque- All torque specifications have i 10% tolerance unless otherwise specified.
- A Product identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter ‘M’ designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains infomiation which will identify the original manufacturing bill of material forthis unit. This complete number will be necessary for proper ordering of many service parts andlor warranty consideration.
TABLE OF CONTENTS:
Komatsu 930E-2 Dump Truck Shop Manual
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 FOREWORD.................................................................................. 5 TABLE OF CONTENTS......................................................................... 7 SECTION A - GENERAL INFORMATION - INDEX................................................... 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION.............................................. 11 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX........................ 15 GENERAL SAFETY.................................................................... 17 Safety Rules.................................................................. 17 Truck Safety Features......................................................... 17 Clothing And Personal Items................................................... 17 Unauthorized Modification..................................................... 17 Leaving The Operator’s Seat................................................... 17 Mounting And Dismounting...................................................... 17 Fire Extinguishers And First Aid Kits......................................... 18 Precautions For High Temperature Fluids....................................... 18 Asbestos Dust Hazard Prevention............................................... 18 Fire Prevention For Fuel And Oil.............................................. 18 ROPS Precautions.............................................................. 19 Preventing Injury From Work Equipment......................................... 19 Precautions For Optional Attachments.......................................... 19 Precautions When Starting The Machine......................................... 19 PRECAUTIONS FOR TRUCK OPERATION............................................... 20 Safety Is Thinking Ahead.................................................. 20 Safety At The Worksite.................................................... 20 Fire Prevention........................................................... 20 Preparing For Operation................................................... 20 Ventilation For Enclosed Areas............................................ 20 Mirrors, Windows, And Lights.............................................. 20 In The Operator’s Cab - Before Starting The Engine........................ 21 OPERATING THE MACHINE......................................................... 21 Starting The Engine....................................................... 21 Truck Operation - General................................................. 21 Traveling In The Truck.................................................... 22 Precautions When Traveling In Reverse..................................... 22 Traveling On Slopes....................................................... 22 Ensuring Good Visibility.................................................. 23 Operating On Snow......................................................... 23 Avoid Damage To The Dump Body............................................. 23 Driving Near High Voltage Cables.......................................... 23 When Loading The Truck.................................................... 23 When Dumping.............................................................. 23 Working On Loose Ground................................................... 23 Parking The Machine....................................................... 24 TOWING........................................................................ 24 WORKING NEAR BATTERIES........................................................ 24 Jump Starting With Booster Cables......................................... 24 PRECAUTIONS FOR MAINTENANCE....................................................... 25 BEFORE PERFORMING MAINTENANCE................................................. 25 Stopping The Engine Before Service........................................ 25 Warning Tag............................................................... 25 Proper Tools.............................................................. 25 Securing The Dump Body.................................................... 25 DURING MAINTENANCE............................................................ 26 Personnel................................................................. 26 Attachments............................................................... 26 Working Under The Machine................................................. 26 Keeping The Machine Clean................................................. 26 Rules To Follow When Adding Fuel Or Oil................................... 26 Radiator Coolant Level.................................................... 26 Use Of Lighting........................................................... 26 Precautions With The Battery.............................................. 27 Handling High Pressure Hoses.............................................. 27 Precautions With High Pressure Oil........................................ 27 Maintenance Near High Temperatures And High Pressures..................... 27 Rotating Fan And Belts.................................................... 27 Waste Materials........................................................... 27 TIRES......................................................................... 28 Handling Tires............................................................ 28 Storing Tires After Removal............................................... 28 ADDITIONAL JOB SITE RULES......................................................... 29 WHEN REPAIRS ARE NECESSARY........................................................ 30 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK................................... 31 Preliminary Procedures before Welding or Performing Maintenance............... 31 Normal Engine Shutdown Procedure.............................................. 31 Engine Shutdown Procedure before Welding or Performing Maintenance............ 31 TRUCK OPERATION................................................................... 34 PREPARING FOR OPERATION....................................................... 34 Safety Is Thinking Ahead.................................................. 34 WALK AROUND INSPECTION........................................................ 34 ENGINE START-UP SAFETY PRACTICES.............................................. 38 AFTER STARTING THE ENGINE..................................................... 39 Additional Guidelines..................................................... 39 MACHINE OPERATION SAFETY PRECAUTIONS.......................................... 39 MACHINE OPERATION ON THE HAUL ROAD............................................ 40 DYNAMIC RETARDING OPERATION................................................... 41 Dynamic Retarder Control Lever............................................ 41 Dynamic Retarder/Service Brake Pedal...................................... 41 STARTING ON A GRADE WITH A LOADED TRUCK....................................... 42 PASSING....................................................................... 42 LOADING....................................................................... 42 DUMPING....................................................................... 42 Raising The Dump Body..................................................... 42 Lowering The Dump Body.................................................... 43 TOWING........................................................................ 44 SAFE PARKING PROCEDURES....................................................... 45 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................. 45 DELAYED ENGINE SHUTDOWN PROCEDURE............................................. 45 SUDDEN LOSS OF ENGINE POWER................................................... 46 SECTION A4 - WARNINGS AND CAUTIONS.................................................... 47 SECTION A5 - STANDARD CHARTS AND TABLES............................................... 55 SECTION A7 - STORAGE AND IDLE MACHINE 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 - POWER TRAIN - 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 - BRAKE CABINET..................................................470 Removal...................................................................470 Installation..............................................................470 Disassembly...............................................................470 Cleaning and Inspection...................................................472 Assembly..................................................................472 ACCUMULATORS - FRAME MOUNTED..................................................474 Removal...................................................................474 Installation..............................................................474 Disassembly...............................................................475 Cleaning and Inspection...................................................476 Assembly..................................................................476 ACCUMULATOR CHARGING PROCEDURE................................................478 Temperature During Precharge..............................................480 Precharge Maintenance.....................................................480 ACCUMULATOR STORAGE...........................................................481 Installing A Bladder Accumulator From Storage.............................481 Bladder Storage Procedures................................................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 HYDRAULIC PUMP MODULE.........................................................529 HOIST CIRCUIT OPERATION.......................................................530 STEERING CIRCUIT OPERATION....................................................532 DISC BRAKE COOLING SYSTEM.....................................................534 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................537 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................539 HOIST PUMP....................................................................539 Removal...................................................................539 Installation..............................................................541 INSPECTION OF PARTS...........................................................546 Assembly..................................................................546 HYDRAULIC TANK................................................................552 Filling Instructions......................................................552 Removal...................................................................552 Installation..............................................................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 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 Filter......................................................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 PRINCIPLE OF OPERATION........................................................574 Full Pump Volume:.........................................................574 Half Pump Volume:.........................................................574 Neutral Position:.........................................................574 Steering Pump.............................................................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 FLOW AMPLIFIER................................................................590 Removal...................................................................590 Installation..............................................................590 FLOW AMPLIFIER REBUILD........................................................590 Disassembly...............................................................592 Assembly..................................................................593 STEERING CYLINDERS............................................................594 Disassembly...............................................................595 Piston Seal & Bearing Installation........................................595 Cylinder Assembly.........................................................595 Test......................................................................595 STEERING AND BRAKE PUMP.......................................................596 Removal...................................................................596 Installation..............................................................596 Disassembly...............................................................598 Control Piston Group......................................................598 Valve Plate Group.........................................................598 Rotating Group............................................................601 Swashblock Group..........................................................601 Driveshaft Group..........................................................601 Inspection................................................................601 Control Piston Group......................................................601 Valve Plate Group.........................................................601 Rotating Group............................................................601 Swashblock Group..........................................................603 Driveshaft Group..........................................................604 Compensator Block and Unloader Module.....................................604 Stroke Adjuster Assembly..................................................604 Assembly..................................................................604 Swashblock Group..........................................................604 Driveshaft Group..........................................................605 Rotating Group............................................................605 Valve Plate Group.........................................................606 STEERING ACCUMULATORS.........................................................607 Removal...................................................................607 Installation..............................................................607 Disassembly...............................................................608 Cleaning and Inspection...................................................609 Steering Accumulator Charging Procedure...................................611 TROUBLESHOOTING CHART.............................................................612 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...................................................................637 Installation..............................................................638 O-Ring Replacement........................................................638 INLET SECTION.................................................................639 Disassembly...............................................................639 Cleaning and Inspection...................................................640 Assembly..................................................................640 REAR SPOOL SECTION (Work Ports)...............................................640 Disassembly...............................................................640 Cleaning and Inspection...................................................642 Assembly..................................................................642 FRONT SPOOL SECTION (Tank Ports)..............................................643 Disassembly...............................................................643 Cleaning and Inspection...................................................643 Assembly..................................................................643 HOIST PILOT VALVE.............................................................645 Removal...................................................................645 Installation..............................................................645 Disassembly...............................................................646 Cleaning and Inspection...................................................647 Assembly..................................................................647 HOIST CYLINDERS...............................................................648 Removal...................................................................648 Installation..............................................................649 Disassembly...............................................................651 Cleaning and Inspection...................................................652 Assembly - Quill and Cylinder.............................................653 Quill Installation........................................................653 Installation Of Check Balls And Plugs In Quill............................654 Assembly of Cylinder......................................................655 OVERCENTER VALVE MANIFOLD.....................................................656 DISABLED TRUCK DUMPING PROCEDURE..............................................657 Hookup....................................................................657 Raising the Body..........................................................657 Lowering the Body.........................................................657 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.........................................659 HYDRAULIC SYSTEM FILTERS..........................................................661 HOIST CIRCUIT FILTER..........................................................661 Filter Element Replacement................................................661 Removal - Hoist Circuit Filter............................................662 Installation - Hoist Circuit Filter.......................................662 Indicator Switch - Hoist Circuit Filter...................................662 STEERING CIRCUIT FILTER.......................................................663 Filter Element Replacement................................................663 Removal - Steering Circuit Filter.........................................664 Installation - Steering Circuit Filter....................................664 Indicator Switch - Steering Circuit Filter................................664 INDICATOR SWITCH..............................................................664 Test Procedure............................................................664 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...................................667 HYDRAULIC CHECK-OUT PROCEDURE.....................................................669 GENERAL INFORMATION...........................................................669 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.............................669 Equipment Requirements....................................................670 Pump Pressure Control Adjustments.............................................670 Steering Control Unit and Flow Amplifier Leakage Test.....................671 Bleeddown Manifold Leakage Test...........................................671 STEERING/BRAKE PUMP STROKE ADJUSTMENT.........................................672 SHOCK AND SUCTION VALVES......................................................673 Equipment Requirements....................................................673 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.................674 Equipment Requirements....................................................674 Pressure Gauge Locations..................................................674 Brake Cooling Circuit Test................................................674 Power Up Relief Pressure Test.............................................675 Adjustment................................................................675 Power Down Relief Pressure Test...........................................676 Hoist Counterbalance Valve Adjustment Preparation.........................677 Counterbalance Valve Pressure Check.......................................677 Counterbalance Valve Adjustment...........................................678 Preparation...............................................................679 Flushing Procedure........................................................679 Filter Element Replacement................................................680 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.............................681 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................682 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.............................................683 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX.............................................685 FIRE CONTROL SYSTEM (MANUAL)......................................................687 Operation.....................................................................687 Inspection and Maintenance....................................................687 Recharging Procedures.........................................................688 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1......................689 Control Module................................................................689 Actuator......................................................................690 Linear Detection Wire.........................................................690 Power Wire....................................................................690 Test Kit......................................................................690 Squib.........................................................................690 Securing the Detection Wire...................................................691 Preliminary Test Before Final Hook-Up.........................................691 Installation Procedure for Squib..............................................693 Placing the Electric Detection & Actuation System Into Service................693 INSPECTION AND MAINTENANCE SCHEDULES..........................................694 Daily.....................................................................694 Normal Maintenance Based On Actual Operating Hours........................694 IN CASE OF FIRE...............................................................695 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.....................................697 SECTION M8 - SPECIAL TOOLS............................................................699 SECTION M20 - PAYLOAD METER III - INDEX...............................................705 OPERATION SECTION.................................................................709 Introduction..................................................................709 Data Summary..............................................................709 Data Gathering............................................................709 COMPONENT DESCRIPTION.........................................................710 System Diagram............................................................710 Suspension Pressure Sensors...............................................710 Inclinometer..............................................................710 Operator Display..........................................................710 Operator Switch...........................................................711 Speed Input...............................................................711 Body-Up Switch............................................................711 Brake Lock Switch.........................................................711 Payload Meter.............................................................711 Communications Ports......................................................711 Keyswitch Input...........................................................712 Payload Meter Power.......................................................712 Load Lights...............................................................712 Wiring and Termination....................................................713 TCI Outputs...............................................................713 OPERATOR’S DISPLAY AND SWITCH.................................................714 Reading the Speedometer...................................................714 Reading the Load Display..................................................714 Using the Operator ID.....................................................714 Using the Load and Ton Counter............................................714 Total Ton Counter.........................................................714 Total Load Counter........................................................715 Clearing the Counters.....................................................715 Viewing Live Sensor Data..................................................715 Other Display Messages....................................................715 PAYLOAD OPERATION & CALCULATION...............................................716 Description of Haul Cycle States..........................................716 Haul Cycle Description....................................................716 Load Calculation..........................................................717 Carry Back................................................................717 Measurement Accuracy......................................................717 SOURCES FOR PAYLOAD ERROR.....................................................717 Payload Error.............................................................717 Loading Conditions........................................................718 Pressure Sensors..........................................................718 Swingloads................................................................718 Speed and Distance........................................................718 HAUL CYCLE DATA...............................................................718 Haul Cycle Data...........................................................719 Haul Cycle Warning Flags..................................................720 M: Haul Cycle Too Long....................................................721 N: Sensor Input Error.....................................................721 Frame Torque Data.........................................................721 Sprung Weight Data........................................................721 Maximum Speed Data........................................................721 Alarm Records.............................................................721 Fault Code Data...........................................................722 PC SOFTWARE OVERVIEW..........................................................723 PC Overview...............................................................723 System Configuration......................................................723 Installing the PLMIII Software............................................723 DOWNLOADING DATA..............................................................724 PLM III SYSTEM CONFIGURATION..................................................725 Starting Communications...................................................725 Displayed Payload Units...................................................725 Time Units................................................................725 Connection Menu...........................................................725 Connecting to the Payload Meter...........................................726 Configure the Payload Meter...............................................726 Setting the Date and Time.................................................726 Setting the Truck Type....................................................727 Setting the Gauge Display Units...........................................727 Setting the Frame Serial Number...........................................727 Setting the Truck Number..................................................727 Setting the Komatsu Distributor...........................................727 Setting the Komatsu Customer..............................................727 Clean Truck Tare..........................................................728 Inclinometer Calibration..................................................728 DATA ANALYSIS.................................................................729 Creating a Query..........................................................729 Sorting on Truck Unit Number..............................................729 Sorting on Truck Type.....................................................729 Sorting on Date Range.....................................................730 Sorting on Time Range.....................................................730 Payload Detail Screen.....................................................731 Creating Reports..........................................................731 Summary - one page report.................................................732 Detailed - multi-page report..............................................732 Creating Graphs...........................................................733 Exporting Data............................................................733 CSV Export................................................................733 Compressed................................................................734 Importing Data............................................................735 Deleting Haul Cycle Records...............................................735 Viewing Alarms............................................................736 Deleting Alarm Records....................................................736 TROUBLESHOOTING SECTION...........................................................737 TROUBLESHOOTING...............................................................737 Viewing Active Alarms.....................................................737 Real-Time Data Display....................................................737 Testing the Payload Lights................................................737 Creating Log Files of Inputs..............................................738 Daily Inspections.........................................................738 Periodic Maintenance......................................................738 Abnormal Displays at Power-Up.............................................739 No Payload Display When Keyswitch is Turned ON............................740 No Display on Speedometer.................................................741 No Display on Operator Display............................................741 No Communications With PC.................................................742 Load Lights Don’t Light During Loading....................................743 Load Lights Remain ON.....................................................744 Load Lights Remain ON During Dumping......................................744 Display Doesn't Clear When The Load Is Dumped.............................744 Calibration Problems......................................................745 Alarm 1 - Left Front Pressure High........................................746 Alarm 2 - Left Front Pressure Low.........................................746 Troubleshoot Wiring to Left Front Suspension..............................746 Alarm 3 - Right Front Pressure High.......................................747 Alarm 4 - Right Front Pressure Low........................................747 Troubleshoot Wiring to Right Front Suspension.............................747 Alarm 5 -Left Rear Pressure High..........................................748 Alarm 6 - Left Rear Pressure Low..........................................748 Troubleshoot Wiring to Left Rear Suspension...............................748 Alarm 7 - Right Rear Pressure High........................................749 Alarm 8 - Right Rear Pressure Low.........................................749 Troubleshoot Wiring to Right Rear Suspension..............................749 Alarm 9 - Inclinometer High...............................................750 Alarm 10 - Inclinometer Low...............................................750 Troubleshoot Inclinometer Wiring..........................................750 Alarm 13 - Body Up Input Failure..........................................751 Alarm 16 - Memory Write Failure...........................................752 Alarm 17 - Memory Read Failure............................................752 Alarm 18..................................................................753 Alarm 19..................................................................753 Alarm 22..................................................................753 Operator Switch Doesn't Work..............................................754 Alarm 26 - User Switch Fault - SELECT.....................................754 Alarm 27 - User Switch Fault - SET........................................754 Connector Map.............................................................755 Connectors................................................................756 PLMIII CHECK OUT PROCEDURE........................................................757 General Description...........................................................757 Tools Required................................................................757 Checkout Procedure............................................................757 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................761 Flashburn Programming.....................................................761 Confirmation Checklist....................................................763 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX.......................................765 RESERVE ENGINE OIL SYSTEM.........................................................767 Operation.....................................................................768 LED Monitor Light.............................................................768 Tank Fill Control (Optional)..................................................769 Filling Procedure (Remote fill feature).......................................769 SERVICE.......................................................................770 Every 10 Hours, or once each shift:.......................................770 Every 500 Hours:..........................................................770 Changing Oil..............................................................770 TROUBLESHOOTING...............................................................771 Circuit Breaker or Fuse...................................................771 SYSTEM ELECTRICAL SCHEMATICS..................................................772 SECTION N - CAB COMPONENTS - INDEX........................................................773 SECTION N2 - TRUCK CAB - INDEX........................................................775 TRUCK CAB.........................................................................777 Description...................................................................777 Preparation...................................................................778 Removal - Cab.................................................................778 Installation - Cab............................................................780 CAB DOOR......................................................................780 Removal...................................................................780 Installation..............................................................780 Door Adjustment...........................................................781 Door Jamb Bolt Adjustment.................................................781 Door Handle Plunger Adjustment............................................782 Door Glass Replacement....................................................783 Door Window Regulator Replacement.........................................787 Door Handle or Latch Assembly Replacement.................................787 Door and Door Hinge Seal Replacement......................................788 Door Opening Seal Removal.................................................788 Installation..............................................................788 GLASS REPLACEMENT.............................................................789 Adhesive Bonded Windows...................................................789 Replacement Procedure.....................................................789 Windshield And Rear Glass.................................................790 Removal...................................................................790 Installation..............................................................791 SECTION N3 - CAB COMPONENTS - INDEX...................................................793 CAB COMPONENTS....................................................................795 WINDSHIELD WIPERS.............................................................795 Wiper Motor Replacement...................................................795 Removal...................................................................795 Installation..............................................................795 Wiper Arm Replacement.....................................................795 Removal...................................................................795 Installation..............................................................796 Wiper Linkage Replacement.................................................796 Removal...................................................................796 Installation..............................................................796 WINDSHIELD WASHER.............................................................797 Operation.................................................................797 Service...................................................................797 OPERATOR COMFORT..................................................................798 OPERATOR SEAT.................................................................798 Adjustment................................................................798 SECTION N4 - OPERATOR COMFORT - INDEX.................................................799 OPERATOR COMFORT..................................................................801 HEATER / AIR CONDITIONER......................................................801 Operation.................................................................801 Heater/Air Conditioner Vents..............................................801 COMPONENTS....................................................................802 Circuit Breakers..........................................................802 Relays....................................................................802 Heater Core...............................................................802 Fan Motor And Speed Control...............................................803 Actuators.................................................................803 Filter....................................................................803 Service...................................................................803 AIR CONDITIONING SYSTEM...........................................................805 Environmental Impact..........................................................805 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................806 PRINCIPLES OF REFRIGERATION...................................................806 Air Conditioning..........................................................806 Refrigeration - The Act Of Cooling........................................807 The Refrigeration Cycle...................................................807 AIR CONDITIONER SYSTEM COMPONENTS.............................................808 Compressor (Refrigerant Pump).............................................808 Service Valves............................................................808 Condenser.................................................................808 Receiver-Drier............................................................808 Expansion Block Valve.....................................................809 Accumulator...............................................................809 Evaporator................................................................809 ELECTRICAL CIRCUIT............................................................810 Thermostat................................................................810 Compressor Clutch.........................................................810 Trinary™ Switch...........................................................811 SYSTEM SERVICING..............................................................812 SERVICE TOOLS AND EQUIPMENT...................................................813 Recovery/Recycle Station..................................................813 Leak Detector.............................................................813 Service Valves............................................................814 Vacuum Pump...............................................................814 Manifold Gauge Set........................................................815 Installing Manifold Gauge Set.............................................816 Purging Air From Service Hoses............................................816 SYSTEM PERFORMANCE TEST.......................................................817 SYSTEM OIL....................................................................818 Handling and Reusing PAG Oil..............................................818 Oil Quantity..............................................................818 Checking System Oil.......................................................818 REFRIGERANT...................................................................819 Recycled Refrigerant......................................................819 Reclaimed Refrigerant.....................................................819 Refrigerant Quantity......................................................819 R-134a Refrigerant Containers.............................................819 SYSTEM LEAK TESTING...........................................................820 Electronic Leak Detector..................................................820 Tracer Dyes...............................................................820 Soap and Water............................................................820 RECOVERING AND RECYCLING THE REFRIGERANT......................................821 Performing the Recovery Cycle.............................................821 Performing the Recycling Procedure........................................821 Evacuating and Charging the A/C System....................................821 SYSTEM REPAIR.................................................................822 System Flushing...........................................................822 COMPONENT REPLACEMENT.........................................................822 Hoses and Fittings........................................................822 Lines.....................................................................822 Expansion Valve...........................................................823 Receiver-Drier............................................................823 Thermostat................................................................823 Compressor................................................................823 Accumulator...............................................................823 Clutch....................................................................824 Servicing the Compressor Clutch...........................................824 Pulley Removal............................................................826 Clutch Coil Check.........................................................827 Pulley Installation.......................................................827 Clutch Assembly Installation..............................................827 EVACUATING THE SYSTEM.........................................................829 CHARGING THE A/C SYSTEM.......................................................831 TROUBLESHOOTING...................................................................832 Preliminary Checks............................................................832 Diagnosis Of Gauge Readings And System Performance............................832 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................833 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................839 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................841 OPERATOR CAB CONTROLS.............................................................843 STEERING COLUMN...............................................................843 Removal...................................................................843 Steering Column Inspection................................................843 Installation..............................................................843 STEERING WHEEL AND CONTROLS...................................................845 Horn Button...............................................................845 Telescope Lock Ring.......................................................845 Tilt Wheel Lever..........................................................845 Turn Signal/Headlight Dimmer..............................................845 DYNAMIC RETARDING.............................................................845 Retarder Control Lever....................................................846 Dynamic Retarder/Service Brake Pedal......................................846 Accelerator (Throttle) Pedal..............................................846 Starting on a Grade With a Loaded Truck...................................846 GRADE/SPEED RETARD CHART......................................................847 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.............................848 Heater/Air Conditioner Vents..............................................848 INSTRUMENT PANEL..............................................................849 OVERHEAD PANEL AND DISPLAYS...................................................849 CENTER CONSOLE................................................................850 F-N-R Selector Switch.....................................................850 Hoist Control Lever.......................................................851 Raising The Dump Body.....................................................851 Lowering The Dump Body....................................................851 Ash Tray..................................................................851 Lighter...................................................................851 L.H. Window Control Switch................................................851 R.H. Window Control Switch................................................851 Engine Shutdown Switch....................................................851 Override/Fault Reset Switch...............................................852 Retard Speed Control (RSC) Switch.........................................852 Retard Speed Control (RSC) Adjust Dial....................................852 PSC Download Port.........................................................853 Engine Diagnostics Download Port..........................................853 Engine Control System.....................................................853 TCI Download Port.........................................................853 Passenger Seat............................................................853 PAYLOAD METER.................................................................853 Payload Meter Download Connector..........................................853 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................855 CONTROL SYMBOLS...............................................................855 INSTRUMENT PANEL..............................................................855 PANEL GAUGES, INDICATORS, AND CONTROLS............................................857 Key Switch....................................................................857 Starting......................................................................857 Cold Weather Starting.........................................................857 Normal Engine Shutdown........................................................857 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................858 Fog Lights (Optional).........................................................858 Ladder Light Switch...........................................................858 Manual Backup Switch..........................................................858 Panel Illumination Lights.....................................................859 Cab/Air Conditioner Vents.....................................................859 Rotating Beacon Light Switch (Optional).......................................859 Heated Mirror Switch (Optional)...............................................859 Wheel Brake Lock Control......................................................859 Parking Brake Control.........................................................859 Tachometer....................................................................860 Right Turn Signal Indicator...................................................860 High Beam Indicator...........................................................860 Left Turn Signal Indicator....................................................860 Speedometer...................................................................860 Voltmeter.....................................................................860 Engine Oil Pressure Gauge.....................................................860 Water Temperature Gauge.......................................................860 Fuel Gauge....................................................................860 AC Drive System Temperature Gauge.............................................861 Hydraulic Oil Temperature Gauge...............................................861 Hourmeter.....................................................................861 Rest Switch...................................................................861 Light Switch..................................................................862 Windshield Wiper and Washer...................................................862 Panel Light Dimmer............................................................862 OVERHEAD STATUS / WARNING INDICATORS..........................................863 STATUS / WARNING INDICATOR LIGHT SYMBOLS......................................864 Hazard Warning Lights.....................................................869 Lamp Test Switch..........................................................869 Link-On Warning Light.....................................................869 SECTION P - LUBRICATION AND SERVICE - INDEX...............................................871 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................873 LUBRICATION AND SERVICE...........................................................875 930E SERVICE CAPACITIES.......................................................875 HYDRAULIC TANK SERVICE........................................................875 Adding Oil................................................................875 WHEEL MOTOR SERVICE...........................................................875 COOLANT LEVEL CHECK...........................................................876 RADIATOR FILLING PROCEDURE....................................................876 RESERVE ENGINE OIL SYSTEM (Optional)..........................................876 Reserve Oil Tank Filling Procedure (Remote fill)..........................876 LUBRICATION CHART.............................................................877 10 HOUR (DAILY) INSPECTION....................................................878 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................881 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................882 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................883 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................886 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................887 5000 HOUR MAINTENANCE CHECKS..................................................888 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.....................................889 AUTOMATIC LUBRICATION SYSTEM......................................................891 GENERAL DESCRIPTION...........................................................891 SYSTEM COMPONENTS.............................................................893 SYSTEM OPERATION..............................................................894 Normal Operation..........................................................894 Pressure Failure Detection Circuits.......................................895 INJECTOR OPERATION............................................................896 GENERAL INSTRUCTIONS..............................................................897 LUBRICANT REQUIREMENTS........................................................897 System Priming................................................................897 LUBRICANT PUMP................................................................897 Pump Housing Oil Level....................................................897 Pump Pressure Control.....................................................897 Pressure Control Valve Adjustment.........................................897 INJECTORS (SL-1 Series “H”))..................................................898 Injector Specifications...................................................898 Injector Adjustment.......................................................898 SYSTEM CHECKOUT...............................................................898 Lubrication Cycle Timer Check.............................................899 Lubrication Cycle Timer Adjustment........................................899 FILTER ASSEMBLY...............................................................899 PUMP REBUILD..................................................................900 Disassembly...............................................................900 Cleaning and Inspection...................................................900 Assembly..................................................................902 SYSTEM TROUBLESHOOTING CHART......................................................903 PREVENTATIVE MAINTENANCE PROCEDURES...............................................906 Daily Lubrication System Inspection...........................................906 250 Hour Inspection...........................................................906 1000 Hour Inspection..........................................................906 SECTION Q ALPHABETICAL INDEX..............................................................907 SECTION R - SYSTEM SCHEMATICS - INDEX.....................................................911 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH347..................................913 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH357..............................................914 PLM III ELECTRICAL SYSTEM SCHEMATIC - HE479...........................................915 PLM III HOOK-UP WIRING - HE483........................................................916 ELECTRICAL SCHEMATIC - XS0500.........................................................917
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