Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30329 – A30363) KOMATSU 930E 3 – PDF DOWNLOAD
Original price was: $81.95.$27.95Current price is: $27.95.
- KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30329 – A30363
- PUBLICATION NUMBER:CEBM014501
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30329 – A30363) KOMATSU 930E 3
KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30329 – A30363) KOMATSU 930E 3 – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30329 – A30363) KOMATSU 930E 3
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator
group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. - The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
- The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 930E-3 DUMP TRUCK SERVICE REPAIR MANUAL (SN:A30329 – A30363) KOMATSU 930E 3
MAIN MENU................................................................................. 0 COVER..................................................................................... 1 FOREWORD.................................................................................. 5 TABLE OF CONTENTS......................................................................... 7 SECTION A - GENERAL INFORMATION - INDEX................................................... 9 SECTION A2 - TRUCK COMPONENTS AND SPECIFICATIONS...................................... 11 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX........................ 15 GENERAL SAFETY.................................................................... 17 Safety Rules.................................................................. 17 Truck Safety Features......................................................... 17 Clothing And Personal Items................................................... 17 Unauthorized Modification..................................................... 17 Leaving The Operator’s Seat................................................... 17 Mounting And Dismounting...................................................... 17 Fire Extinguishers And First Aid Kits......................................... 18 Precautions For High Temperature Fluids....................................... 18 Asbestos Dust Hazard Prevention............................................... 18 Fire Prevention For Fuel And Oil.............................................. 18 ROPS Precautions.............................................................. 19 Preventing Injury From Work Equipment......................................... 19 Precautions For Optional Attachments.......................................... 19 Precautions When Starting The Machine......................................... 19 PRECAUTIONS FOR TRUCK OPERATION............................................... 20 Safety Is Thinking Ahead.................................................. 20 Safety At The Worksite.................................................... 20 Fire Prevention........................................................... 20 Preparing For Operation................................................... 20 Ventilation For Enclosed Areas............................................ 20 Mirrors, Windows, And Lights.............................................. 20 In The Operator’s Cab - Before Starting The Engine........................ 21 OPERATING THE MACHINE......................................................... 21 Starting The Engine....................................................... 21 Truck Operation - General................................................. 21 Traveling In The Truck.................................................... 22 Precautions When Traveling In Reverse..................................... 22 Traveling On Slopes....................................................... 22 Ensuring Good Visibility.................................................. 23 Operating On Snow......................................................... 23 Avoid Damage To The Dump Body............................................. 23 Driving Near High Voltage Cables.......................................... 23 When Loading The Truck.................................................... 23 When Dumping.............................................................. 23 Working On Loose Ground................................................... 23 Parking The Machine....................................................... 24 TOWING........................................................................ 24 WORKING NEAR BATTERIES........................................................ 24 Jump Starting With Booster Cables......................................... 24 PRECAUTIONS FOR MAINTENANCE....................................................... 25 BEFORE PERFORMING MAINTENANCE................................................. 25 Stopping The Engine Before Service........................................ 25 Warning Tag............................................................... 25 Proper Tools.............................................................. 25 Securing The Dump Body.................................................... 25 DURING MAINTENANCE............................................................ 26 Personnel................................................................. 26 Attachments............................................................... 26 Working Under The Machine................................................. 26 Keeping The Machine Clean................................................. 26 Rules To Follow When Adding Fuel Or Oil................................... 26 Radiator Coolant Level.................................................... 26 Use Of Lighting........................................................... 26 Precautions With The Battery.............................................. 27 Handling High Pressure Hoses.............................................. 27 Precautions With High Pressure Oil........................................ 27 Maintenance Near High Temperatures And High Pressures..................... 27 Rotating Fan And Belts.................................................... 27 Waste Materials........................................................... 27 TIRES......................................................................... 28 Handling Tires............................................................ 28 Storing Tires After Removal............................................... 28 ADDITIONAL JOB SITE RULES......................................................... 29 WHEN REPAIRS ARE NECESSARY........................................................ 30 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK................................... 31 Preliminary Procedures before Welding or Performing Maintenance............... 31 Normal Engine Shutdown Procedure.............................................. 31 Engine Shutdown Procedure before Welding or Performing Maintenance............ 31 TRUCK OPERATION................................................................... 34 PREPARING FOR OPERATION....................................................... 34 Safety Is Thinking Ahead.................................................. 34 WALK AROUND INSPECTION........................................................ 34 ENGINE START-UP SAFETY PRACTICES.............................................. 38 AFTER STARTING THE ENGINE..................................................... 39 Additional Guidelines..................................................... 39 MACHINE OPERATION SAFETY PRECAUTIONS.......................................... 39 MACHINE OPERATION ON THE HAUL ROAD............................................ 40 DYNAMIC RETARDING OPERATION................................................... 41 Dynamic Retarder Control Lever............................................ 41 Dynamic Retarder/Service Brake Pedal...................................... 41 STARTING ON A GRADE WITH A LOADED TRUCK....................................... 42 PASSING....................................................................... 42 LOADING....................................................................... 42 DUMPING....................................................................... 42 Raising The Dump Body..................................................... 42 Lowering The Dump Body.................................................... 43 TOWING........................................................................ 44 SAFE PARKING PROCEDURES....................................................... 45 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................. 45 DELAYED ENGINE SHUTDOWN PROCEDURE............................................. 45 SUDDEN LOSS OF ENGINE POWER................................................... 46 SECTION A4 - WARNINGS AND CAUTIONS.................................................... 47 SECTION A5 - STANDARD CHARTS AND TABLES............................................... 57 SECTION A7 - STORAGE AND IDLE MACHINE PREPARATION - INDEX............................. 63 STORAGE AND IDLE MACHINE PREPARATION.............................................. 65 Short Term Idle Periods....................................................... 65 PREPARATION FOR STORAGE....................................................... 66 REMOVAL FROM STORAGE.......................................................... 67 RECONDITIONING AN IDLE VEHICLE................................................ 69 ENGINE OPERATION.............................................................. 72 After The Engine Has Started.............................................. 73 ENGINE STORAGE................................................................ 74 Preparing Engine For Storage.............................................. 74 Temporary Storage (30 Days Or Less)....................................... 74 Extended Storage (more Than 30 Days)...................................... 74 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................... 76 ELECTRIC DRIVE TRUCKS......................................................... 77 Storage Instructions and Procedures....................................... 77 Placing Equipment Into Storage............................................ 77 Storing A Truck That Is Operational....................................... 77 Storing A Truck That Is Not Operational................................... 78 Storing A Major Component................................................. 78 Periodic Inspections...................................................... 79 Placing Equipment Into Service After Storage.............................. 79 When A Truck Is Operational............................................... 79 When A Truck Is Not Operational........................................... 79 For The First Hour........................................................ 80 SECTION B - STRUCTURES - INDEX............................................................ 81 SECTION B2 - STRUCTURAL COMPONENTS - INDEX............................................ 83 STRUCTURAL COMPONENTS............................................................. 85 Preparation................................................................... 85 GRILLE, HOOD AND LADDER....................................................... 86 Removal................................................................... 86 Installation.............................................................. 86 DECKS......................................................................... 87 RIGHT DECK AND COMPONENTS..................................................... 87 Removal................................................................... 87 Installation.............................................................. 88 LEFT DECK..................................................................... 88 Removal................................................................... 88 Installation.............................................................. 88 CENTER DECK................................................................... 88 SECTION B3 - DUMP BODY - INDEX........................................................ 89 DUMP BODY......................................................................... 91 Removal....................................................................... 91 Installation.................................................................. 92 BODY PADS..................................................................... 93 Adjustment................................................................ 93 BODY GUIDE.................................................................... 94 HOIST LIMIT SWITCH............................................................ 94 BODY UP SWITCH................................................................ 94 BODY-UP RETENTION CABLE....................................................... 94 ROCK EJECTORS................................................................. 95 Rock Ejectors................................................................. 95 Inspection................................................................ 95 SECTION B4 - FUEL TANK - INDEX........................................................ 97 FUEL TANK......................................................................... 99 Removal.......................................................................100 Installation..................................................................100 Repair........................................................................100 Cleaning......................................................................100 FUEL GAUGE SENDER.............................................................101 Removal...................................................................101 Installation..............................................................101 LOW FUEL SWITCH...............................................................101 WIGGINS QUICK FILL FUEL SYSTEM....................................................102 FUEL RECEIVER.................................................................102 TANK BREATHER VALVE...........................................................102 Removal...................................................................102 Installation..............................................................102 Disassembly...............................................................102 Assembly..................................................................102 LEFT SIDE FILL................................................................103 SECTION C - ENGINE - INDEX................................................................105 SECTION C2 - POWER MODULE - INDEX.....................................................107 POWER MODULE......................................................................109 Preparation...................................................................109 Preparation for Removal.......................................................110 Removal - Power Module........................................................113 Installation - Power Module...................................................115 Hookup - Power Module.........................................................115 SECTION C3 - COOLING SYSTEM - INDEX...................................................117 COOLING SYSTEM....................................................................119 RADIATOR......................................................................119 Removal - Radiator........................................................119 Installation - Radiator...................................................121 RADIATOR FILLING PROCEDURE....................................................122 RADIATOR REPAIR...............................................................122 Internal Inspection.......................................................122 External Cleaning.........................................................122 Disassembly...............................................................123 Cleaning and Inspection...................................................124 Assembly..................................................................124 Pressure Testing..........................................................125 Additional Service Information............................................125 COOLANT SYSTEM TROUBLESHOOTING................................................126 SECTION C4 - POWERTRAIN - INDEX.......................................................127 POWER TRAIN.......................................................................129 ALTERNATOR....................................................................129 Removal - Alternator......................................................129 ENGINE/ALTERNATOR MATING......................................................131 General Instructions......................................................131 Measuring Procedure.......................................................131 Joining The Alternator and Engine.........................................133 ENGINE........................................................................134 Removal...................................................................134 Service...................................................................134 Installation..............................................................134 SECTION C5 - AIR CLEANERS - INDEX.....................................................135 AIR CLEANERS......................................................................137 AIR CLEANERS..................................................................137 Operation.................................................................137 General Service Information...............................................137 FILTER ELEMENT REPLACEMENT....................................................138 Main Filter Element Cleaning..............................................139 Precleaner Section........................................................140 Cleaning Precleaner Tubes.................................................140 AIR INTAKE TROUBLESHOOTING....................................................141 SECTION C7 - FAN CLUTCH - INDEX.......................................................143 FAN CLUTCH........................................................................145 REMOVAL & INSTALLATION TOOLING................................................145 FAN CLUTCH - DISASSEMBLY......................................................148 CLEANING AND INSPECTION.......................................................158 ASSEMBLY - FAN CLUTCH.........................................................162 TEST PROCEDURE................................................................176 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..............................177 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX.....................................179 24VDC ELECTRIC SUPPLY SYSTEM......................................................181 ELECTRICAL SYSTEM DESCRIPTION.................................................181 BATTERIES.................................................................181 Maintenance and Service...................................................181 Troubleshooting...........................................................181 BATTERY SUPPLY SYSTEM.........................................................183 24VDC Batter Charging Alternator..........................................183 Battery Box...............................................................183 Batter Control Box........................................................184 Battery Disconnect Switches...............................................184 24VDC Auxiliary Battery Connectors........................................184 24VDC to 12VDC Converter..................................................185 Isolation Diodes..........................................................185 Engine Starter Relay......................................................185 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX...............................187 24 VDC ELECTRICAL SYSTEM COMPONENTS...............................................189 TRUCK SHUTDOWN PROCEDURE......................................................189 24 VDC ELECTRICAL SYSTEM COMPONENTS...........................................189 Brake Warning Buzzer (BWB)................................................189 AUXILIARY CONTROL CABINET COMPONENTS..........................................189 Fuse Block 1 & 2..........................................................190 Power Distribution Terminals..............................................190 PULSE VOLTAGE MODULATOR...................................................190 5 Minute Idle Timer Components............................................192 5 Minute Idle Timer.......................................................192 5 Minute Idle Circuit Test................................................192 Tail Light Resistor Diode Assemblies......................................192 Engine Starter Failure Delay Timer........................................192 Lubrication System Timer..................................................194 Auto Lube Delay Timer.....................................................194 Barometric Pressure Transducer............................................194 Kontrol Power Relay.......................................................194 Alarm Indicating Device (AID) System......................................196 Temperature and Latch.....................................................197 Hot Switch Inverter.......................................................197 Hot Switch Inverter Card (Slot 4) (Not Used)..............................197 Oil Level.................................................................197 Temperature...............................................................197 Diode Matrix (Without Sound)..............................................197 Diode Matrix (With Sound).................................................197 Lamp Test.................................................................198 Diode Board - DB1.........................................................198 Diode Testing.............................................................198 RELAY BOARDS..................................................................199 Relay Boards RB1, RB3, RB4, RB5...........................................199 Service...................................................................199 Relay Board Identification................................................200 RELAY BOARD FUNCTIONS.........................................................201 Relay Board 1 (RB1).......................................................201 Relay Board 3 (RB3).......................................................201 Relay Board 6, 7 & 8 (RB6, RB7, RB8)......................................202 Installing Additional Circuits............................................202 BODY-UP SWITCH................................................................203 Operation.................................................................203 Adjustment................................................................203 Service...................................................................203 HOIST LIMIT SWITCH............................................................204 Operation.................................................................204 Adjustment................................................................204 Service...................................................................204 FUSE BLOCKS...................................................................205 CIRCUIT BREAKERS..............................................................205 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX.....................................207 BATTERY CHARGING ALTERNATOR.......................................................209 ELECTRICAL SYSTEM DESCRIPTION.................................................209 BATTERY.......................................................................209 Maintenance and Service...................................................209 Troubleshooting...........................................................209 BATTERY CHARGING SYSTEM (Niehoff).............................................211 General Description.......................................................211 TROUBLESHOOTING PROCEDURES (On-Truck).........................................211 Equipment Required:.......................................................211 Preliminary Checks........................................................212 Test Setup................................................................212 Test Procedure............................................................212 Regulator Bypass Test.....................................................213 ON VEHICLE TROUBLESHOOTING GUIDE..................................................215 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage....215 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................215 CHARGE VOLT AND AMP VALUES....................................................216 DEFINITIONS...................................................................216 ADVANCED SYSTEM TROUBLESHOOTING...................................................217 Static Test - Engine OFF, Key ON, Battery Switch ON...........................217 Go To Alternator..............................................................217 Go To Regulator (If Required).................................................218 Go To Regulator Connector On The Alternator...................................218 ALTERNATOR OVERHAUL...............................................................219 ALTERNATOR DIMENSIONS.........................................................219 ALTERNATOR SPECIFICATIONS.....................................................220 SERVICE PARTS.................................................................221 ON-VEHICLE TEST...............................................................223 Equipment:................................................................223 Preliminary Checks:.......................................................223 Test Set-up...............................................................223 Test Procedure............................................................223 ON-VEHICLE TEST...............................................................224 Bypass Test:..............................................................224 BENCH TEST....................................................................225 STATIC TESTS..................................................................226 Regulator Tests...........................................................226 Control Box Tests.........................................................227 ALTERNATOR DISASSEMBLY........................................................229 ASSEMBLY- ALTERNATOR..........................................................234 BF4822 STATOR SERVICE TOOL INSTRUCTIONS...........................................243 Stator Removal And Replacement................................................243 Stator Installation...........................................................244 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX..........................................247 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX..........................249 ELECTRICAL PROPULSION SYSTEM COMPONENTS...........................................251 GENERAL SYSTEM DESCRIPTION....................................................251 SYSTEM COMPONENTS.............................................................253 Propulsion System Controller(PSC).........................................253 Truck Control Interface (TCI).............................................253 Diagnostic Information Display............................................255 DID Panel Event Codes.....................................................255 PSC SOFTWARE FUNCTIONS........................................................279 Input Processing..........................................................279 STATE MANAGEMENT..............................................................279 State Machine.............................................................279 DC Link State.............................................................282 Powering the Link.........................................................282 De-Powering the Link......................................................282 Control Functions.........................................................282 ALTERNATOR FIELD CONTROL......................................................283 Desired Three-Phase Voltage...............................................283 Desired DC Link Voltage...................................................283 Self-load.................................................................283 Propel Torque Control.....................................................284 Retard Torque Control.....................................................284 Wheel Slide Control.......................................................284 Resistor Grid Control.....................................................285 Chopper Voltage Control...................................................285 EVENT PROCESSING..............................................................285 Event Detection...........................................................285 Power On Tests............................................................285 Initiated Tests...........................................................286 Periodic Tests............................................................286 EVENT RESTRICTIONS............................................................286 EVENT LOGGING AND STORAGE.....................................................286 Event History Buffer......................................................287 Data Packs................................................................287 To Record and Save a Data Pack to a Floppy Disk...........................287 Event Reset...............................................................288 SERIAL DATA COMMUNICATIONS....................................................289 PSC - PTU Communications Processing.......................................289 Inverter Communications Processing........................................289 OUTPUT PROCESSING.............................................................290 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS......................................290 Fast Start................................................................290 Engine Shutdown/Engine Not Running........................................290 Limp Home Mode............................................................290 Entering/Exiting Limp Home Mode...........................................290 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.....................................291 ELECTRONIC ACCELERATOR AND RETARD PEDALS......................................303 Removal...................................................................303 Installation..............................................................303 Disassembly...............................................................303 Assembly..................................................................303 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX....................305 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.....................................307 AC DRIVE SYSTEM MAINTENANCE...................................................307 TRUCK SHUTDOWN PROCEDURES.....................................................307 NORMAL TRUCK SHUTDOWN PROCEDURE...............................................308 SHUTDOWN AFTER SYSTEM FAILURE.................................................309 SYSTEM CHECKOUT...............................................................310 Battery and Control Checks of System WITH Battery Power OFF...............310 Battery and Control Circuit Checks of System With Battery Power ON........313 Checks with Key Switch OFF................................................314 CPU Battery Checks........................................................316 MEMORY BACKUP BATTERY REPLACEMENT.............................................316 TCI PROGRAMMING...............................................................317 PSC PROGRAMMING...............................................................317 INVERTER PROGRAMMING..........................................................318 TCI CHECKOUT..................................................................318 Modular Mining Communication Port.........................................319 TCI Input Checks..........................................................320 TCI Digital Output Tests..................................................322 TCI Digital Input Tests...................................................324 PSC Checkout Procedure....................................................326 PSC Digital Input Checks..................................................330 Miscellaneous Checks......................................................331 A3PV Panel................................................................331 LINKV Panel...............................................................331 Thermistor Checks.........................................................331 17FM384 Panel Check.......................................................331 Pedal Percentages and Meter Calibration...................................332 Meter Calibration Procedure...............................................332 Reprogram With Serial Numbers and Pedal Percentages.......................334 LOAD TESTING..................................................................336 Preload Checks............................................................336 ADDITIONAL TRUCK CHECKS.......................................................338 On-Board Load Testing.....................................................340 Preparation...............................................................340 Initiate Loadbox Test.....................................................343 Manual Offset HP Output Adjustment........................................345 TROUBLESHOOTING...................................................................347 PVM Optimum Load Curve Handshaking Troubleshooting............................347 MISCELLANEOUS COMPONENT REPAIR................................................348 Troubleshooting Phase Modules and Chopper Modules.........................348 Phase Module Removal and Snubber Resistor Replacement.....................348 Snubber Resistor Installation.............................................349 Phase Module Installation.................................................349 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING..............................350 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING..............................353 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING......................................354 IGBT TROUBLESHOOTING..........................................................355 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX........................................357 SECTION G2 - TIRES AND RIMS - INDEX...................................................359 TIRES AND RIMS....................................................................361 WHEEL STUD MAINTENANCE........................................................362 FRONT TIRES AND RIMS..........................................................363 Removal...................................................................363 Installation..............................................................364 REAR TIRES AND RIMS...........................................................365 Removal...................................................................365 Installation..............................................................366 RIM...........................................................................367 Tire Removal..............................................................367 Tire Installation.........................................................368 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX......................................371 FRONT WHEEL HUB AND SPINDLE.......................................................373 WHEEL HUB AND SPINDLE ASSEMBLY................................................373 Preparation...............................................................373 Removal...................................................................373 Installation - Wheel Hub and Spindle Assembly.............................376 Disassembly - Wheel Hub and Spindle Assembly..............................377 Cleaning and Inspection - Wheel Hub and Spindle Assembly..................377 Assembly - Wheel Hub and Spindle Assembly.................................379 Wheel Bearing Adjustment:.................................................379 Brake Installation........................................................380 Seal Assembly Gap Check...................................................381 STEERING CYLINDERS AND TIE ROD................................................382 Spherical Bearing Wear Limits.............................................382 Removal - Steering Cylinder and Tie Rod...................................383 Installation - Steering Cylinder and Tie Rod..............................384 Bearing Replacement.......................................................384 TOE-IN ADJUSTMENT.............................................................385 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX.....................................387 REAR AXLE HOUSING ATTACHMENT......................................................389 PIVOT PIN.....................................................................389 Removal...................................................................389 Installation..............................................................390 PIVOT EYE BEARING.............................................................391 Removal...................................................................391 Installation..............................................................391 PIVOT EYE REPAIR..............................................................391 Removal...................................................................391 Disassembly...............................................................391 Assembly..................................................................392 Installation..............................................................392 ANTI-SWAY BAR.................................................................392 Removal...................................................................392 Installation..............................................................393 Disassembly...............................................................393 Cleaning and Inspection...................................................393 Assembly..................................................................393 SECTION G5 - REAR AXLE HOUSING - INDEX................................................395 REAR AXLE HOUSING.................................................................397 REAR AXLE HOUSING.............................................................397 Preparation...............................................................397 Removal...................................................................397 Cleaning and Inspection - Rear Axle Housing...............................399 Installation - Rear Axle Housing..........................................399 WHEEL MOTOR...................................................................400 Preparation...............................................................400 Removal...................................................................400 Cleaning and Inspection - Wheel Motor.....................................401 Installation - Wheel Motor................................................402 WHEEL MOTOR GEAR OIL..........................................................405 Filtering Requirements....................................................405 Particle Size Analysis....................................................405 Flushing..................................................................405 Oil Sample Analysis.......................................................406 ELEMENT SPECIFICATION CHARTS..................................................407 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................411 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................413 FRONT SUSPENSION..................................................................415 Removal.......................................................................415 Installation - Front Suspension...............................................416 "Turn-Of-The-Nut" Tightening Procedure........................................419 MINOR REPAIRS (LOWER BEARING & SEALS).........................................420 Removal - Bearing Retainer................................................420 Installation - Bearing Retainer...........................................420 MAJOR SUSPENSION REBUILD......................................................422 Disassembly...............................................................422 Assembly..................................................................422 SECTION H3 - REAR SUSPENSIONS - INDEX.................................................425 REAR SUSPENSIONS..................................................................427 SUSPENSION CYLINDER...........................................................428 Removal...................................................................428 Installation - Rear Suspension............................................430 Disassembly - Rear Suspension.............................................430 Cleaning and Inspection - Rear Suspension.................................430 Assembly - Rear Suspension................................................431 SUSPENSION PRESSURE TEST......................................................433 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX.........................435 SUSPENSION OILING AND CHARGING PROCEDURE..........................................437 GENERAL.......................................................................437 EQUIPMENT LIST................................................................437 Hydrair® Charging Kit.....................................................437 Installation of Charging Kit..............................................437 Removal of Charging Kit...................................................438 Support Blocks For Oiling And Charging Dimensions.........................438 FRONT SUSPENSION..............................................................439 Front Suspension Oiling...................................................439 Front Suspension Nitrogen Charging........................................440 REAR SUSPENSION...............................................................441 Rear Suspension Oiling....................................................441 Rear Suspension Nitrogen Charging.........................................443 OIL AND NITROGEN SPECIFICATIONS CHART.............................................444 SECTION J - BRAKE CIRCUIT - INDEX.........................................................445 SECTION J2 - BRAKE CIRCUIT - INDEX....................................................447 BRAKE CIRCUIT.....................................................................449 SERVICE BRAKE CIRCUIT.........................................................449 SECONDARY BRAKING AND AUTOMATIC APPLY.........................................451 PARKING BRAKE CIRCUIT.........................................................451 Normal Operation (key switch on, engine running)..........................451 BRAKE LOCK CIRCUIT............................................................452 WARNING CIRCUIT...............................................................452 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX..................................455 BRAKE CIRCUIT COMPONENT SERVICE...................................................457 BRAKE VALVE...................................................................457 Rebuild Criteria..........................................................457 Removal...................................................................458 Installation..............................................................458 Disassembly...............................................................459 Cleaning and Inspection...................................................462 Assembly..................................................................462 Actuator Base Threaded Inserts............................................462 Boot and Cap..............................................................462 Valve Body Seal Installation..............................................462 Regulator Sleeve O-Ring Installation......................................463 Actuator Plunger O-ring Installation......................................463 Assembly of Valve.........................................................463 DIFFERENTIAL PRESSURE SWITCH..................................................465 Disassembly...............................................................465 Cleaning and Inspection...................................................465 Assembly..................................................................465 VALVE BENCH TEST AND ADJUSTMENT...............................................466 Test Set Up Procedure.....................................................467 Brake Valve Output Pressure Adjustment....................................467 Differential Pressure Switch Adjustment...................................467 Final Test and Adjustment.................................................468 Installation Of Brake Pedal Actuator Assembly to Brake Valve..............469 Installation of Retard Pedal To Brake Pedal...............................469 DUAL RELAY VALVE..............................................................471 Removal...................................................................471 Installation..............................................................471 Disassembly...............................................................473 Cleaning and Inspection...................................................473 Assembly..................................................................473 DIFFERENTIAL PRESSURE SWITCH..................................................474 Disassembly...............................................................474 Cleaning and Inspection...................................................474 Assembly..................................................................474 VALVE TEST AND ADJUSTMENT.....................................................475 Test Set Up Procedure.....................................................476 Relay Valve Output Pressure Adjustment....................................476 Differential Pressure Switch Adjustment...................................477 BRAKE MANIFOLD................................................................478 Removal...................................................................478 Installation..............................................................479 Disassembly...............................................................479 Cleaning and Inspection...................................................479 Assembly..................................................................479 BRAKE ACCUMULATORS............................................................480 Brake Accumulator Bleeddown Procedure.....................................480 BRAKE ACCUMULATOR REPAIR......................................................481 Removal...................................................................481 Installation..............................................................481 Disassembly...............................................................482 Cleaning and Inspection...................................................483 Assembly..................................................................483 ACCUMULATOR CHARGING PROCEDURE................................................485 Temperature During Precharge..............................................486 Precharge Maintenance.....................................................487 Recharging Accumulators...................................................487 Accumulator Storage procedures............................................488 Bladder Storage Procedures................................................488 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)..................................489 Removal.......................................................................489 Installation..................................................................489 Disassembly and Adjustment....................................................489 Potentiometer Check...........................................................491 Assembly......................................................................491 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................493 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................495 REQUIRED EQUIPMENT............................................................497 INITIAL SYSTEM SET-UP.........................................................498 BRAKE SYSTEM CHECKOUT.........................................................499 Failure Modes Check-Out...................................................500 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART...............................502 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................505 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................506 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX..........................................507 WET DISC BRAKE ASSEMBLY...........................................................509 OPERATION.....................................................................509 MAINTENANCE...................................................................510 Brake Disc Wear Indicator.................................................510 Removal/Installation - Wet Disc Brake Assembly............................510 BRAKE REBUILD.................................................................512 Disassembly...............................................................512 Cleaning and Inspection...................................................515 Assembly..................................................................516 Floating Ring Seal Assembly/Installation..................................519 WET DISC BRAKE BLEEDING PROCEDURE.............................................522 SECTION J7 - PARKING BRAKE - INDEX....................................................523 PARKING BRAKE.....................................................................525 OPERATION.....................................................................525 MAINTENANCE...................................................................526 Inspection - Parking Brake................................................526 Removal - Parking Brake...................................................526 Installation - Parking Brake..............................................527 Disassembly - Parking Brake...............................................528 Cleaning and Inspection - Parking Brake...................................528 Assembly - Parking Brake..................................................528 PARKING BRAKE BLEEDING PROCEDURE..............................................530 SECTION L - HYDRAULIC SYSTEM - INDEX......................................................531 SECTION L2 - HYDRAULIC SYSTEM - INDEX.................................................533 HYDRAULIC SYSTEM..................................................................535 HYDRAULIC PUMP MODULE.........................................................535 HOIST CIRCUIT OPERATION.......................................................536 STEERING CIRCUIT OPERATION....................................................538 DISC BRAKE COOLING SYSTEM.....................................................540 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................543 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................545 HOIST PUMP....................................................................545 Removal...................................................................545 Installation..............................................................547 INSPECTION OF PARTS...........................................................552 Assembly..................................................................552 HYDRAULIC TANK................................................................558 Filling Instructions......................................................558 Removal...................................................................558 Installation..............................................................559 HYDRAULIC TANK STRAINERS......................................................559 Removal...................................................................559 Inspect and Clean.........................................................559 Installation..............................................................559 HYDRAULIC TANK BREATHERS......................................................560 SECTION L4 - STEERING CIRCUIT - INDEX.................................................561 STEERING CIRCUIT..................................................................563 COMPONENT DESCRIPTION.........................................................564 Steering Control Unit.....................................................564 Bleeddown Manifold Valve..................................................565 Bleeddown Solenoid........................................................565 Relief Valves.............................................................567 Hoist Limit Solenoid......................................................567 Accumulators..............................................................567 Low Precharge Warning Switch..............................................567 High Pressure Filter......................................................567 Quick Disconnect Ports....................................................567 Flow Amplifier............................................................568 FLOW AMPLIFIER SYSTEM OPERATION...............................................570 No Steer..................................................................570 Steering Left.............................................................572 Steering Right............................................................574 No Steer, External Shock Load.............................................576 STEERING PUMP.................................................................578 Operation.................................................................578 PRINCIPLE OF OPERATION........................................................580 Full Pump Volume:.........................................................580 Half Pump Volume:.........................................................580 Neutral Position:.........................................................580 Steering Pump.............................................................581 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................583 STEERING CONTROL UNIT.............................................................585 Removal.......................................................................585 Spline Inspection.............................................................585 Installation..................................................................586 STEERING CONTROL UNIT REBUILD.................................................586 Disassembly...............................................................586 Cleaning and Inspection - Steering Control Unit...........................587 Assembly - Steering Control Unit..........................................589 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................593 STEERING CIRCUIT COMPONENT REPAIR.................................................595 BLEEDDOWN MANIFOLD VALVE......................................................595 Removal...................................................................595 Installation..............................................................595 FLOW AMPLIFIER................................................................597 Removal...................................................................597 Installation..............................................................597 FLOW AMPLIFIER REBUILD........................................................597 Disassembly...............................................................600 Assembly..................................................................601 STEERING CYLINDERS............................................................602 Disassembly...............................................................603 Piston Seal & Bearing Installation........................................603 Cylinder Assembly.........................................................603 Test......................................................................603 STEERING AND BRAKE PUMP.......................................................604 Removal...................................................................604 Installation..............................................................604 Disassembly...............................................................606 Control Piston Group......................................................606 Valve Plate Group.........................................................606 Rotating Group............................................................609 Swashblock Group..........................................................609 Driveshaft Group..........................................................609 Inspection................................................................609 Control Piston Group......................................................609 Valve Plate Group.........................................................609 Rotating Group............................................................609 Swashblock Group..........................................................611 Driveshaft Group..........................................................612 Compensator Block and Unloader Module.....................................612 Stroke Adjuster Assembly..................................................612 Assembly..................................................................612 Swashblock Group..........................................................612 Driveshaft Group..........................................................613 Rotating Group............................................................613 Valve Plate Group.........................................................614 STEERING ACCUMULATORS.........................................................615 Removal...................................................................615 Installation..............................................................615 Disassembly...............................................................616 Cleaning and Inspection...................................................616 Assembly..................................................................617 Leak Testing..............................................................619 Charging Procedure........................................................620 Temperature During Precharge..............................................621 Precharge Maintenance.....................................................622 Accumulator Storage procedures............................................623 Bladder Storage Procedures................................................623 TROUBLESHOOTING CHART.............................................................624 SECTION L7 - HOIST CIRCUIT - INDEX....................................................629 HOIST CIRCUIT.....................................................................631 HOIST CIRCUIT OPERATION.......................................................631 COMPONENT DESCRIPTION.........................................................632 Hydraulic Tank............................................................632 Hydraulic Pump............................................................632 High Pressure Filters.....................................................632 Hoist Valve...............................................................632 Inlet Sections - Hoist Valve..............................................632 Spool Sections - Hoist Valve..............................................633 Hoist Pilot Valve.........................................................633 Bleeddown Manifold........................................................634 Hoist-up Limit Solenoid...................................................634 Pilot Operated Check Valve................................................634 Overcenter Manifold.......................................................634 HOIST CIRCUIT OPERATION...........................................................635 Float Position Of Pilot Valve With Truck Body On Frame........................636 Power Up Operation............................................................638 Hold Operation................................................................640 Power Down Operation..........................................................642 Float Operation...............................................................644 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...................................647 HOIST CIRCUIT COMPONENT REPAIR....................................................649 HOIST VALVE...................................................................649 Removal...................................................................649 Installation..............................................................650 O-Ring Replacement........................................................650 INLET SECTION.................................................................651 Disassembly...............................................................651 Cleaning and Inspection...................................................652 Assembly..................................................................652 REAR SPOOL SECTION (Work Ports)...............................................652 Disassembly...............................................................652 Cleaning and Inspection...................................................654 Assembly..................................................................654 FRONT SPOOL SECTION (Tank Ports)..............................................655 Disassembly...............................................................655 Cleaning and Inspection...................................................655 Assembly..................................................................655 HOIST PILOT VALVE.............................................................657 Removal...................................................................657 Installation..............................................................657 Disassembly...............................................................658 Cleaning and Inspection...................................................659 Assembly..................................................................659 HOIST CYLINDERS...............................................................660 Removal...................................................................660 Installation..............................................................661 Disassembly...............................................................663 Cleaning and Inspection...................................................664 Assembly - Quill and Cylinder.............................................665 Quill Installation........................................................665 Installation Of Check Balls And Plugs In Quill............................666 Assembly of Cylinder......................................................667 OVERCENTER VALVE MANIFOLD.....................................................668 DISABLED TRUCK DUMPING PROCEDURE..............................................669 Hookup....................................................................669 Raising the Body..........................................................669 Lowering the Body.........................................................669 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.........................................671 HYDRAULIC SYSTEM FILTERS..........................................................673 HOIST CIRCUIT FILTER..........................................................673 Filter Element Replacement................................................673 Removal - Hoist Circuit Filter............................................674 Installation - Hoist Circuit Filter.......................................674 Indicator Switch - Hoist Circuit Filter...................................674 STEERING CIRCUIT FILTER.......................................................675 Filter Element Replacement................................................675 Removal - Steering Circuit Filter.........................................676 Installation - Steering Circuit Filter....................................676 Indicator Switch - Steering Circuit Filter................................676 INDICATOR SWITCH..............................................................676 Test Procedure............................................................676 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...................................679 HYDRAULIC CHECK-OUT PROCEDURE.....................................................681 GENERAL INFORMATION...........................................................681 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.............................681 Equipment Requirements....................................................682 Pump Pressure Control Adjustments.........................................682 Steering Control Valve and Flow Amplifier Leakage Test....................683 Bleeddown Manifold Leakage Test...........................................683 STEERING/BRAKE PUMP STROKE ADJUSTMENT.........................................684 SHOCK AND SUCTION VALVES......................................................685 Equipment Requirements....................................................685 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.................686 Equipment Requirements....................................................686 Pressure Gauge Locations..................................................686 Brake Cooling Circuit Test................................................686 Power Up Relief Pressure Test.............................................687 Adjustment................................................................687 Power Down Relief Pressure Test...........................................688 Hoist Counterbalance Valve Adjustment Preparation.........................689 Counterbalance Valve Pressure Check.......................................689 Counterbalance Valve Adjustment...........................................690 Preparation...............................................................691 Flushing Procedure........................................................691 Filter Element Replacement................................................692 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.............................693 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................694 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.............................................695 SECTION M2 - FIRE CONTROL SYSTEM - INDEX .............................................697 FIRE CONTROL SYSTEM (MANUAL)......................................................699 Operation.....................................................................699 Inspection and Maintenance....................................................699 Recharging Procedures.........................................................700 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1......................701 Control Module................................................................701 Actuator......................................................................702 Linear Detection Wire.........................................................702 Power Wire....................................................................702 Test Kit......................................................................702 Squib.........................................................................702 Securing the Detection Wire...................................................703 Preliminary Test Before Final Hook-Up.........................................703 Installation Procedure for Squib..............................................705 Placing the Electric Detection & Actuation System Into Service................705 INSPECTION AND MAINTENANCE SCHEDULES..........................................706 Daily.....................................................................706 Normal Maintenance Based On Actual Operating Hours........................706 IN CASE OF FIRE...............................................................707 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.....................................709 SECTION M8 - SPECIAL TOOLS............................................................711 SECTION M20 - PAYLOAD METER III - INDEX...............................................717 OPERATION SECTION.................................................................721 Introduction..................................................................721 Data Summary..............................................................721 Data Gathering............................................................721 COMPONENT DESCRIPTION.........................................................722 System Diagram............................................................722 Suspension Pressure Sensors...............................................722 Inclinometer..............................................................722 Operator Display..........................................................722 Operator Switch...........................................................723 Speed Input...............................................................723 Body-Up Switch............................................................723 Brake Lock Switch.........................................................723 Payload Meter.............................................................723 Communications Ports......................................................723 Keyswitch Input...........................................................724 Payload Meter Power.......................................................724 Load Lights...............................................................724 Wiring and Termination....................................................725 TCI Outputs...............................................................725 OPERATOR’S DISPLAY AND SWITCH.................................................726 Reading the Speedometer...................................................726 Reading the Load Display..................................................726 Using the Operator ID.....................................................726 Using the Load and Ton Counter............................................726 Total Ton Counter.........................................................726 Total Load Counter........................................................727 Clearing the Counters.....................................................727 Viewing Live Sensor Data..................................................727 Other Display Messages....................................................727 PAYLOAD OPERATION & CALCULATION...............................................728 Description of Haul Cycle States..........................................728 Haul Cycle Description....................................................728 Load Calculation..........................................................729 Carry Back................................................................729 Measurement Accuracy......................................................729 SOURCES FOR PAYLOAD ERROR.....................................................729 Payload Error.............................................................729 Loading Conditions........................................................730 Pressure Sensors..........................................................730 Swingloads................................................................730 Speed and Distance........................................................730 HAUL CYCLE DATA...............................................................730 Haul Cycle Data...........................................................731 Haul Cycle Warning Flags..................................................732 M: Haul Cycle Too Long....................................................733 N: Sensor Input Error.....................................................733 Frame Torque Data.........................................................733 Sprung Weight Data........................................................733 Maximum Speed Data........................................................733 Alarm Records.............................................................733 Fault Code Data...........................................................734 PC SOFTWARE OVERVIEW..........................................................735 PC Overview...............................................................735 System Configuration......................................................735 Installing the PLMIII Software............................................735 DOWNLOADING DATA..............................................................736 PLM III SYSTEM CONFIGURATION..................................................737 Starting Communications...................................................737 Displayed Payload Units...................................................737 Time Units................................................................737 Connection Menu...........................................................737 Connecting to the Payload Meter...........................................738 Configure the Payload Meter...............................................738 Setting the Date and Time.................................................738 Setting the Truck Type....................................................739 Setting the Gauge Display Units...........................................739 Setting the Frame Serial Number...........................................739 Setting the Truck Number..................................................739 Setting the Komatsu Distributor...........................................739 Setting the Komatsu Customer..............................................739 Clean Truck Tare..........................................................740 Inclinometer Calibration..................................................740 DATA ANALYSIS.................................................................741 Creating a Query..........................................................741 Sorting on Truck Unit Number..............................................741 Sorting on Truck Type.....................................................741 Sorting on Date Range.....................................................742 Sorting on Time Range.....................................................742 Payload Detail Screen.....................................................743 Creating Reports..........................................................743 Summary - one page report.................................................744 Detailed - multi-page report..............................................744 Creating Graphs...........................................................745 Exporting Data............................................................745 CSV Export................................................................745 Compressed................................................................746 Importing Data............................................................747 Deleting Haul Cycle Records...............................................747 Viewing Alarms............................................................748 Deleting Alarm Records....................................................748 TROUBLESHOOTING SECTION...........................................................749 TROUBLESHOOTING...............................................................749 Viewing Active Alarms.....................................................749 Real-Time Data Display....................................................749 Testing the Payload Lights................................................749 Creating Log Files of Inputs..............................................750 Daily Inspections.........................................................750 Periodic Maintenance......................................................750 Abnormal Displays at Power-Up.............................................751 No Payload Display When Keyswitch is Turned ON............................752 No Display on Speedometer.................................................753 No Display on Operator Display............................................753 No Communications With PC.................................................754 Load Lights Don’t Light During Loading....................................755 Load Lights Remain ON.....................................................756 Load Lights Remain ON During Dumping......................................756 Display Doesn't Clear When The Load Is Dumped.............................756 Calibration Problems......................................................757 Alarm 1 - Left Front Pressure High........................................758 Alarm 2 - Left Front Pressure Low.........................................758 Troubleshoot Wiring to Left Front Suspension..............................758 Alarm 3 - Right Front Pressure High.......................................759 Alarm 4 - Right Front Pressure Low........................................759 Troubleshoot Wiring to Right Front Suspension.............................759 Alarm 5 -Left Rear Pressure High..........................................760 Alarm 6 - Left Rear Pressure Low..........................................760 Troubleshoot Wiring to Left Rear Suspension...............................760 Alarm 7 - Right Rear Pressure High........................................761 Alarm 8 - Right Rear Pressure Low.........................................761 Troubleshoot Wiring to Right Rear Suspension..............................761 Alarm 9 - Inclinometer High...............................................762 Alarm 10 - Inclinometer Low...............................................762 Troubleshoot Inclinometer Wiring..........................................762 Alarm 13 - Body Up Input Failure..........................................763 Alarm 16 - Memory Write Failure...........................................764 Alarm 17 - Memory Read Failure............................................764 Alarm 18..................................................................765 Alarm 19..................................................................765 Alarm 22..................................................................765 Operator Switch Doesn't Work..............................................766 Alarm 26 - User Switch Fault - SELECT.....................................766 Alarm 27 - User Switch Fault - SET........................................766 Connector Map.............................................................767 Connectors................................................................768 PLMIII CHECK OUT PROCEDURE........................................................769 General Description...........................................................769 Tools Required................................................................769 Checkout Procedure............................................................769 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................773 Flashburn Programming.....................................................773 Confirmation Checklist....................................................775 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX.......................................777 RESERVE ENGINE OIL SYSTEM.........................................................779 Operation.....................................................................779 LED Monitor Light.............................................................780 Tank Fill Control (Optional)..................................................780 Filling Procedure (Remote fill feature).......................................780 SERVICE.......................................................................781 Every 10 Hours, or once each shift:.......................................781 Every 500 Hours:..........................................................781 Changing Oil..............................................................781 TROUBLESHOOTING...............................................................782 Circuit Breaker or Fuse...................................................782 SYSTEM ELECTRICAL SCHEMATICS..................................................783 SECTION N - CAB COMPONENTS - INDEX........................................................785 SECTION N2 - TRUCK CAB - INDEX........................................................787 TRUCK CAB.........................................................................789 Description...................................................................789 Preparation...................................................................790 Removal - Cab.................................................................790 Installation - Cab............................................................792 CAB DOOR......................................................................792 Removal...................................................................792 Installation..............................................................792 Door Adjustment...........................................................793 Door Jamb Bolt Adjustment.................................................793 Door Handle Plunger Adjustment............................................794 Door Glass Replacement....................................................795 Door Window Regulator Replacement.........................................799 Door Handle or Latch Assembly Replacement.................................799 Door and Door Hinge Seal Replacement......................................800 Door Opening Seal Removal.................................................800 Installation..............................................................800 GLASS REPLACEMENT.............................................................801 Adhesive Bonded Windows...................................................801 Replacement Procedure.....................................................801 Windshield And Rear Glass.................................................802 Removal...................................................................802 Installation..............................................................803 SECTION N3 - CAB COMPONENTS - INDEX...................................................805 CAB COMPONENTS....................................................................807 WINDSHIELD WIPERS.............................................................807 Wiper Motor Replacement...................................................807 Removal...................................................................807 Installation..............................................................807 Wiper Arm.................................................................807 Removal...................................................................807 Installation..............................................................808 Wiper Linkage Replacement.................................................808 Removal...................................................................808 Installation..............................................................808 WINDSHIELD WASHER.............................................................809 Operation.................................................................809 Service...................................................................809 OPERATOR SEAT.................................................................810 Adjustment................................................................810 Seat Removal..............................................................810 Seat Installation.........................................................810 SECTION N4 - OPERATOR COMFORT - INDEX.................................................811 OPERATOR COMFORT..................................................................813 HEATER / AIR CONDITIONER......................................................813 Operation.................................................................813 Heater/Air Conditioner Vents..............................................813 COMPONENTS....................................................................814 Circuit Breakers..........................................................814 Relays....................................................................814 Heater Core...............................................................814 Fan Motor And Speed Control...............................................815 Actuators.................................................................815 Cab Air Filter............................................................815 AIR CONDITIONING SYSTEM...........................................................817 Environmental Impact..........................................................817 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................818 PRINCIPLES OF REFRIGERATION...................................................818 Air Conditioning..........................................................818 Refrigeration - The Act Of Cooling........................................819 The Refrigeration Cycle...................................................819 AIR CONDITIONER SYSTEM COMPONENTS.............................................820 Compressor (Refrigerant Pump).............................................820 Service Valves............................................................820 Condenser.................................................................820 Receiver-Drier............................................................820 Expansion Block Valve.....................................................821 Accumulator...............................................................821 Evaporator................................................................821 ELECTRICAL CIRCUIT............................................................822 Thermostat................................................................822 Compressor Clutch.........................................................822 Trinary™ Switch...........................................................823 SYSTEM SERVICING..............................................................824 SERVICE TOOLS AND EQUIPMENT...................................................825 Recovery/Recycle Station..................................................825 Leak Detector.............................................................825 Service Valves............................................................826 Vacuum Pump...............................................................826 Manifold Gauge Set........................................................827 Installing Manifold Gauge Set.............................................828 Purging Air From Service Hoses............................................828 SYSTEM PERFORMANCE TEST.......................................................829 SYSTEM OIL....................................................................830 Handling and Reusing PAG Oil..............................................830 Oil Quantity..............................................................830 Checking System Oil.......................................................830 REFRIGERANT...................................................................831 Recycled Refrigerant......................................................831 Reclaimed Refrigerant.....................................................831 Refrigerant Quantity......................................................831 R-134a Refrigerant Containers.............................................831 SYSTEM LEAK TESTING...........................................................832 Electronic Leak Detector..................................................832 Tracer Dyes...............................................................832 Soap and Water............................................................832 RECOVERING AND RECYCLING THE REFRIGERANT......................................833 Performing the Recovery Cycle.............................................833 Performing the Recycling Procedure........................................833 Evacuating and Charging the A/C System....................................833 SYSTEM REPAIR.................................................................834 System Flushing...........................................................834 COMPONENT REPLACEMENT.........................................................834 Hoses and Fittings........................................................834 Lines.....................................................................834 Expansion Valve...........................................................835 Receiver-Drier............................................................835 Thermostat................................................................835 Compressor................................................................835 Accumulator...............................................................835 Clutch....................................................................836 Servicing the Compressor Clutch...........................................836 Pulley Removal............................................................838 Clutch Coil Check.........................................................839 Pulley Installation.......................................................839 Clutch Assembly Installation..............................................839 EVACUATING THE SYSTEM.........................................................841 CHARGING THE A/C SYSTEM.......................................................843 TROUBLESHOOTING...................................................................844 Preliminary Checks............................................................844 Diagnosis Of Gauge Readings And System Performance............................844 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................845 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................851 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................853 OPERATOR CAB CONTROLS.............................................................855 STEERING COLUMN...............................................................855 Removal...................................................................855 Steering Column Inspection................................................855 Installation..............................................................855 STEERING WHEEL AND CONTROLS...................................................857 Horn Button...............................................................857 Telescope Lock Ring.......................................................857 Tilt Wheel Lever..........................................................857 Multi-Function Turn Signal Switch.........................................857 DYNAMIC RETARDING.............................................................858 Retarder Control Lever....................................................858 Dynamic Retarder/Service Brake Pedal......................................858 Accelerator (Throttle) Pedal..............................................859 Starting on a Grade With a Loaded Truck...................................859 GRADE/SPEED RETARD CHART......................................................859 INSTRUMENT PANEL..............................................................861 OVERHEAD PANEL AND DISPLAYS...................................................861 CENTER CONSOLE................................................................862 F-N-R Selector Switch.....................................................862 Hoist Control Lever.......................................................863 Raising The Dump Body.....................................................863 Lowering The Dump Body....................................................863 Ash Tray..................................................................863 Lighter...................................................................863 L.H. Window Control Switch................................................863 R.H. Window Control Switch................................................863 Engine Shutdown Switch....................................................863 Override/Fault Reset Switch...............................................864 Retard Speed Control (RSC) Switch.........................................864 Retard Speed Control (RSC) Adjust Dial....................................864 Data Store Button.........................................................865 Engine Control System.....................................................865 Service Engine Light......................................................865 Engine Diagnostics Download Port..........................................865 Payload Meter.............................................................865 TCI Download Port.........................................................865 PSC Download Port.........................................................865 Payload Meter.............................................................865 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................867 CONTROL SYMBOLS...............................................................867 INSTRUMENT PANEL..............................................................867 PANEL GAUGES, INDICATORS, AND CONTROLS............................................869 Key Switch....................................................................869 Starting......................................................................869 Cold Weather Starting.........................................................869 Normal Engine Shutdown........................................................869 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................870 Fog Lights (Optional).........................................................870 Ladder Light Switch...........................................................870 Manual Backup Switch..........................................................870 Panel Illumination Lights.....................................................871 Cab/Air Conditioner Vents.....................................................871 Rotating Beacon Light Switch (Optional).......................................871 Heated Mirror Switch (Optional)...............................................871 Wheel Brake Lock Control......................................................871 Parking Brake Control.........................................................871 Tachometer....................................................................872 Right Turn Signal Indicator...................................................872 High Beam Indicator...........................................................872 Left Turn Signal Indicator....................................................872 Speedometer / Payload Meter...................................................872 Voltmeter.....................................................................872 Engine Oil Pressure Gauge.....................................................872 Water Temperature Gauge.......................................................872 Fuel Gauge....................................................................872 AC Drive System Temperature Gauge.............................................873 Hydraulic Oil Temperature Gauge...............................................873 Hourmeter.....................................................................873 Rest Switch...................................................................873 Light Switch..................................................................874 Windshield Wiper and Washer...................................................874 Panel Light Dimmer............................................................874 Payload Meter Switch..........................................................874 OVERHEAD STATUS / WARNING INDICATORS..........................................875 STATUS / WARNING INDICATOR LIGHT SYMBOLS......................................876 Hazard Warning Lights.....................................................881 Lamp Test Switch..........................................................881 Link-On Warning Light.....................................................881 SECTION P - LUBRICATION AND SERVICE - INDEX...............................................883 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................885 LUBRICATION AND SERVICE...........................................................887 930E SERVICE CAPACITIES.......................................................887 HYDRAULIC TANK SERVICE........................................................887 Adding Oil................................................................887 WHEEL MOTOR SERVICE...........................................................887 COOLANT LEVEL CHECK...........................................................888 RADIATOR FILLING PROCEDURE....................................................888 RESERVE ENGINE OIL SYSTEM (Optional)..........................................888 Reserve Oil Tank Filling Procedure (Remote fill)..........................888 LUBRICATION CHART.............................................................889 10 HOUR (DAILY) INSPECTION....................................................890 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................893 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................894 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................895 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................898 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................899 5000 HOUR MAINTENANCE CHECKS..................................................900 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.....................................901 AUTOMATIC LUBRICATION SYSTEM......................................................903 GENERAL DESCRIPTION...........................................................903 SYSTEM COMPONENTS.............................................................905 Filter....................................................................905 Hydraulic Motor and Pump..................................................905 Grease Reservoir..........................................................905 Pressure Reducing Valve...................................................905 Flow Control Valve........................................................905 Solenoid Valve............................................................905 Vent Valve................................................................905 Lubrication Cycle Timer...................................................905 Time Delay Module.........................................................905 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])..................905 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])...............905 Pressure Gauge............................................................905 Injectors.................................................................905 SYSTEM OPERATION..............................................................906 Normal Operation..........................................................906 Pressure Failure Detection Circuits.......................................907 GENERAL INSTRUCTIONS..........................................................908 Lubricant Requirements....................................................908 System Priming............................................................908 LUBRICANT PUMP................................................................908 Pump Housing Oil Level....................................................908 Pump Pressure Control.....................................................908 Lubrication Cycle Timer Check.............................................909 Lubrication Cycle Timer Adjustment........................................909 FILTER ASSEMBLY...............................................................909 SYSTEM CHECKOUT...............................................................910 INJECTORS (SL-1 Series “H”))..................................................910 Injector Specifications...................................................910 Injector Adjustment.......................................................910 INJECTOR OPERATION............................................................911 PUMP REBUILD..................................................................912 Disassembly...............................................................912 Cleaning and Inspection...................................................914 Assembly..................................................................914 SYSTEM TROUBLESHOOTING CHART......................................................916 PREVENTATIVE MAINTENANCE PROCEDURES...............................................919 Daily Lubrication System Inspection...........................................919 250 Hour Inspection...........................................................919 1000 Hour Inspection..........................................................919 SECTION Q ALPHABETICAL INDEX..............................................................921 SECTION R - SYSTEM SCHEMATIC - INDEX......................................................925 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH358..............................................927 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH359..................................928 ELECTRICAL SCHEMATIC - XS1300.........................................................929
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
