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KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL(SN:A30019, A30026 thru A30119 w/DDC 4000 Engine Manual) KOMATSU 930E – PDF DOWNLOAD
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- KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL
- SERIAL NUMBER:A30019, A30026 thru A30119 w/DDC 4000 Engine Manual
- PUBLICATION NUMBER:CEBM010200
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KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL(SN:A30019, A30026 thru A30119 w/DDC 4000 Engine Manual) KOMATSU 930E
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL(SN:A30019, A30026 THRU A30119 W/DDC 4000 ENGINE MANUAL) KOMATSU 930E – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E DUMP TRUCK SERVICE REPAIR MANUAL(SN:A30019, A30026 thru A30119 w/DDC 4000 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:A30019, A30026 thru A30119 w/DDC 4000 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 Preparation for Removal................................................................112 Power Module Removal...................................................................115 Power Module Installation..............................................................117 Power Module Hookup....................................................................117 Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)....119 SECTION C3 - COOLING SYSTEM - INDEX............................................................121 COOLING SYSTEM.............................................................................123 COOLING SYSTEM DESCRIPTION.............................................................123 Coolant Flow.......................................................................123 RADIATOR...............................................................................124 Removal............................................................................124 RADIATOR REPAIR........................................................................126 Internal Inspection................................................................126 External Cleaning..................................................................126 Disassembly........................................................................127 Cleaning and Inspection............................................................128 Assembly...........................................................................128 Pressure Testing...................................................................129 Additional Service Information.....................................................129 Installation.......................................................................130 RADIATOR FILL PROCEDURE................................................................130 Radiator Pressure Regulator Valve..................................................131 COOLING SYSTEM TROUBLESHOOTING.........................................................131 SECTION C4 - POWERTRAIN - INDEX................................................................133 POWER TRAIN................................................................................135 ALTERNATOR REMOVAL PROCEDURE...........................................................135 Removal (MTU/DDC 4000 Engine)......................................................135 ENGINE/ALTERNATOR MATING...............................................................137 General Instructions...............................................................137 MEASURING PROCEDURE....................................................................137 Joining Alternator and MTU/DDC Engine..............................................139 ENGINE.................................................................................140 Removal............................................................................140 Service............................................................................140 Installation.......................................................................140 SECTION C5 - AIR CLEANERS - INDEX..............................................................141 AIR CLEANERS...............................................................................143 AIR CLEANERS...........................................................................143 Operation..........................................................................143 General Service Information........................................................143 FILTER ELEMENT REPLACEMENT.............................................................144 Main Filter Element Cleaning.......................................................145 Precleaner Section.................................................................146 Cleaning Precleaner Tubes..........................................................146 AIR INTAKE TROUBLESHOOTING.............................................................147 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX.......................................149 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX..............................................151 24VDC ELECTRIC SUPPLY SYSTEM...............................................................153 ELECTRICAL SYSTEM DESCRIPTION..........................................................153 BATTERIES..............................................................................153 Maintenance and Service............................................................153 Troubleshooting....................................................................153 BATTERY SUPPLY SYSTEM..................................................................155 24VDC Battery Charging Alternator..................................................155 Battery Box........................................................................155 Battery Control Box................................................................155 System Battery Starter Disconnect Relay............................................155 Battery Disconnect Switches........................................................156 24VDC Auxiliary Battery Connectors.................................................156 Battery Equalizer..................................................................157 Troubleshooting....................................................................157 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX........................................159 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................161 PASSENGER SEAT BASE COMPARTMENT........................................................161 TRUCK SHUTDOWN PROCEDURE...............................................................161 COMPONENTS.............................................................................161 Tail Light Resistor Diode Assemblies...............................................161 5 Minute Idle Timer Components.....................................................161 Inclinometer.......................................................................163 Brake Warning Buzzer (BWB).........................................................163 Alarm Indicating Device (AID) System...............................................163 ELECTRICAL INTERFACE CABINET...........................................................166 Lubrication System Timer...........................................................166 Barometric Pressure Transducer.....................................................166 Special Interface Module...........................................................166 Power Distribution Terminals.......................................................166 Truck Control Interface Panel......................................................166 Control Power Relay................................................................166 Circuit Breaker Panel..............................................................166 Diode Board - DB1..................................................................168 Diode Testing......................................................................168 RELAY BOARDS...........................................................................169 Relay Boards - RB1, RB2, RB3, RB4, RB5.............................................169 Service............................................................................169 Relay Board Identification.........................................................170 Relay Board Functions..............................................................171 Relay Board 6 (RB6)................................................................172 BODY-UP SWITCH.........................................................................173 Operation..........................................................................173 Adjustment.........................................................................173 Service............................................................................173 HOIST LIMIT SWITCH.....................................................................174 Operation..........................................................................174 Adjustment.........................................................................174 Service............................................................................174 SECTION D5 - DDEC ELECTRONIC ENGINE CONTROL - INDEX............................................177 DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE..............................179 COMPONENT DESCRIPTION..................................................................180 Electronic Control Module..........................................................180 Electronic Unit Nozzles............................................................182 System Sensors and Operator Inputs.................................................182 ENGINE PROTECTION SYSTEM...............................................................183 DIAGNOSTICS............................................................................184 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX..............................................185 BATTERY CHARGING ALTERNATOR................................................................187 ELECTRICAL SYSTEM DESCRIPTION..........................................................187 BATTERY................................................................................187 Maintenance and Service............................................................187 Troubleshooting....................................................................187 BATTERY CHARGING SYSTEM (Niehoff)......................................................189 General Description................................................................189 TROUBLESHOOTING PROCEDURES (On-Truck)..................................................189 Equipment Required:................................................................189 Preliminary Checks.................................................................190 Test Setup.........................................................................190 Test Procedure.....................................................................190 Regulator Bypass Test..............................................................191 ON VEHICLE TROUBLESHOOTING GUIDE...........................................................193 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage.............193 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:.......................................193 CHARGE VOLT AND AMP VALUES.............................................................194 DEFINITIONS............................................................................194 ADVANCED SYSTEM TROUBLESHOOTING............................................................195 Static Test - Engine OFF, Key ON, Battery Switch ON....................................195 Go To Alternator.......................................................................195 Go To Regulator (If Required)..........................................................196 Go To Regulator Connector On The Alternator............................................196 ALTERNATOR OVERHAUL........................................................................197 ALTERNATOR DIMENSIONS..................................................................197 ALTERNATOR SPECIFICATIONS..............................................................198 SERVICE PARTS..........................................................................199 ON-VEHICLE TEST........................................................................201 Equipment:.........................................................................201 Preliminary Checks:................................................................201 Test Set-up........................................................................201 Test Procedure.....................................................................201 ON-VEHICLE TEST........................................................................202 Bypass Test:.......................................................................202 BENCH TEST.............................................................................203 STATIC TESTS...........................................................................204 Regulator Tests....................................................................204 Control Box Tests..................................................................205 ALTERNATOR DISASSEMBLY.................................................................207 ASSEMBLY- ALTERNATOR...................................................................212 BF4822 STATOR SERVICE TOOL INSTRUCTIONS....................................................221 Stator Removal And Replacement.........................................................221 Stator Installation....................................................................222 SECTION E - ELECTRICAL PROPULSION - INDEX..........................................................225 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX...................................227 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................229 GENERAL SYSTEM DESCRIPTION.............................................................229 SYSTEM COMPONENTS......................................................................231 Auxiliary Blower System............................................................231 Propulsion System Controller (PSC).................................................231 TRUCK CONTROL INTERFACE PANEL (TCI)....................................................232 Diagnostic Information Display.....................................................233 DID PANEL EVENT CODES..................................................................233 PSC SOFTWARE FUNCTIONS.................................................................258 Input Processing...................................................................258 STATE MANAGEMENT.......................................................................258 State Machine......................................................................258 Transitions Between States.........................................................259 DC Link State......................................................................261 Powering the Link..................................................................261 De-Powering the Link...............................................................261 Control Functions..................................................................261 Engine Control.....................................................................261 ALTERNATOR FIELD CONTROL...............................................................262 Desired Three-Phase Voltage........................................................262 Desired DC Link Voltage............................................................262 Self-load..........................................................................262 Propel Torque Control..............................................................263 Retard Torque Control..............................................................263 Wheel Slide Control................................................................263 Resistor Grid Control..............................................................264 Chopper Voltage Control............................................................264 AUXILIARY BLOWER CONTROL...............................................................264 EVENT PROCESSING.......................................................................264 Event Detection....................................................................264 Power On Tests.....................................................................264 Initiated Tests....................................................................265 Periodic Tests.....................................................................265 EVENT RESTRICTIONS.....................................................................265 EVENT LOGGING AND STORAGE..............................................................265 Event History Buffer...............................................................266 Data Packs.........................................................................266 To Record and Save a Data Pack to a Floppy Disk....................................266 Event Reset........................................................................267 SERIAL DATA COMMUNICATIONS.............................................................268 PSC - TCI Communications processing................................................268 PSC - PTU Communications Processing................................................268 Inverter Communications Processing.................................................268 OUTPUT PROCESSING......................................................................269 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS...............................................269 Fast Start.........................................................................269 Engine Shutdown/Engine Not Running.................................................269 Limp Home Mode.....................................................................269 Entering/Exiting Limp Home Mode....................................................269 PROPULSION SYSTEM COMPONENT ABBREVIATIONS..............................................270 ELECTRONIC ACCELERATOR AND RETARD PEDALS...............................................280 Removal............................................................................280 Installation.......................................................................280 Disassembly........................................................................280 Assembly...........................................................................280 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX.............................281 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE..............................................283 AC DRIVE SYSTEM MAINTENANCE............................................................283 TRUCK SHUTDOWN PROCEDURES..............................................................283 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................284 SHUTDOWN AFTER SYSTEM FAILURE..........................................................285 SYSTEM CHECKOUT........................................................................286 Battery and Control Checks of System WITH Battery Power OFF........................286 Battery and Control Circuit Checks of System With Battery Power ON.................289 Checks with Key Switch OFF.........................................................290 CPU Battery Checks.................................................................292 MEMORY BACKUP BATTERY REPLACEMENT......................................................292 TCI PROGRAMMING........................................................................293 PSC PROGRAMMING........................................................................293 INVERTER PROGRAMMING...................................................................294 TCI CHECKOUT...........................................................................294 Modular Mining Communication Port..................................................295 TCI Input Checks...................................................................296 TCI Digital Output Tests...........................................................298 TCI Digital Input Tests............................................................300 PSC Checkout Procedure.............................................................302 PSC Digital Input Checks...........................................................306 Miscellaneous Checks...............................................................307 A3PV Panel.........................................................................307 LINKV Panel........................................................................307 Thermistor Checks..................................................................307 17FM384 Panel Check................................................................307 Pedal Percentages and Meter Calibration............................................308 Meter Calibration Procedure........................................................308 Reprogram With Serial Numbers and Pedal Percentages................................310 LOAD TESTING...........................................................................312 Preload Checks.....................................................................312 ADDITIONAL TRUCK CHECKS................................................................314 On-Board Load Testing..............................................................316 Preparation........................................................................316 Initiate Loadbox Test..............................................................319 Manual Offset HP Output Adjustment.................................................321 TROUBLESHOOTING............................................................................323 PVM Optimum Load Curve Handshaking Troubleshooting.....................................323 MISCELLANEOUS COMPONENT REPAIR.........................................................324 Troubleshooting Phase Modules and Chopper Modules..................................324 Phase Module Removal and Snubber Resistor Replacement..............................324 Snubber Resistor Installation......................................................325 Phase Module Installation..........................................................325 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING.......................................326 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING.......................................329 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING...............................................330 IGBT TROUBLESHOOTING...................................................................331 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX.................................................333 SECTION G2 - TIRES AND RIMS - INDEX............................................................335 TIRES AND RIMS.............................................................................337 FRONT TIRES AND RIMS...................................................................338 Removal............................................................................338 Installation.......................................................................339 REAR TIRES AND RIMS....................................................................339 Removal............................................................................339 Installation.......................................................................340 RIM....................................................................................341 Tire Removal.......................................................................341 Tire Installation..................................................................342 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...............................................343 FRONT WHEEL HUB AND SPINDLE................................................................345 WHEEL HUB AND SPINDLE ASSEMBLY.........................................................345 Preparation........................................................................345 Removal............................................................................345 Installation.......................................................................348 Disassembly........................................................................349 Cleaning and Inspection............................................................349 Assembly...........................................................................351 Wheel Bearing Adjustment:..........................................................351 Brake Installation.................................................................352 Seal Assembly Gap Check:...........................................................353 STEERING CYLINDERS AND TIE ROD.........................................................354 Spherical Bearing Wear Limits......................................................354 Removal............................................................................355 Installation.......................................................................356 Bearing Replacement................................................................356 TOE-IN ADJUSTMENT......................................................................357 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX..............................................359 REAR AXLE HOUSING ATTACHMENT...............................................................361 PIVOT PIN..............................................................................361 Removal............................................................................361 Installation.......................................................................361 PIVOT EYE BEARING......................................................................362 Disassembly........................................................................362 PIVOT EYE REPAIR.......................................................................363 Removal............................................................................363 Disassembly........................................................................363 Assembly...........................................................................363 Installation.......................................................................363 ANTI-SWAY BAR..........................................................................364 Removal............................................................................364 Installation.......................................................................364 Disassembly........................................................................364 Assembly...........................................................................364 SECTION G5 - REAR AXLE HOUSING - INDEX.........................................................365 REAR AXLE HOUSING..........................................................................367 REAR AXLE HOUSING......................................................................367 PREPARATION........................................................................367 Removal............................................................................367 Cleaning and Inspection............................................................369 Installation.......................................................................369 WHEEL MOTOR............................................................................370 Preparation........................................................................370 Removal............................................................................370 Cleaning and Inspection............................................................371 Installation.......................................................................372 WHEEL MOTOR GEAR OIL...................................................................375 Filtering Requirements.............................................................375 Particle Size Analysis.............................................................375 Flushing...........................................................................375 Oil Sample Analysis................................................................376 ELEMENT SPECIFICATION CHARTS...........................................................377 SECTION H - HYDRAIR II SUSPENSIONS - INDEX.........................................................381 SECTION H2 - FRONT SUSPENSION - INDEX..........................................................383 FRONT SUSPENSION...........................................................................385 Removal................................................................................385 Installation...........................................................................386 "TURN-OF-THE-NUT" Tightening Procedure.................................................388 MINOR REPAIR ONLY (LOWER BEARING & SEALS)..............................................389 Lower Bearing Removal..............................................................389 Lower Bearing Installation.........................................................389 MAJOR SUSPENSION REBUILD...............................................................391 Disassembly........................................................................391 Assembly...........................................................................391 SECTION H3 - REAR SUSPENSIONS - INDEX..........................................................393 REAR SUSPENSIONS...........................................................................395 Removal................................................................................395 Installation...........................................................................397 Disassembly............................................................................398 Cleaning and Inspection................................................................398 Assembly...............................................................................398 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX..................................401 SUSPENSION OILING AND CHARGING PROCEDURE...................................................403 GENERAL................................................................................403 EQUIPMENT LIST.........................................................................403 Hydrair® Charging Kit..............................................................403 Installation of Charging Kit.......................................................403 Removal of Charging Kit............................................................404 Support Blocks For Oiling And Charging Dimensions..................................404 FRONT SUSPENSION.......................................................................405 Front Suspension Oiling............................................................405 Front Suspension Nitrogen Charging.................................................406 REAR SUSPENSION........................................................................407 Rear Suspension Oiling.............................................................407 Rear Suspension Nitrogen Charging..................................................408 OIL AND NITROGEN SPECIFICATIONS CHART......................................................410 SECTION J - BRAKE CIRCUIT - INDEX..................................................................411 SECTION J2 - BRAKE CIRCUIT - INDEX.............................................................413 BRAKE CIRCUIT..............................................................................415 SERVICE BRAKE CIRCUIT..................................................................415 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................417 PARKING BRAKE CIRCUIT..................................................................417 BRAKE LOCK CIRCUIT.....................................................................418 WARNING CIRCUIT........................................................................418 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX...........................................421 BRAKE CIRCUIT COMPONENT SERVICE............................................................423 BRAKE VALVE............................................................................423 Rebuild Criteria...................................................................423 Removal - Brake Valve..............................................................424 Installation - Brake Valve.........................................................424 Disassembly - Brake Valve..........................................................425 Cleaning and Inspection - Brake Valve..............................................428 Assembly - Actuator Base Threaded Inserts..........................................428 Assembly - Boot and Cap............................................................428 Installation - Valve Body Seal.....................................................428 Installation - Regulator Sleeve O-Ring.............................................429 Installation - Actuator Plunger O-ring.............................................429 Assembly - Brake Valve.............................................................429 DIFFERENTIAL PRESSURE SWITCH...........................................................431 Disassembly........................................................................431 Cleaning and Inspection............................................................431 Assembly...........................................................................431 VALVE BENCH TEST AND ADJUSTMENT........................................................432 Test Set Up Procedure..............................................................433 Adjustment - Brake Valve Output Pressure...........................................433 Adjustment - Differential Pressure Switch..........................................433 Final Test and Adjustment..........................................................434 Installation - Brake Pedal Actuator Assembly to Brake Valve........................435 Installation - Retard Pedal To Brake Pedal.........................................435 DUAL RELAY VALVE.......................................................................437 Removal............................................................................437 Installation.......................................................................437 Disassembly - Dual Relay Valve.....................................................439 Cleaning and Inspection - Dual Relay Valve.........................................439 Assembly - Dual Relay Valve........................................................439 DIFFERENTIAL PRESSURE SWITCH...........................................................440 Disassembly........................................................................440 Cleaning and Inspection............................................................440 Assembly...........................................................................440 VALVE TEST AND ADJUSTMENT..............................................................441 Test Set Up Procedure..............................................................442 Adjustment - Brake Valve Output Pressure...........................................442 Adjustment - Differential Pressure Switch..........................................443 HYDRAULIC BRAKE ACCUMULATORS...........................................................444 Brake Accumulator Bleed Down Procedure.............................................444 ACCUMULUTOR - HYDRAULIC COMPONENTS CABINET.............................................444 Removal............................................................................444 Installation.......................................................................444 Disassembly........................................................................444 Cleaning and Inspection - Accumulator..............................................445 Assembly - Accumulator.............................................................446 Charging Procedure - Accumulator...................................................447 ACCUMULATORS - FRAME MOUNTED...........................................................448 Removal............................................................................448 Installation.......................................................................448 Disassembly - Accumulator..........................................................449 Cleaning and Inspection - Accumulator..............................................449 Assembly - Accumulator.............................................................450 Testing - Accumulator..............................................................450 ACCUMULATOR CHARGING PROCEDURE (Frame Mounted Brake Accumulators)......................451 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................452 Removal - Retarder Control Lever...................................................452 Installation - Retarder Control Lever..............................................452 Disassembly and Adjustment - Retarder Control Lever................................453 Potentiometer Check - Retarder Control Lever.......................................453 Assembly - Retarder Control Lever..................................................453 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX.........................................455 BRAKE CIRCUIT CHECK-OUT PROCEDURE..........................................................457 EQUIPMENT REQUIRED.....................................................................459 INITIAL SYSTEM SET-UP..................................................................460 BRAKE SYSTEM CHECKOUT..................................................................461 Failure Modes Check-Out............................................................462 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING..............................................465 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET......................................469 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX...................................................471 WET DISC BRAKE ASSEMBLY....................................................................473 Operation..............................................................................473 MAINTENANCE............................................................................474 Brake Disc Wear Indicator..........................................................474 Removal/Installation...............................................................474 BRAKE REBUILD..........................................................................476 Disassembly........................................................................476 Cleaning and Inspection............................................................479 Assembly...........................................................................480 Floating Ring Seal Assembly/Installation...........................................483 WET DISC BRAKE BLEEDING PROCEDURE......................................................486 SECTION J7 - PARKING BRAKE - INDEX.............................................................487 PARKING BRAKE..............................................................................489 OPERATION..............................................................................489 MAINTENANCE............................................................................490 Inspection - Parking Brake.........................................................490 Removal - Parking Brake............................................................490 Installation - Parking Brake.......................................................491 Disassembly - Parking Brake........................................................492 Cleaning and Inspection - Parking Brake............................................492 Assembly - Parking Brake...........................................................492 PARKING BRAKE BLEEDING PROCEDURE.......................................................494 SECTION L - HYDRAULIC SYSTEM - INDEX...............................................................495 SECTION L2 - HYDRAULIC SYSTEM - INDEX..........................................................497 HYDRAULIC SYSTEM...........................................................................499 Hoist Circuit Operation................................................................500 Steering Circuit Operation.............................................................502 Disc Brake Cooling System..............................................................504 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX.........................................507 HYDRAULIC SYSTEM COMPONENT REPAIR..........................................................509 HOIST PUMP.............................................................................509 Removal............................................................................509 Installation.......................................................................511 Disassembly........................................................................512 Inspection Of Parts................................................................516 Assembly...........................................................................516 TROUBLESHOOTING GUIDE......................................................................521 HYDRAULIC TANK.........................................................................522 Filling Instructions...............................................................522 Removal............................................................................522 Installation.......................................................................523 HYDRAULIC TANK STRAINERS...............................................................523 Removal............................................................................523 Inspect and Clean..................................................................523 Installation.......................................................................523 Hydraulic Tank Breathers...........................................................524 SECTION L4 - STEERING CIRCUIT - INDEX..........................................................525 STEERING CIRCUIT...........................................................................527 STEERING CIRCUIT OPERATION.............................................................527 COMPONENT DESCRIPTION..................................................................528 Steering Control Valve.............................................................528 Bleeddown Manifold Valve...........................................................529 Bleeddown Solenoids................................................................529 Accumulators.......................................................................530 Low Precharge Warning Switch.......................................................530 High Pressure Filter...............................................................530 Flow Amplifier.....................................................................530 FLOW AMPLIFIER SYSTEM OPERATION........................................................532 No Steer...........................................................................532 Steering Left......................................................................534 Steering Right.....................................................................536 No Steer, External Shock Load......................................................538 STEERING PUMP..........................................................................540 Operation..........................................................................540 High Altitude Operation............................................................540 PRINCIPLE OF OPERATION.................................................................542 Steering Pump......................................................................543 SECTION L5 - STEERING CONTROL UNIT - INDEX.....................................................545 STEERING CONTROL UNIT......................................................................547 Removal................................................................................547 Installation...........................................................................547 STEERING CONTROL UNIT REBUILD..........................................................548 Disassembly........................................................................548 Cleaning and Inspection - Steering Control Unit....................................549 Assembly - Steering Control Unit...................................................551 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX.........................................555 STEERING CIRCUIT COMPONENT REPAIR..........................................................557 BLEEDDOWN MANIFOLD VALVE...............................................................557 Removal............................................................................557 Installation.......................................................................557 ACCUMULATORS...........................................................................558 Removal............................................................................558 Installation.......................................................................558 Disassembly........................................................................559 Cleaning and Inspection............................................................559 Assembly...........................................................................560 Testing............................................................................560 STEERING ACCUMULATOR CHARGING PROCEDURE................................................561 FLOW AMPLIFIER.........................................................................562 Removal............................................................................562 Installation.......................................................................562 Flow Amplifier Rebuild.............................................................562 Disassembly........................................................................564 Assembly...........................................................................565 STEERING CYLINDERS.....................................................................566 Disassembly........................................................................567 Piston Seal & Bearing Installation.................................................567 Cylinder Assembly..................................................................567 Test...............................................................................567 STEERING AND BRAKE PUMP................................................................568 Removal............................................................................568 Installation.......................................................................568 Disassembly........................................................................570 Control Piston Group...............................................................570 Valve Plate Group..................................................................570 Rotating Group.....................................................................573 Swashblock Group...................................................................573 Driveshaft Group...................................................................573 Inspection.........................................................................573 Control Piston Group...............................................................573 Valve Plate Group..................................................................573 Rotating Group.....................................................................573 Swashblock Group...................................................................575 Driveshaft Group...................................................................576 Compensator Block and Unloader Module..............................................576 Stroke Adjuster Assembly...........................................................576 Assembly...........................................................................576 Swashblock Group...................................................................576 Driveshaft Group...................................................................577 Rotating Group.....................................................................577 Control Piston Group...............................................................577 Valve Plate Group..................................................................578 TROUBLESHOOTING............................................................................579 SECTION L7 - HOIST CIRCUIT - INDEX.............................................................585 HOIST CIRCUIT..............................................................................587 HOIST CIRCUIT OPERATION................................................................587 COMPONENT DESCRIPTION..................................................................588 Hydraulic Tank.....................................................................588 Hydraulic Pump.....................................................................588 High Pressure Filters..............................................................588 Hoist Valve........................................................................588 Inlet Sections.....................................................................588 Spool Sections.....................................................................589 Work Ports (Rear) Spool Section....................................................589 Tank Ports (Front) Spool Section...................................................589 Hoist Pilot Valve..................................................................589 Hoist Up Limit Solenoid............................................................590 Pilot Operated Check Valve.........................................................590 Snubber Valve......................................................................590 Counterbalance Valve...............................................................590 HOIST CIRCUIT OPERATION................................................................590 POWER UP OPERATION (Figure 7-5)....................................................592 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX............................................601 HOIST CIRCUIT COMPONENT REPAIR.............................................................603 HOIST VALVE............................................................................603 Removal............................................................................603 Installation.......................................................................604 O-Ring Replacement.................................................................604 INLET SECTION......................................................................605 Disassembly........................................................................605 Cleaning and Inspection............................................................606 Assembly...........................................................................606 REAR SPOOL SECTION (Work Ports)....................................................606 Disassembly........................................................................606 Cleaning and Inspection............................................................608 Assembly...........................................................................608 FRONT SPOOL SECTION (Tank Ports)...................................................609 Disassembly........................................................................609 Cleaning and Inspection............................................................609 Assembly...........................................................................609 HOIST PILOT VALVE......................................................................611 Removal............................................................................611 Installation.......................................................................611 Disassembly........................................................................612 Cleaning and Inspection............................................................613 Assembly...........................................................................613 Hoist Up Limit Solenoid............................................................614 HOIST CYLINDERS........................................................................614 Removal............................................................................614 Installation.......................................................................615 Disassembly........................................................................617 Cleaning and Inspection............................................................618 Quill and Cylinder - Assembly......................................................619 Quill Installation.................................................................619 Installation Of Check Balls And Plugs In Quill.....................................620 Assembly of Cylinder...............................................................621 DISABLED TRUCK DUMPING PROCEDURE.......................................................622 Hookup.............................................................................622 Raising the Body:..................................................................622 Lowering the Body:.................................................................622 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX..................................................623 HYDRAULIC SYSTEM FILTERS...................................................................625 HOIST CIRCUIT FILTER...................................................................625 Filter Element Replacement.........................................................625 Removal - Hoist Circuit Filter.....................................................626 Installation - Hoist Circuit Filter................................................626 Indicator Switch - Hoist Circuit Filter............................................626 STEERING CIRCUIT FILTER................................................................627 Filter Element Replacement.........................................................627 Removal - Steering Circuit Filter..................................................628 Installation - Steering Circuit Filter.............................................628 Indicator Switch - Steering Circuit Filter.........................................628 INDICATOR SWITCH.......................................................................628 Test Procedure.....................................................................628 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX............................................631 HYDRAULIC CHECK-OUT PROCEDURE..............................................................633 GENERAL INFORMATION....................................................................633 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................633 Equipment Requirements.............................................................634 Pump Pressure Control Adjustments..................................................634 Steering Control Valve and Flow Amplifier Leakage Test.............................635 Bleeddown Manifold Leakage Test....................................................635 Steering / Brake Pump Stroke Adjustment............................................636 Shock And Suction Valves...........................................................637 Equipment Requirements.............................................................637 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES..........................638 Equipment Requirements.............................................................638 Pressure Checks....................................................................638 Brake Cooling Circuit Test.........................................................638 Power Up Relief Pressure Test......................................................639 Adjustment.........................................................................639 Power Down Relief Pressure Test....................................................640 Adjustment.........................................................................640 Hoist Counterbalance Valve Adjustment..............................................641 HYDRAULIC SYSTEM FLUSHING PROCEDURE........................................................642 Preparation............................................................................642 Flushing Procedure.....................................................................642 Filter Element Replacement.............................................................643 930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET........................................645 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX......................................................647 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX......................................................649 FIRE CONTROL SYSTEM (MANUAL)...............................................................651 Operation..............................................................................651 Inspection and Maintenance.............................................................651 Recharging Procedures..................................................................652 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1...............................653 Control Module.........................................................................653 Actuator...............................................................................654 Linear Detection Wire..................................................................654 Power Wire.............................................................................654 Test Kit...............................................................................654 Squib..................................................................................654 Securing the Detection Wire............................................................655 Preliminary Test Before Final Hook-Up..................................................655 Installation Procedure for Squib.......................................................657 Placing the Electric Detection & Actuation System Into Service.........................657 INSPECTION AND MAINTENANCE SCHEDULES...................................................658 Daily..............................................................................658 Normal Maintenance Based On Actual Operating Hours.................................658 IN CASE OF FIRE........................................................................659 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM..............................................661 SECTION M8 - SPECIAL TOOLS ....................................................................663 SECTION M20 - PAYLOAD METER II - INDEX.........................................................671 GENERAL INFORMATION........................................................................673 Haul Cycles............................................................................673 LIGHTS, SWITCHES AND COMPONENTS............................................................674 TIPS FOR OPERATION.........................................................................675 EXTERNAL DISPLAY LIGHTS....................................................................675 THEORY OF OPERATION........................................................................676 Basic Description......................................................................676 Inclinometer...........................................................................676 Linkage Factor.........................................................................676 Gain Factor............................................................................677 Brake Lock.............................................................................677 Sources of Error.......................................................................677 Typical Data From Service Check Mode...................................................677 Example Calculation of Payload.........................................................678 Viewing Payload Calculation Inputs.....................................................678 Checking the Gain......................................................................679 Adjusting the Gain.....................................................................679 TYPES OF DATA STORED.......................................................................680 Cycle Data.............................................................................680 Engine ON/OFF Data.....................................................................681 Fault Codes and Warning Data...........................................................681 Engine Operation.......................................................................682 Total Payload and Total Number of Cycles...............................................682 Other Data.............................................................................682 OPERATOR FUNCTIONS.........................................................................683 Using the Operator Load Counter........................................................683 Viewing the Operator Load Counter......................................................683 Clearing the Operator Load Counter.....................................................683 Dimming the Lights on the Display......................................................683 INITIAL SETUP OF PAYLOAD METER.............................................................684 Switch Settings........................................................................684 Checking the Operator Check Mode.......................................................685 Checking the Service Check Mode........................................................685 Checking the Gt setting:...............................................................686 Checking the Inclinometer Settings.....................................................686 Calibrating a Truck....................................................................686 DISPLAYS AT START-UP.......................................................................687 Normal Operation.......................................................................687 SETUP AND MAINTENANCE......................................................................688 Setting The Speed Limit................................................................688 Setting the Option Code................................................................688 Setting The Machine I.D. Code..........................................................689 Setting The Operator I.D. Code.........................................................689 Setting The Time and Date..............................................................689 DOWNLOAD OF INFORMATION....................................................................690 DISPLAY OF FAULT CODES.....................................................................690 Monitoring Input Signals...............................................................694 Service Check Mode.....................................................................694 UP FACTOR - PAYLOAD CALCULATION GAIN.......................................................695 PL MODE -LOAD CALCULATION TIMING...........................................................695 FINAL GEAR RATIO SELECTION.................................................................696 BATTERY REPLACEMENT PROCEDURE..............................................................697 Replacing the Battery..................................................................697 After Replacing the Battery............................................................698 SUSPENSION PRESSURE SENSOR.................................................................698 Removal................................................................................698 Installation...........................................................................699 INCLINOMETER...............................................................................699 Removal................................................................................699 Installation...........................................................................699 Adjustment.............................................................................699 PAYLOAD METER BACK PANEL...................................................................700 CONNECTIONS................................................................................701 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE..............................................702 PAYLOAD CIRCUIT NUMBERS....................................................................703 TROUBLESHOOTING............................................................................704 COMMON PROBLEMS........................................................................704 Suspension Charging................................................................704 Symptom Table......................................................................705 Missing Body-Up Signal.............................................................705 Missing Speed Signal...............................................................706 F-18: Alternator R-Terminal, Oil Pressure Signals..................................706 Shorted 18v Sensor Power Supply (930E).............................................706 FAULT TREE DIAGNOSIS...................................................................707 Payload Lights Won't Illuminate....................................................707 Red, Amber or Green Payload Light Does Not Illuminate..............................708 Cannot Download - PC Communications................................................709 PC Communications Configuration....................................................710 F.CAL: Payload Meter Won't Calibrate...............................................711 F-20: Sensor Power Fault...........................................................712 F-21, F-25: Left Front Pressure Sensor.............................................714 F-22, F-26: Right Front Pressure Sensor............................................714 F-23, F-27: Left Rear Pressure Sensor..............................................714 F-24, F-28: Right Rear Pressure Sensor.............................................714 F-31, F-32: Inclinometer...........................................................716 Body Up Input......................................................................718 Brake Lock Input...................................................................719 Speed Signal.......................................................................720 Adjusting the Speed Sensor.........................................................720 CONNECTORS AND PRESSURE SENSORS........................................................722 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM................................................725 Menu Functions.........................................................................728 Using Scope............................................................................728 Log File Information...................................................................728 Connections to Payload Meter II™.......................................................729 USING SCOPE................................................................................730 Monitoring Inputs Using Scope..........................................................730 Monitoring Suspension Charging Using Scope.............................................730 Pressure Sensor Dummy Loads............................................................733 GAIN ADJUSTMENT WORKSHEET..................................................................734 SECTION N - CAB COMPONENTS - INDEX.................................................................735 SECTION N2 - TRUCK CAB - INDEX.................................................................737 TRUCK CAB..................................................................................739 Description............................................................................739 Preparation............................................................................740 Removal - Cab..........................................................................740 Installation - Cab.....................................................................742 CAB DOOR...............................................................................742 Removal............................................................................742 Installation.......................................................................742 Door Adjustment....................................................................743 Door Jamb Bolt Adjustment..........................................................743 Door Handle Plunger Adjustment.....................................................744 Door Glass Replacement.............................................................745 Door Window Regulator Replacement..................................................749 Door Handle or Latch Assembly Replacement..........................................749 Door and Door Hinge Seal Replacement...............................................750 Door Opening Seal Removal..........................................................750 Installation.......................................................................750 GLASS REPLACEMENT......................................................................751 Adhesive Bonded Windows............................................................751 Replacement Procedure..............................................................751 Windshield And Rear Glass..........................................................752 Removal............................................................................752 Installation.......................................................................753 SECTION N3 - CAB COMPONENTS - INDEX............................................................755 CAB COMPONENTS.............................................................................757 WINDSHIELD WIPERS......................................................................757 Wiper Motor Replacement............................................................757 Removal............................................................................757 Installation.......................................................................757 Wiper Arm Replacement..............................................................757 Removal............................................................................757 Installation.......................................................................758 Wiper Linkage Replacement..........................................................758 Removal............................................................................758 Installation.......................................................................758 WINDSHIELD WASHER......................................................................759 Operation..........................................................................759 Service............................................................................759 OPERATOR SEAT..........................................................................760 Adjustment.........................................................................760 Removal............................................................................760 Installation.......................................................................760 SECTION N4 - OPERATOR COMFORT - INDEX..........................................................761 OPERATOR COMFORT...........................................................................763 HEATER/AIR CONDITIONER.................................................................763 Operation..........................................................................763 HEATER COMPONENTS......................................................................764 Circuit Breakers...................................................................764 Heater Control Components..........................................................764 Heater Coil........................................................................764 Fan Motor And Speed Control........................................................765 Actuators..........................................................................765 Filter.............................................................................765 AIR CONDITIONING SYSTEM....................................................................767 Environmental Impact...................................................................767 OPERATOR CAB AIR CONDITIONING..........................................................768 PRINCIPLES OF REFRIGERATION............................................................768 Air Conditioning...................................................................768 Refrigeration - The Act Of Cooling.................................................769 The Refrigeration Cycle............................................................769 AIR CONDITIONER SYSTEM COMPONENTS......................................................770 Compressor (Refrigerant Pump)......................................................770 Service Valves.....................................................................770 Condenser..........................................................................770 Receiver-Drier.....................................................................770 Expansion Block Valve..............................................................771 Evaporator.........................................................................771 ELECTRICAL CIRCUIT.....................................................................772 Thermostat.........................................................................772 Compressor Clutch..................................................................772 Trinary™ Switch....................................................................773 SYSTEM SERVICING.......................................................................774 SYSTEM OIL.............................................................................775 Handling and Reusing PAG Oil.......................................................775 Oil Quantity.......................................................................775 Replacing Oil After Servicing the System...........................................775 Setting Up a New Compressor........................................................775 REFRIGERANT............................................................................776 Recycled Refrigerant...............................................................776 Reclaimed Refrigerant..............................................................776 Refrigerant Quantity...............................................................776 R-134a Refrigerant Containers......................................................776 SERVICE TOOLS AND EQUIPMENT............................................................777 Recovery/Recycle Station...........................................................777 Leak Detector......................................................................777 Service Valves.....................................................................778 Vacuum Pump........................................................................778 Manifold Gauge Set.................................................................779 Installing Manifold Gauge Set......................................................780 Purging Air From Service Hoses.....................................................781 Stabilizing the AC System..........................................................782 SYSTEM PERFORMANCE TEST................................................................782 SYSTEM LEAK TESTING....................................................................783 Electronic Leak Detector...........................................................783 Tracer Dyes........................................................................783 Soap and Water.....................................................................783 SYSTEM REPAIR..........................................................................784 System Cleaning....................................................................784 Hoses and Fittings.................................................................784 Lines..............................................................................784 Expansion Valve....................................................................784 Receiver-Drier.....................................................................785 Thermostat.........................................................................785 Compressor.........................................................................785 Clutch.............................................................................785 Servicing the Compressor Clutch....................................................786 Pulley Removal.....................................................................788 Clutch Coil Check..................................................................788 Pulley Installation................................................................788 Clutch Assembly Installation.......................................................789 RECOVERING AND RECYCLING THE REFRIGERANT...............................................790 Performing the Recovery Cycle......................................................790 Performing the Recycling Procedure.................................................790 Evacuating and Charging the AC System..............................................790 EVACUATING THE SYSTEM..................................................................791 CHARGING THE AC SYSTEM.................................................................792 TROUBLESHOOTING............................................................................793 Pre-Diagnosis Checks...................................................................793 Preparing For Diagnosis................................................................793 Preliminary Steps......................................................................793 System Performance Test................................................................793 Diagnosis Of Gauge Readings And System Performance.....................................794 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.............................................795 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM............................................801 SECTION N5 - OPERATOR CAB CONTROLS - INDEX.....................................................803 OPERATOR CAB CONTROLS......................................................................805 STEERING COLUMN........................................................................805 Removal............................................................................805 Installation.......................................................................805 STEERING WHEEL AND CONTROLS............................................................807 DYNAMIC RETARDING......................................................................807 RETARDER CONTROL LEVER.............................................................808 DYNAMIC RETARDER/SERVICE BRAKE PEDAL...............................................808 ACCELERATOR (THROTTLE) PEDAL.......................................................808 Starting on a Grade With a Loaded Truck............................................808 GRADE/SPEED RETARD CHART...............................................................809 HEATER / AIR CONDITIONER VENTS.........................................................810 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................................810 DEFROSTER VENT CONTROL SWITCH......................................................810 HEAT VENT CONTROL SWITCH...........................................................810 FAN CONTROL KNOB...................................................................810 AIR CONDITIONER CONTROL KNOB.......................................................810 OUTSIDE/INSIDE AIR CONTROL SWITCH..................................................810 SELECTION CONTROL SWITCH...........................................................810 HEATER/AIR CONDITIONER VENTS.......................................................810 INSTRUMENT PANEL.......................................................................811 OVERHEAD PANEL AND DISPLAYS............................................................811 F-N-R SELECTOR SWITCH..............................................................812 HOIST CONTROL LEVER................................................................813 OVERRIDE /FAULT RESET SWITCH.......................................................814 10, FIGURE 5-5 - BLANK.............................................................814 RETARD SPEED CONTROL (RSC) "OFF/ON" SWITCH.........................................814 RETARD SPEED CONTROL (RSC) ADJUST DIAL.............................................814 TCI DOWNLOAD PORT..................................................................815 PASSENGER SEAT.....................................................................815 INSTRUMENT PANEL AND INDICATOR LIGHTS......................................................817 CONTROL SYMBOLS........................................................................817 INSTRUMENT PANEL (Figure 5-6)..........................................................817 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)........................................819 KEY SWITCH.............................................................................819 Starting...............................................................................819 Cold Weather Starting..................................................................819 Normal Engine Shutdown.................................................................819 Operation..............................................................................820 PARKING BRAKE CONTROL..................................................................821 AC DRIVE SYSTEM TEMPERATURE GAUGE......................................................823 STATUS / WARNING INDICATOR LIGHT SYMBOLS...................................................826 SECTION P - LUBRICATION AND SERVICE - INDEX........................................................833 SECTION P2 - LUBRICATION AND SERVCIE - INDEX...................................................835 LUBRICATION AND SERVICE....................................................................837 930E SERVICE CAPACITIES................................................................837 HYDRAULIC TANK SERVICE.................................................................837 Adding Oil.........................................................................837 WHEEL MOTOR SERVICE....................................................................837 COOLANT LEVEL CHECK....................................................................838 RADIATOR FILLING PROCEDURE.............................................................838 LUBRICATION CHART......................................................................839 10 HOUR (DAILY) INSPECTION.............................................................840 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................843 100 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................844 250 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................845 500 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................848 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS..........................................849 2500 HOUR MAINTENANCE CHECKS...........................................................850 5000 HOUR MAINTENANCE CHECKS...........................................................850 SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX......................................851 LINCOLN AUTOMATIC LUBRICATION SYSTEM.......................................................853 System Components......................................................................853 System Operation.......................................................................855 GENERAL INSTRUCTIONS...................................................................856 Lubricant Required for System......................................................856 System Priming.....................................................................856 SYSTEM CHECKOUT........................................................................856 24 VDC SOLID STATE TIMER CHECK.........................................................857 24 VDC Solid State Timer Adjustment................................................857 INJECTORS (SL-1 Series "H")............................................................858 Injector Specifications............................................................858 Injector Adjustment................................................................858 INJECTOR OPERATION.....................................................................859 PUMP CYCLE TIMER (FLASHER TIMER).......................................................860 Pump Cycle Timer (Flasher Timer) Installation......................................860 Pump Cycle Timer (Flasher Timer) Adjustment:.......................................860 Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.).....................860 PRESSURE REDUCER ADJUSTMENT............................................................862 TROUBLESHOOTING CHART......................................................................863 Preventative Maintenance Procedures........................................................866 Daily Lubrication System Inspection....................................................866 250 Hour Inspection....................................................................866 SECTION Q ALPHABETICAL INDEX.......................................................................867 SECTION R - SYSTEM SCHEMATICS......................................................................871 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH341.......................................................873 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH348.......................................................874 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC...................................................875 ELECTRICAL SCHEMATIC...........................................................................876 24 VOLT ELECTRICAL SCHEMATIC...................................................................889
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