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KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL (SN:32604 – 32789, 32803 – 32815 wMTU Engine Manual) KOMATSU 930E – PDF DOWNLOAD
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- KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:32604 – 32789, 32803 – 32815 wMTU Engine Manual
- PUBLICATION NUMBER:CEBM010100
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Description
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL (SN:32604 – 32789, 32803 – 32815 wMTU Engine Manual) KOMATSU 930E
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL (SN:32604 – 32789, 32803 – 32815 WMTU ENGINE MANUAL) KOMATSU 930E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL (SN:32604 – 32789, 32803 – 32815 wMTU Engine Manual) KOMATSU 930E
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have æ10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL (SN:32604 – 32789, 32803 – 32815 wMTU Engine Manual) KOMATSU 930E
MAIN MENU....................................................................................... 0 COVER........................................................................................... 1 FOREWORD........................................................................................ 5 TABLE OF CONTENTS............................................................................... 7 SECTION A - GENERAL INFORMATION - INDEX......................................................... 9 SECTION A2 - MAJOR COMPONENT DESCRIPTION.................................................... 11 SECTION A3 - GENERAL SAFETY AND OPERATING INSTRUCTIONS - INDEX.............................. 15 GENERAL SAFETY.......................................................................... 17 Safety Rules........................................................................ 17 Safety Features..................................................................... 17 Clothing And Personal Items......................................................... 17 Unauthorized Modification........................................................... 17 Leaving The Operator’s Seat......................................................... 18 Mounting And Dismounting............................................................ 18 Fire Prevention For Fuel And Oil.................................................... 18 Precautions When Handling At High Temperatures...................................... 19 Asbestos Dust Hazard Prevention..................................................... 19 Prevention Of Injury By Work Equipment.............................................. 19 Fire Extinguisher And First Aid Kit................................................. 19 Precautions When Using ROPS......................................................... 20 Precautions For Attachments......................................................... 20 PRECAUTIONS DURING OPERATION............................................................ 21 Safety Is Thinking Ahead............................................................ 21 Safety At The Worksite.............................................................. 21 Fire Prevention..................................................................... 21 Preparing For Operation............................................................. 21 Ventilation For Enclosed Areas...................................................... 21 In Operator’s Cab - Before Starting The Engine...................................... 22 Mirrors, Windows, And Lights........................................................ 22 OPERATING THE MACHINE............................................................... 22 When Starting The Engine........................................................ 22 Truck Operation - General....................................................... 22 Check When Traveling In Reverse................................................. 23 Traveling....................................................................... 23 Traveling On Slopes............................................................. 24 Ensure Good Visibility.......................................................... 24 Operate Carefully On Snow....................................................... 24 Avoid Damage To Dump Body....................................................... 24 Driving Near High Voltage Cables................................................ 24 When Dumping.................................................................... 25 Working On Loose Ground......................................................... 25 When Loading.................................................................... 25 Parking The Machine............................................................. 25 TOWING.............................................................................. 25 WORKING NEAR BATTERIES.............................................................. 26 Starting With Booster Cables.................................................... 26 PRECAUTIONS FOR MAINTENANCE............................................................. 27 BEFORE PERFORMING MAINTENANCE....................................................... 27 Warning Tag..................................................................... 27 Proper Tools.................................................................... 27 Stopping The Engine Before Service.............................................. 27 Securing The Dump Body.......................................................... 27 DURING MAINTENANCE.................................................................. 28 Personnel....................................................................... 28 Attachments..................................................................... 28 Working Under The Machine....................................................... 28 Keep The Machine Clean.......................................................... 28 Rules To Follow When Adding Fuel Or Oil......................................... 28 Radiator Water Level............................................................ 29 Use Of Lighting................................................................. 29 Precautions With The Battery.................................................... 29 Handling High Pressure Hoses.................................................... 29 Precautions With High Pressure Oil.............................................. 29 Precautions When Performing Maintenance At High Temperature Or High Pressure.... 30 Rotating Fan And Belts.......................................................... 30 Waste Materials................................................................. 30 TIRES............................................................................... 31 Handling Tires.................................................................. 31 Storing Tires After Removal..................................................... 31 ADDITIONAL JOB SITE RULES............................................................... 32 WHEN REPAIRS ARE NECESSARY.............................................................. 33 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK......................................... 34 Preliminary Procedures before Welding or Performing Maintenance..................... 34 Normal Engine Shutdown Procedure.................................................... 34 Engine Shutdown Procedure before Welding or Performing Maintenance.................. 35 TRUCK OPERATION......................................................................... 37 PREPARING FOR OPERATION............................................................. 37 Safety Is Thinking Ahead........................................................ 37 At The Truck - Ground Level Walk Around Inspection.............................. 37 ENGINE START-UP SAFETY PRACTICES.................................................... 40 Cold Weather Starting........................................................... 41 AFTER ENGINE HAS STARTED............................................................ 41 MACHINE OPERATION SAFETY PRECAUTIONS................................................ 42 MACHINE OPERATION ON THE HAUL ROAD.................................................. 42 DYNAMIC RETARDING OPERATION......................................................... 43 Dynamic Retarder Control Lever.................................................. 43 Dynamic Retarder/Service Brake Pedal............................................ 43 Starting On A Grade With A Loaded Truck......................................... 44 PASSING............................................................................. 44 LOADING............................................................................. 44 DUMPING............................................................................. 44 Raising The Dump Body........................................................... 44 Lowering The Dump Body.......................................................... 45 TOWING.............................................................................. 46 SAFE PARKING PROCEDURES............................................................. 47 NORMAL ENGINE SHUTDOWN PROCEDURE.................................................... 47 DELAYED ENGINE SHUTDOWN PROCEDURE................................................... 47 SUDDEN LOSS OF ENGINE POWER......................................................... 48 SECTION A4 - WARNINGS AND CAUTIONS.......................................................... 49 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 (Type I).......................................................... 95 Inspection...................................................................... 95 Rock Ejectors (Type II)......................................................... 96 Inspection...................................................................... 96 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 FUEL - WATER SEPARATOR..............................................................104 Installation....................................................................104 Filter Service..................................................................105 Backflushing Procedure..........................................................105 Filter Element Replacement......................................................105 SECTION C - ENGINE - INDEX......................................................................107 SECTION C2 - POWER MODULE - INDEX...........................................................109 POWER MODULE............................................................................111 PREPARATION.........................................................................111 Removal.............................................................................112 Power Module Removal................................................................115 Power Module Installation...........................................................116 Power Module Hookup.................................................................118 SECTION C3 - COOLING SYSTEM - INDEX.........................................................119 COOLING SYSTEM..........................................................................121 RADIATOR............................................................................121 Removal.........................................................................121 RADIATOR REPAIR.....................................................................123 Internal Inspection.............................................................123 External Cleaning...............................................................123 Disassembly.....................................................................123 Cleaning and Inspection.........................................................124 Assembly........................................................................125 Pressure Testing................................................................126 Additional Service Information..................................................126 Installation....................................................................126 Radiator Fill Procedure.........................................................127 Troubleshooting.................................................................127 SECTION C4 - POWERTRAIN - INDEX.............................................................129 POWER TRAIN.............................................................................131 ALTERNATOR REMOVAL PROCEDURE........................................................131 Removal (MTU Engine)............................................................131 ENGINE/ALTERNATOR MATING............................................................132 MTU Engine......................................................................132 Joining Alternator and MTU Engine...............................................134 ENGINE..............................................................................135 Removal.........................................................................135 Service.........................................................................135 Installation....................................................................135 SECTION C5 - AIR CLEANERS - INDEX...........................................................137 AIR CLEANERS............................................................................139 Service Checks......................................................................139 Filter Element Replacement..........................................................139 Main Filter Element Cleaning........................................................141 Precleaner Section..................................................................142 Cleaning Precleaner Tubes...........................................................143 Air Intake Troubleshooting..........................................................143 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION)............................................145 SECTION D2 - 24VDC ELECTRICAL SUPPLY SYSTEM - INDEX.........................................147 24VDC ELECTRIC SUPPLY SYSTEM............................................................149 ELECTRICAL SYSTEM DESCRIPTION.......................................................149 BATTERIES.......................................................................149 Maintenance and Service.........................................................149 Troubleshooting.................................................................149 BATTERY SUPPLY SYSTEM...............................................................151 24VDC BATTERY CHARGING ALTERNATOR...............................................151 BATTERY BOX.....................................................................151 BATTERY CONTROL BOX.............................................................151 SYSTEM BATTERY STARTER DISCONNECT RELAY.........................................151 START REPEAT RELAY..............................................................152 BATTERY DISCONNECT SWITCHES.....................................................152 24VDC AUXILIARY BATTERY CONNECTORS..............................................152 BATTERY EQUALIZER AND MONITOR...................................................153 Troubleshooting.................................................................153 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX.....................................155 24 VDC ELECTRICAL SYSTEM COMPONENTS.....................................................157 PASSENGER SEAT BASE COMPARTMENT.....................................................157 TRUCK SHUTDOWN PROCEDURE........................................................157 COMPONENTS......................................................................157 ELECTRICAL INTERFACE CABINET........................................................162 DIODE BOARD - DB1...............................................................162 Diode Testing...................................................................162 TRUCK CONTROL INTERFACE PANEL...................................................164 CIRCUIT BREAKER CB1.............................................................165 RELAY BOARDS........................................................................166 RELAY BOARDS RB1, RB2, RB3, RB4, RB5............................................166 Service.........................................................................166 RELAY BOARD IDENTIFICATION..........................................................167 RELAY BOARD FUNCTIONS...........................................................168 Relay Board 1 (RB1).............................................................168 Relay Board 2 (RB2).............................................................168 Relay Board 3 (RB3).............................................................168 Relay Board 4 (RB4).............................................................168 Relay Board 5 (RB5).............................................................168 Relay Board 6 (RB6).............................................................169 Installing Additional Circuits..................................................169 Relay Board 7 (RB7).............................................................169 BODY-UP SWITCH......................................................................170 Operation.......................................................................170 Adjustment......................................................................170 Service.........................................................................170 HOIST LIMIT SWITCH..................................................................171 Operation.......................................................................171 Adjustment......................................................................171 Service.........................................................................171 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX...........................................173 BATTERY CHARGING ALTERNATOR.............................................................175 ELECTRICAL SYSTEM DESCRIPTION.......................................................175 BATTERY.............................................................................175 Maintenance and Service.........................................................175 Troubleshooting.................................................................175 BATTERY CHARGING SYSTEM (Niehoff)...................................................177 General Description.............................................................177 TROUBLESHOOTING PROCEDURES (On-Truck)...............................................177 Equipment Required:.............................................................177 Preliminary Checks..............................................................178 Test Setup......................................................................178 Test Procedure..................................................................178 Regulator Bypass Test...........................................................179 ON VEHICLE TROUBLESHOOTING GUIDE........................................................181 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage..........181 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:....................................181 CHARGE VOLT AND AMP VALUES..........................................................182 DEFINITIONS.........................................................................182 ADVANCED SYSTEM TROUBLESHOOTING.........................................................183 Static Test - Engine OFF, Key ON, Battery Switch ON.................................183 Go To Alternator....................................................................183 Go To Regulator (If Required).......................................................184 Go To Regulator Connector On The Alternator.........................................184 ALTERNATOR OVERHAUL.....................................................................185 ALTERNATOR DIMENSIONS...............................................................185 ALTERNATOR SPECIFICATIONS...........................................................186 SERVICE PARTS.......................................................................187 ON-VEHICLE TEST.....................................................................189 Equipment:......................................................................189 Preliminary Checks:.............................................................189 Test Set-up.....................................................................189 Test Procedure..................................................................189 ON-VEHICLE TEST.....................................................................190 Bypass Test:....................................................................190 BENCH TEST..........................................................................191 STATIC TESTS........................................................................192 Regulator Tests.................................................................192 Control Box Tests...............................................................193 ALTERNATOR DISASSEMBLY..............................................................195 ASSEMBLY- ALTERNATOR................................................................200 BF4822 STATOR SERVICE TOOL INSTRUCTIONS.................................................209 Stator Removal And Replacement......................................................209 Stator Installation.................................................................210 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX................................................213 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX................................215 ELECTRICAL PROPULSION SYSTEM COMPONENTS.................................................217 GENERAL SYSTEM DESCRIPTION..........................................................217 SYSTEM COMPONENTS...................................................................219 Auxiliary Blower System.........................................................219 Propulsion System Controller (PSC)..............................................219 TRUCK CONTROL INTERFACE PANEL (TCI).................................................220 Diagnostic Information Display..................................................221 DID PANEL EVENT CODES...............................................................221 PSC SOFTWARE FUNCTIONS..............................................................246 Input Processing................................................................246 STATE MANAGEMENT....................................................................246 State Machine...................................................................246 Transitions Between States......................................................247 DC Link State...................................................................249 Powering the Link...............................................................249 De-Powering the Link............................................................249 Control Functions...............................................................249 Engine Control..................................................................249 ALTERNATOR FIELD CONTROL............................................................250 Desired Three-Phase Voltage.....................................................250 Desired DC Link Voltage.........................................................250 Self-load.......................................................................250 Propel Torque Control...........................................................251 Retard Torque Control...........................................................251 Wheel Slide Control.............................................................251 Resistor Grid Control...........................................................252 Chopper Voltage Control.........................................................252 AUXILIARY BLOWER CONTROL............................................................252 EVENT PROCESSING....................................................................252 Event Detection.................................................................252 Power On Tests..................................................................252 Initiated Tests.................................................................253 Periodic Tests..................................................................253 EVENT RESTRICTIONS..................................................................253 EVENT LOGGING AND STORAGE...........................................................253 Event History Buffer............................................................254 Data Packs......................................................................254 To Record and Save a Data Pack to a Floppy Disk.................................254 Event Reset.....................................................................255 SERIAL DATA COMMUNICATIONS..........................................................256 PSC - TCI Communications processing.............................................256 PSC - PTU Communications Processing.............................................256 Inverter Communications Processing..............................................256 OUTPUT PROCESSING...................................................................257 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS............................................257 Fast Start......................................................................257 Engine Shutdown/Engine Not Running..............................................257 Limp Home Mode..................................................................257 Entering/Exiting Limp Home Mode.................................................257 PROPULSION SYSTEM COMPONENT ABBREVIATIONS...........................................258 ELECTRONIC ACCELERATOR AND RETARD PEDALS............................................268 Removal.........................................................................268 Installation....................................................................268 Disassembly.....................................................................268 Assembly........................................................................268 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX..........................269 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE...........................................271 AC DRIVE SYSTEM MAINTENANCE.........................................................271 TRUCK SHUTDOWN PROCEDURES...........................................................271 NORMAL TRUCK SHUTDOWN PROCEDURE.....................................................272 SHUTDOWN AFTER SYSTEM FAILURE.......................................................273 SYSTEM CHECKOUT.....................................................................274 Battery and Control Checks of System WITH Battery Power OFF.....................274 Battery and Control Circuit Checks of System With Battery Power ON..............277 Checks with Key Switch OFF......................................................278 CPU Battery Checks..............................................................280 MEMORY BACKUP BATTERY REPLACEMENT...................................................280 TCI PROGRAMMING.....................................................................281 PSC PROGRAMMING.....................................................................281 INVERTER PROGRAMMING................................................................282 TCI CHECKOUT........................................................................282 Modular Mining Communication Port...............................................283 TCI Input Checks................................................................284 TCI Digital Output Tests........................................................286 TCI Digital Input Tests.........................................................288 PSC Checkout Procedure..........................................................290 PSC Digital Input Checks........................................................294 Miscellaneous Checks............................................................295 A3PV Panel......................................................................295 LINKV Panel.....................................................................295 Thermistor Checks...............................................................295 17FM384 Panel Check.............................................................295 Pedal Percentages and Meter Calibration.........................................296 Meter Calibration Procedure.....................................................296 Reprogram With Serial Numbers and Pedal Percentages.............................298 LOAD TESTING........................................................................300 Preload Checks..................................................................300 ADDITIONAL TRUCK CHECKS.............................................................302 On-Board Load Testing...........................................................304 Preparation.....................................................................304 Initiate Loadbox Test...........................................................307 Manual Offset HP Output Adjustment..............................................309 TROUBLESHOOTING.........................................................................311 PVM Optimum Load Curve Handshaking Troubleshooting..................................311 MISCELLANEOUS COMPONENT REPAIR......................................................312 Troubleshooting Phase Modules and Chopper Modules...............................312 Phase Module Removal and Snubber Resistor Replacement...........................312 Snubber Resistor Installation...................................................313 Phase Module Installation.......................................................313 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING....................................314 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING....................................317 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING............................................318 IGBT TROUBLESHOOTING................................................................319 SECTION G - REAR AXLE, SPINDLES, AND WHEELS - INDEX.............................................321 SECTION G2 - TIRES AND RIMS - INDEX.........................................................323 TIRES AND RIMS..........................................................................325 FRONT TIRES AND RIMS................................................................326 Removal.........................................................................326 Installation....................................................................327 REAR TIRES AND RIMS.................................................................327 Removal.........................................................................327 Installation....................................................................328 RIM.................................................................................329 Tire Removal....................................................................329 Tire Installation...............................................................330 SECTION G3 - FRONT WHEEL HUB AND SPINDLES - INDEX...........................................331 FRONT WHEEL HUB AND SPINDLE.............................................................333 WHEEL HUB AND SPINDLE ASSEMBLY......................................................333 PREPARATION.....................................................................333 Removal.........................................................................333 Installation....................................................................336 Disassembly.....................................................................337 Cleaning and Inspection.........................................................337 Assembly........................................................................339 Wheel Bearing Adjustment:.......................................................340 Seal Assembly Gap Check:........................................................341 STEERING CYLINDERS AND TIE ROD......................................................342 Spherical Bearing Wear Limits...................................................342 Removal.........................................................................343 Installation....................................................................344 Bearing Replacement.............................................................344 TOE-IN ADJUSTMENT...................................................................345 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX...........................................347 REAR AXLE HOUSING ATTACHMENT............................................................349 PIVOT PIN...........................................................................349 Removal.........................................................................349 Installation....................................................................349 PIVOT EYE BEARING...................................................................350 Disassembly.....................................................................350 PIVOT EYE REPAIR....................................................................351 Removal.........................................................................351 Disassembly.....................................................................351 Assembly........................................................................351 Installation....................................................................351 ANTI-SWAY BAR.......................................................................352 Removal.........................................................................352 Installation....................................................................352 Disassembly.....................................................................352 Assembly........................................................................352 SECTION G5 - REAR AXLE HOUSING - INDEX......................................................353 REAR AXLE HOUSING.......................................................................355 REAR AXLE HOUSING...................................................................355 PREPARATION.....................................................................355 Removal.........................................................................355 Cleaning and Inspection.........................................................357 Installation....................................................................357 WHEEL MOTOR.........................................................................358 Preparation.....................................................................358 Removal.........................................................................358 Cleaning and Inspection.........................................................359 Installation....................................................................360 WHEEL MOTOR GEAR OIL................................................................363 Filtering Requirements..........................................................363 Particle Size Analysis..........................................................363 Flushing........................................................................363 Oil Sample Analysis.............................................................364 ELEMENT SPECIFICATION CHARTS........................................................365 SECTION H - HYDRAIR II SUSPENSIONS - INDEX......................................................369 SECTION H2 - FRONT SUSPENSION - INDEX.......................................................371 FRONT SUSPENSION........................................................................373 Removal.............................................................................373 Installation........................................................................374 "TURN-OF-THE-NUT" Tightening Procedure..............................................376 MINOR REPAIR ONLY (LOWER BEARING & SEALS)...........................................377 Lower Bearing Removal...........................................................377 Lower Bearing Installation......................................................377 MAJOR SUSPENSION REBUILD............................................................379 Disassembly.....................................................................379 Assembly........................................................................379 SECTION H3 - REAR SUSPENSION - INDEX........................................................381 REAR SUSPENSIONS........................................................................383 Removal.............................................................................383 Installation........................................................................385 Disassembly.........................................................................386 Cleaning and Inspection.............................................................386 Assembly............................................................................386 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX...............................389 SUSPENSION OILING AND CHARGING PROCEDURE................................................391 GENERAL.............................................................................391 EQUIPMENT LIST......................................................................391 Hydrair® Charging Kit...........................................................391 Installation of Charging Kit....................................................391 Removal of Charging Kit.........................................................392 Support Blocks For Oiling And Charging Dimensions...............................392 FRONT SUSPENSION....................................................................393 Front Suspension Oiling.........................................................393 Front Suspension Nitrogen Charging..............................................394 REAR SUSPENSION.....................................................................395 Rear Suspension Oiling..........................................................395 Rear Suspension Nitrogen Charging...............................................396 OIL AND NITROGEN SPECIFICATIONS CHART...................................................398 SECTION J - BRAKE CIRCUIT - INDEX...............................................................399 SECTION J2 - BRAKE CIRCUIT - INDEX..........................................................401 BRAKE CIRCUIT...........................................................................403 SERVICE BRAKE CIRCUIT...............................................................403 SECONDARY BRAKING AND AUTOMATIC APPLY...............................................405 PARKING BRAKE CIRCUIT...............................................................405 BRAKE LOCK CIRCUIT..................................................................406 WARNING CIRCUIT.....................................................................406 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX........................................409 BRAKE CIRCUIT COMPONENT SERVICE.........................................................411 BRAKE VALVE.........................................................................411 Rebuild Criteria................................................................411 Removal - Brake Valve...........................................................412 Installation - Brake Valve......................................................412 Disassembly - Brake Valve.......................................................413 Cleaning and Inspection - Brake Valve...........................................416 Assembly - Actuator Base Threaded Inserts.......................................416 Assembly - Boot and Cap.........................................................416 Installation - Valve Body Seal..................................................416 Installation - Regulator Sleeve O-Ring..........................................417 Installation - Actuator Plunger O-ring..........................................417 Assembly - Brake Valve..........................................................417 DIFFERENTIAL PRESSURE SWITCH........................................................419 Disassembly.....................................................................419 Cleaning and Inspection.........................................................419 Assembly........................................................................419 VALVE BENCH TEST AND ADJUSTMENT.....................................................420 Test Set Up Procedure...........................................................421 Adjustment - Brake Valve Output Pressure........................................421 Adjustment - Differential Pressure Switch.......................................421 Final Test and Adjustment.......................................................422 Installation - Brake Pedal Actuator Assembly to Brake Valve.....................423 Installation - Retard Pedal To Brake Pedal......................................423 DUAL RELAY VALVE....................................................................425 Removal.........................................................................425 Installation....................................................................425 Disassembly - Dual Relay Valve..................................................427 Cleaning and Inspection - Dual Relay Valve......................................427 Assembly - Dual Relay Valve.....................................................427 DIFFERENTIAL PRESSURE SWITCH........................................................428 Disassembly.....................................................................428 Cleaning and Inspection.........................................................428 Assembly........................................................................428 VALVE TEST AND ADJUSTMENT...........................................................429 Test Set Up Procedure...........................................................430 Adjustment - Brake Valve Output Pressure........................................430 Adjustment - Differential Pressure Switch.......................................431 HYDRAULIC BRAKE ACCUMULATORS........................................................432 Brake Accumulator Bleed Down Procedure..........................................432 ACCUMULUTOR - HYDRAULIC COMPONENTS CABINET..........................................432 Removal.........................................................................432 Installation....................................................................432 Disassembly.....................................................................432 Cleaning and Inspection - Accumulator...........................................433 Assembly - Accumulator..........................................................434 Charging Procedure - Accumulator................................................435 ACCUMULATORS - FRAME MOUNTED........................................................436 Removal.........................................................................436 Installation....................................................................436 Disassembly - Accumulator.......................................................437 Cleaning and Inspection - Accumulator...........................................437 Assembly - Accumulator..........................................................438 Testing - Accumulator...........................................................438 ACCUMULATOR CHARGING PROCEDURE (Frame Mounted Brake Accumulators)...................439 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)....................................440 Removal - Retarder Control Lever................................................440 Installation - Retarder Control Lever...........................................440 Disassembly and Adjustment - Retarder Control Lever.............................441 Potentiometer Check - Retarder Control Lever....................................441 Assembly - Retarder Control Lever...............................................441 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX......................................443 BRAKE CIRCUIT CHECK-OUT PROCEDURE.......................................................445 EQUIPMENT REQUIRED..................................................................447 INITIAL SYSTEM SET-UP...............................................................448 BRAKE SYSTEM CHECKOUT...............................................................449 Failure Modes Check-Out.........................................................450 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING...........................................453 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET...................................457 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX................................................459 WET DISC BRAKE ASSEMBLY.................................................................461 Operation...........................................................................461 MAINTENANCE.........................................................................462 Brake Disc Wear Indicator.......................................................462 Removal/Installation............................................................462 BRAKE REBUILD.......................................................................464 Disassembly.....................................................................464 Cleaning and Inspection.........................................................467 Assembly........................................................................468 Floating Ring Seal Assembly/Installation........................................471 WET DISC BRAKE BLEEDING PROCEDURE...................................................474 SECTION J7 - PARKING BRAKE - INDEX..........................................................475 PARKING BRAKE...........................................................................477 OPERATION...........................................................................477 MAINTENANCE.........................................................................478 Inspection - Parking Brake......................................................478 Removal - Parking Brake.........................................................478 Installation - Parking Brake....................................................479 Disassembly - Parking Brake.....................................................480 Cleaning and Inspection - Parking Brake.........................................480 Assembly - Parking Brake........................................................480 PARKING BRAKE BLEEDING PROCEDURE....................................................482 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................483 SECTION L2 - HYDRAULIC SYSTEM DESCRIPTION - INDEX...........................................485 HYDRAULIC SYSTEM........................................................................487 Hoist Circuit Operation.............................................................488 Steering Circuit Operation..........................................................490 Disc Brake Cooling System...........................................................492 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX......................................495 HYDRAULIC SYSTEM COMPONENT REPAIR.......................................................497 HOIST PUMP..........................................................................497 Removal.........................................................................497 Installation....................................................................499 Disassembly.....................................................................500 INSPECTION OF PARTS.................................................................504 Assembly........................................................................504 HYDRAULIC TANK......................................................................510 Filling Instructions............................................................510 Removal.........................................................................510 Installation....................................................................511 HYDRAULIC TANK STRAINERS............................................................511 Removal.........................................................................511 Inspect and Clean...............................................................511 Installation....................................................................511 HYDRAULIC TANK BREATHERS............................................................512 SECTION L4 - STEERING CIRCUIT - INDEX.......................................................513 STEERING CIRCUIT........................................................................515 STEERING CIRCUIT OPERATION..........................................................515 COMPONENT DESCRIPTION...............................................................516 Steering Control Valve..........................................................516 Bleeddown Manifold Valve........................................................517 Bleeddown Solenoid..............................................................517 Accumulators....................................................................518 Low Precharge Warning Switch....................................................518 High Pressure Filter............................................................518 Flow Amplifier..................................................................518 FLOW AMPLIFIER SYSTEM OPERATION.....................................................520 No Steer........................................................................520 Steering Left...................................................................522 Steering Right..................................................................524 No Steer, External Shock Load...................................................526 STEERING PUMP.......................................................................528 Operation.......................................................................528 Principle Of Operation..........................................................530 Steering Pump...................................................................531 SECTION L5 - STEERING CONTROL UNIT - INDEX..................................................533 STEERING CONTROL UNIT...................................................................535 Removal.............................................................................535 Installation........................................................................535 STEERING CONTROL UNIT REBUILD.......................................................536 Disassembly.....................................................................536 Cleaning and Inspection - Steering Control Unit.................................537 Assembly - Steering Control Unit................................................539 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX......................................543 STEERING CIRCUIT COMPONENT REPAIR.......................................................545 BLEEDDOWN MANIFOLD VALVE............................................................545 Removal.........................................................................545 Installation....................................................................545 ACCUMULATORS........................................................................546 Removal.........................................................................546 Installation....................................................................546 Disassembly.....................................................................547 Cleaning and Inspection.........................................................547 Assembly........................................................................547 STEERING ACCUMULATOR CHARGING PROCEDURE.............................................548 FLOW AMPLIFIER......................................................................549 Removal.........................................................................549 Installation....................................................................549 FLOW AMPLIFIER REBUILD..........................................................549 Disassembly.....................................................................549 Assembly........................................................................552 STEERING CYLINDERS..................................................................553 Disassembly.....................................................................554 Piston Seal & Bearing Installation..............................................554 Cylinder Assembly...............................................................554 Test............................................................................554 STEERING AND BRAKE PUMP.............................................................555 Removal.........................................................................555 Installation....................................................................555 Disassembly.....................................................................557 Control Piston Group............................................................557 Valve Plate Group...............................................................557 Rotating Group..................................................................558 Swashblock Group................................................................558 Driveshaft Group................................................................558 Inspection......................................................................558 Control Piston Group............................................................558 Valve Plate Group...............................................................558 Rotating Group..................................................................558 Swashblock Group................................................................562 Driveshaft Group................................................................563 Compensator Block and Unloader Module...........................................563 ASSEMBLY........................................................................563 Swashblock Group................................................................563 Driveshaft Group................................................................563 Rotating Group..................................................................564 Control Piston Group............................................................564 Valve Plate Group...............................................................565 TROUBLESHOOTING CHART...................................................................566 SECTION L7 - HOIST CIRCUIT DESCRIPTION - INDEX..............................................571 HOIST CIRCUIT...........................................................................573 HOIST CIRCUIT OPERATION.............................................................573 COMPONENT DESCRIPTION...............................................................574 HYDRAULIC TANK..................................................................574 HYDRAULIC PUMP..................................................................574 HIGH PRESSURE FILTERS...........................................................574 HOIST VALVE.....................................................................574 Inlet Sections..................................................................574 Spool Sections..................................................................575 Work Ports (Rear) Spool Section.................................................575 Tank Ports (Front) Spool Section................................................575 HOIST PILOT VALVE...............................................................575 HOIST-UP LIMIT SOLENOID.........................................................576 PILOT OPERATED CHECK VALVE......................................................576 HOIST VALVE OPERATION...............................................................576 FLOAT POSITION OF PILOT VALVE WITH TRUCK BODY ON FRAME..........................576 POWER UP OPERATION (Figure 7-5).................................................578 HOLD OPERATION (Figure 7-6).....................................................580 POWER DOWN OPERATION (Figure 7-7)...............................................582 FLOAT OPERATION (Figure 7-8)....................................................584 SECTION L8 - HOIST COMPONENT REPAIR - INDEX.................................................587 HOIST CIRCUIT COMPONENT REPAIR..........................................................589 HOIST VALVE.........................................................................589 Removal.........................................................................589 Installation....................................................................590 O-Ring Replacement..............................................................590 INLET SECTION.......................................................................591 Disassembly.....................................................................591 Cleaning and Inspection.........................................................592 Assembly........................................................................592 REAR SPOOL SECTION (Work Ports).....................................................592 Disassembly.....................................................................592 Cleaning and Inspection.........................................................594 Assembly........................................................................594 FRONT SPOOL SECTION (Tank Ports)....................................................595 Disassembly.....................................................................595 Cleaning and Inspection.........................................................595 Assembly........................................................................595 HOIST PILOT VALVE...................................................................597 Removal.........................................................................597 Installation....................................................................597 Disassembly.....................................................................598 Cleaning and Inspection.........................................................599 Assembly........................................................................599 HOIST - UP LIMIT SOLENOID VALVE.....................................................600 HOIST CYLINDERS.....................................................................600 Removal.........................................................................600 Installation....................................................................601 Disassembly.....................................................................603 Cleaning and Inspection.........................................................604 ASSEMBLY OF QUILL AND CYLINDER..................................................605 Quill Installation..............................................................605 Installation Of Check Balls And Plugs In Quill..................................606 Assembly of Cylinder............................................................607 DISABLED TRUCK DUMPING PROCEDURE....................................................608 HOOKUP..........................................................................608 DUMPING PROCEDURE...............................................................608 Raising the Body:...............................................................608 Lowering the Body:..............................................................608 SECTION L9 - HIGH PRESSURE FILTERS - INDEX..................................................609 HIGH PRESSURE FILTERS...................................................................611 HOIST CIRCUIT FILTERS...............................................................611 FILTER ELEMENT REPLACEMENT......................................................612 Removal.........................................................................612 Installation....................................................................612 INDICATOR SWITCH................................................................612 STEERING CIRCUIT FILTER.............................................................613 FILTER ELEMENT REPLACEMENT......................................................614 Removal.........................................................................614 Installation....................................................................614 INDICATOR SWITCH................................................................614 BRAKE CIRCUIT FILTER................................................................615 FILTER ELEMENT REPLACEMENT......................................................615 Removal.........................................................................615 Installation....................................................................615 INDICATOR SWITCH....................................................................616 Test Procedure..................................................................616 SECTION L10 - HYDRAULIC CHECKOUT PROCEDURES - INDEX.........................................619 HYDRAULIC CHECK-OUT PROCEDURE...........................................................621 GENERAL INFORMATION.................................................................621 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE...................................621 Equipment Requirements..........................................................622 Pump Pressure Control Adjustments...............................................622 Steering Components Leakage Test................................................623 SHOCK AND SUCTION VALVES........................................................624 Equipment Requirements..........................................................624 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.......................626 Equipment Requirements..........................................................626 Pressure Checks.................................................................626 Brake Cooling Circuit Test......................................................626 Power Up Relief Pressure Test...................................................627 Adjustment......................................................................627 Power Down Relief Pressure Test.................................................628 Adjustment......................................................................628 HOIST COUNTERBALANCE VALVE ADJUSTMENT...........................................629 HYDRAULIC SYSTEM FLUSHING PROCEDURE.....................................................630 Preparation.........................................................................630 Flushing Procedure..................................................................630 Filter Element Replacement..........................................................631 930E CHECK-OUT PROCEDURE................................................................633 930E CHECK-OUT PROCEDURE................................................................634 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX...................................................635 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX...................................................637 FIRE CONTROL SYSTEM (MANUAL)............................................................639 Operation...........................................................................639 Inspection and Maintenance..........................................................639 Recharging Procedures...............................................................640 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1............................641 Control Module......................................................................641 Actuator............................................................................642 Linear Detection Wire...............................................................642 Power Wire..........................................................................642 Test Kit............................................................................642 Squib...............................................................................642 Securing the Detection Wire.........................................................643 Preliminary Test Before Final Hook-Up...............................................643 Installation Procedure for Squib....................................................645 Placing the Electric Detection & Actuation System Into Service......................645 INSPECTION AND MAINTENANCE SCHEDULES................................................646 Daily...........................................................................646 Normal Maintenance Based On Actual Operating Hours..............................646 IN CASE OF FIRE.....................................................................647 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM...........................................649 SECTION M8 - SPECIAL TOOLS..................................................................651 SECTION M20 - PAYLOAD METER II -INDEX.......................................................659 GENERAL INFORMATION.....................................................................661 Haul Cycles.........................................................................661 LIGHTS, SWITCHES AND COMPONENTS.........................................................662 TIPS FOR OPERATION......................................................................663 EXTERNAL DISPLAY LIGHTS.................................................................663 THEORY OF OPERATION.....................................................................664 Basic Description...................................................................664 Inclinometer........................................................................664 Linkage Factor......................................................................664 Gain Factor.........................................................................665 Brake Lock..........................................................................665 Sources of Error....................................................................665 Typical Data From Service Check Mode................................................665 Example Calculation of Payload......................................................666 Viewing Payload Calculation Inputs..................................................666 Checking the Gain...................................................................667 Adjusting the Gain..................................................................667 TYPES OF DATA STORED....................................................................668 Cycle Data..........................................................................668 Engine ON/OFF Data..................................................................669 Fault Codes and Warning Data........................................................669 Engine Operation....................................................................670 Total Payload and Total Number of Cycles............................................670 Other Data..........................................................................670 OPERATOR FUNCTIONS......................................................................671 Using the Operator Load Counter.....................................................671 Viewing the Operator Load Counter...................................................671 Clearing the Operator Load Counter..................................................671 Dimming the Lights on the Display...................................................671 INITIAL SETUP OF PAYLOAD METER..........................................................672 Switch Settings.....................................................................672 Checking the Operator Check Mode....................................................673 Checking the Service Check Mode.....................................................673 Checking the Gt setting:............................................................674 Checking the Inclinometer Settings..................................................674 Calibrating a Truck.................................................................674 DISPLAYS AT START-UP....................................................................675 Normal Operation....................................................................675 SETUP AND MAINTENANCE...................................................................676 Setting The Speed Limit.............................................................676 Setting the Option Code.............................................................676 Setting The Machine I.D. Code.......................................................677 Setting The Operator I.D. Code......................................................677 Setting The Time and Date...........................................................677 DOWNLOAD OF INFORMATION.................................................................678 DISPLAY OF FAULT CODES..................................................................678 Monitoring Input Signals............................................................682 Service Check Mode..................................................................682 UP FACTOR - PAYLOAD CALCULATION GAIN....................................................683 PL MODE -LOAD CALCULATION TIMING........................................................683 FINAL GEAR RATIO SELECTION..............................................................684 BATTERY REPLACEMENT PROCEDURE...........................................................685 Replacing the Battery...............................................................685 After Replacing the Battery.........................................................686 SUSPENSION PRESSURE SENSOR..............................................................686 Removal.............................................................................686 Installation........................................................................687 INCLINOMETER............................................................................687 Removal.............................................................................687 Installation........................................................................687 Adjustment..........................................................................687 PAYLOAD METER BACK PANEL................................................................688 CONNECTIONS.............................................................................689 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE...........................................690 PAYLOAD CIRCUIT NUMBERS.................................................................691 TROUBLESHOOTING.........................................................................692 COMMON PROBLEMS.....................................................................692 Suspension Charging.............................................................692 Symptom Table...................................................................693 Missing Body-Up Signal..........................................................693 Missing Speed Signal............................................................694 F-18: Alternator R-Terminal, Oil Pressure Signals...............................694 Shorted 18v Sensor Power Supply (930E)..........................................694 FAULT TREE DIAGNOSIS................................................................695 Payload Lights Won't Illuminate.................................................695 Red, Amber or Green Payload Light Does Not Illuminate...........................696 Cannot Download - PC Communications.............................................697 PC Communications Configuration.................................................698 F.CAL: Payload Meter Won't Calibrate............................................699 F-20: Sensor Power Fault........................................................700 F-21, F-25: Left Front Pressure Sensor..........................................702 F-22, F-26: Right Front Pressure Sensor.........................................702 F-23, F-27: Left Rear Pressure Sensor...........................................702 F-24, F-28: Right Rear Pressure Sensor..........................................702 F-31, F-32: Inclinometer........................................................704 Body Up Input...................................................................706 Brake Lock Input................................................................707 Speed Signal....................................................................708 Adjusting the Speed Sensor......................................................708 CONNECTORS AND PRESSURE SENSORS.....................................................710 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM.............................................713 Menu Functions......................................................................716 Using Scope.........................................................................716 Log File Information................................................................716 Connections to Payload Meter II™....................................................717 USING SCOPE.............................................................................718 Monitoring Inputs Using Scope.......................................................718 Monitoring Suspension Charging Using Scope..........................................718 Pressure Sensor Dummy Loads.........................................................721 GAIN ADJUSTMENT WORKSHEET...............................................................722 SECTION N - CAB COMPONENTS - INDEX..............................................................723 SECTION N2 TRUCK CAB - INDEX................................................................725 TRUCK CAB...............................................................................727 Description.........................................................................727 Preparation.........................................................................728 Removal - Cab.......................................................................728 Installation - Cab..................................................................730 CAB DOOR............................................................................730 Removal.........................................................................730 Installation....................................................................730 Door Adjustment.................................................................731 Door Jamb Bolt Adjustment.......................................................731 Door Handle Plunger Adjustment..................................................732 Door Glass Replacement..........................................................733 Door Window Regulator Replacement...............................................737 Door Handle or Latch Assembly Replacement.......................................737 Door and Door Hinge Seal Replacement............................................738 Door Opening Seal Removal.......................................................738 Installation....................................................................738 GLASS REPLACEMENT...................................................................739 Adhesive Bonded Windows.........................................................739 Replacement Procedure...........................................................739 Windshield And Rear Glass.......................................................740 Removal.........................................................................740 Installation....................................................................741 SECTION N3 - CAB COMPONENTS - INDEX.........................................................743 CAB COMPONENTS..........................................................................745 WINDSHIELD WIPERS...................................................................745 Wiper Motor Replacement.........................................................745 Removal.........................................................................745 Installation....................................................................745 Wiper Arm Replacement...........................................................745 Removal.........................................................................745 Installation....................................................................746 Wiper Linkage Replacement.......................................................746 Removal.........................................................................746 Installation....................................................................746 WINDSHIELD WASHER...................................................................747 Operation.......................................................................747 Service.........................................................................747 OPERATOR SEAT.......................................................................748 Adjustment......................................................................748 Removal.........................................................................748 Installation....................................................................748 SECTION N4 - OPERATOR COMFORT - INDEX.......................................................749 OPERATOR COMFORT........................................................................751 HEATER/AIR CONDITIONER..............................................................751 Operation.......................................................................751 HEATER COMPONENTS...................................................................752 Circuit Breakers................................................................752 Heater Water Control Solenoid...................................................752 Test............................................................................753 Heater Coil.....................................................................753 Fan Motor And Speed Control.....................................................754 Actuators.......................................................................754 Filter..........................................................................754 AIR CONDITIONING SYSTEM.............................................................756 Environmental Impact............................................................756 OPERATOR CAB AIR CONDITIONING...................................................757 PRINCIPLES OF REFRIGERATION.....................................................757 Air Conditioning............................................................757 Refrigeration - The Act Of Cooling..........................................758 The Refrigeration Cycle.....................................................758 AIR CONDITIONER SYSTEM COMPONENTS...............................................759 Compressor (Refrigerant Pump)...............................................759 Service Valves..............................................................759 Condenser...................................................................759 Receiver-Drier..............................................................759 Expansion Block Valve.......................................................760 Evaporator..................................................................760 ELECTRICAL CIRCUIT..............................................................761 Thermostat..................................................................761 Compressor Clutch...........................................................761 Trinary™ Switch.............................................................762 SYSTEM SERVICING................................................................763 SYSTEM OIL......................................................................764 Handling and Reusing PAG Oil................................................764 Oil Quantity................................................................764 Replacing Oil After Servicing the System....................................764 Setting Up a New Compressor.................................................764 REFRIGERANT.....................................................................765 Recycled Refrigerant........................................................765 Reclaimed Refrigerant.......................................................765 Refrigerant Quantity........................................................765 R-134a Refrigerant Containers...............................................765 SERVICE TOOLS AND EQUIPMENT.....................................................766 Recovery/Recycle Station....................................................766 Leak Detector...............................................................766 Service Valves..............................................................767 Vacuum Pump.................................................................767 Manifold Gauge Set..........................................................768 Installing Manifold Gauge Set...............................................769 Purging Air From Service Hoses..............................................770 Stabilizing the AC System...................................................771 SYSTEM PERFORMANCE TEST.........................................................771 SYSTEM LEAK TESTING.............................................................772 Electronic Leak Detector....................................................772 Tracer Dyes.................................................................772 Soap and Water..............................................................772 SYSTEM REPAIR...................................................................773 System Cleaning.............................................................773 Hoses and Fittings..........................................................773 Lines.......................................................................773 Expansion Valve.............................................................773 Receiver-Drier..............................................................774 Thermostat..................................................................774 Compressor..................................................................774 Clutch......................................................................774 Servicing the Compressor Clutch.............................................775 Pulley Removal..............................................................777 Clutch Coil Check...........................................................777 Pulley Installation.........................................................777 Clutch Assembly Installation................................................778 RECOVERING AND RECYCLING THE REFRIGERANT........................................779 Performing the Recovery Cycle...............................................779 Performing the Recycling Procedure..........................................779 Evacuating and Charging the AC System.......................................779 EVACUATING THE SYSTEM...........................................................780 CHARGING THE AC SYSTEM..........................................................781 TROUBLESHOOTING.....................................................................782 Pre-Diagnosis Checks............................................................782 Preparing For Diagnosis.........................................................782 Preliminary Steps...............................................................782 System Performance Test.........................................................782 Diagnosis Of Gauge Readings And System Performance..............................783 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS......................................784 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.....................................790 SECTION N5 OPERATOR CAB CONTROLS - INDEX....................................................791 OPERATOR CAB CONTROLS...................................................................793 STEERING COLUMN.....................................................................793 Removal.........................................................................793 Installation....................................................................793 STEERING WHEEL AND CONTROLS.........................................................795 Horn Button.....................................................................795 Telescope Lock Ring.............................................................795 Tilt Wheel Lever................................................................795 Turn Signal/Headlight Dimmer....................................................795 DYNAMIC RETARDING...................................................................795 Dynamic Retarder Control Lever..................................................796 Dynamic Retarder/Service Brake Pedal............................................796 Accelerator (Throttle) Pedal....................................................796 Starting on a Grade With a Loaded Truck.........................................796 GRADE/SPEED RETARD CHART............................................................797 INSTRUMENT PANEL....................................................................798 OVERHEAD PANEL AND DISPLAYS.........................................................798 F-N-R SELECTOR SWITCH...........................................................799 HOIST CONTROL LEVER.............................................................800 OVERRIDE /FAULT RESET SWITCH....................................................801 10, FIGURE 5-5 - BLANK..........................................................801 RETARD SPEED CONTROL (RSC) "OFF/ON" SWITCH......................................801 RETARD SPEED CONTROL (RSC) ADJUST DIAL..........................................801 TCI DOWNLOAD PORT...............................................................802 PASSENGER SEAT..................................................................802 INSTRUMENT PANEL AND INDICATOR LIGHTS...................................................803 CONTROL SYMBOLS.....................................................................803 INSTRUMENT PANEL (Figure 5-5).......................................................803 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-5).....................................805 KEY SWITCH..........................................................................805 Starting............................................................................805 Cold Weather Starting...............................................................805 Normal Engine Shutdown..............................................................805 PARKING BRAKE CONTROL...............................................................807 AC DRIVE SYSTEM TEMPERATURE GAUGE...................................................809 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................................812 SECTION P - LUBRICATION AND SERVICE - INDEX.....................................................819 SECTION P2 - LUBRICATION AND SERVICE - INDEX................................................821 LUBRICATION AND SERVICE.................................................................823 930E SERVICE CAPACITIES.............................................................823 HYDRAULIC TANK SERVICE..............................................................823 Adding Oil......................................................................823 WHEEL MOTOR SERVICE.................................................................823 COOLANT LEVEL CHECK.................................................................824 RADIATOR FILLING PROCEDURE..........................................................824 LUBRICATION CHART...................................................................825 10 HOUR (DAILY) INSPECTION..........................................................826 50 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................829 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................830 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................831 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.........................................834 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.......................................835 2500 HOUR MAINTENANCE CHECKS........................................................836 5000 HOUR MAINTENANCE CHECKS........................................................836 SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX...................................837 LINCOLN AUTOMATIC LUBRICATION SYSTEM....................................................839 System Components...................................................................839 System Operation....................................................................841 GENERAL INSTRUCTIONS................................................................842 Lubricant Required for System...................................................842 System Priming..................................................................842 SYSTEM CHECKOUT.....................................................................842 24 VDC SOLID STATE TIMER CHECK......................................................843 24 VDC Solid State Timer Adjustment.............................................843 INJECTORS (SL-1 Series "H").........................................................844 Injector Specifications.........................................................844 Injector Adjustment.............................................................844 INJECTOR OPERATION..................................................................845 PUMP CYCLE TIMER (FLASHER TIMER)....................................................846 Pump Cycle Timer (Flasher Timer) Installation...................................846 Pump Cycle Timer (Flasher Timer) Adjustment:....................................846 Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.)..................846 PRESSURE REDUCER ADJUSTMENT.........................................................848 TROUBLESHOOTING CHART...................................................................849 Preventative Maintenance Procedures.....................................................852 Daily Lubrication System Inspection.................................................852 250 Hour Inspection.................................................................852 SECTION Q ALPHABETICAL INDEX....................................................................853 SECTION R - SYSTEM SCHEMATICS - INDEX...........................................................857 HYDRAULIC BRAKE SYSTEM SCHEMATIC............................................................859 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC................................................860 ELECTRICAL SCHEMATIC........................................................................861
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