Komatsu 930E-3 Dump Truck Shop Manual CEBM015700 PDF

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Komatsu 930E-3 Dump Truck Shop Manual CEBM015700 – PDF DOWNLOAD

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Komatsu 930E-3 Dump Truck Shop Manual CEBM015700 – PDF DOWNLOAD 

Language : English
Pages : 1043
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 930E-3 Dump Truck Shop Manual CEBM015700 – PDF DOWNLOAD 

SN A30364-A30461

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per- sonnel 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 accom- plishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other gen- eral 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 10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig- nates 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 man- ufacturing 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 compo- nents. 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 Shop Manual CEBM015700 – PDF DOWNLOAD 

SN A30364-A30461

MAIN MENU 0
COVER 0
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 D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT & TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
PSC PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 424
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 427
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 428
IGBT TROUBLESHOOTING 429
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 431
SECTION G2 – TIRES AND RIMS – INDEX 433
TIRES AND RIMS 435
WHEEL STUD MAINTENANCE 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
Tire Installation 442
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Preparation 447
Removal 447
Installation – Wheel Hub and Spindle Assembly 450
Disassembly – Wheel Hub and Spindle Assembly 451
Cleaning and Inspection – Wheel Hub and Spindle Assembly 451
Assembly – Wheel Hub and Spindle Assembly 453
Wheel Bearing Adjustment: 453
Brake Installation 454
Seal Assembly Gap Check 455
STEERING CYLINDERS AND TIE ROD 456
Spherical Bearing Wear Limits 456
Removal – Steering Cylinder and Tie Rod 457
Installation – Steering Cylinder and Tie Rod 458
Bearing Replacement 458
TOE-IN ADJUSTMENT 459
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 464
PIVOT EYE BEARING 465
Removal 465
Installation 465
PIVOT EYE REPAIR 465
Removal 465
Disassembly 465
Assembly 466
Installation 466
ANTI-SWAY BAR 466
Removal 466
Installation 467
Disassembly 467
Cleaning and Inspection 467
Assembly 467
SECTION G5 – REAR AXLE HOUSING – INDEX 469
REAR AXLE HOUSING 471
REAR AXLE HOUSING 471
Preparation 471
Removal 471
Cleaning and Inspection – Rear Axle Housing 473
Installation – Rear Axle Housing 473
WHEEL MOTOR 474
Preparation 474
Removal 474
Cleaning and Inspection – Wheel Motor 475
Installation – Wheel Motor 476
WHEEL MOTOR GEAR OIL 479
Filtering Requirements 479
Particle Size Analysis 479
Flushing 479
Oil Sample Analysis 480
ELEMENT SPECIFICATION CHARTS 481
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 485
SECTION H2 – FRONT SUSPENSIONS – INDEX 487
FRONT SUSPENSION 489
Removal 489
Installation – Front Suspension 490
“Turn-Of-The-Nut” Tightening Procedure 493
MINOR REPAIRS (LOWER BEARING & SEALS) 494
Removal – Bearing Retainer 494
Installation – Bearing Retainer 494
MAJOR SUSPENSION REBUILD 496
Disassembly 496
Assembly 496
SECTION H3 – REAR SUSPENSIONS – INDEX 499
REAR SUSPENSIONS 501
SUSPENSION CYLINDER 502
Removal 502
Installation – Rear Suspension 504
Disassembly – Rear Suspension 504
Cleaning and Inspection – Rear Suspension 504
Assembly – Rear Suspension 505
SUSPENSION PRESSURE TEST 507
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 509
SUSPENSION OILING AND CHARGING PROCEDURE 511
GENERAL 511
EQUIPMENT LIST 511
Hydrair® Charging Kit 511
Installation of Charging Kit 511
Removal of Charging Kit 512
Support Blocks For Oiling And Charging Dimensions 512
FRONT SUSPENSION 513
Front Suspension Oiling 513
Front Suspension Nitrogen Charging 514
REAR SUSPENSION 515
Rear Suspension Oiling 515
Rear Suspension Nitrogen Charging 517
OIL AND NITROGEN SPECIFICATIONS CHART 518
SECTION J – BRAKE CIRCUIT – INDEX 519
SECTION J2 – BRAKE CIRCUIT – INDEX 521
BRAKE CIRCUIT 523
SERVICE BRAKE CIRCUIT 523
SECONDARY BRAKING AND AUTOMATIC APPLY 525
PARKING BRAKE CIRCUIT 525
Normal Operation (key switch on, engine running) 525
BRAKE LOCK CIRCUIT 526
WARNING CIRCUIT 526
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 529
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE VALVE 531
Rebuild Criteria 531
Removal 532
Installation 532
Disassembly 533
Cleaning and Inspection 536
Assembly 536
Actuator Base Threaded Inserts 536
Boot and Cap 536
Valve Body Seal Installation 536
Regulator Sleeve O-Ring Installation 537
Actuator Plunger O-ring Installation 537
Assembly of Valve 537
DIFFERENTIAL PRESSURE SWITCH 539
Disassembly 539
Cleaning and Inspection 539
Assembly 539
VALVE BENCH TEST AND ADJUSTMENT 540
Test Set Up Procedure 541
Brake Valve Output Pressure Adjustment 541
Differential Pressure Switch Adjustment 541
Final Test and Adjustment 542
Installation Of Brake Pedal Actuator Assembly to Brake Valve 543
Installation of Retard Pedal To Brake Pedal 543
DUAL RELAY VALVE 545
Removal 545
Installation 545
Disassembly 547
Cleaning and Inspection 547
Assembly 547
DIFFERENTIAL PRESSURE SWITCH 548
Disassembly 548
Cleaning and Inspection 548
Assembly 548
VALVE TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Relay Valve Output Pressure Adjustment 550
Differential Pressure Switch Adjustment 551
BRAKE MANIFOLD 552
Removal 552
Installation 553
Disassembly 553
Cleaning and Inspection 553
Assembly 553
BRAKE ACCUMULATORS 554
Brake Accumulator Bleeddown Procedure 554
BRAKE ACCUMULATOR REPAIR 555
Removal 555
Installation 555
Disassembly 556
Cleaning and Inspection 557
Assembly 557
ACCUMULATOR CHARGING PROCEDURE 559
Temperature During Precharge 560
Precharge Maintenance 561
Recharging Accumulators 561
Accumulator Storage procedures 562
Bladder Storage Procedures 562
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 563
Removal 563
Installation 563
Disassembly and Adjustment 563
Potentiometer Check 565
Assembly 565
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 567
BRAKE CIRCUIT CHECK-OUT PROCEDURE 569
REQUIRED EQUIPMENT 571
INITIAL SYSTEM SET-UP 572
BRAKE SYSTEM CHECKOUT 573
Failure Modes Check-Out 574
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 576
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 579
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 580
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 581
WET DISC BRAKE ASSEMBLY 583
OPERATION 583
MAINTENANCE 584
Brake Disc Wear Indicator 584
Removal/Installation – Wet Disc Brake Assembly 584
BRAKE REBUILD 586
Disassembly 586
Cleaning and Inspection 589
Assembly 590
Floating Ring Seal Assembly/Installation 593
WET DISC BRAKE BLEEDING PROCEDURE 596
SECTION J7 – PARKING BRAKE – INDEX 597
PARKING BRAKE 599
OPERATION 599
MAINTENANCE 600
Inspection – Parking Brake 600
Removal – Parking Brake 600
Installation – Parking Brake 601
Disassembly – Parking Brake 602
Cleaning and Inspection – Parking Brake 602
Assembly – Parking Brake 602
PARKING BRAKE BLEEDING PROCEDURE 604
SECTION L – HYDRAULIC SYSTEM – INDEX 605
SECTION L2 – HYDRAULIC SYSTEM – INDEX 607
HYDRAULIC SYSTEM 609
HYDRAULIC PUMP MODULE 609
HOIST CIRCUIT OPERATION 610
STEERING CIRCUIT OPERATION 612
DISC BRAKE COOLING SYSTEM 614
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 617
HYDRAULIC SYSTEM COMPONENT REPAIR 619
HOIST PUMP 619
Removal 619
Installation 621
INSPECTION OF PARTS 626
Assembly 626
HYDRAULIC TANK 632
Filling Instructions 632
Removal 632
Installation 633
HYDRAULIC TANK STRAINERS 633
Removal 633
Inspect and Clean 633
Installation 633
HYDRAULIC TANK BREATHERS 634
SECTION L4 – STEERING CIRCUIT – INDEX 635
STEERING CIRCUIT 637
COMPONENT DESCRIPTION 638
Steering Control Unit 638
Bleeddown Manifold Valve 639
Bleeddown Solenoid 639
Relief Valves 641
Hoist Limit Solenoid 641
Accumulators 641
Low Precharge Warning Switch 641
High Pressure Filter 641
Quick Disconnect Ports 641
Flow Amplifier 642
FLOW AMPLIFIER SYSTEM OPERATION 644
No Steer 644
Steering Left 646
Steering Right 648
No Steer, External Shock Load 650
STEERING PUMP 652
Operation 652
PRINCIPLE OF OPERATION 654
Full Pump Volume: 654
Half Pump Volume: 654
Neutral Position: 654
Steering Pump 655
SECTION L5 – STEERING CONTROL UNIT – INDEX 657
STEERING CONTROL UNIT 659
Removal 659
Spline Inspection 659
Installation 660
STEERING CONTROL UNIT REBUILD 660
Disassembly 660
Cleaning and Inspection – Steering Control Unit 661
Assembly – Steering Control Unit 663
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEEDDOWN MANIFOLD VALVE 669
Removal 669
Installation 669
FLOW AMPLIFIER 671
Removal 671
Installation 671
FLOW AMPLIFIER REBUILD 671
Disassembly 674
Assembly 675
STEERING CYLINDERS 676
Disassembly 677
Piston Seal & Bearing Installation 677
Cylinder Assembly 677
Test 677
STEERING AND BRAKE PUMP 678
Removal 678
Installation 678
Disassembly 680
Control Piston Group 680
Valve Plate Group 680
Rotating Group 683
Swashblock Group 683
Driveshaft Group 683
Inspection 683
Control Piston Group 683
Valve Plate Group 683
Rotating Group 683
Swashblock Group 685
Driveshaft Group 686
Compensator Block and Unloader Module 686
Stroke Adjuster Assembly 686
Assembly 686
Swashblock Group 686
Driveshaft Group 687
Rotating Group 687
Valve Plate Group 688
STEERING ACCUMULATORS 689
Removal 689
Installation 689
Disassembly 690
Cleaning and Inspection 690
Assembly 691
Leak Testing 693
Charging Procedure 694
Temperature During Precharge 695
Precharge Maintenance 696
Accumulator Storage procedures 697
Bladder Storage Procedures 697
TROUBLESHOOTING CHART 698
SECTION L7 – HOIST CIRCUIT – INDEX 703
HOIST CIRCUIT 705
HOIST CIRCUIT OPERATION 705
COMPONENT DESCRIPTION 706
Hydraulic Tank 706
Hydraulic Pump 706
High Pressure Filters 706
Hoist Valve 706
Inlet Sections – Hoist Valve 706
Spool Sections – Hoist Valve 707
Hoist Pilot Valve 707
Bleeddown Manifold 708
Hoist-up Limit Solenoid 708
Pilot Operated Check Valve 708
Overcenter Manifold 708
HOIST CIRCUIT OPERATION 709
Float Position Of Pilot Valve With Truck Body On Frame 710
Power Up Operation 712
Hold Operation 714
Power Down Operation 716
Float Operation 718
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 721
HOIST CIRCUIT COMPONENT REPAIR 723
HOIST VALVE 723
Removal 723
Installation 724
O-Ring Replacement 724
INLET SECTION 725
Disassembly 725
Cleaning and Inspection 726
Assembly 726
REAR SPOOL SECTION (Work Ports) 726
Disassembly 726
Cleaning and Inspection 728
Assembly 728
FRONT SPOOL SECTION (Tank Ports) 729
Disassembly 729
Cleaning and Inspection 729
Assembly 729
HOIST PILOT VALVE 731
Removal 731
Installation 731
Disassembly 732
Cleaning and Inspection 733
Assembly 733
HOIST CYLINDERS 734
Removal 734
Installation 735
Disassembly 737
Cleaning and Inspection 738
Assembly – Quill and Cylinder 739
Quill Installation 739
Installation Of Check Balls And Plugs In Quill 740
Assembly of Cylinder 741
OVERCENTER VALVE MANIFOLD 742
DISABLED TRUCK DUMPING PROCEDURE 743
Hookup 743
Raising the Body 743
Lowering the Body 743
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 745
HYDRAULIC SYSTEM FILTERS 747
HOIST CIRCUIT FILTER 747
Filter Element Replacement 747
Removal – Hoist Circuit Filter 748
Installation – Hoist Circuit Filter 748
Indicator Switch – Hoist Circuit Filter 748
STEERING CIRCUIT FILTER 749
Filter Element Replacement 749
Removal – Steering Circuit Filter 750
Installation – Steering Circuit Filter 750
Indicator Switch – Steering Circuit Filter 750
INDICATOR SWITCH 750
Test Procedure 750
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 753
HYDRAULIC CHECK-OUT PROCEDURE 755
GENERAL INFORMATION 755
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 755
Equipment Requirements 756
Pump Pressure Control Adjustments 756
Steering Control Valve and Flow Amplifier Leakage Test 757
Bleeddown Manifold Leakage Test 757
STEERING/BRAKE PUMP STROKE ADJUSTMENT 758
SHOCK AND SUCTION VALVES 759
Equipment Requirements 759
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 760
Equipment Requirements 760
Pressure Gauge Locations 760
Brake Cooling Circuit Test 760
Power Up Relief Pressure Test 761
Adjustment 761
Power Down Relief Pressure Test 762
Hoist Counterbalance Valve Adjustment Preparation 763
Counterbalance Valve Pressure Check 763
Counterbalance Valve Adjustment 764
Preparation 765
Flushing Procedure 765
Filter Element Replacement 766
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 766
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 768
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 769
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 771
FIRE CONTROL SYSTEM (MANUAL) 773
Operation 773
Inspection and Maintenance 773
Recharging Procedures 774
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 775
Control Module 775
Actuator 776
Linear Detection Wire 776
Power Wire 776
Test Kit 776
Squib 776
Securing the Detection Wire 777
Preliminary Test Before Final Hook-Up 777
Installation Procedure for Squib 779
Placing the Electric Detection & Actuation System Into Service 779
INSPECTION AND MAINTENANCE SCHEDULES 780
Daily 780
Normal Maintenance Based On Actual Operating Hours 780
IN CASE OF FIRE 781
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 783
SECTION M8 – SPECIAL TOOLS 785
SECTION M20 – PAYLOAD METER III – INDEX 791
OPERATION SECTION 795
Introduction 795
Data Summary 795
Data Gathering 795
COMPONENT DESCRIPTION 796
System Diagram 796
Suspension Pressure Sensors 796
Inclinometer 796
Operator Display 796
Operator Switch 797
Speed Input 797
Body-Up Switch 797
Brake Lock Switch 797
Payload Meter 797
Communications Ports 797
Keyswitch Input 798
Payload Meter Power 798
Load Lights 798
Wiring and Termination 799
TCI Outputs 799
OPERATOR’S DISPLAY AND SWITCH 800
Reading the Speedometer 800
Reading the Load Display 800
Using the Operator ID 800
Using the Load and Ton Counter 800
Total Ton Counter 800
Total Load Counter 801
Clearing the Counters 801
Viewing Live Sensor Data 801
Other Display Messages 801
PAYLOAD OPERATION & CALCULATION 802
Description of Haul Cycle States 802
Haul Cycle Description 802
Load Calculation 803
Carry Back 803
Measurement Accuracy 803
SOURCES FOR PAYLOAD ERROR 803
Payload Error 803
Loading Conditions 804
Pressure Sensors 804
Swingloads 804
Speed and Distance 804
HAUL CYCLE DATA 804
Haul Cycle Data 805
Haul Cycle Warning Flags 806
M: Haul Cycle Too Long 807
N: Sensor Input Error 807
Frame Torque Data 807
Sprung Weight Data 807
Maximum Speed Data 807
Alarm Records 807
Fault Code Data 808
PC SOFTWARE OVERVIEW 809
PC Overview 809
System Configuration 809
Installing the PLMIII Software 809
DOWNLOADING DATA 810
PLM III SYSTEM CONFIGURATION 811
Starting Communications 811
Displayed Payload Units 811
Time Units 811
Connection Menu 811
Connecting to the Payload Meter 812
Configure the Payload Meter 812
Setting the Date and Time 812
Setting the Truck Type 813
Setting the Gauge Display Units 813
Setting the Frame Serial Number 813
Setting the Truck Number 813
Setting the Komatsu Distributor 813
Setting the Komatsu Customer 813
Clean Truck Tare 814
Inclinometer Calibration 814
DATA ANALYSIS 815
Creating a Query 815
Sorting on Truck Unit Number 815
Sorting on Truck Type 815
Sorting on Date Range 816
Sorting on Time Range 816
Payload Detail Screen 817
Creating Reports 817
Summary – one page report 818
Detailed – multi-page report 818
Creating Graphs 819
Exporting Data 819
CSV Export 819
Compressed 820
Importing Data 821
Deleting Haul Cycle Records 821
Viewing Alarms 822
Deleting Alarm Records 822
TROUBLESHOOTING SECTION 823
TROUBLESHOOTING 823
Viewing Active Alarms 823
Real-Time Data Display 823
Testing the Payload Lights 823
Creating Log Files of Inputs 824
Daily Inspections 824
Periodic Maintenance 824
Abnormal Displays at Power-Up 825
No Payload Display When Keyswitch is Turned ON 826
No Display on Speedometer 827
No Display on Operator Display 827
No Communications With PC 828
Load Lights Don’t Light During Loading 829
Load Lights Remain ON 830
Load Lights Remain ON During Dumping 830
Display Doesn’t Clear When The Load Is Dumped 830
Calibration Problems 831
Alarm 1 – Left Front Pressure High 832
Alarm 2 – Left Front Pressure Low 832
Troubleshoot Wiring to Left Front Suspension 832
Alarm 3 – Right Front Pressure High 833
Alarm 4 – Right Front Pressure Low 833
Troubleshoot Wiring to Right Front Suspension 833
Alarm 5 -Left Rear Pressure High 834
Alarm 6 – Left Rear Pressure Low 834
Troubleshoot Wiring to Left Rear Suspension 834
Alarm 7 – Right Rear Pressure High 835
Alarm 8 – Right Rear Pressure Low 835
Troubleshoot Wiring to Right Rear Suspension 835
Alarm 9 – Inclinometer High 836
Alarm 10 – Inclinometer Low 836
Troubleshoot Inclinometer Wiring 836
Alarm 13 – Body Up Input Failure 837
Alarm 16 – Memory Write Failure 838
Alarm 17 – Memory Read Failure 838
Alarm 18 839
Alarm 19 839
Alarm 22 839
Operator Switch Doesn’t Work 840
Alarm 26 – User Switch Fault – SELECT 840
Alarm 27 – User Switch Fault – SET 840
Connector Map 841
Connectors 842
PLMIII CHECK OUT PROCEDURE 843
General Description 843
Tools Required 843
Checkout Procedure 843
PLMIII CHECKOUT PROCEDURE CONFIRMATION 847
Flashburn Programming 847
Confirmation Checklist 849
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 851
RESERVE ENGINE OIL SYSTEM 853
Operation 853
LED Monitor Light 854
Tank Fill Control (Optional) 854
Filling Procedure (Remote fill feature) 854
SERVICE 855
Every 10 Hours, or once each shift: 855
Every 500 Hours: 855
Changing Oil 855
TROUBLESHOOTING 856
Circuit Breaker or Fuse 856
SYSTEM ELECTRICAL SCHEMATICS 857
SECTION N – CAB COMPONENTS – INDEX 859
SECTION N2 – TRUCK CAB – INDEX 861
TRUCK CAB 863
Description 863
Preparation 864
Removal – Cab 864
Installation – Cab 866
CAB DOOR 866
Removal 866
Installation 866
Door Adjustment 867
Door Jamb Bolt Adjustment 867
Door Handle Plunger Adjustment 868
Door Glass Replacement 869
Door Window Regulator Replacement 873
Door Handle or Latch Assembly Replacement 873
Door and Door Hinge Seal Replacement 874
Door Opening Seal Removal 874
Installation 874
GLASS REPLACEMENT 875
Adhesive Bonded Windows 875
Replacement Procedure 875
Windshield And Rear Glass 876
Removal 876
Installation 877
SECTION N3 – CAB COMPONENTS – INDEX 879
CAB COMPONENTS 881
WINDSHIELD WIPERS 881
Wiper Motor Replacement 881
Removal 881
Installation 881
Wiper Arm 881
Removal 881
Installation 882
Wiper Linkage Replacement 882
Removal 882
Installation 882
WINDSHIELD WASHER 883
Operation 883
Service 883
OPERATOR SEAT 884
Adjustment 884
Seat Removal 884
Seat Installation 884
SECTION N4 – OPERATOR COMFORT – INDEX 885
OPERATOR COMFORT 887
HEATER / AIR CONDITIONER 887
Operation 887
Heater/Air Conditioner Vents 887
COMPONENTS 888
Circuit Breakers 888
Relays 888
Heater Core 888
Fan Motor And Speed Control 889
Actuators 889
Cab Air Filter 889
AIR CONDITIONING SYSTEM 891
Environmental Impact 891
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 892
PRINCIPLES OF REFRIGERATION 892
Air Conditioning 892
Refrigeration – The Act Of Cooling 893
The Refrigeration Cycle 893
AIR CONDITIONER SYSTEM COMPONENTS 894
Compressor (Refrigerant Pump) 894
Service Valves 894
Condenser 894
Receiver-Drier 894
Expansion Block Valve 895
Accumulator 895
Evaporator 895
ELECTRICAL CIRCUIT 896
Thermostat 896
Compressor Clutch 896
Trinary™ Switch 897
SYSTEM SERVICING 898
SERVICE TOOLS AND EQUIPMENT 899
Recovery/Recycle Station 899
Leak Detector 899
Service Valves 900
Vacuum Pump 900
Manifold Gauge Set 901
Installing Manifold Gauge Set 902
Purging Air From Service Hoses 902
SYSTEM PERFORMANCE TEST 903
SYSTEM OIL 904
Handling and Reusing PAG Oil 904
Oil Quantity 904
Checking System Oil 904
REFRIGERANT 905
Recycled Refrigerant 905
Reclaimed Refrigerant 905
Refrigerant Quantity 905
R-134a Refrigerant Containers 905
SYSTEM LEAK TESTING 906
Electronic Leak Detector 906
Tracer Dyes 906
Soap and Water 906
RECOVERING AND RECYCLING THE REFRIGERANT 907
Performing the Recovery Cycle 907
Performing the Recycling Procedure 907
Evacuating and Charging the A/C System 907
SYSTEM REPAIR 908
System Flushing 908
COMPONENT REPLACEMENT 908
Hoses and Fittings 908
Lines 908
Expansion Valve 909
Receiver-Drier 909
Thermostat 909
Compressor 909
Accumulator 909
Clutch 910
Servicing the Compressor Clutch 910
Pulley Removal 912
Clutch Coil Check 913
Pulley Installation 913
Clutch Assembly Installation 913
EVACUATING THE SYSTEM 915
CHARGING THE A/C SYSTEM 917
TROUBLESHOOTING 918
Preliminary Checks 918
Diagnosis Of Gauge Readings And System Performance 918
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 919
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 925
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 927
OPERATOR CAB CONTROLS 929
STEERING COLUMN 929
Removal 929
Steering Column Inspection 929
Installation 929
STEERING WHEEL AND CONTROLS 931
Horn Button 931
Telescope Lock Ring 931
Tilt Wheel Lever 931
Multi-Function Turn Signal Switch 931
DYNAMIC RETARDING 932
Retarder Control Lever 932
Dynamic Retarder/Service Brake Pedal 932
Accelerator (Throttle) Pedal 933
Starting on a Grade With a Loaded Truck 933
GRADE/SPEED RETARD CHART 933
INSTRUMENT PANEL 935
OVERHEAD PANEL AND DISPLAYS 935
CENTER CONSOLE 936
F-N-R Selector Switch 936
Hoist Control Lever 937
Raising The Dump Body 937
Lowering The Dump Body 937
Ash Tray 937
Lighter 937
L H Window Control Switch 937
R H Window Control Switch 937
Engine Shutdown Switch 937
Override/Fault Reset Switch 938
Retard Speed Control (RSC) Switch 938
Retard Speed Control (RSC) Adjust Dial 938
Data Store Button 939
Engine Control System 939
Service Engine Light 939
Engine Diagnostics Download Port 939
Payload Meter 939
TCI Download Port 939
PSC Download Port 939
Payload Meter 939
INSTRUMENT PANEL AND INDICATOR LIGHTS 941
CONTROL SYMBOLS 941
INSTRUMENT PANEL 941
PANEL GAUGES, INDICATORS, AND CONTROLS 943
Key Switch 943
Starting 943
Cold Weather Starting 943
Normal Engine Shutdown 943
Engine Shutdown Switch with 5 Minute Idle Timer Delay 944
Fog Lights (Optional) 944
Ladder Light Switch 944
Manual Backup Switch 944
Panel Illumination Lights 945
Cab/Air Conditioner Vents 945
Rotating Beacon Light Switch (Optional) 945
Heated Mirror Switch (Optional) 945
Wheel Brake Lock Control 945
Parking Brake Control 945
Tachometer 946
Right Turn Signal Indicator 946
High Beam Indicator 946
Left Turn Signal Indicator 946
Speedometer / Payload Meter 946
Voltmeter 946
Engine Oil Pressure Gauge 946
Water Temperature Gauge 946
Fuel Gauge 946
AC Drive System Temperature Gauge 947
Hydraulic Oil Temperature Gauge 947
Hourmeter 947
Rest Switch 947
Light Switch 948
Windshield Wiper and Washer 948
Panel Light Dimmer 948
Payload Meter Switch 948
OVERHEAD STATUS / WARNING INDICATORS 949
STATUS / WARNING INDICATOR LIGHT SYMBOLS 950
Hazard Warning Lights 955
Lamp Test Switch 955
Link-On Warning Light 955
SECTION P – LUBRICATION AND SERVICE – INDEX 957
SECTION P2 – LUBRICATION AND SERVICE – INDEX 959
LUBRICATION AND SERVICE 961
930E SERVICE CAPACITIES 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
WHEEL MOTOR SERVICE 961
COOLANT LEVEL CHECK 962
RADIATOR FILLING PROCEDURE 962
RESERVE ENGINE OIL SYSTEM (Optional) 962
Reserve Oil Tank Filling Procedure (Remote fill) 962
LUBRICATION CHART 963
10 HOUR (DAILY) INSPECTION 964
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR MAINTENANCE CHECKS 974
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 975
AUTOMATIC LUBRICATION SYSTEM 977
GENERAL DESCRIPTION 977
SYSTEM COMPONENTS 979
Filter 979
Hydraulic Motor and Pump 979
Grease Reservoir 979
Pressure Reducing Valve 979
Flow Control Valve 979
Solenoid Valve 979
Vent Valve 979
Lubrication Cycle Timer 979
Time Delay Module 979
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 979
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 979
Pressure Gauge 979
Injectors 979
SYSTEM OPERATION 980
Normal Operation 980
Pressure Failure Detection Circuits 981
GENERAL INSTRUCTIONS 982
Lubricant Requirements 982
System Priming 982
LUBRICANT PUMP 982
Pump Housing Oil Level 982
Pump Pressure Control 982
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 983
FILTER ASSEMBLY 983
SYSTEM CHECKOUT 984
INJECTORS (SL-1 Series “H”)) 984
Injector Specifications 984
Injector Adjustment 984
INJECTOR OPERATION 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 988
Assembly 988
SYSTEM TROUBLESHOOTING CHART 990
PREVENTATIVE MAINTENANCE PROCEDURES 993
Daily Lubrication System Inspection 993
250 Hour Inspection 993
1000 Hour Inspection 993
SECTION Q – ALPHABETICAL INDEX 995
SECTION R – SYSTEM SCHEMATIC – INDEX 999
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 1001
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 1002
ELECTRICAL SCHEMATIC – XS1300 1003
VHMS ELECTRICAL SCHEMATIC 1037MAIN MENU 0
COVER 0
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 D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT & TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
PSC PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 424
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 427
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 428
IGBT TROUBLESHOOTING 429
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 431
SECTION G2 – TIRES AND RIMS – INDEX 433
TIRES AND RIMS 435
WHEEL STUD MAINTENANCE 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
Tire Installation 442
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Preparation 447
Removal 447
Installation – Wheel Hub and Spindle Assembly 450
Disassembly – Wheel Hub and Spindle Assembly 451
Cleaning and Inspection – Wheel Hub and Spindle Assembly 451
Assembly – Wheel Hub and Spindle Assembly 453
Wheel Bearing Adjustment: 453
Brake Installation 454
Seal Assembly Gap Check 455
STEERING CYLINDERS AND TIE ROD 456
Spherical Bearing Wear Limits 456
Removal – Steering Cylinder and Tie Rod 457
Installation – Steering Cylinder and Tie Rod 458
Bearing Replacement 458
TOE-IN ADJUSTMENT 459
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 464
PIVOT EYE BEARING 465
Removal 465
Installation 465
PIVOT EYE REPAIR 465
Removal 465
Disassembly 465
Assembly 466
Installation 466
ANTI-SWAY BAR 466
Removal 466
Installation 467
Disassembly 467
Cleaning and Inspection 467
Assembly 467
SECTION G5 – REAR AXLE HOUSING – INDEX 469
REAR AXLE HOUSING 471
REAR AXLE HOUSING 471
Preparation 471
Removal 471
Cleaning and Inspection – Rear Axle Housing 473
Installation – Rear Axle Housing 473
WHEEL MOTOR 474
Preparation 474
Removal 474
Cleaning and Inspection – Wheel Motor 475
Installation – Wheel Motor 476
WHEEL MOTOR GEAR OIL 479
Filtering Requirements 479
Particle Size Analysis 479
Flushing 479
Oil Sample Analysis 480
ELEMENT SPECIFICATION CHARTS 481
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 485
SECTION H2 – FRONT SUSPENSIONS – INDEX 487
FRONT SUSPENSION 489
Removal 489
Installation – Front Suspension 490
“Turn-Of-The-Nut” Tightening Procedure 493
MINOR REPAIRS (LOWER BEARING & SEALS) 494
Removal – Bearing Retainer 494
Installation – Bearing Retainer 494
MAJOR SUSPENSION REBUILD 496
Disassembly 496
Assembly 496
SECTION H3 – REAR SUSPENSIONS – INDEX 499
REAR SUSPENSIONS 501
SUSPENSION CYLINDER 502
Removal 502
Installation – Rear Suspension 504
Disassembly – Rear Suspension 504
Cleaning and Inspection – Rear Suspension 504
Assembly – Rear Suspension 505
SUSPENSION PRESSURE TEST 507
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 509
SUSPENSION OILING AND CHARGING PROCEDURE 511
GENERAL 511
EQUIPMENT LIST 511
Hydrair® Charging Kit 511
Installation of Charging Kit 511
Removal of Charging Kit 512
Support Blocks For Oiling And Charging Dimensions 512
FRONT SUSPENSION 513
Front Suspension Oiling 513
Front Suspension Nitrogen Charging 514
REAR SUSPENSION 515
Rear Suspension Oiling 515
Rear Suspension Nitrogen Charging 517
OIL AND NITROGEN SPECIFICATIONS CHART 518
SECTION J – BRAKE CIRCUIT – INDEX 519
SECTION J2 – BRAKE CIRCUIT – INDEX 521
BRAKE CIRCUIT 523
SERVICE BRAKE CIRCUIT 523
SECONDARY BRAKING AND AUTOMATIC APPLY 525
PARKING BRAKE CIRCUIT 525
Normal Operation (key switch on, engine running) 525
BRAKE LOCK CIRCUIT 526
WARNING CIRCUIT 526
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 529
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE VALVE 531
Rebuild Criteria 531
Removal 532
Installation 532
Disassembly 533
Cleaning and Inspection 536
Assembly 536
Actuator Base Threaded Inserts 536
Boot and Cap 536
Valve Body Seal Installation 536
Regulator Sleeve O-Ring Installation 537
Actuator Plunger O-ring Installation 537
Assembly of Valve 537
DIFFERENTIAL PRESSURE SWITCH 539
Disassembly 539
Cleaning and Inspection 539
Assembly 539
VALVE BENCH TEST AND ADJUSTMENT 540
Test Set Up Procedure 541
Brake Valve Output Pressure Adjustment 541
Differential Pressure Switch Adjustment 541
Final Test and Adjustment 542
Installation Of Brake Pedal Actuator Assembly to Brake Valve 543
Installation of Retard Pedal To Brake Pedal 543
DUAL RELAY VALVE 545
Removal 545
Installation 545
Disassembly 547
Cleaning and Inspection 547
Assembly 547
DIFFERENTIAL PRESSURE SWITCH 548
Disassembly 548
Cleaning and Inspection 548
Assembly 548
VALVE TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Relay Valve Output Pressure Adjustment 550
Differential Pressure Switch Adjustment 551
BRAKE MANIFOLD 552
Removal 552
Installation 553
Disassembly 553
Cleaning and Inspection 553
Assembly 553
BRAKE ACCUMULATORS 554
Brake Accumulator Bleeddown Procedure 554
BRAKE ACCUMULATOR REPAIR 555
Removal 555
Installation 555
Disassembly 556
Cleaning and Inspection 557
Assembly 557
ACCUMULATOR CHARGING PROCEDURE 559
Temperature During Precharge 560
Precharge Maintenance 561
Recharging Accumulators 561
Accumulator Storage procedures 562
Bladder Storage Procedures 562
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 563
Removal 563
Installation 563
Disassembly and Adjustment 563
Potentiometer Check 565
Assembly 565
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 567
BRAKE CIRCUIT CHECK-OUT PROCEDURE 569
REQUIRED EQUIPMENT 571
INITIAL SYSTEM SET-UP 572
BRAKE SYSTEM CHECKOUT 573
Failure Modes Check-Out 574
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 576
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 579
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 580
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 581
WET DISC BRAKE ASSEMBLY 583
OPERATION 583
MAINTENANCE 584
Brake Disc Wear Indicator 584
Removal/Installation – Wet Disc Brake Assembly 584
BRAKE REBUILD 586
Disassembly 586
Cleaning and Inspection 589
Assembly 590
Floating Ring Seal Assembly/Installation 593
WET DISC BRAKE BLEEDING PROCEDURE 596
SECTION J7 – PARKING BRAKE – INDEX 597
PARKING BRAKE 599
OPERATION 599
MAINTENANCE 600
Inspection – Parking Brake 600
Removal – Parking Brake 600
Installation – Parking Brake 601
Disassembly – Parking Brake 602
Cleaning and Inspection – Parking Brake 602
Assembly – Parking Brake 602
PARKING BRAKE BLEEDING PROCEDURE 604
SECTION L – HYDRAULIC SYSTEM – INDEX 605
SECTION L2 – HYDRAULIC SYSTEM – INDEX 607
HYDRAULIC SYSTEM 609
HYDRAULIC PUMP MODULE 609
HOIST CIRCUIT OPERATION 610
STEERING CIRCUIT OPERATION 612
DISC BRAKE COOLING SYSTEM 614
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 617
HYDRAULIC SYSTEM COMPONENT REPAIR 619
HOIST PUMP 619
Removal 619
Installation 621
INSPECTION OF PARTS 626
Assembly 626
HYDRAULIC TANK 632
Filling Instructions 632
Removal 632
Installation 633
HYDRAULIC TANK STRAINERS 633
Removal 633
Inspect and Clean 633
Installation 633
HYDRAULIC TANK BREATHERS 634
SECTION L4 – STEERING CIRCUIT – INDEX 635
STEERING CIRCUIT 637
COMPONENT DESCRIPTION 638
Steering Control Unit 638
Bleeddown Manifold Valve 639
Bleeddown Solenoid 639
Relief Valves 641
Hoist Limit Solenoid 641
Accumulators 641
Low Precharge Warning Switch 641
High Pressure Filter 641
Quick Disconnect Ports 641
Flow Amplifier 642
FLOW AMPLIFIER SYSTEM OPERATION 644
No Steer 644
Steering Left 646
Steering Right 648
No Steer, External Shock Load 650
STEERING PUMP 652
Operation 652
PRINCIPLE OF OPERATION 654
Full Pump Volume: 654
Half Pump Volume: 654
Neutral Position: 654
Steering Pump 655
SECTION L5 – STEERING CONTROL UNIT – INDEX 657
STEERING CONTROL UNIT 659
Removal 659
Spline Inspection 659
Installation 660
STEERING CONTROL UNIT REBUILD 660
Disassembly 660
Cleaning and Inspection – Steering Control Unit 661
Assembly – Steering Control Unit 663
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEEDDOWN MANIFOLD VALVE 669
Removal 669
Installation 669
FLOW AMPLIFIER 671
Removal 671
Installation 671
FLOW AMPLIFIER REBUILD 671
Disassembly 674
Assembly 675
STEERING CYLINDERS 676
Disassembly 677
Piston Seal & Bearing Installation 677
Cylinder Assembly 677
Test 677
STEERING AND BRAKE PUMP 678
Removal 678
Installation 678
Disassembly 680
Control Piston Group 680
Valve Plate Group 680
Rotating Group 683
Swashblock Group 683
Driveshaft Group 683
Inspection 683
Control Piston Group 683
Valve Plate Group 683
Rotating Group 683
Swashblock Group 685
Driveshaft Group 686
Compensator Block and Unloader Module 686
Stroke Adjuster Assembly 686
Assembly 686
Swashblock Group 686
Driveshaft Group 687
Rotating Group 687
Valve Plate Group 688
STEERING ACCUMULATORS 689
Removal 689
Installation 689
Disassembly 690
Cleaning and Inspection 690
Assembly 691
Leak Testing 693
Charging Procedure 694
Temperature During Precharge 695
Precharge Maintenance 696
Accumulator Storage procedures 697
Bladder Storage Procedures 697
TROUBLESHOOTING CHART 698
SECTION L7 – HOIST CIRCUIT – INDEX 703
HOIST CIRCUIT 705
HOIST CIRCUIT OPERATION 705
COMPONENT DESCRIPTION 706
Hydraulic Tank 706
Hydraulic Pump 706
High Pressure Filters 706
Hoist Valve 706
Inlet Sections – Hoist Valve 706
Spool Sections – Hoist Valve 707
Hoist Pilot Valve 707
Bleeddown Manifold 708
Hoist-up Limit Solenoid 708
Pilot Operated Check Valve 708
Overcenter Manifold 708
HOIST CIRCUIT OPERATION 709
Float Position Of Pilot Valve With Truck Body On Frame 710
Power Up Operation 712
Hold Operation 714
Power Down Operation 716
Float Operation 718
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 721
HOIST CIRCUIT COMPONENT REPAIR 723
HOIST VALVE 723
Removal 723
Installation 724
O-Ring Replacement 724
INLET SECTION 725
Disassembly 725
Cleaning and Inspection 726
Assembly 726
REAR SPOOL SECTION (Work Ports) 726
Disassembly 726
Cleaning and Inspection 728
Assembly 728
FRONT SPOOL SECTION (Tank Ports) 729
Disassembly 729
Cleaning and Inspection 729
Assembly 729
HOIST PILOT VALVE 731
Removal 731
Installation 731
Disassembly 732
Cleaning and Inspection 733
Assembly 733
HOIST CYLINDERS 734
Removal 734
Installation 735
Disassembly 737
Cleaning and Inspection 738
Assembly – Quill and Cylinder 739
Quill Installation 739
Installation Of Check Balls And Plugs In Quill 740
Assembly of Cylinder 741
OVERCENTER VALVE MANIFOLD 742
DISABLED TRUCK DUMPING PROCEDURE 743
Hookup 743
Raising the Body 743
Lowering the Body 743
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 745
HYDRAULIC SYSTEM FILTERS 747
HOIST CIRCUIT FILTER 747
Filter Element Replacement 747
Removal – Hoist Circuit Filter 748
Installation – Hoist Circuit Filter 748
Indicator Switch – Hoist Circuit Filter 748
STEERING CIRCUIT FILTER 749
Filter Element Replacement 749
Removal – Steering Circuit Filter 750
Installation – Steering Circuit Filter 750
Indicator Switch – Steering Circuit Filter 750
INDICATOR SWITCH 750
Test Procedure 750
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 753
HYDRAULIC CHECK-OUT PROCEDURE 755
GENERAL INFORMATION 755
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 755
Equipment Requirements 756
Pump Pressure Control Adjustments 756
Steering Control Valve and Flow Amplifier Leakage Test 757
Bleeddown Manifold Leakage Test 757
STEERING/BRAKE PUMP STROKE ADJUSTMENT 758
SHOCK AND SUCTION VALVES 759
Equipment Requirements 759
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 760
Equipment Requirements 760
Pressure Gauge Locations 760
Brake Cooling Circuit Test 760
Power Up Relief Pressure Test 761
Adjustment 761
Power Down Relief Pressure Test 762
Hoist Counterbalance Valve Adjustment Preparation 763
Counterbalance Valve Pressure Check 763
Counterbalance Valve Adjustment 764
Preparation 765
Flushing Procedure 765
Filter Element Replacement 766
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 766
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 768
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 769
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 771
FIRE CONTROL SYSTEM (MANUAL) 773
Operation 773
Inspection and Maintenance 773
Recharging Procedures 774
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 775
Control Module 775
Actuator 776
Linear Detection Wire 776
Power Wire 776
Test Kit 776
Squib 776
Securing the Detection Wire 777
Preliminary Test Before Final Hook-Up 777
Installation Procedure for Squib 779
Placing the Electric Detection & Actuation System Into Service 779
INSPECTION AND MAINTENANCE SCHEDULES 780
Daily 780
Normal Maintenance Based On Actual Operating Hours 780
IN CASE OF FIRE 781
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 783
SECTION M8 – SPECIAL TOOLS 785
SECTION M20 – PAYLOAD METER III – INDEX 791
OPERATION SECTION 795
Introduction 795
Data Summary 795
Data Gathering 795
COMPONENT DESCRIPTION 796
System Diagram 796
Suspension Pressure Sensors 796
Inclinometer 796
Operator Display 796
Operator Switch 797
Speed Input 797
Body-Up Switch 797
Brake Lock Switch 797
Payload Meter 797
Communications Ports 797
Keyswitch Input 798
Payload Meter Power 798
Load Lights 798
Wiring and Termination 799
TCI Outputs 799
OPERATOR’S DISPLAY AND SWITCH 800
Reading the Speedometer 800
Reading the Load Display 800
Using the Operator ID 800
Using the Load and Ton Counter 800
Total Ton Counter 800
Total Load Counter 801
Clearing the Counters 801
Viewing Live Sensor Data 801
Other Display Messages 801
PAYLOAD OPERATION & CALCULATION 802
Description of Haul Cycle States 802
Haul Cycle Description 802
Load Calculation 803
Carry Back 803
Measurement Accuracy 803
SOURCES FOR PAYLOAD ERROR 803
Payload Error 803
Loading Conditions 804
Pressure Sensors 804
Swingloads 804
Speed and Distance 804
HAUL CYCLE DATA 804
Haul Cycle Data 805
Haul Cycle Warning Flags 806
M: Haul Cycle Too Long 807
N: Sensor Input Error 807
Frame Torque Data 807
Sprung Weight Data 807
Maximum Speed Data 807
Alarm Records 807
Fault Code Data 808
PC SOFTWARE OVERVIEW 809
PC Overview 809
System Configuration 809
Installing the PLMIII Software 809
DOWNLOADING DATA 810
PLM III SYSTEM CONFIGURATION 811
Starting Communications 811
Displayed Payload Units 811
Time Units 811
Connection Menu 811
Connecting to the Payload Meter 812
Configure the Payload Meter 812
Setting the Date and Time 812
Setting the Truck Type 813
Setting the Gauge Display Units 813
Setting the Frame Serial Number 813
Setting the Truck Number 813
Setting the Komatsu Distributor 813
Setting the Komatsu Customer 813
Clean Truck Tare 814
Inclinometer Calibration 814
DATA ANALYSIS 815
Creating a Query 815
Sorting on Truck Unit Number 815
Sorting on Truck Type 815
Sorting on Date Range 816
Sorting on Time Range 816
Payload Detail Screen 817
Creating Reports 817
Summary – one page report 818
Detailed – multi-page report 818
Creating Graphs 819
Exporting Data 819
CSV Export 819
Compressed 820
Importing Data 821
Deleting Haul Cycle Records 821
Viewing Alarms 822
Deleting Alarm Records 822
TROUBLESHOOTING SECTION 823
TROUBLESHOOTING 823
Viewing Active Alarms 823
Real-Time Data Display 823
Testing the Payload Lights 823
Creating Log Files of Inputs 824
Daily Inspections 824
Periodic Maintenance 824
Abnormal Displays at Power-Up 825
No Payload Display When Keyswitch is Turned ON 826
No Display on Speedometer 827
No Display on Operator Display 827
No Communications With PC 828
Load Lights Don’t Light During Loading 829
Load Lights Remain ON 830
Load Lights Remain ON During Dumping 830
Display Doesn’t Clear When The Load Is Dumped 830
Calibration Problems 831
Alarm 1 – Left Front Pressure High 832
Alarm 2 – Left Front Pressure Low 832
Troubleshoot Wiring to Left Front Suspension 832
Alarm 3 – Right Front Pressure High 833
Alarm 4 – Right Front Pressure Low 833
Troubleshoot Wiring to Right Front Suspension 833
Alarm 5 -Left Rear Pressure High 834
Alarm 6 – Left Rear Pressure Low 834
Troubleshoot Wiring to Left Rear Suspension 834
Alarm 7 – Right Rear Pressure High 835
Alarm 8 – Right Rear Pressure Low 835
Troubleshoot Wiring to Right Rear Suspension 835
Alarm 9 – Inclinometer High 836
Alarm 10 – Inclinometer Low 836
Troubleshoot Inclinometer Wiring 836
Alarm 13 – Body Up Input Failure 837
Alarm 16 – Memory Write Failure 838
Alarm 17 – Memory Read Failure 838
Alarm 18 839
Alarm 19 839
Alarm 22 839
Operator Switch Doesn’t Work 840
Alarm 26 – User Switch Fault – SELECT 840
Alarm 27 – User Switch Fault – SET 840
Connector Map 841
Connectors 842
PLMIII CHECK OUT PROCEDURE 843
General Description 843
Tools Required 843
Checkout Procedure 843
PLMIII CHECKOUT PROCEDURE CONFIRMATION 847
Flashburn Programming 847
Confirmation Checklist 849
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 851
RESERVE ENGINE OIL SYSTEM 853
Operation 853
LED Monitor Light 854
Tank Fill Control (Optional) 854
Filling Procedure (Remote fill feature) 854
SERVICE 855
Every 10 Hours, or once each shift: 855
Every 500 Hours: 855
Changing Oil 855
TROUBLESHOOTING 856
Circuit Breaker or Fuse 856
SYSTEM ELECTRICAL SCHEMATICS 857
SECTION N – CAB COMPONENTS – INDEX 859
SECTION N2 – TRUCK CAB – INDEX 861
TRUCK CAB 863
Description 863
Preparation 864
Removal – Cab 864
Installation – Cab 866
CAB DOOR 866
Removal 866
Installation 866
Door Adjustment 867
Door Jamb Bolt Adjustment 867
Door Handle Plunger Adjustment 868
Door Glass Replacement 869
Door Window Regulator Replacement 873
Door Handle or Latch Assembly Replacement 873
Door and Door Hinge Seal Replacement 874
Door Opening Seal Removal 874
Installation 874
GLASS REPLACEMENT 875
Adhesive Bonded Windows 875
Replacement Procedure 875
Windshield And Rear Glass 876
Removal 876
Installation 877
SECTION N3 – CAB COMPONENTS – INDEX 879
CAB COMPONENTS 881
WINDSHIELD WIPERS 881
Wiper Motor Replacement 881
Removal 881
Installation 881
Wiper Arm 881
Removal 881
Installation 882
Wiper Linkage Replacement 882
Removal 882
Installation 882
WINDSHIELD WASHER 883
Operation 883
Service 883
OPERATOR SEAT 884
Adjustment 884
Seat Removal 884
Seat Installation 884
SECTION N4 – OPERATOR COMFORT – INDEX 885
OPERATOR COMFORT 887
HEATER / AIR CONDITIONER 887
Operation 887
Heater/Air Conditioner Vents 887
COMPONENTS 888
Circuit Breakers 888
Relays 888
Heater Core 888
Fan Motor And Speed Control 889
Actuators 889
Cab Air Filter 889
AIR CONDITIONING SYSTEM 891
Environmental Impact 891
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 892
PRINCIPLES OF REFRIGERATION 892
Air Conditioning 892
Refrigeration – The Act Of Cooling 893
The Refrigeration Cycle 893
AIR CONDITIONER SYSTEM COMPONENTS 894
Compressor (Refrigerant Pump) 894
Service Valves 894
Condenser 894
Receiver-Drier 894
Expansion Block Valve 895
Accumulator 895
Evaporator 895
ELECTRICAL CIRCUIT 896
Thermostat 896
Compressor Clutch 896
Trinary™ Switch 897
SYSTEM SERVICING 898
SERVICE TOOLS AND EQUIPMENT 899
Recovery/Recycle Station 899
Leak Detector 899
Service Valves 900
Vacuum Pump 900
Manifold Gauge Set 901
Installing Manifold Gauge Set 902
Purging Air From Service Hoses 902
SYSTEM PERFORMANCE TEST 903
SYSTEM OIL 904
Handling and Reusing PAG Oil 904
Oil Quantity 904
Checking System Oil 904
REFRIGERANT 905
Recycled Refrigerant 905
Reclaimed Refrigerant 905
Refrigerant Quantity 905
R-134a Refrigerant Containers 905
SYSTEM LEAK TESTING 906
Electronic Leak Detector 906
Tracer Dyes 906
Soap and Water 906
RECOVERING AND RECYCLING THE REFRIGERANT 907
Performing the Recovery Cycle 907
Performing the Recycling Procedure 907
Evacuating and Charging the A/C System 907
SYSTEM REPAIR 908
System Flushing 908
COMPONENT REPLACEMENT 908
Hoses and Fittings 908
Lines 908
Expansion Valve 909
Receiver-Drier 909
Thermostat 909
Compressor 909
Accumulator 909
Clutch 910
Servicing the Compressor Clutch 910
Pulley Removal 912
Clutch Coil Check 913
Pulley Installation 913
Clutch Assembly Installation 913
EVACUATING THE SYSTEM 915
CHARGING THE A/C SYSTEM 917
TROUBLESHOOTING 918
Preliminary Checks 918
Diagnosis Of Gauge Readings And System Performance 918
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 919
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 925
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 927
OPERATOR CAB CONTROLS 929
STEERING COLUMN 929
Removal 929
Steering Column Inspection 929
Installation 929
STEERING WHEEL AND CONTROLS 931
Horn Button 931
Telescope Lock Ring 931
Tilt Wheel Lever 931
Multi-Function Turn Signal Switch 931
DYNAMIC RETARDING 932
Retarder Control Lever 932
Dynamic Retarder/Service Brake Pedal 932
Accelerator (Throttle) Pedal 933
Starting on a Grade With a Loaded Truck 933
GRADE/SPEED RETARD CHART 933
INSTRUMENT PANEL 935
OVERHEAD PANEL AND DISPLAYS 935
CENTER CONSOLE 936
F-N-R Selector Switch 936
Hoist Control Lever 937
Raising The Dump Body 937
Lowering The Dump Body 937
Ash Tray 937
Lighter 937
L H Window Control Switch 937
R H Window Control Switch 937
Engine Shutdown Switch 937
Override/Fault Reset Switch 938
Retard Speed Control (RSC) Switch 938
Retard Speed Control (RSC) Adjust Dial 938
Data Store Button 939
Engine Control System 939
Service Engine Light 939
Engine Diagnostics Download Port 939
Payload Meter 939
TCI Download Port 939
PSC Download Port 939
Payload Meter 939
INSTRUMENT PANEL AND INDICATOR LIGHTS 941
CONTROL SYMBOLS 941
INSTRUMENT PANEL 941
PANEL GAUGES, INDICATORS, AND CONTROLS 943
Key Switch 943
Starting 943
Cold Weather Starting 943
Normal Engine Shutdown 943
Engine Shutdown Switch with 5 Minute Idle Timer Delay 944
Fog Lights (Optional) 944
Ladder Light Switch 944
Manual Backup Switch 944
Panel Illumination Lights 945
Cab/Air Conditioner Vents 945
Rotating Beacon Light Switch (Optional) 945
Heated Mirror Switch (Optional) 945
Wheel Brake Lock Control 945
Parking Brake Control 945
Tachometer 946
Right Turn Signal Indicator 946
High Beam Indicator 946
Left Turn Signal Indicator 946
Speedometer / Payload Meter 946
Voltmeter 946
Engine Oil Pressure Gauge 946
Water Temperature Gauge 946
Fuel Gauge 946
AC Drive System Temperature Gauge 947
Hydraulic Oil Temperature Gauge 947
Hourmeter 947
Rest Switch 947
Light Switch 948
Windshield Wiper and Washer 948
Panel Light Dimmer 948
Payload Meter Switch 948
OVERHEAD STATUS / WARNING INDICATORS 949
STATUS / WARNING INDICATOR LIGHT SYMBOLS 950
Hazard Warning Lights 955
Lamp Test Switch 955
Link-On Warning Light 955
SECTION P – LUBRICATION AND SERVICE – INDEX 957
SECTION P2 – LUBRICATION AND SERVICE – INDEX 959
LUBRICATION AND SERVICE 961
930E SERVICE CAPACITIES 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
WHEEL MOTOR SERVICE 961
COOLANT LEVEL CHECK 962
RADIATOR FILLING PROCEDURE 962
RESERVE ENGINE OIL SYSTEM (Optional) 962
Reserve Oil Tank Filling Procedure (Remote fill) 962
LUBRICATION CHART 963
10 HOUR (DAILY) INSPECTION 964
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR MAINTENANCE CHECKS 974
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 975
AUTOMATIC LUBRICATION SYSTEM 977
GENERAL DESCRIPTION 977
SYSTEM COMPONENTS 979
Filter 979
Hydraulic Motor and Pump 979
Grease Reservoir 979
Pressure Reducing Valve 979
Flow Control Valve 979
Solenoid Valve 979
Vent Valve 979
Lubrication Cycle Timer 979
Time Delay Module 979
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 979
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 979
Pressure Gauge 979
Injectors 979
SYSTEM OPERATION 980
Normal Operation 980
Pressure Failure Detection Circuits 981
GENERAL INSTRUCTIONS 982
Lubricant Requirements 982
System Priming 982
LUBRICANT PUMP 982
Pump Housing Oil Level 982
Pump Pressure Control 982
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 983
FILTER ASSEMBLY 983
SYSTEM CHECKOUT 984
INJECTORS (SL-1 Series “H”)) 984
Injector Specifications 984
Injector Adjustment 984
INJECTOR OPERATION 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 988
Assembly 988
SYSTEM TROUBLESHOOTING CHART 990
PREVENTATIVE MAINTENANCE PROCEDURES 993
Daily Lubrication System Inspection 993
250 Hour Inspection 993
1000 Hour Inspection 993
SECTION Q – ALPHABETICAL INDEX 995
SECTION R – SYSTEM SCHEMATIC – INDEX 999
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 1001
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 1002
ELECTRICAL SCHEMATIC – XS1300 1003
VHMS ELECTRICAL SCHEMATIC 1037MAIN MENU 0
COVER 0
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 D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT & TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
PSC PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 424
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 427
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 428
IGBT TROUBLESHOOTING 429
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 431
SECTION G2 – TIRES AND RIMS – INDEX 433
TIRES AND RIMS 435
WHEEL STUD MAINTENANCE 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
Tire Installation 442
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Preparation 447
Removal 447
Installation – Wheel Hub and Spindle Assembly 450
Disassembly – Wheel Hub and Spindle Assembly 451
Cleaning and Inspection – Wheel Hub and Spindle Assembly 451
Assembly – Wheel Hub and Spindle Assembly 453
Wheel Bearing Adjustment: 453
Brake Installation 454
Seal Assembly Gap Check 455
STEERING CYLINDERS AND TIE ROD 456
Spherical Bearing Wear Limits 456
Removal – Steering Cylinder and Tie Rod 457
Installation – Steering Cylinder and Tie Rod 458
Bearing Replacement 458
TOE-IN ADJUSTMENT 459
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 464
PIVOT EYE BEARING 465
Removal 465
Installation 465
PIVOT EYE REPAIR 465
Removal 465
Disassembly 465
Assembly 466
Installation 466
ANTI-SWAY BAR 466
Removal 466
Installation 467
Disassembly 467
Cleaning and Inspection 467
Assembly 467
SECTION G5 – REAR AXLE HOUSING – INDEX 469
REAR AXLE HOUSING 471
REAR AXLE HOUSING 471
Preparation 471
Removal 471
Cleaning and Inspection – Rear Axle Housing 473
Installation – Rear Axle Housing 473
WHEEL MOTOR 474
Preparation 474
Removal 474
Cleaning and Inspection – Wheel Motor 475
Installation – Wheel Motor 476
WHEEL MOTOR GEAR OIL 479
Filtering Requirements 479
Particle Size Analysis 479
Flushing 479
Oil Sample Analysis 480
ELEMENT SPECIFICATION CHARTS 481
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 485
SECTION H2 – FRONT SUSPENSIONS – INDEX 487
FRONT SUSPENSION 489
Removal 489
Installation – Front Suspension 490
“Turn-Of-The-Nut” Tightening Procedure 493
MINOR REPAIRS (LOWER BEARING & SEALS) 494
Removal – Bearing Retainer 494
Installation – Bearing Retainer 494
MAJOR SUSPENSION REBUILD 496
Disassembly 496
Assembly 496
SECTION H3 – REAR SUSPENSIONS – INDEX 499
REAR SUSPENSIONS 501
SUSPENSION CYLINDER 502
Removal 502
Installation – Rear Suspension 504
Disassembly – Rear Suspension 504
Cleaning and Inspection – Rear Suspension 504
Assembly – Rear Suspension 505
SUSPENSION PRESSURE TEST 507
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 509
SUSPENSION OILING AND CHARGING PROCEDURE 511
GENERAL 511
EQUIPMENT LIST 511
Hydrair® Charging Kit 511
Installation of Charging Kit 511
Removal of Charging Kit 512
Support Blocks For Oiling And Charging Dimensions 512
FRONT SUSPENSION 513
Front Suspension Oiling 513
Front Suspension Nitrogen Charging 514
REAR SUSPENSION 515
Rear Suspension Oiling 515
Rear Suspension Nitrogen Charging 517
OIL AND NITROGEN SPECIFICATIONS CHART 518
SECTION J – BRAKE CIRCUIT – INDEX 519
SECTION J2 – BRAKE CIRCUIT – INDEX 521
BRAKE CIRCUIT 523
SERVICE BRAKE CIRCUIT 523
SECONDARY BRAKING AND AUTOMATIC APPLY 525
PARKING BRAKE CIRCUIT 525
Normal Operation (key switch on, engine running) 525
BRAKE LOCK CIRCUIT 526
WARNING CIRCUIT 526
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 529
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE VALVE 531
Rebuild Criteria 531
Removal 532
Installation 532
Disassembly 533
Cleaning and Inspection 536
Assembly 536
Actuator Base Threaded Inserts 536
Boot and Cap 536
Valve Body Seal Installation 536
Regulator Sleeve O-Ring Installation 537
Actuator Plunger O-ring Installation 537
Assembly of Valve 537
DIFFERENTIAL PRESSURE SWITCH 539
Disassembly 539
Cleaning and Inspection 539
Assembly 539
VALVE BENCH TEST AND ADJUSTMENT 540
Test Set Up Procedure 541
Brake Valve Output Pressure Adjustment 541
Differential Pressure Switch Adjustment 541
Final Test and Adjustment 542
Installation Of Brake Pedal Actuator Assembly to Brake Valve 543
Installation of Retard Pedal To Brake Pedal 543
DUAL RELAY VALVE 545
Removal 545
Installation 545
Disassembly 547
Cleaning and Inspection 547
Assembly 547
DIFFERENTIAL PRESSURE SWITCH 548
Disassembly 548
Cleaning and Inspection 548
Assembly 548
VALVE TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Relay Valve Output Pressure Adjustment 550
Differential Pressure Switch Adjustment 551
BRAKE MANIFOLD 552
Removal 552
Installation 553
Disassembly 553
Cleaning and Inspection 553
Assembly 553
BRAKE ACCUMULATORS 554
Brake Accumulator Bleeddown Procedure 554
BRAKE ACCUMULATOR REPAIR 555
Removal 555
Installation 555
Disassembly 556
Cleaning and Inspection 557
Assembly 557
ACCUMULATOR CHARGING PROCEDURE 559
Temperature During Precharge 560
Precharge Maintenance 561
Recharging Accumulators 561
Accumulator Storage procedures 562
Bladder Storage Procedures 562
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 563
Removal 563
Installation 563
Disassembly and Adjustment 563
Potentiometer Check 565
Assembly 565
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 567
BRAKE CIRCUIT CHECK-OUT PROCEDURE 569
REQUIRED EQUIPMENT 571
INITIAL SYSTEM SET-UP 572
BRAKE SYSTEM CHECKOUT 573
Failure Modes Check-Out 574
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 576
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 579
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 580
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 581
WET DISC BRAKE ASSEMBLY 583
OPERATION 583
MAINTENANCE 584
Brake Disc Wear Indicator 584
Removal/Installation – Wet Disc Brake Assembly 584
BRAKE REBUILD 586
Disassembly 586
Cleaning and Inspection 589
Assembly 590
Floating Ring Seal Assembly/Installation 593
WET DISC BRAKE BLEEDING PROCEDURE 596
SECTION J7 – PARKING BRAKE – INDEX 597
PARKING BRAKE 599
OPERATION 599
MAINTENANCE 600
Inspection – Parking Brake 600
Removal – Parking Brake 600
Installation – Parking Brake 601
Disassembly – Parking Brake 602
Cleaning and Inspection – Parking Brake 602
Assembly – Parking Brake 602
PARKING BRAKE BLEEDING PROCEDURE 604
SECTION L – HYDRAULIC SYSTEM – INDEX 605
SECTION L2 – HYDRAULIC SYSTEM – INDEX 607
HYDRAULIC SYSTEM 609
HYDRAULIC PUMP MODULE 609
HOIST CIRCUIT OPERATION 610
STEERING CIRCUIT OPERATION 612
DISC BRAKE COOLING SYSTEM 614
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 617
HYDRAULIC SYSTEM COMPONENT REPAIR 619
HOIST PUMP 619
Removal 619
Installation 621
INSPECTION OF PARTS 626
Assembly 626
HYDRAULIC TANK 632
Filling Instructions 632
Removal 632
Installation 633
HYDRAULIC TANK STRAINERS 633
Removal 633
Inspect and Clean 633
Installation 633
HYDRAULIC TANK BREATHERS 634
SECTION L4 – STEERING CIRCUIT – INDEX 635
STEERING CIRCUIT 637
COMPONENT DESCRIPTION 638
Steering Control Unit 638
Bleeddown Manifold Valve 639
Bleeddown Solenoid 639
Relief Valves 641
Hoist Limit Solenoid 641
Accumulators 641
Low Precharge Warning Switch 641
High Pressure Filter 641
Quick Disconnect Ports 641
Flow Amplifier 642
FLOW AMPLIFIER SYSTEM OPERATION 644
No Steer 644
Steering Left 646
Steering Right 648
No Steer, External Shock Load 650
STEERING PUMP 652
Operation 652
PRINCIPLE OF OPERATION 654
Full Pump Volume: 654
Half Pump Volume: 654
Neutral Position: 654
Steering Pump 655
SECTION L5 – STEERING CONTROL UNIT – INDEX 657
STEERING CONTROL UNIT 659
Removal 659
Spline Inspection 659
Installation 660
STEERING CONTROL UNIT REBUILD 660
Disassembly 660
Cleaning and Inspection – Steering Control Unit 661
Assembly – Steering Control Unit 663
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEEDDOWN MANIFOLD VALVE 669
Removal 669
Installation 669
FLOW AMPLIFIER 671
Removal 671
Installation 671
FLOW AMPLIFIER REBUILD 671
Disassembly 674
Assembly 675
STEERING CYLINDERS 676
Disassembly 677
Piston Seal & Bearing Installation 677
Cylinder Assembly 677
Test 677
STEERING AND BRAKE PUMP 678
Removal 678
Installation 678
Disassembly 680
Control Piston Group 680
Valve Plate Group 680
Rotating Group 683
Swashblock Group 683
Driveshaft Group 683
Inspection 683
Control Piston Group 683
Valve Plate Group 683
Rotating Group 683
Swashblock Group 685
Driveshaft Group 686
Compensator Block and Unloader Module 686
Stroke Adjuster Assembly 686
Assembly 686
Swashblock Group 686
Driveshaft Group 687
Rotating Group 687
Valve Plate Group 688
STEERING ACCUMULATORS 689
Removal 689
Installation 689
Disassembly 690
Cleaning and Inspection 690
Assembly 691
Leak Testing 693
Charging Procedure 694
Temperature During Precharge 695
Precharge Maintenance 696
Accumulator Storage procedures 697
Bladder Storage Procedures 697
TROUBLESHOOTING CHART 698
SECTION L7 – HOIST CIRCUIT – INDEX 703
HOIST CIRCUIT 705
HOIST CIRCUIT OPERATION 705
COMPONENT DESCRIPTION 706
Hydraulic Tank 706
Hydraulic Pump 706
High Pressure Filters 706
Hoist Valve 706
Inlet Sections – Hoist Valve 706
Spool Sections – Hoist Valve 707
Hoist Pilot Valve 707
Bleeddown Manifold 708
Hoist-up Limit Solenoid 708
Pilot Operated Check Valve 708
Overcenter Manifold 708
HOIST CIRCUIT OPERATION 709
Float Position Of Pilot Valve With Truck Body On Frame 710
Power Up Operation 712
Hold Operation 714
Power Down Operation 716
Float Operation 718
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 721
HOIST CIRCUIT COMPONENT REPAIR 723
HOIST VALVE 723
Removal 723
Installation 724
O-Ring Replacement 724
INLET SECTION 725
Disassembly 725
Cleaning and Inspection 726
Assembly 726
REAR SPOOL SECTION (Work Ports) 726
Disassembly 726
Cleaning and Inspection 728
Assembly 728
FRONT SPOOL SECTION (Tank Ports) 729
Disassembly 729
Cleaning and Inspection 729
Assembly 729
HOIST PILOT VALVE 731
Removal 731
Installation 731
Disassembly 732
Cleaning and Inspection 733
Assembly 733
HOIST CYLINDERS 734
Removal 734
Installation 735
Disassembly 737
Cleaning and Inspection 738
Assembly – Quill and Cylinder 739
Quill Installation 739
Installation Of Check Balls And Plugs In Quill 740
Assembly of Cylinder 741
OVERCENTER VALVE MANIFOLD 742
DISABLED TRUCK DUMPING PROCEDURE 743
Hookup 743
Raising the Body 743
Lowering the Body 743
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 745
HYDRAULIC SYSTEM FILTERS 747
HOIST CIRCUIT FILTER 747
Filter Element Replacement 747
Removal – Hoist Circuit Filter 748
Installation – Hoist Circuit Filter 748
Indicator Switch – Hoist Circuit Filter 748
STEERING CIRCUIT FILTER 749
Filter Element Replacement 749
Removal – Steering Circuit Filter 750
Installation – Steering Circuit Filter 750
Indicator Switch – Steering Circuit Filter 750
INDICATOR SWITCH 750
Test Procedure 750
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 753
HYDRAULIC CHECK-OUT PROCEDURE 755
GENERAL INFORMATION 755
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 755
Equipment Requirements 756
Pump Pressure Control Adjustments 756
Steering Control Valve and Flow Amplifier Leakage Test 757
Bleeddown Manifold Leakage Test 757
STEERING/BRAKE PUMP STROKE ADJUSTMENT 758
SHOCK AND SUCTION VALVES 759
Equipment Requirements 759
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 760
Equipment Requirements 760
Pressure Gauge Locations 760
Brake Cooling Circuit Test 760
Power Up Relief Pressure Test 761
Adjustment 761
Power Down Relief Pressure Test 762
Hoist Counterbalance Valve Adjustment Preparation 763
Counterbalance Valve Pressure Check 763
Counterbalance Valve Adjustment 764
Preparation 765
Flushing Procedure 765
Filter Element Replacement 766
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 766
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 768
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 769
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 771
FIRE CONTROL SYSTEM (MANUAL) 773
Operation 773
Inspection and Maintenance 773
Recharging Procedures 774
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 775
Control Module 775
Actuator 776
Linear Detection Wire 776
Power Wire 776
Test Kit 776
Squib 776
Securing the Detection Wire 777
Preliminary Test Before Final Hook-Up 777
Installation Procedure for Squib 779
Placing the Electric Detection & Actuation System Into Service 779
INSPECTION AND MAINTENANCE SCHEDULES 780
Daily 780
Normal Maintenance Based On Actual Operating Hours 780
IN CASE OF FIRE 781
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 783
SECTION M8 – SPECIAL TOOLS 785
SECTION M20 – PAYLOAD METER III – INDEX 791
OPERATION SECTION 795
Introduction 795
Data Summary 795
Data Gathering 795
COMPONENT DESCRIPTION 796
System Diagram 796
Suspension Pressure Sensors 796
Inclinometer 796
Operator Display 796
Operator Switch 797
Speed Input 797
Body-Up Switch 797
Brake Lock Switch 797
Payload Meter 797
Communications Ports 797
Keyswitch Input 798
Payload Meter Power 798
Load Lights 798
Wiring and Termination 799
TCI Outputs 799
OPERATOR’S DISPLAY AND SWITCH 800
Reading the Speedometer 800
Reading the Load Display 800
Using the Operator ID 800
Using the Load and Ton Counter 800
Total Ton Counter 800
Total Load Counter 801
Clearing the Counters 801
Viewing Live Sensor Data 801
Other Display Messages 801
PAYLOAD OPERATION & CALCULATION 802
Description of Haul Cycle States 802
Haul Cycle Description 802
Load Calculation 803
Carry Back 803
Measurement Accuracy 803
SOURCES FOR PAYLOAD ERROR 803
Payload Error 803
Loading Conditions 804
Pressure Sensors 804
Swingloads 804
Speed and Distance 804
HAUL CYCLE DATA 804
Haul Cycle Data 805
Haul Cycle Warning Flags 806
M: Haul Cycle Too Long 807
N: Sensor Input Error 807
Frame Torque Data 807
Sprung Weight Data 807
Maximum Speed Data 807
Alarm Records 807
Fault Code Data 808
PC SOFTWARE OVERVIEW 809
PC Overview 809
System Configuration 809
Installing the PLMIII Software 809
DOWNLOADING DATA 810
PLM III SYSTEM CONFIGURATION 811
Starting Communications 811
Displayed Payload Units 811
Time Units 811
Connection Menu 811
Connecting to the Payload Meter 812
Configure the Payload Meter 812
Setting the Date and Time 812
Setting the Truck Type 813
Setting the Gauge Display Units 813
Setting the Frame Serial Number 813
Setting the Truck Number 813
Setting the Komatsu Distributor 813
Setting the Komatsu Customer 813
Clean Truck Tare 814
Inclinometer Calibration 814
DATA ANALYSIS 815
Creating a Query 815
Sorting on Truck Unit Number 815
Sorting on Truck Type 815
Sorting on Date Range 816
Sorting on Time Range 816
Payload Detail Screen 817
Creating Reports 817
Summary – one page report 818
Detailed – multi-page report 818
Creating Graphs 819
Exporting Data 819
CSV Export 819
Compressed 820
Importing Data 821
Deleting Haul Cycle Records 821
Viewing Alarms 822
Deleting Alarm Records 822
TROUBLESHOOTING SECTION 823
TROUBLESHOOTING 823
Viewing Active Alarms 823
Real-Time Data Display 823
Testing the Payload Lights 823
Creating Log Files of Inputs 824
Daily Inspections 824
Periodic Maintenance 824
Abnormal Displays at Power-Up 825
No Payload Display When Keyswitch is Turned ON 826
No Display on Speedometer 827
No Display on Operator Display 827
No Communications With PC 828
Load Lights Don’t Light During Loading 829
Load Lights Remain ON 830
Load Lights Remain ON During Dumping 830
Display Doesn’t Clear When The Load Is Dumped 830
Calibration Problems 831
Alarm 1 – Left Front Pressure High 832
Alarm 2 – Left Front Pressure Low 832
Troubleshoot Wiring to Left Front Suspension 832
Alarm 3 – Right Front Pressure High 833
Alarm 4 – Right Front Pressure Low 833
Troubleshoot Wiring to Right Front Suspension 833
Alarm 5 -Left Rear Pressure High 834
Alarm 6 – Left Rear Pressure Low 834
Troubleshoot Wiring to Left Rear Suspension 834
Alarm 7 – Right Rear Pressure High 835
Alarm 8 – Right Rear Pressure Low 835
Troubleshoot Wiring to Right Rear Suspension 835
Alarm 9 – Inclinometer High 836
Alarm 10 – Inclinometer Low 836
Troubleshoot Inclinometer Wiring 836
Alarm 13 – Body Up Input Failure 837
Alarm 16 – Memory Write Failure 838
Alarm 17 – Memory Read Failure 838
Alarm 18 839
Alarm 19 839
Alarm 22 839
Operator Switch Doesn’t Work 840
Alarm 26 – User Switch Fault – SELECT 840
Alarm 27 – User Switch Fault – SET 840
Connector Map 841
Connectors 842
PLMIII CHECK OUT PROCEDURE 843
General Description 843
Tools Required 843
Checkout Procedure 843
PLMIII CHECKOUT PROCEDURE CONFIRMATION 847
Flashburn Programming 847
Confirmation Checklist 849
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 851
RESERVE ENGINE OIL SYSTEM 853
Operation 853
LED Monitor Light 854
Tank Fill Control (Optional) 854
Filling Procedure (Remote fill feature) 854
SERVICE 855
Every 10 Hours, or once each shift: 855
Every 500 Hours: 855
Changing Oil 855
TROUBLESHOOTING 856
Circuit Breaker or Fuse 856
SYSTEM ELECTRICAL SCHEMATICS 857
SECTION N – CAB COMPONENTS – INDEX 859
SECTION N2 – TRUCK CAB – INDEX 861
TRUCK CAB 863
Description 863
Preparation 864
Removal – Cab 864
Installation – Cab 866
CAB DOOR 866
Removal 866
Installation 866
Door Adjustment 867
Door Jamb Bolt Adjustment 867
Door Handle Plunger Adjustment 868
Door Glass Replacement 869
Door Window Regulator Replacement 873
Door Handle or Latch Assembly Replacement 873
Door and Door Hinge Seal Replacement 874
Door Opening Seal Removal 874
Installation 874
GLASS REPLACEMENT 875
Adhesive Bonded Windows 875
Replacement Procedure 875
Windshield And Rear Glass 876
Removal 876
Installation 877
SECTION N3 – CAB COMPONENTS – INDEX 879
CAB COMPONENTS 881
WINDSHIELD WIPERS 881
Wiper Motor Replacement 881
Removal 881
Installation 881
Wiper Arm 881
Removal 881
Installation 882
Wiper Linkage Replacement 882
Removal 882
Installation 882
WINDSHIELD WASHER 883
Operation 883
Service 883
OPERATOR SEAT 884
Adjustment 884
Seat Removal 884
Seat Installation 884
SECTION N4 – OPERATOR COMFORT – INDEX 885
OPERATOR COMFORT 887
HEATER / AIR CONDITIONER 887
Operation 887
Heater/Air Conditioner Vents 887
COMPONENTS 888
Circuit Breakers 888
Relays 888
Heater Core 888
Fan Motor And Speed Control 889
Actuators 889
Cab Air Filter 889
AIR CONDITIONING SYSTEM 891
Environmental Impact 891
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 892
PRINCIPLES OF REFRIGERATION 892
Air Conditioning 892
Refrigeration – The Act Of Cooling 893
The Refrigeration Cycle 893
AIR CONDITIONER SYSTEM COMPONENTS 894
Compressor (Refrigerant Pump) 894
Service Valves 894
Condenser 894
Receiver-Drier 894
Expansion Block Valve 895
Accumulator 895
Evaporator 895
ELECTRICAL CIRCUIT 896
Thermostat 896
Compressor Clutch 896
Trinary™ Switch 897
SYSTEM SERVICING 898
SERVICE TOOLS AND EQUIPMENT 899
Recovery/Recycle Station 899
Leak Detector 899
Service Valves 900
Vacuum Pump 900
Manifold Gauge Set 901
Installing Manifold Gauge Set 902
Purging Air From Service Hoses 902
SYSTEM PERFORMANCE TEST 903
SYSTEM OIL 904
Handling and Reusing PAG Oil 904
Oil Quantity 904
Checking System Oil 904
REFRIGERANT 905
Recycled Refrigerant 905
Reclaimed Refrigerant 905
Refrigerant Quantity 905
R-134a Refrigerant Containers 905
SYSTEM LEAK TESTING 906
Electronic Leak Detector 906
Tracer Dyes 906
Soap and Water 906
RECOVERING AND RECYCLING THE REFRIGERANT 907
Performing the Recovery Cycle 907
Performing the Recycling Procedure 907
Evacuating and Charging the A/C System 907
SYSTEM REPAIR 908
System Flushing 908
COMPONENT REPLACEMENT 908
Hoses and Fittings 908
Lines 908
Expansion Valve 909
Receiver-Drier 909
Thermostat 909
Compressor 909
Accumulator 909
Clutch 910
Servicing the Compressor Clutch 910
Pulley Removal 912
Clutch Coil Check 913
Pulley Installation 913
Clutch Assembly Installation 913
EVACUATING THE SYSTEM 915
CHARGING THE A/C SYSTEM 917
TROUBLESHOOTING 918
Preliminary Checks 918
Diagnosis Of Gauge Readings And System Performance 918
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 919
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 925
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 927
OPERATOR CAB CONTROLS 929
STEERING COLUMN 929
Removal 929
Steering Column Inspection 929
Installation 929
STEERING WHEEL AND CONTROLS 931
Horn Button 931
Telescope Lock Ring 931
Tilt Wheel Lever 931
Multi-Function Turn Signal Switch 931
DYNAMIC RETARDING 932
Retarder Control Lever 932
Dynamic Retarder/Service Brake Pedal 932
Accelerator (Throttle) Pedal 933
Starting on a Grade With a Loaded Truck 933
GRADE/SPEED RETARD CHART 933
INSTRUMENT PANEL 935
OVERHEAD PANEL AND DISPLAYS 935
CENTER CONSOLE 936
F-N-R Selector Switch 936
Hoist Control Lever 937
Raising The Dump Body 937
Lowering The Dump Body 937
Ash Tray 937
Lighter 937
L H Window Control Switch 937
R H Window Control Switch 937
Engine Shutdown Switch 937
Override/Fault Reset Switch 938
Retard Speed Control (RSC) Switch 938
Retard Speed Control (RSC) Adjust Dial 938
Data Store Button 939
Engine Control System 939
Service Engine Light 939
Engine Diagnostics Download Port 939
Payload Meter 939
TCI Download Port 939
PSC Download Port 939
Payload Meter 939
INSTRUMENT PANEL AND INDICATOR LIGHTS 941
CONTROL SYMBOLS 941
INSTRUMENT PANEL 941
PANEL GAUGES, INDICATORS, AND CONTROLS 943
Key Switch 943
Starting 943
Cold Weather Starting 943
Normal Engine Shutdown 943
Engine Shutdown Switch with 5 Minute Idle Timer Delay 944
Fog Lights (Optional) 944
Ladder Light Switch 944
Manual Backup Switch 944
Panel Illumination Lights 945
Cab/Air Conditioner Vents 945
Rotating Beacon Light Switch (Optional) 945
Heated Mirror Switch (Optional) 945
Wheel Brake Lock Control 945
Parking Brake Control 945
Tachometer 946
Right Turn Signal Indicator 946
High Beam Indicator 946
Left Turn Signal Indicator 946
Speedometer / Payload Meter 946
Voltmeter 946
Engine Oil Pressure Gauge 946
Water Temperature Gauge 946
Fuel Gauge 946
AC Drive System Temperature Gauge 947
Hydraulic Oil Temperature Gauge 947
Hourmeter 947
Rest Switch 947
Light Switch 948
Windshield Wiper and Washer 948
Panel Light Dimmer 948
Payload Meter Switch 948
OVERHEAD STATUS / WARNING INDICATORS 949
STATUS / WARNING INDICATOR LIGHT SYMBOLS 950
Hazard Warning Lights 955
Lamp Test Switch 955
Link-On Warning Light 955
SECTION P – LUBRICATION AND SERVICE – INDEX 957
SECTION P2 – LUBRICATION AND SERVICE – INDEX 959
LUBRICATION AND SERVICE 961
930E SERVICE CAPACITIES 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
WHEEL MOTOR SERVICE 961
COOLANT LEVEL CHECK 962
RADIATOR FILLING PROCEDURE 962
RESERVE ENGINE OIL SYSTEM (Optional) 962
Reserve Oil Tank Filling Procedure (Remote fill) 962
LUBRICATION CHART 963
10 HOUR (DAILY) INSPECTION 964
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR MAINTENANCE CHECKS 974
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 975
AUTOMATIC LUBRICATION SYSTEM 977
GENERAL DESCRIPTION 977
SYSTEM COMPONENTS 979
Filter 979
Hydraulic Motor and Pump 979
Grease Reservoir 979
Pressure Reducing Valve 979
Flow Control Valve 979
Solenoid Valve 979
Vent Valve 979
Lubrication Cycle Timer 979
Time Delay Module 979
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 979
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 979
Pressure Gauge 979
Injectors 979
SYSTEM OPERATION 980
Normal Operation 980
Pressure Failure Detection Circuits 981
GENERAL INSTRUCTIONS 982
Lubricant Requirements 982
System Priming 982
LUBRICANT PUMP 982
Pump Housing Oil Level 982
Pump Pressure Control 982
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 983
FILTER ASSEMBLY 983
SYSTEM CHECKOUT 984
INJECTORS (SL-1 Series “H”)) 984
Injector Specifications 984
Injector Adjustment 984
INJECTOR OPERATION 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 988
Assembly 988
SYSTEM TROUBLESHOOTING CHART 990
PREVENTATIVE MAINTENANCE PROCEDURES 993
Daily Lubrication System Inspection 993
250 Hour Inspection 993
1000 Hour Inspection 993
SECTION Q – ALPHABETICAL INDEX 995
SECTION R – SYSTEM SCHEMATIC – INDEX 999
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 1001
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 1002
ELECTRICAL SCHEMATIC – XS1300 1003
VHMS ELECTRICAL SCHEMATIC 1037MAIN MENU 0
COVER 0
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 D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT & TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
PSC PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 424
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 427
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 428
IGBT TROUBLESHOOTING 429
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 431
SECTION G2 – TIRES AND RIMS – INDEX 433
TIRES AND RIMS 435
WHEEL STUD MAINTENANCE 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
Tire Installation 442
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Preparation 447
Removal 447
Installation – Wheel Hub and Spindle Assembly 450
Disassembly – Wheel Hub and Spindle Assembly 451
Cleaning and Inspection – Wheel Hub and Spindle Assembly 451
Assembly – Wheel Hub and Spindle Assembly 453
Wheel Bearing Adjustment: 453
Brake Installation 454
Seal Assembly Gap Check 455
STEERING CYLINDERS AND TIE ROD 456
Spherical Bearing Wear Limits 456
Removal – Steering Cylinder and Tie Rod 457
Installation – Steering Cylinder and Tie Rod 458
Bearing Replacement 458
TOE-IN ADJUSTMENT 459
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 464
PIVOT EYE BEARING 465
Removal 465
Installation 465
PIVOT EYE REPAIR 465
Removal 465
Disassembly 465
Assembly 466
Installation 466
ANTI-SWAY BAR 466
Removal 466
Installation 467
Disassembly 467
Cleaning and Inspection 467
Assembly 467
SECTION G5 – REAR AXLE HOUSING – INDEX 469
REAR AXLE HOUSING 471
REAR AXLE HOUSING 471
Preparation 471
Removal 471
Cleaning and Inspection – Rear Axle Housing 473
Installation – Rear Axle Housing 473
WHEEL MOTOR 474
Preparation 474
Removal 474
Cleaning and Inspection – Wheel Motor 475
Installation – Wheel Motor 476
WHEEL MOTOR GEAR OIL 479
Filtering Requirements 479
Particle Size Analysis 479
Flushing 479
Oil Sample Analysis 480
ELEMENT SPECIFICATION CHARTS 481
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 485
SECTION H2 – FRONT SUSPENSIONS – INDEX 487
FRONT SUSPENSION 489
Removal 489
Installation – Front Suspension 490
“Turn-Of-The-Nut” Tightening Procedure 493
MINOR REPAIRS (LOWER BEARING & SEALS) 494
Removal – Bearing Retainer 494
Installation – Bearing Retainer 494
MAJOR SUSPENSION REBUILD 496
Disassembly 496
Assembly 496
SECTION H3 – REAR SUSPENSIONS – INDEX 499
REAR SUSPENSIONS 501
SUSPENSION CYLINDER 502
Removal 502
Installation – Rear Suspension 504
Disassembly – Rear Suspension 504
Cleaning and Inspection – Rear Suspension 504
Assembly – Rear Suspension 505
SUSPENSION PRESSURE TEST 507
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 509
SUSPENSION OILING AND CHARGING PROCEDURE 511
GENERAL 511
EQUIPMENT LIST 511
Hydrair® Charging Kit 511
Installation of Charging Kit 511
Removal of Charging Kit 512
Support Blocks For Oiling And Charging Dimensions 512
FRONT SUSPENSION 513
Front Suspension Oiling 513
Front Suspension Nitrogen Charging 514
REAR SUSPENSION 515
Rear Suspension Oiling 515
Rear Suspension Nitrogen Charging 517
OIL AND NITROGEN SPECIFICATIONS CHART 518
SECTION J – BRAKE CIRCUIT – INDEX 519
SECTION J2 – BRAKE CIRCUIT – INDEX 521
BRAKE CIRCUIT 523
SERVICE BRAKE CIRCUIT 523
SECONDARY BRAKING AND AUTOMATIC APPLY 525
PARKING BRAKE CIRCUIT 525
Normal Operation (key switch on, engine running) 525
BRAKE LOCK CIRCUIT 526
WARNING CIRCUIT 526
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 529
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE VALVE 531
Rebuild Criteria 531
Removal 532
Installation 532
Disassembly 533
Cleaning and Inspection 536
Assembly 536
Actuator Base Threaded Inserts 536
Boot and Cap 536
Valve Body Seal Installation 536
Regulator Sleeve O-Ring Installation 537
Actuator Plunger O-ring Installation 537
Assembly of Valve 537
DIFFERENTIAL PRESSURE SWITCH 539
Disassembly 539
Cleaning and Inspection 539
Assembly 539
VALVE BENCH TEST AND ADJUSTMENT 540
Test Set Up Procedure 541
Brake Valve Output Pressure Adjustment 541
Differential Pressure Switch Adjustment 541
Final Test and Adjustment 542
Installation Of Brake Pedal Actuator Assembly to Brake Valve 543
Installation of Retard Pedal To Brake Pedal 543
DUAL RELAY VALVE 545
Removal 545
Installation 545
Disassembly 547
Cleaning and Inspection 547
Assembly 547
DIFFERENTIAL PRESSURE SWITCH 548
Disassembly 548
Cleaning and Inspection 548
Assembly 548
VALVE TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Relay Valve Output Pressure Adjustment 550
Differential Pressure Switch Adjustment 551
BRAKE MANIFOLD 552
Removal 552
Installation 553
Disassembly 553
Cleaning and Inspection 553
Assembly 553
BRAKE ACCUMULATORS 554
Brake Accumulator Bleeddown Procedure 554
BRAKE ACCUMULATOR REPAIR 555
Removal 555
Installation 555
Disassembly 556
Cleaning and Inspection 557
Assembly 557
ACCUMULATOR CHARGING PROCEDURE 559
Temperature During Precharge 560
Precharge Maintenance 561
Recharging Accumulators 561
Accumulator Storage procedures 562
Bladder Storage Procedures 562
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 563
Removal 563
Installation 563
Disassembly and Adjustment 563
Potentiometer Check 565
Assembly 565
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 567
BRAKE CIRCUIT CHECK-OUT PROCEDURE 569
REQUIRED EQUIPMENT 571
INITIAL SYSTEM SET-UP 572
BRAKE SYSTEM CHECKOUT 573
Failure Modes Check-Out 574
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 576
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 579
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 580
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 581
WET DISC BRAKE ASSEMBLY 583
OPERATION 583
MAINTENANCE 584
Brake Disc Wear Indicator 584
Removal/Installation – Wet Disc Brake Assembly 584
BRAKE REBUILD 586
Disassembly 586
Cleaning and Inspection 589
Assembly 590
Floating Ring Seal Assembly/Installation 593
WET DISC BRAKE BLEEDING PROCEDURE 596
SECTION J7 – PARKING BRAKE – INDEX 597
PARKING BRAKE 599
OPERATION 599
MAINTENANCE 600
Inspection – Parking Brake 600
Removal – Parking Brake 600
Installation – Parking Brake 601
Disassembly – Parking Brake 602
Cleaning and Inspection – Parking Brake 602
Assembly – Parking Brake 602
PARKING BRAKE BLEEDING PROCEDURE 604
SECTION L – HYDRAULIC SYSTEM – INDEX 605
SECTION L2 – HYDRAULIC SYSTEM – INDEX 607
HYDRAULIC SYSTEM 609
HYDRAULIC PUMP MODULE 609
HOIST CIRCUIT OPERATION 610
STEERING CIRCUIT OPERATION 612
DISC BRAKE COOLING SYSTEM 614
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 617
HYDRAULIC SYSTEM COMPONENT REPAIR 619
HOIST PUMP 619
Removal 619
Installation 621
INSPECTION OF PARTS 626
Assembly 626
HYDRAULIC TANK 632
Filling Instructions 632
Removal 632
Installation 633
HYDRAULIC TANK STRAINERS 633
Removal 633
Inspect and Clean 633
Installation 633
HYDRAULIC TANK BREATHERS 634
SECTION L4 – STEERING CIRCUIT – INDEX 635
STEERING CIRCUIT 637
COMPONENT DESCRIPTION 638
Steering Control Unit 638
Bleeddown Manifold Valve 639
Bleeddown Solenoid 639
Relief Valves 641
Hoist Limit Solenoid 641
Accumulators 641
Low Precharge Warning Switch 641
High Pressure Filter 641
Quick Disconnect Ports 641
Flow Amplifier 642
FLOW AMPLIFIER SYSTEM OPERATION 644
No Steer 644
Steering Left 646
Steering Right 648
No Steer, External Shock Load 650
STEERING PUMP 652
Operation 652
PRINCIPLE OF OPERATION 654
Full Pump Volume: 654
Half Pump Volume: 654
Neutral Position: 654
Steering Pump 655
SECTION L5 – STEERING CONTROL UNIT – INDEX 657
STEERING CONTROL UNIT 659
Removal 659
Spline Inspection 659
Installation 660
STEERING CONTROL UNIT REBUILD 660
Disassembly 660
Cleaning and Inspection – Steering Control Unit 661
Assembly – Steering Control Unit 663
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEEDDOWN MANIFOLD VALVE 669
Removal 669
Installation 669
FLOW AMPLIFIER 671
Removal 671
Installation 671
FLOW AMPLIFIER REBUILD 671
Disassembly 674
Assembly 675
STEERING CYLINDERS 676
Disassembly 677
Piston Seal & Bearing Installation 677
Cylinder Assembly 677
Test 677
STEERING AND BRAKE PUMP 678
Removal 678
Installation 678
Disassembly 680
Control Piston Group 680
Valve Plate Group 680
Rotating Group 683
Swashblock Group 683
Driveshaft Group 683
Inspection 683
Control Piston Group 683
Valve Plate Group 683
Rotating Group 683
Swashblock Group 685
Driveshaft Group 686
Compensator Block and Unloader Module 686
Stroke Adjuster Assembly 686
Assembly 686
Swashblock Group 686
Driveshaft Group 687
Rotating Group 687
Valve Plate Group 688
STEERING ACCUMULATORS 689
Removal 689
Installation 689
Disassembly 690
Cleaning and Inspection 690
Assembly 691
Leak Testing 693
Charging Procedure 694
Temperature During Precharge 695
Precharge Maintenance 696
Accumulator Storage procedures 697
Bladder Storage Procedures 697
TROUBLESHOOTING CHART 698
SECTION L7 – HOIST CIRCUIT – INDEX 703
HOIST CIRCUIT 705
HOIST CIRCUIT OPERATION 705
COMPONENT DESCRIPTION 706
Hydraulic Tank 706
Hydraulic Pump 706
High Pressure Filters 706
Hoist Valve 706
Inlet Sections – Hoist Valve 706
Spool Sections – Hoist Valve 707
Hoist Pilot Valve 707
Bleeddown Manifold 708
Hoist-up Limit Solenoid 708
Pilot Operated Check Valve 708
Overcenter Manifold 708
HOIST CIRCUIT OPERATION 709
Float Position Of Pilot Valve With Truck Body On Frame 710
Power Up Operation 712
Hold Operation 714
Power Down Operation 716
Float Operation 718
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 721
HOIST CIRCUIT COMPONENT REPAIR 723
HOIST VALVE 723
Removal 723
Installation 724
O-Ring Replacement 724
INLET SECTION 725
Disassembly 725
Cleaning and Inspection 726
Assembly 726
REAR SPOOL SECTION (Work Ports) 726
Disassembly 726
Cleaning and Inspection 728
Assembly 728
FRONT SPOOL SECTION (Tank Ports) 729
Disassembly 729
Cleaning and Inspection 729
Assembly 729
HOIST PILOT VALVE 731
Removal 731
Installation 731
Disassembly 732
Cleaning and Inspection 733
Assembly 733
HOIST CYLINDERS 734
Removal 734
Installation 735
Disassembly 737
Cleaning and Inspection 738
Assembly – Quill and Cylinder 739
Quill Installation 739
Installation Of Check Balls And Plugs In Quill 740
Assembly of Cylinder 741
OVERCENTER VALVE MANIFOLD 742
DISABLED TRUCK DUMPING PROCEDURE 743
Hookup 743
Raising the Body 743
Lowering the Body 743
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 745
HYDRAULIC SYSTEM FILTERS 747
HOIST CIRCUIT FILTER 747
Filter Element Replacement 747
Removal – Hoist Circuit Filter 748
Installation – Hoist Circuit Filter 748
Indicator Switch – Hoist Circuit Filter 748
STEERING CIRCUIT FILTER 749
Filter Element Replacement 749
Removal – Steering Circuit Filter 750
Installation – Steering Circuit Filter 750
Indicator Switch – Steering Circuit Filter 750
INDICATOR SWITCH 750
Test Procedure 750
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 753
HYDRAULIC CHECK-OUT PROCEDURE 755
GENERAL INFORMATION 755
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 755
Equipment Requirements 756
Pump Pressure Control Adjustments 756
Steering Control Valve and Flow Amplifier Leakage Test 757
Bleeddown Manifold Leakage Test 757
STEERING/BRAKE PUMP STROKE ADJUSTMENT 758
SHOCK AND SUCTION VALVES 759
Equipment Requirements 759
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 760
Equipment Requirements 760
Pressure Gauge Locations 760
Brake Cooling Circuit Test 760
Power Up Relief Pressure Test 761
Adjustment 761
Power Down Relief Pressure Test 762
Hoist Counterbalance Valve Adjustment Preparation 763
Counterbalance Valve Pressure Check 763
Counterbalance Valve Adjustment 764
Preparation 765
Flushing Procedure 765
Filter Element Replacement 766
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 766
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 768
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 769
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 771
FIRE CONTROL SYSTEM (MANUAL) 773
Operation 773
Inspection and Maintenance 773
Recharging Procedures 774
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 775
Control Module 775
Actuator 776
Linear Detection Wire 776
Power Wire 776
Test Kit 776
Squib 776
Securing the Detection Wire 777
Preliminary Test Before Final Hook-Up 777
Installation Procedure for Squib 779
Placing the Electric Detection & Actuation System Into Service 779
INSPECTION AND MAINTENANCE SCHEDULES 780
Daily 780
Normal Maintenance Based On Actual Operating Hours 780
IN CASE OF FIRE 781
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 783
SECTION M8 – SPECIAL TOOLS 785
SECTION M20 – PAYLOAD METER III – INDEX 791
OPERATION SECTION 795
Introduction 795
Data Summary 795
Data Gathering 795
COMPONENT DESCRIPTION 796
System Diagram 796
Suspension Pressure Sensors 796
Inclinometer 796
Operator Display 796
Operator Switch 797
Speed Input 797
Body-Up Switch 797
Brake Lock Switch 797
Payload Meter 797
Communications Ports 797
Keyswitch Input 798
Payload Meter Power 798
Load Lights 798
Wiring and Termination 799
TCI Outputs 799
OPERATOR’S DISPLAY AND SWITCH 800
Reading the Speedometer 800
Reading the Load Display 800
Using the Operator ID 800
Using the Load and Ton Counter 800
Total Ton Counter 800
Total Load Counter 801
Clearing the Counters 801
Viewing Live Sensor Data 801
Other Display Messages 801
PAYLOAD OPERATION & CALCULATION 802
Description of Haul Cycle States 802
Haul Cycle Description 802
Load Calculation 803
Carry Back 803
Measurement Accuracy 803
SOURCES FOR PAYLOAD ERROR 803
Payload Error 803
Loading Conditions 804
Pressure Sensors 804
Swingloads 804
Speed and Distance 804
HAUL CYCLE DATA 804
Haul Cycle Data 805
Haul Cycle Warning Flags 806
M: Haul Cycle Too Long 807
N: Sensor Input Error 807
Frame Torque Data 807
Sprung Weight Data 807
Maximum Speed Data 807
Alarm Records 807
Fault Code Data 808
PC SOFTWARE OVERVIEW 809
PC Overview 809
System Configuration 809
Installing the PLMIII Software 809
DOWNLOADING DATA 810
PLM III SYSTEM CONFIGURATION 811
Starting Communications 811
Displayed Payload Units 811
Time Units 811
Connection Menu 811
Connecting to the Payload Meter 812
Configure the Payload Meter 812
Setting the Date and Time 812
Setting the Truck Type 813
Setting the Gauge Display Units 813
Setting the Frame Serial Number 813
Setting the Truck Number 813
Setting the Komatsu Distributor 813
Setting the Komatsu Customer 813
Clean Truck Tare 814
Inclinometer Calibration 814
DATA ANALYSIS 815
Creating a Query 815
Sorting on Truck Unit Number 815
Sorting on Truck Type 815
Sorting on Date Range 816
Sorting on Time Range 816
Payload Detail Screen 817
Creating Reports 817
Summary – one page report 818
Detailed – multi-page report 818
Creating Graphs 819
Exporting Data 819
CSV Export 819
Compressed 820
Importing Data 821
Deleting Haul Cycle Records 821
Viewing Alarms 822
Deleting Alarm Records 822
TROUBLESHOOTING SECTION 823
TROUBLESHOOTING 823
Viewing Active Alarms 823
Real-Time Data Display 823
Testing the Payload Lights 823
Creating Log Files of Inputs 824
Daily Inspections 824
Periodic Maintenance 824
Abnormal Displays at Power-Up 825
No Payload Display When Keyswitch is Turned ON 826
No Display on Speedometer 827
No Display on Operator Display 827
No Communications With PC 828
Load Lights Don’t Light During Loading 829
Load Lights Remain ON 830
Load Lights Remain ON During Dumping 830
Display Doesn’t Clear When The Load Is Dumped 830
Calibration Problems 831
Alarm 1 – Left Front Pressure High 832
Alarm 2 – Left Front Pressure Low 832
Troubleshoot Wiring to Left Front Suspension 832
Alarm 3 – Right Front Pressure High 833
Alarm 4 – Right Front Pressure Low 833
Troubleshoot Wiring to Right Front Suspension 833
Alarm 5 -Left Rear Pressure High 834
Alarm 6 – Left Rear Pressure Low 834
Troubleshoot Wiring to Left Rear Suspension 834
Alarm 7 – Right Rear Pressure High 835
Alarm 8 – Right Rear Pressure Low 835
Troubleshoot Wiring to Right Rear Suspension 835
Alarm 9 – Inclinometer High 836
Alarm 10 – Inclinometer Low 836
Troubleshoot Inclinometer Wiring 836
Alarm 13 – Body Up Input Failure 837
Alarm 16 – Memory Write Failure 838
Alarm 17 – Memory Read Failure 838
Alarm 18 839
Alarm 19 839
Alarm 22 839
Operator Switch Doesn’t Work 840
Alarm 26 – User Switch Fault – SELECT 840
Alarm 27 – User Switch Fault – SET 840
Connector Map 841
Connectors 842
PLMIII CHECK OUT PROCEDURE 843
General Description 843
Tools Required 843
Checkout Procedure 843
PLMIII CHECKOUT PROCEDURE CONFIRMATION 847
Flashburn Programming 847
Confirmation Checklist 849
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 851
RESERVE ENGINE OIL SYSTEM 853
Operation 853
LED Monitor Light 854
Tank Fill Control (Optional) 854
Filling Procedure (Remote fill feature) 854
SERVICE 855
Every 10 Hours, or once each shift: 855
Every 500 Hours: 855
Changing Oil 855
TROUBLESHOOTING 856
Circuit Breaker or Fuse 856
SYSTEM ELECTRICAL SCHEMATICS 857
SECTION N – CAB COMPONENTS – INDEX 859
SECTION N2 – TRUCK CAB – INDEX 861
TRUCK CAB 863
Description 863
Preparation 864
Removal – Cab 864
Installation – Cab 866
CAB DOOR 866
Removal 866
Installation 866
Door Adjustment 867
Door Jamb Bolt Adjustment 867
Door Handle Plunger Adjustment 868
Door Glass Replacement 869
Door Window Regulator Replacement 873
Door Handle or Latch Assembly Replacement 873
Door and Door Hinge Seal Replacement 874
Door Opening Seal Removal 874
Installation 874
GLASS REPLACEMENT 875
Adhesive Bonded Windows 875
Replacement Procedure 875
Windshield And Rear Glass 876
Removal 876
Installation 877
SECTION N3 – CAB COMPONENTS – INDEX 879
CAB COMPONENTS 881
WINDSHIELD WIPERS 881
Wiper Motor Replacement 881
Removal 881
Installation 881
Wiper Arm 881
Removal 881
Installation 882
Wiper Linkage Replacement 882
Removal 882
Installation 882
WINDSHIELD WASHER 883
Operation 883
Service 883
OPERATOR SEAT 884
Adjustment 884
Seat Removal 884
Seat Installation 884
SECTION N4 – OPERATOR COMFORT – INDEX 885
OPERATOR COMFORT 887
HEATER / AIR CONDITIONER 887
Operation 887
Heater/Air Conditioner Vents 887
COMPONENTS 888
Circuit Breakers 888
Relays 888
Heater Core 888
Fan Motor And Speed Control 889
Actuators 889
Cab Air Filter 889
AIR CONDITIONING SYSTEM 891
Environmental Impact 891
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 892
PRINCIPLES OF REFRIGERATION 892
Air Conditioning 892
Refrigeration – The Act Of Cooling 893
The Refrigeration Cycle 893
AIR CONDITIONER SYSTEM COMPONENTS 894
Compressor (Refrigerant Pump) 894
Service Valves 894
Condenser 894
Receiver-Drier 894
Expansion Block Valve 895
Accumulator 895
Evaporator 895
ELECTRICAL CIRCUIT 896
Thermostat 896
Compressor Clutch 896
Trinary™ Switch 897
SYSTEM SERVICING 898
SERVICE TOOLS AND EQUIPMENT 899
Recovery/Recycle Station 899
Leak Detector 899
Service Valves 900
Vacuum Pump 900
Manifold Gauge Set 901
Installing Manifold Gauge Set 902
Purging Air From Service Hoses 902
SYSTEM PERFORMANCE TEST 903
SYSTEM OIL 904
Handling and Reusing PAG Oil 904
Oil Quantity 904
Checking System Oil 904
REFRIGERANT 905
Recycled Refrigerant 905
Reclaimed Refrigerant 905
Refrigerant Quantity 905
R-134a Refrigerant Containers 905
SYSTEM LEAK TESTING 906
Electronic Leak Detector 906
Tracer Dyes 906
Soap and Water 906
RECOVERING AND RECYCLING THE REFRIGERANT 907
Performing the Recovery Cycle 907
Performing the Recycling Procedure 907
Evacuating and Charging the A/C System 907
SYSTEM REPAIR 908
System Flushing 908
COMPONENT REPLACEMENT 908
Hoses and Fittings 908
Lines 908
Expansion Valve 909
Receiver-Drier 909
Thermostat 909
Compressor 909
Accumulator 909
Clutch 910
Servicing the Compressor Clutch 910
Pulley Removal 912
Clutch Coil Check 913
Pulley Installation 913
Clutch Assembly Installation 913
EVACUATING THE SYSTEM 915
CHARGING THE A/C SYSTEM 917
TROUBLESHOOTING 918
Preliminary Checks 918
Diagnosis Of Gauge Readings And System Performance 918
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 919
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 925
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 927
OPERATOR CAB CONTROLS 929
STEERING COLUMN 929
Removal 929
Steering Column Inspection 929
Installation 929
STEERING WHEEL AND CONTROLS 931
Horn Button 931
Telescope Lock Ring 931
Tilt Wheel Lever 931
Multi-Function Turn Signal Switch 931
DYNAMIC RETARDING 932
Retarder Control Lever 932
Dynamic Retarder/Service Brake Pedal 932
Accelerator (Throttle) Pedal 933
Starting on a Grade With a Loaded Truck 933
GRADE/SPEED RETARD CHART 933
INSTRUMENT PANEL 935
OVERHEAD PANEL AND DISPLAYS 935
CENTER CONSOLE 936
F-N-R Selector Switch 936
Hoist Control Lever 937
Raising The Dump Body 937
Lowering The Dump Body 937
Ash Tray 937
Lighter 937
L H Window Control Switch 937
R H Window Control Switch 937
Engine Shutdown Switch 937
Override/Fault Reset Switch 938
Retard Speed Control (RSC) Switch 938
Retard Speed Control (RSC) Adjust Dial 938
Data Store Button 939
Engine Control System 939
Service Engine Light 939
Engine Diagnostics Download Port 939
Payload Meter 939
TCI Download Port 939
PSC Download Port 939
Payload Meter 939
INSTRUMENT PANEL AND INDICATOR LIGHTS 941
CONTROL SYMBOLS 941
INSTRUMENT PANEL 941
PANEL GAUGES, INDICATORS, AND CONTROLS 943
Key Switch 943
Starting 943
Cold Weather Starting 943
Normal Engine Shutdown 943
Engine Shutdown Switch with 5 Minute Idle Timer Delay 944
Fog Lights (Optional) 944
Ladder Light Switch 944
Manual Backup Switch 944
Panel Illumination Lights 945
Cab/Air Conditioner Vents 945
Rotating Beacon Light Switch (Optional) 945
Heated Mirror Switch (Optional) 945
Wheel Brake Lock Control 945
Parking Brake Control 945
Tachometer 946
Right Turn Signal Indicator 946
High Beam Indicator 946
Left Turn Signal Indicator 946
Speedometer / Payload Meter 946
Voltmeter 946
Engine Oil Pressure Gauge 946
Water Temperature Gauge 946
Fuel Gauge 946
AC Drive System Temperature Gauge 947
Hydraulic Oil Temperature Gauge 947
Hourmeter 947
Rest Switch 947
Light Switch 948
Windshield Wiper and Washer 948
Panel Light Dimmer 948
Payload Meter Switch 948
OVERHEAD STATUS / WARNING INDICATORS 949
STATUS / WARNING INDICATOR LIGHT SYMBOLS 950
Hazard Warning Lights 955
Lamp Test Switch 955
Link-On Warning Light 955
SECTION P – LUBRICATION AND SERVICE – INDEX 957
SECTION P2 – LUBRICATION AND SERVICE – INDEX 959
LUBRICATION AND SERVICE 961
930E SERVICE CAPACITIES 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
WHEEL MOTOR SERVICE 961
COOLANT LEVEL CHECK 962
RADIATOR FILLING PROCEDURE 962
RESERVE ENGINE OIL SYSTEM (Optional) 962
Reserve Oil Tank Filling Procedure (Remote fill) 962
LUBRICATION CHART 963
10 HOUR (DAILY) INSPECTION 964
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR MAINTENANCE CHECKS 974
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 975
AUTOMATIC LUBRICATION SYSTEM 977
GENERAL DESCRIPTION 977
SYSTEM COMPONENTS 979
Filter 979
Hydraulic Motor and Pump 979
Grease Reservoir 979
Pressure Reducing Valve 979
Flow Control Valve 979
Solenoid Valve 979
Vent Valve 979
Lubrication Cycle Timer 979
Time Delay Module 979
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 979
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 979
Pressure Gauge 979
Injectors 979
SYSTEM OPERATION 980
Normal Operation 980
Pressure Failure Detection Circuits 981
GENERAL INSTRUCTIONS 982
Lubricant Requirements 982
System Priming 982
LUBRICANT PUMP 982
Pump Housing Oil Level 982
Pump Pressure Control 982
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 983
FILTER ASSEMBLY 983
SYSTEM CHECKOUT 984
INJECTORS (SL-1 Series “H”)) 984
Injector Specifications 984
Injector Adjustment 984
INJECTOR OPERATION 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 988
Assembly 988
SYSTEM TROUBLESHOOTING CHART 990
PREVENTATIVE MAINTENANCE PROCEDURES 993
Daily Lubrication System Inspection 993
250 Hour Inspection 993
1000 Hour Inspection 993
SECTION Q – ALPHABETICAL INDEX 995
SECTION R – SYSTEM SCHEMATIC – INDEX 999
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 1001
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 1002
ELECTRICAL SCHEMATIC – XS1300 1003
VHMS ELECTRICAL SCHEMATIC 1037

MAIN MENU 0
COVER 0
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 D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT & TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
PSC PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 424
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 427
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 428
IGBT TROUBLESHOOTING 429
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 431
SECTION G2 – TIRES AND RIMS – INDEX 433
TIRES AND RIMS 435
WHEEL STUD MAINTENANCE 436
FRONT TIRES AND RIMS 437
Removal 437
Installation 438
REAR TIRES AND RIMS 439
Removal 439
Installation 440
RIM 441
Tire Removal 441
Tire Installation 442
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 445
FRONT WHEEL HUB AND SPINDLE 447
WHEEL HUB AND SPINDLE ASSEMBLY 447
Preparation 447
Removal 447
Installation – Wheel Hub and Spindle Assembly 450
Disassembly – Wheel Hub and Spindle Assembly 451
Cleaning and Inspection – Wheel Hub and Spindle Assembly 451
Assembly – Wheel Hub and Spindle Assembly 453
Wheel Bearing Adjustment: 453
Brake Installation 454
Seal Assembly Gap Check 455
STEERING CYLINDERS AND TIE ROD 456
Spherical Bearing Wear Limits 456
Removal – Steering Cylinder and Tie Rod 457
Installation – Steering Cylinder and Tie Rod 458
Bearing Replacement 458
TOE-IN ADJUSTMENT 459
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 464
PIVOT EYE BEARING 465
Removal 465
Installation 465
PIVOT EYE REPAIR 465
Removal 465
Disassembly 465
Assembly 466
Installation 466
ANTI-SWAY BAR 466
Removal 466
Installation 467
Disassembly 467
Cleaning and Inspection 467
Assembly 467
SECTION G5 – REAR AXLE HOUSING – INDEX 469
REAR AXLE HOUSING 471
REAR AXLE HOUSING 471
Preparation 471
Removal 471
Cleaning and Inspection – Rear Axle Housing 473
Installation – Rear Axle Housing 473
WHEEL MOTOR 474
Preparation 474
Removal 474
Cleaning and Inspection – Wheel Motor 475
Installation – Wheel Motor 476
WHEEL MOTOR GEAR OIL 479
Filtering Requirements 479
Particle Size Analysis 479
Flushing 479
Oil Sample Analysis 480
ELEMENT SPECIFICATION CHARTS 481
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 485
SECTION H2 – FRONT SUSPENSIONS – INDEX 487
FRONT SUSPENSION 489
Removal 489
Installation – Front Suspension 490
“Turn-Of-The-Nut” Tightening Procedure 493
MINOR REPAIRS (LOWER BEARING & SEALS) 494
Removal – Bearing Retainer 494
Installation – Bearing Retainer 494
MAJOR SUSPENSION REBUILD 496
Disassembly 496
Assembly 496
SECTION H3 – REAR SUSPENSIONS – INDEX 499
REAR SUSPENSIONS 501
SUSPENSION CYLINDER 502
Removal 502
Installation – Rear Suspension 504
Disassembly – Rear Suspension 504
Cleaning and Inspection – Rear Suspension 504
Assembly – Rear Suspension 505
SUSPENSION PRESSURE TEST 507
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 509
SUSPENSION OILING AND CHARGING PROCEDURE 511
GENERAL 511
EQUIPMENT LIST 511
Hydrair® Charging Kit 511
Installation of Charging Kit 511
Removal of Charging Kit 512
Support Blocks For Oiling And Charging Dimensions 512
FRONT SUSPENSION 513
Front Suspension Oiling 513
Front Suspension Nitrogen Charging 514
REAR SUSPENSION 515
Rear Suspension Oiling 515
Rear Suspension Nitrogen Charging 517
OIL AND NITROGEN SPECIFICATIONS CHART 518
SECTION J – BRAKE CIRCUIT – INDEX 519
SECTION J2 – BRAKE CIRCUIT – INDEX 521
BRAKE CIRCUIT 523
SERVICE BRAKE CIRCUIT 523
SECONDARY BRAKING AND AUTOMATIC APPLY 525
PARKING BRAKE CIRCUIT 525
Normal Operation (key switch on, engine running) 525
BRAKE LOCK CIRCUIT 526
WARNING CIRCUIT 526
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 529
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE VALVE 531
Rebuild Criteria 531
Removal 532
Installation 532
Disassembly 533
Cleaning and Inspection 536
Assembly 536
Actuator Base Threaded Inserts 536
Boot and Cap 536
Valve Body Seal Installation 536
Regulator Sleeve O-Ring Installation 537
Actuator Plunger O-ring Installation 537
Assembly of Valve 537
DIFFERENTIAL PRESSURE SWITCH 539
Disassembly 539
Cleaning and Inspection 539
Assembly 539
VALVE BENCH TEST AND ADJUSTMENT 540
Test Set Up Procedure 541
Brake Valve Output Pressure Adjustment 541
Differential Pressure Switch Adjustment 541
Final Test and Adjustment 542
Installation Of Brake Pedal Actuator Assembly to Brake Valve 543
Installation of Retard Pedal To Brake Pedal 543
DUAL RELAY VALVE 545
Removal 545
Installation 545
Disassembly 547
Cleaning and Inspection 547
Assembly 547
DIFFERENTIAL PRESSURE SWITCH 548
Disassembly 548
Cleaning and Inspection 548
Assembly 548
VALVE TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Relay Valve Output Pressure Adjustment 550
Differential Pressure Switch Adjustment 551
BRAKE MANIFOLD 552
Removal 552
Installation 553
Disassembly 553
Cleaning and Inspection 553
Assembly 553
BRAKE ACCUMULATORS 554
Brake Accumulator Bleeddown Procedure 554
BRAKE ACCUMULATOR REPAIR 555
Removal 555
Installation 555
Disassembly 556
Cleaning and Inspection 557
Assembly 557
ACCUMULATOR CHARGING PROCEDURE 559
Temperature During Precharge 560
Precharge Maintenance 561
Recharging Accumulators 561
Accumulator Storage procedures 562
Bladder Storage Procedures 562
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 563
Removal 563
Installation 563
Disassembly and Adjustment 563
Potentiometer Check 565
Assembly 565
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 567
BRAKE CIRCUIT CHECK-OUT PROCEDURE 569
REQUIRED EQUIPMENT 571
INITIAL SYSTEM SET-UP 572
BRAKE SYSTEM CHECKOUT 573
Failure Modes Check-Out 574
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 576
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 579
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 580
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 581
WET DISC BRAKE ASSEMBLY 583
OPERATION 583
MAINTENANCE 584
Brake Disc Wear Indicator 584
Removal/Installation – Wet Disc Brake Assembly 584
BRAKE REBUILD 586
Disassembly 586
Cleaning and Inspection 589
Assembly 590
Floating Ring Seal Assembly/Installation 593
WET DISC BRAKE BLEEDING PROCEDURE 596
SECTION J7 – PARKING BRAKE – INDEX 597
PARKING BRAKE 599
OPERATION 599
MAINTENANCE 600
Inspection – Parking Brake 600
Removal – Parking Brake 600
Installation – Parking Brake 601
Disassembly – Parking Brake 602
Cleaning and Inspection – Parking Brake 602
Assembly – Parking Brake 602
PARKING BRAKE BLEEDING PROCEDURE 604
SECTION L – HYDRAULIC SYSTEM – INDEX 605
SECTION L2 – HYDRAULIC SYSTEM – INDEX 607
HYDRAULIC SYSTEM 609
HYDRAULIC PUMP MODULE 609
HOIST CIRCUIT OPERATION 610
STEERING CIRCUIT OPERATION 612
DISC BRAKE COOLING SYSTEM 614
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 617
HYDRAULIC SYSTEM COMPONENT REPAIR 619
HOIST PUMP 619
Removal 619
Installation 621
INSPECTION OF PARTS 626
Assembly 626
HYDRAULIC TANK 632
Filling Instructions 632
Removal 632
Installation 633
HYDRAULIC TANK STRAINERS 633
Removal 633
Inspect and Clean 633
Installation 633
HYDRAULIC TANK BREATHERS 634
SECTION L4 – STEERING CIRCUIT – INDEX 635
STEERING CIRCUIT 637
COMPONENT DESCRIPTION 638
Steering Control Unit 638
Bleeddown Manifold Valve 639
Bleeddown Solenoid 639
Relief Valves 641
Hoist Limit Solenoid 641
Accumulators 641
Low Precharge Warning Switch 641
High Pressure Filter 641
Quick Disconnect Ports 641
Flow Amplifier 642
FLOW AMPLIFIER SYSTEM OPERATION 644
No Steer 644
Steering Left 646
Steering Right 648
No Steer, External Shock Load 650
STEERING PUMP 652
Operation 652
PRINCIPLE OF OPERATION 654
Full Pump Volume: 654
Half Pump Volume: 654
Neutral Position: 654
Steering Pump 655
SECTION L5 – STEERING CONTROL UNIT – INDEX 657
STEERING CONTROL UNIT 659
Removal 659
Spline Inspection 659
Installation 660
STEERING CONTROL UNIT REBUILD 660
Disassembly 660
Cleaning and Inspection – Steering Control Unit 661
Assembly – Steering Control Unit 663
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEEDDOWN MANIFOLD VALVE 669
Removal 669
Installation 669
FLOW AMPLIFIER 671
Removal 671
Installation 671
FLOW AMPLIFIER REBUILD 671
Disassembly 674
Assembly 675
STEERING CYLINDERS 676
Disassembly 677
Piston Seal & Bearing Installation 677
Cylinder Assembly 677
Test 677
STEERING AND BRAKE PUMP 678
Removal 678
Installation 678
Disassembly 680
Control Piston Group 680
Valve Plate Group 680
Rotating Group 683
Swashblock Group 683
Driveshaft Group 683
Inspection 683
Control Piston Group 683
Valve Plate Group 683
Rotating Group 683
Swashblock Group 685
Driveshaft Group 686
Compensator Block and Unloader Module 686
Stroke Adjuster Assembly 686
Assembly 686
Swashblock Group 686
Driveshaft Group 687
Rotating Group 687
Valve Plate Group 688
STEERING ACCUMULATORS 689
Removal 689
Installation 689
Disassembly 690
Cleaning and Inspection 690
Assembly 691
Leak Testing 693
Charging Procedure 694
Temperature During Precharge 695
Precharge Maintenance 696
Accumulator Storage procedures 697
Bladder Storage Procedures 697
TROUBLESHOOTING CHART 698
SECTION L7 – HOIST CIRCUIT – INDEX 703
HOIST CIRCUIT 705
HOIST CIRCUIT OPERATION 705
COMPONENT DESCRIPTION 706
Hydraulic Tank 706
Hydraulic Pump 706
High Pressure Filters 706
Hoist Valve 706
Inlet Sections – Hoist Valve 706
Spool Sections – Hoist Valve 707
Hoist Pilot Valve 707
Bleeddown Manifold 708
Hoist-up Limit Solenoid 708
Pilot Operated Check Valve 708
Overcenter Manifold 708
HOIST CIRCUIT OPERATION 709
Float Position Of Pilot Valve With Truck Body On Frame 710
Power Up Operation 712
Hold Operation 714
Power Down Operation 716
Float Operation 718
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 721
HOIST CIRCUIT COMPONENT REPAIR 723
HOIST VALVE 723
Removal 723
Installation 724
O-Ring Replacement 724
INLET SECTION 725
Disassembly 725
Cleaning and Inspection 726
Assembly 726
REAR SPOOL SECTION (Work Ports) 726
Disassembly 726
Cleaning and Inspection 728
Assembly 728
FRONT SPOOL SECTION (Tank Ports) 729
Disassembly 729
Cleaning and Inspection 729
Assembly 729
HOIST PILOT VALVE 731
Removal 731
Installation 731
Disassembly 732
Cleaning and Inspection 733
Assembly 733
HOIST CYLINDERS 734
Removal 734
Installation 735
Disassembly 737
Cleaning and Inspection 738
Assembly – Quill and Cylinder 739
Quill Installation 739
Installation Of Check Balls And Plugs In Quill 740
Assembly of Cylinder 741
OVERCENTER VALVE MANIFOLD 742
DISABLED TRUCK DUMPING PROCEDURE 743
Hookup 743
Raising the Body 743
Lowering the Body 743
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 745
HYDRAULIC SYSTEM FILTERS 747
HOIST CIRCUIT FILTER 747
Filter Element Replacement 747
Removal – Hoist Circuit Filter 748
Installation – Hoist Circuit Filter 748
Indicator Switch – Hoist Circuit Filter 748
STEERING CIRCUIT FILTER 749
Filter Element Replacement 749
Removal – Steering Circuit Filter 750
Installation – Steering Circuit Filter 750
Indicator Switch – Steering Circuit Filter 750
INDICATOR SWITCH 750
Test Procedure 750
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 753
HYDRAULIC CHECK-OUT PROCEDURE 755
GENERAL INFORMATION 755
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 755
Equipment Requirements 756
Pump Pressure Control Adjustments 756
Steering Control Valve and Flow Amplifier Leakage Test 757
Bleeddown Manifold Leakage Test 757
STEERING/BRAKE PUMP STROKE ADJUSTMENT 758
SHOCK AND SUCTION VALVES 759
Equipment Requirements 759
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 760
Equipment Requirements 760
Pressure Gauge Locations 760
Brake Cooling Circuit Test 760
Power Up Relief Pressure Test 761
Adjustment 761
Power Down Relief Pressure Test 762
Hoist Counterbalance Valve Adjustment Preparation 763
Counterbalance Valve Pressure Check 763
Counterbalance Valve Adjustment 764
Preparation 765
Flushing Procedure 765
Filter Element Replacement 766
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 766
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 768
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 769
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 771
FIRE CONTROL SYSTEM (MANUAL) 773
Operation 773
Inspection and Maintenance 773
Recharging Procedures 774
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 775
Control Module 775
Actuator 776
Linear Detection Wire 776
Power Wire 776
Test Kit 776
Squib 776
Securing the Detection Wire 777
Preliminary Test Before Final Hook-Up 777
Installation Procedure for Squib 779
Placing the Electric Detection & Actuation System Into Service 779
INSPECTION AND MAINTENANCE SCHEDULES 780
Daily 780
Normal Maintenance Based On Actual Operating Hours 780
IN CASE OF FIRE 781
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 783
SECTION M8 – SPECIAL TOOLS 785
SECTION M20 – PAYLOAD METER III – INDEX 791
OPERATION SECTION 795
Introduction 795
Data Summary 795
Data Gathering 795
COMPONENT DESCRIPTION 796
System Diagram 796
Suspension Pressure Sensors 796
Inclinometer 796
Operator Display 796
Operator Switch 797
Speed Input 797
Body-Up Switch 797
Brake Lock Switch 797
Payload Meter 797
Communications Ports 797
Keyswitch Input 798
Payload Meter Power 798
Load Lights 798
Wiring and Termination 799
TCI Outputs 799
OPERATOR’S DISPLAY AND SWITCH 800
Reading the Speedometer 800
Reading the Load Display 800
Using the Operator ID 800
Using the Load and Ton Counter 800
Total Ton Counter 800
Total Load Counter 801
Clearing the Counters 801
Viewing Live Sensor Data 801
Other Display Messages 801
PAYLOAD OPERATION & CALCULATION 802
Description of Haul Cycle States 802
Haul Cycle Description 802
Load Calculation 803
Carry Back 803
Measurement Accuracy 803
SOURCES FOR PAYLOAD ERROR 803
Payload Error 803
Loading Conditions 804
Pressure Sensors 804
Swingloads 804
Speed and Distance 804
HAUL CYCLE DATA 804
Haul Cycle Data 805
Haul Cycle Warning Flags 806
M: Haul Cycle Too Long 807
N: Sensor Input Error 807
Frame Torque Data 807
Sprung Weight Data 807
Maximum Speed Data 807
Alarm Records 807
Fault Code Data 808
PC SOFTWARE OVERVIEW 809
PC Overview 809
System Configuration 809
Installing the PLMIII Software 809
DOWNLOADING DATA 810
PLM III SYSTEM CONFIGURATION 811
Starting Communications 811
Displayed Payload Units 811
Time Units 811
Connection Menu 811
Connecting to the Payload Meter 812
Configure the Payload Meter 812
Setting the Date and Time 812
Setting the Truck Type 813
Setting the Gauge Display Units 813
Setting the Frame Serial Number 813
Setting the Truck Number 813
Setting the Komatsu Distributor 813
Setting the Komatsu Customer 813
Clean Truck Tare 814
Inclinometer Calibration 814
DATA ANALYSIS 815
Creating a Query 815
Sorting on Truck Unit Number 815
Sorting on Truck Type 815
Sorting on Date Range 816
Sorting on Time Range 816
Payload Detail Screen 817
Creating Reports 817
Summary – one page report 818
Detailed – multi-page report 818
Creating Graphs 819
Exporting Data 819
CSV Export 819
Compressed 820
Importing Data 821
Deleting Haul Cycle Records 821
Viewing Alarms 822
Deleting Alarm Records 822
TROUBLESHOOTING SECTION 823
TROUBLESHOOTING 823
Viewing Active Alarms 823
Real-Time Data Display 823
Testing the Payload Lights 823
Creating Log Files of Inputs 824
Daily Inspections 824
Periodic Maintenance 824
Abnormal Displays at Power-Up 825
No Payload Display When Keyswitch is Turned ON 826
No Display on Speedometer 827
No Display on Operator Display 827
No Communications With PC 828
Load Lights Don’t Light During Loading 829
Load Lights Remain ON 830
Load Lights Remain ON During Dumping 830
Display Doesn’t Clear When The Load Is Dumped 830
Calibration Problems 831
Alarm 1 – Left Front Pressure High 832
Alarm 2 – Left Front Pressure Low 832
Troubleshoot Wiring to Left Front Suspension 832
Alarm 3 – Right Front Pressure High 833
Alarm 4 – Right Front Pressure Low 833
Troubleshoot Wiring to Right Front Suspension 833
Alarm 5 -Left Rear Pressure High 834
Alarm 6 – Left Rear Pressure Low 834
Troubleshoot Wiring to Left Rear Suspension 834
Alarm 7 – Right Rear Pressure High 835
Alarm 8 – Right Rear Pressure Low 835
Troubleshoot Wiring to Right Rear Suspension 835
Alarm 9 – Inclinometer High 836
Alarm 10 – Inclinometer Low 836
Troubleshoot Inclinometer Wiring 836
Alarm 13 – Body Up Input Failure 837
Alarm 16 – Memory Write Failure 838
Alarm 17 – Memory Read Failure 838
Alarm 18 839
Alarm 19 839
Alarm 22 839
Operator Switch Doesn’t Work 840
Alarm 26 – User Switch Fault – SELECT 840
Alarm 27 – User Switch Fault – SET 840
Connector Map 841
Connectors 842
PLMIII CHECK OUT PROCEDURE 843
General Description 843
Tools Required 843
Checkout Procedure 843
PLMIII CHECKOUT PROCEDURE CONFIRMATION 847
Flashburn Programming 847
Confirmation Checklist 849
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 851
RESERVE ENGINE OIL SYSTEM 853
Operation 853
LED Monitor Light 854
Tank Fill Control (Optional) 854
Filling Procedure (Remote fill feature) 854
SERVICE 855
Every 10 Hours, or once each shift: 855
Every 500 Hours: 855
Changing Oil 855
TROUBLESHOOTING 856
Circuit Breaker or Fuse 856
SYSTEM ELECTRICAL SCHEMATICS 857
SECTION N – CAB COMPONENTS – INDEX 859
SECTION N2 – TRUCK CAB – INDEX 861
TRUCK CAB 863
Description 863
Preparation 864
Removal – Cab 864
Installation – Cab 866
CAB DOOR 866
Removal 866
Installation 866
Door Adjustment 867
Door Jamb Bolt Adjustment 867
Door Handle Plunger Adjustment 868
Door Glass Replacement 869
Door Window Regulator Replacement 873
Door Handle or Latch Assembly Replacement 873
Door and Door Hinge Seal Replacement 874
Door Opening Seal Removal 874
Installation 874
GLASS REPLACEMENT 875
Adhesive Bonded Windows 875
Replacement Procedure 875
Windshield And Rear Glass 876
Removal 876
Installation 877
SECTION N3 – CAB COMPONENTS – INDEX 879
CAB COMPONENTS 881
WINDSHIELD WIPERS 881
Wiper Motor Replacement 881
Removal 881
Installation 881
Wiper Arm 881
Removal 881
Installation 882
Wiper Linkage Replacement 882
Removal 882
Installation 882
WINDSHIELD WASHER 883
Operation 883
Service 883
OPERATOR SEAT 884
Adjustment 884
Seat Removal 884
Seat Installation 884
SECTION N4 – OPERATOR COMFORT – INDEX 885
OPERATOR COMFORT 887
HEATER / AIR CONDITIONER 887
Operation 887
Heater/Air Conditioner Vents 887
COMPONENTS 888
Circuit Breakers 888
Relays 888
Heater Core 888
Fan Motor And Speed Control 889
Actuators 889
Cab Air Filter 889
AIR CONDITIONING SYSTEM 891
Environmental Impact 891
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 892
PRINCIPLES OF REFRIGERATION 892
Air Conditioning 892
Refrigeration – The Act Of Cooling 893
The Refrigeration Cycle 893
AIR CONDITIONER SYSTEM COMPONENTS 894
Compressor (Refrigerant Pump) 894
Service Valves 894
Condenser 894
Receiver-Drier 894
Expansion Block Valve 895
Accumulator 895
Evaporator 895
ELECTRICAL CIRCUIT 896
Thermostat 896
Compressor Clutch 896
Trinary™ Switch 897
SYSTEM SERVICING 898
SERVICE TOOLS AND EQUIPMENT 899
Recovery/Recycle Station 899
Leak Detector 899
Service Valves 900
Vacuum Pump 900
Manifold Gauge Set 901
Installing Manifold Gauge Set 902
Purging Air From Service Hoses 902
SYSTEM PERFORMANCE TEST 903
SYSTEM OIL 904
Handling and Reusing PAG Oil 904
Oil Quantity 904
Checking System Oil 904
REFRIGERANT 905
Recycled Refrigerant 905
Reclaimed Refrigerant 905
Refrigerant Quantity 905
R-134a Refrigerant Containers 905
SYSTEM LEAK TESTING 906
Electronic Leak Detector 906
Tracer Dyes 906
Soap and Water 906
RECOVERING AND RECYCLING THE REFRIGERANT 907
Performing the Recovery Cycle 907
Performing the Recycling Procedure 907
Evacuating and Charging the A/C System 907
SYSTEM REPAIR 908
System Flushing 908
COMPONENT REPLACEMENT 908
Hoses and Fittings 908
Lines 908
Expansion Valve 909
Receiver-Drier 909
Thermostat 909
Compressor 909
Accumulator 909
Clutch 910
Servicing the Compressor Clutch 910
Pulley Removal 912
Clutch Coil Check 913
Pulley Installation 913
Clutch Assembly Installation 913
EVACUATING THE SYSTEM 915
CHARGING THE A/C SYSTEM 917
TROUBLESHOOTING 918
Preliminary Checks 918
Diagnosis Of Gauge Readings And System Performance 918
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 919
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 925
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 927
OPERATOR CAB CONTROLS 929
STEERING COLUMN 929
Removal 929
Steering Column Inspection 929
Installation 929
STEERING WHEEL AND CONTROLS 931
Horn Button 931
Telescope Lock Ring 931
Tilt Wheel Lever 931
Multi-Function Turn Signal Switch 931
DYNAMIC RETARDING 932
Retarder Control Lever 932
Dynamic Retarder/Service Brake Pedal 932
Accelerator (Throttle) Pedal 933
Starting on a Grade With a Loaded Truck 933
GRADE/SPEED RETARD CHART 933
INSTRUMENT PANEL 935
OVERHEAD PANEL AND DISPLAYS 935
CENTER CONSOLE 936
F-N-R Selector Switch 936
Hoist Control Lever 937
Raising The Dump Body 937
Lowering The Dump Body 937
Ash Tray 937
Lighter 937
L H Window Control Switch 937
R H Window Control Switch 937
Engine Shutdown Switch 937
Override/Fault Reset Switch 938
Retard Speed Control (RSC) Switch 938
Retard Speed Control (RSC) Adjust Dial 938
Data Store Button 939
Engine Control System 939
Service Engine Light 939
Engine Diagnostics Download Port 939
Payload Meter 939
TCI Download Port 939
PSC Download Port 939
Payload Meter 939
INSTRUMENT PANEL AND INDICATOR LIGHTS 941
CONTROL SYMBOLS 941
INSTRUMENT PANEL 941
PANEL GAUGES, INDICATORS, AND CONTROLS 943
Key Switch 943
Starting 943
Cold Weather Starting 943
Normal Engine Shutdown 943
Engine Shutdown Switch with 5 Minute Idle Timer Delay 944
Fog Lights (Optional) 944
Ladder Light Switch 944
Manual Backup Switch 944
Panel Illumination Lights 945
Cab/Air Conditioner Vents 945
Rotating Beacon Light Switch (Optional) 945
Heated Mirror Switch (Optional) 945
Wheel Brake Lock Control 945
Parking Brake Control 945
Tachometer 946
Right Turn Signal Indicator 946
High Beam Indicator 946
Left Turn Signal Indicator 946
Speedometer / Payload Meter 946
Voltmeter 946
Engine Oil Pressure Gauge 946
Water Temperature Gauge 946
Fuel Gauge 946
AC Drive System Temperature Gauge 947
Hydraulic Oil Temperature Gauge 947
Hourmeter 947
Rest Switch 947
Light Switch 948
Windshield Wiper and Washer 948
Panel Light Dimmer 948
Payload Meter Switch 948
OVERHEAD STATUS / WARNING INDICATORS 949
STATUS / WARNING INDICATOR LIGHT SYMBOLS 950
Hazard Warning Lights 955
Lamp Test Switch 955
Link-On Warning Light 955
SECTION P – LUBRICATION AND SERVICE – INDEX 957
SECTION P2 – LUBRICATION AND SERVICE – INDEX 959
LUBRICATION AND SERVICE 961
930E SERVICE CAPACITIES 961
HYDRAULIC TANK SERVICE 961
Adding Oil 961
WHEEL MOTOR SERVICE 961
COOLANT LEVEL CHECK 962
RADIATOR FILLING PROCEDURE 962
RESERVE ENGINE OIL SYSTEM (Optional) 962
Reserve Oil Tank Filling Procedure (Remote fill) 962
LUBRICATION CHART 963
10 HOUR (DAILY) INSPECTION 964
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 967
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 968
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 969
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 972
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 973
5000 HOUR MAINTENANCE CHECKS 974
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 975
AUTOMATIC LUBRICATION SYSTEM 977
GENERAL DESCRIPTION 977
SYSTEM COMPONENTS 979
Filter 979
Hydraulic Motor and Pump 979
Grease Reservoir 979
Pressure Reducing Valve 979
Flow Control Valve 979
Solenoid Valve 979
Vent Valve 979
Lubrication Cycle Timer 979
Time Delay Module 979
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 979
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 979
Pressure Gauge 979
Injectors 979
SYSTEM OPERATION 980
Normal Operation 980
Pressure Failure Detection Circuits 981
GENERAL INSTRUCTIONS 982
Lubricant Requirements 982
System Priming 982
LUBRICANT PUMP 982
Pump Housing Oil Level 982
Pump Pressure Control 982
Lubrication Cycle Timer Check 983
Lubrication Cycle Timer Adjustment 983
FILTER ASSEMBLY 983
SYSTEM CHECKOUT 984
INJECTORS (SL-1 Series “H”)) 984
Injector Specifications 984
Injector Adjustment 984
INJECTOR OPERATION 985
PUMP REBUILD 986
Disassembly 986
Cleaning and Inspection 988
Assembly 988
SYSTEM TROUBLESHOOTING CHART 990
PREVENTATIVE MAINTENANCE PROCEDURES 993
Daily Lubrication System Inspection 993
250 Hour Inspection 993
1000 Hour Inspection 993
SECTION Q – ALPHABETICAL INDEX 995
SECTION R – SYSTEM SCHEMATIC – INDEX 999
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 1001
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 1002
ELECTRICAL SCHEMATIC – XS1300 1003
VHMS ELECTRICAL SCHEMATIC 1037