Komatsu 930E Dump Truck Shop Manual CEBM010100 – PDF DOWNLOAD

Description

Komatsu 930E Dump Truck Shop Manual CEBM010100 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E Dump Truck Shop Manual CEBM010100 – PDF DOWNLOAD

Language : English
Pages :874
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E Dump Truck Shop Manual CEBM010100 – PDF DOWNLOAD

SERIAL NUMBERS 32604 – 32789, 32803 – 32815
w/MTU Engine

FOREWORD

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
• All safety notices, 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.

TABLE OF CONTENTS:

Komatsu 930E Dump Truck Shop Manual CEBM010100 – PDF DOWNLOAD

SERIAL NUMBERS 32604 – 32789, 32803 – 32815
w/MTU Engine

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
Removal100
Installation100
Repair100
Cleaning100
FUEL GAUGE SENDER101
Removal101
Installation101
LOW FUEL SWITCH101
WIGGINS QUICK FILL FUEL SYSTEM102
FUEL RECEIVER102
TANK BREATHER VALVE102
Removal102
Installation102
Disassembly102
Assembly102
LEFT SIDE FILL103
FUEL – WATER SEPARATOR104
Installation104
Filter Service105
Backflushing Procedure105
Filter Element Replacement105
SECTION C – ENGINE – INDEX107
SECTION C2 – POWER MODULE – INDEX109
POWER MODULE111
PREPARATION111
Removal112
Power Module Removal115
Power Module Installation116
Power Module Hookup118
SECTION C3 – COOLING SYSTEM – INDEX119
COOLING SYSTEM121
RADIATOR121
Removal121
RADIATOR REPAIR123
Internal Inspection123
External Cleaning123
Disassembly123
Cleaning and Inspection124
Assembly125
Pressure Testing126
Additional Service Information126
Installation126
Radiator Fill Procedure127
Troubleshooting127
SECTION C4 – POWERTRAIN – INDEX129
POWER TRAIN131
ALTERNATOR REMOVAL PROCEDURE131
Removal (MTU Engine)131
ENGINE/ALTERNATOR MATING132
MTU Engine132
Joining Alternator and MTU Engine134
ENGINE135
Removal135
Service135
Installation135
SECTION C5 – AIR CLEANERS – INDEX137
AIR CLEANERS139
Service Checks139
Filter Element Replacement139
Main Filter Element Cleaning141
Precleaner Section142
Cleaning Precleaner Tubes143
Air Intake Troubleshooting143
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION)145
SECTION D2 – 24VDC ELECTRICAL SUPPLY SYSTEM – INDEX147
24VDC ELECTRIC SUPPLY SYSTEM149
ELECTRICAL SYSTEM DESCRIPTION149
BATTERIES149
Maintenance and Service149
Troubleshooting149
BATTERY SUPPLY SYSTEM151
24VDC BATTERY CHARGING ALTERNATOR151
BATTERY BOX151
BATTERY CONTROL BOX151
SYSTEM BATTERY STARTER DISCONNECT RELAY151
START REPEAT RELAY152
BATTERY DISCONNECT SWITCHES152
24VDC AUXILIARY BATTERY CONNECTORS152
BATTERY EQUALIZER AND MONITOR153
Troubleshooting153
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX155
24 VDC ELECTRICAL SYSTEM COMPONENTS157
PASSENGER SEAT BASE COMPARTMENT157
TRUCK SHUTDOWN PROCEDURE157
COMPONENTS157
ELECTRICAL INTERFACE CABINET162
DIODE BOARD – DB1162
Diode Testing162
TRUCK CONTROL INTERFACE PANEL164
CIRCUIT BREAKER CB1165
RELAY BOARDS166
RELAY BOARDS RB1, RB2, RB3, RB4, RB5166
Service166
RELAY BOARD IDENTIFICATION167
RELAY BOARD FUNCTIONS168
Relay Board 1 (RB1)168
Relay Board 2 (RB2)168
Relay Board 3 (RB3)168
Relay Board 4 (RB4)168
Relay Board 5 (RB5)168
Relay Board 6 (RB6)169
Installing Additional Circuits169
Relay Board 7 (RB7)169
BODY-UP SWITCH170
Operation170
Adjustment170
Service170
HOIST LIMIT SWITCH171
Operation171
Adjustment171
Service171
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX173
BATTERY CHARGING ALTERNATOR175
ELECTRICAL SYSTEM DESCRIPTION175
BATTERY175
Maintenance and Service175
Troubleshooting175
BATTERY CHARGING SYSTEM (Niehoff)177
General Description177
TROUBLESHOOTING PROCEDURES (On-Truck)177
Equipment Required:177
Preliminary Checks178
Test Setup178
Test Procedure178
Regulator Bypass Test179
ON VEHICLE TROUBLESHOOTING GUIDE181
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage181
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:181
CHARGE VOLT AND AMP VALUES182
DEFINITIONS182
ADVANCED SYSTEM TROUBLESHOOTING183
Static Test – Engine OFF, Key ON, Battery Switch ON183
Go To Alternator183
Go To Regulator (If Required)184
Go To Regulator Connector On The Alternator184
ALTERNATOR OVERHAUL185
ALTERNATOR DIMENSIONS185
ALTERNATOR SPECIFICATIONS186
SERVICE PARTS187
ON-VEHICLE TEST189
Equipment:189
Preliminary Checks:189
Test Set-up189
Test Procedure189
ON-VEHICLE TEST190
Bypass Test:190
BENCH TEST191
STATIC TESTS192
Regulator Tests192
Control Box Tests193
ALTERNATOR DISASSEMBLY195
ASSEMBLY- ALTERNATOR200
BF4822 STATOR SERVICE TOOL INSTRUCTIONS209
Stator Removal And Replacement209
Stator Installation210
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX213
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX215
ELECTRICAL PROPULSION SYSTEM COMPONENTS217
GENERAL SYSTEM DESCRIPTION217
SYSTEM COMPONENTS219
Auxiliary Blower System219
Propulsion System Controller (PSC)219
TRUCK CONTROL INTERFACE PANEL (TCI)220
Diagnostic Information Display221
DID PANEL EVENT CODES221
PSC SOFTWARE FUNCTIONS246
Input Processing246
STATE MANAGEMENT246
State Machine246
Transitions Between States247
DC Link State249
Powering the Link249
De-Powering the Link249
Control Functions249
Engine Control249
ALTERNATOR FIELD CONTROL250
Desired Three-Phase Voltage250
Desired DC Link Voltage250
Self-load250
Propel Torque Control251
Retard Torque Control251
Wheel Slide Control251
Resistor Grid Control252
Chopper Voltage Control252
AUXILIARY BLOWER CONTROL252
EVENT PROCESSING252
Event Detection252
Power On Tests252
Initiated Tests253
Periodic Tests253
EVENT RESTRICTIONS253
EVENT LOGGING AND STORAGE253
Event History Buffer254
Data Packs254
To Record and Save a Data Pack to a Floppy Disk254
Event Reset255
SERIAL DATA COMMUNICATIONS256
PSC – TCI Communications processing256
PSC – PTU Communications Processing256
Inverter Communications Processing256
OUTPUT PROCESSING257
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS257
Fast Start257
Engine Shutdown/Engine Not Running257
Limp Home Mode257
Entering/Exiting Limp Home Mode257
PROPULSION SYSTEM COMPONENT ABBREVIATIONS258
ELECTRONIC ACCELERATOR AND RETARD PEDALS268
Removal268
Installation268
Disassembly268
Assembly268
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX269
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE271
AC DRIVE SYSTEM MAINTENANCE271
TRUCK SHUTDOWN PROCEDURES271
NORMAL TRUCK SHUTDOWN PROCEDURE272
SHUTDOWN AFTER SYSTEM FAILURE273
SYSTEM CHECKOUT274
Battery and Control Checks of System WITH Battery Power OFF274
Battery and Control Circuit Checks of System With Battery Power ON277
Checks with Key Switch OFF278
CPU Battery Checks280
MEMORY BACKUP BATTERY REPLACEMENT280
TCI PROGRAMMING281
PSC PROGRAMMING281
INVERTER PROGRAMMING282
TCI CHECKOUT282
Modular Mining Communication Port283
TCI Input Checks284
TCI Digital Output Tests286
TCI Digital Input Tests288
PSC Checkout Procedure290
PSC Digital Input Checks294
Miscellaneous Checks295
A3PV Panel295
LINKV Panel295
Thermistor Checks295
17FM384 Panel Check295
Pedal Percentages and Meter Calibration296
Meter Calibration Procedure296
Reprogram With Serial Numbers and Pedal Percentages298
LOAD TESTING300
Preload Checks300
ADDITIONAL TRUCK CHECKS302
On-Board Load Testing304
Preparation304
Initiate Loadbox Test307
Manual Offset HP Output Adjustment309
TROUBLESHOOTING311
PVM Optimum Load Curve Handshaking Troubleshooting311
MISCELLANEOUS COMPONENT REPAIR312
Troubleshooting Phase Modules and Chopper Modules312
Phase Module Removal and Snubber Resistor Replacement312
Snubber Resistor Installation313
Phase Module Installation313
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING314
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING317
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING318
IGBT TROUBLESHOOTING319
SECTION G – REAR AXLE, SPINDLES, AND WHEELS – INDEX321
SECTION G2 – TIRES AND RIMS – INDEX323
TIRES AND RIMS325
FRONT TIRES AND RIMS326
Removal326
Installation327
REAR TIRES AND RIMS327
Removal327
Installation328
RIM329
Tire Removal329
Tire Installation330
SECTION G3 – FRONT WHEEL HUB AND SPINDLES – INDEX331
FRONT WHEEL HUB AND SPINDLE333
WHEEL HUB AND SPINDLE ASSEMBLY333
PREPARATION333
Removal333
Installation336
Disassembly337
Cleaning and Inspection337
Assembly339
Wheel Bearing Adjustment:340
Seal Assembly Gap Check:341
STEERING CYLINDERS AND TIE ROD342
Spherical Bearing Wear Limits342
Removal343
Installation344
Bearing Replacement344
TOE-IN ADJUSTMENT345
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX347
REAR AXLE HOUSING ATTACHMENT349
PIVOT PIN349
Removal349
Installation349
PIVOT EYE BEARING350
Disassembly350
PIVOT EYE REPAIR351
Removal351
Disassembly351
Assembly351
Installation351
ANTI-SWAY BAR352
Removal352
Installation352
Disassembly352
Assembly352
SECTION G5 – REAR AXLE HOUSING – INDEX353
REAR AXLE HOUSING355
REAR AXLE HOUSING355
PREPARATION355
Removal355
Cleaning and Inspection357
Installation357
WHEEL MOTOR358
Preparation358
Removal358
Cleaning and Inspection359
Installation360
WHEEL MOTOR GEAR OIL363
Filtering Requirements363
Particle Size Analysis363
Flushing363
Oil Sample Analysis364
ELEMENT SPECIFICATION CHARTS365
SECTION H – HYDRAIR II SUSPENSIONS – INDEX369
SECTION H2 – FRONT SUSPENSION – INDEX371
FRONT SUSPENSION373
Removal373
Installation374
“TURN-OF-THE-NUT” Tightening Procedure376
MINOR REPAIR ONLY (LOWER BEARING & SEALS)377
Lower Bearing Removal377
Lower Bearing Installation377
MAJOR SUSPENSION REBUILD379
Disassembly379
Assembly379
SECTION H3 – REAR SUSPENSION – INDEX381
REAR SUSPENSIONS383
Removal383
Installation385
Disassembly386
Cleaning and Inspection386
Assembly386
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX389
SUSPENSION OILING AND CHARGING PROCEDURE391
GENERAL391
EQUIPMENT LIST391
Hydrair® Charging Kit391
Installation of Charging Kit391
Removal of Charging Kit392
Support Blocks For Oiling And Charging Dimensions392
FRONT SUSPENSION393
Front Suspension Oiling393
Front Suspension Nitrogen Charging394
REAR SUSPENSION395
Rear Suspension Oiling395
Rear Suspension Nitrogen Charging396
OIL AND NITROGEN SPECIFICATIONS CHART398
SECTION J – BRAKE CIRCUIT – INDEX399
SECTION J2 – BRAKE CIRCUIT – INDEX401
BRAKE CIRCUIT403
SERVICE BRAKE CIRCUIT403
SECONDARY BRAKING AND AUTOMATIC APPLY405
PARKING BRAKE CIRCUIT405
BRAKE LOCK CIRCUIT406
WARNING CIRCUIT406
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX409
BRAKE CIRCUIT COMPONENT SERVICE411
BRAKE VALVE411
Rebuild Criteria411
Removal – Brake Valve412
Installation – Brake Valve412
Disassembly – Brake Valve413
Cleaning and Inspection – Brake Valve416
Assembly – Actuator Base Threaded Inserts416
Assembly – Boot and Cap416
Installation – Valve Body Seal416
Installation – Regulator Sleeve O-Ring417
Installation – Actuator Plunger O-ring417
Assembly – Brake Valve417
DIFFERENTIAL PRESSURE SWITCH419
Disassembly419
Cleaning and Inspection419
Assembly419
VALVE BENCH TEST AND ADJUSTMENT420
Test Set Up Procedure421
Adjustment – Brake Valve Output Pressure421
Adjustment – Differential Pressure Switch421
Final Test and Adjustment422
Installation – Brake Pedal Actuator Assembly to Brake Valve423
Installation – Retard Pedal To Brake Pedal423
DUAL RELAY VALVE425
Removal425
Installation425
Disassembly – Dual Relay Valve427
Cleaning and Inspection – Dual Relay Valve427
Assembly – Dual Relay Valve427
DIFFERENTIAL PRESSURE SWITCH428
Disassembly428
Cleaning and Inspection428
Assembly428
VALVE TEST AND ADJUSTMENT429
Test Set Up Procedure430
Adjustment – Brake Valve Output Pressure430
Adjustment – Differential Pressure Switch431
HYDRAULIC BRAKE ACCUMULATORS432
Brake Accumulator Bleed Down Procedure432
ACCUMULUTOR – HYDRAULIC COMPONENTS CABINET432
Removal432
Installation432
Disassembly432
Cleaning and Inspection – Accumulator433
Assembly – Accumulator434
Charging Procedure – Accumulator435
ACCUMULATORS – FRAME MOUNTED436
Removal436
Installation436
Disassembly – Accumulator437
Cleaning and Inspection – Accumulator437
Assembly – Accumulator438
Testing – Accumulator438
ACCUMULATOR CHARGING PROCEDURE (Frame Mounted Brake Accumulators)439
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)440
Removal – Retarder Control Lever440
Installation – Retarder Control Lever440
Disassembly and Adjustment – Retarder Control Lever441
Potentiometer Check – Retarder Control Lever441
Assembly – Retarder Control Lever441
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX443
BRAKE CIRCUIT CHECK-OUT PROCEDURE445
EQUIPMENT REQUIRED447
INITIAL SYSTEM SET-UP448
BRAKE SYSTEM CHECKOUT449
Failure Modes Check-Out450
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING453
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET457
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX459
WET DISC BRAKE ASSEMBLY461
Operation461
MAINTENANCE462
Brake Disc Wear Indicator462
Removal/Installation462
BRAKE REBUILD464
Disassembly464
Cleaning and Inspection467
Assembly468
Floating Ring Seal Assembly/Installation471
WET DISC BRAKE BLEEDING PROCEDURE474
SECTION J7 – PARKING BRAKE – INDEX475
PARKING BRAKE477
OPERATION477
MAINTENANCE478
Inspection – Parking Brake478
Removal – Parking Brake478
Installation – Parking Brake479
Disassembly – Parking Brake480
Cleaning and Inspection – Parking Brake480
Assembly – Parking Brake480
PARKING BRAKE BLEEDING PROCEDURE482
SECTION L – HYDRAULIC SYSTEM – INDEX483
SECTION L2 – HYDRAULIC SYSTEM DESCRIPTION – INDEX485
HYDRAULIC SYSTEM487
Hoist Circuit Operation488
Steering Circuit Operation490
Disc Brake Cooling System492
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX495
HYDRAULIC SYSTEM COMPONENT REPAIR497
HOIST PUMP497
Removal497
Installation499
Disassembly500
INSPECTION OF PARTS504
Assembly504
HYDRAULIC TANK510
Filling Instructions510
Removal510
Installation511
HYDRAULIC TANK STRAINERS511
Removal511
Inspect and Clean511
Installation511
HYDRAULIC TANK BREATHERS512
SECTION L4 – STEERING CIRCUIT – INDEX513
STEERING CIRCUIT515
STEERING CIRCUIT OPERATION515
COMPONENT DESCRIPTION516
Steering Control Valve516
Bleeddown Manifold Valve517
Bleeddown Solenoid517
Accumulators518
Low Precharge Warning Switch518
High Pressure Filter518
Flow Amplifier518
FLOW AMPLIFIER SYSTEM OPERATION520
No Steer520
Steering Left522
Steering Right524
No Steer, External Shock Load526
STEERING PUMP528
Operation528
Principle Of Operation530
Steering Pump531
SECTION L5 – STEERING CONTROL UNIT – INDEX533
STEERING CONTROL UNIT535
Removal535
Installation535
STEERING CONTROL UNIT REBUILD536
Disassembly536
Cleaning and Inspection – Steering Control Unit537
Assembly – Steering Control Unit539
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX543
STEERING CIRCUIT COMPONENT REPAIR545
BLEEDDOWN MANIFOLD VALVE545
Removal545
Installation545
ACCUMULATORS546
Removal546
Installation546
Disassembly547
Cleaning and Inspection547
Assembly547
STEERING ACCUMULATOR CHARGING PROCEDURE548
FLOW AMPLIFIER549
Removal549
Installation549
FLOW AMPLIFIER REBUILD549
Disassembly549
Assembly552
STEERING CYLINDERS553
Disassembly554
Piston Seal & Bearing Installation554
Cylinder Assembly554
Test554
STEERING AND BRAKE PUMP555
Removal555
Installation555
Disassembly557
Control Piston Group557
Valve Plate Group557
Rotating Group558
Swashblock Group558
Driveshaft Group558
Inspection558
Control Piston Group558
Valve Plate Group558
Rotating Group558
Swashblock Group562
Driveshaft Group563
Compensator Block and Unloader Module563
ASSEMBLY563
Swashblock Group563
Driveshaft Group563
Rotating Group564
Control Piston Group564
Valve Plate Group565
TROUBLESHOOTING CHART566
SECTION L7 – HOIST CIRCUIT DESCRIPTION – INDEX571
HOIST CIRCUIT573
HOIST CIRCUIT OPERATION573
COMPONENT DESCRIPTION574
HYDRAULIC TANK574
HYDRAULIC PUMP574
HIGH PRESSURE FILTERS574
HOIST VALVE574
Inlet Sections574
Spool Sections575
Work Ports (Rear) Spool Section575
Tank Ports (Front) Spool Section575
HOIST PILOT VALVE575
HOIST-UP LIMIT SOLENOID576
PILOT OPERATED CHECK VALVE576
HOIST VALVE OPERATION576
FLOAT POSITION OF PILOT VALVE WITH TRUCK BODY ON FRAME576
POWER UP OPERATION (Figure 7-5)578
HOLD OPERATION (Figure 7-6)580
POWER DOWN OPERATION (Figure 7-7)582
FLOAT OPERATION (Figure 7-8)584
SECTION L8 – HOIST COMPONENT REPAIR – INDEX587
HOIST CIRCUIT COMPONENT REPAIR589
HOIST VALVE589
Removal589
Installation590
O-Ring Replacement590
INLET SECTION591
Disassembly591
Cleaning and Inspection592
Assembly592
REAR SPOOL SECTION (Work Ports)592
Disassembly592
Cleaning and Inspection594
Assembly594
FRONT SPOOL SECTION (Tank Ports)595
Disassembly595
Cleaning and Inspection595
Assembly595
HOIST PILOT VALVE597
Removal597
Installation597
Disassembly598
Cleaning and Inspection599
Assembly599
HOIST – UP LIMIT SOLENOID VALVE600
HOIST CYLINDERS600
Removal600
Installation601
Disassembly603
Cleaning and Inspection604
ASSEMBLY OF QUILL AND CYLINDER605
Quill Installation605
Installation Of Check Balls And Plugs In Quill606
Assembly of Cylinder607
DISABLED TRUCK DUMPING PROCEDURE608
HOOKUP608
DUMPING PROCEDURE608
Raising the Body:608
Lowering the Body:608
SECTION L9 – HIGH PRESSURE FILTERS – INDEX609
HIGH PRESSURE FILTERS611
HOIST CIRCUIT FILTERS611
FILTER ELEMENT REPLACEMENT612
Removal612
Installation612
INDICATOR SWITCH612
STEERING CIRCUIT FILTER613
FILTER ELEMENT REPLACEMENT614
Removal614
Installation614
INDICATOR SWITCH614
BRAKE CIRCUIT FILTER615
FILTER ELEMENT REPLACEMENT615
Removal615
Installation615
INDICATOR SWITCH616
Test Procedure616
SECTION L10 – HYDRAULIC CHECKOUT PROCEDURES – INDEX619
HYDRAULIC CHECK-OUT PROCEDURE621
GENERAL INFORMATION621
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE621
Equipment Requirements622
Pump Pressure Control Adjustments622
Steering Components Leakage Test623
SHOCK AND SUCTION VALVES624
Equipment Requirements624
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES626
Equipment Requirements626
Pressure Checks626
Brake Cooling Circuit Test626
Power Up Relief Pressure Test627
Adjustment627
Power Down Relief Pressure Test628
Adjustment628
HOIST COUNTERBALANCE VALVE ADJUSTMENT629
HYDRAULIC SYSTEM FLUSHING PROCEDURE630
Preparation630
Flushing Procedure630
Filter Element Replacement631
930E CHECK-OUT PROCEDURE633
930E CHECK-OUT PROCEDURE634
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX635
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX637
FIRE CONTROL SYSTEM (MANUAL)639
Operation639
Inspection and Maintenance639
Recharging Procedures640
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1641
Control Module641
Actuator642
Linear Detection Wire642
Power Wire642
Test Kit642
Squib642
Securing the Detection Wire643
Preliminary Test Before Final Hook-Up643
Installation Procedure for Squib645
Placing the Electric Detection & Actuation System Into Service645
INSPECTION AND MAINTENANCE SCHEDULES646
Daily646
Normal Maintenance Based On Actual Operating Hours646
IN CASE OF FIRE647
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM649
SECTION M8 – SPECIAL TOOLS651
SECTION M20 – PAYLOAD METER II -INDEX659
GENERAL INFORMATION661
Haul Cycles661
LIGHTS, SWITCHES AND COMPONENTS662
TIPS FOR OPERATION663
EXTERNAL DISPLAY LIGHTS663
THEORY OF OPERATION664
Basic Description664
Inclinometer664
Linkage Factor664
Gain Factor665
Brake Lock665
Sources of Error665
Typical Data From Service Check Mode665
Example Calculation of Payload666
Viewing Payload Calculation Inputs666
Checking the Gain667
Adjusting the Gain667
TYPES OF DATA STORED668
Cycle Data668
Engine ON/OFF Data669
Fault Codes and Warning Data669
Engine Operation670
Total Payload and Total Number of Cycles670
Other Data670
OPERATOR FUNCTIONS671
Using the Operator Load Counter671
Viewing the Operator Load Counter671
Clearing the Operator Load Counter671
Dimming the Lights on the Display671
INITIAL SETUP OF PAYLOAD METER672
Switch Settings672
Checking the Operator Check Mode673
Checking the Service Check Mode673
Checking the Gt setting:674
Checking the Inclinometer Settings674
Calibrating a Truck674
DISPLAYS AT START-UP675
Normal Operation675
SETUP AND MAINTENANCE676
Setting The Speed Limit676
Setting the Option Code676
Setting The Machine ID Code677
Setting The Operator ID Code677
Setting The Time and Date677
DOWNLOAD OF INFORMATION678
DISPLAY OF FAULT CODES678
Monitoring Input Signals682
Service Check Mode682
UP FACTOR – PAYLOAD CALCULATION GAIN683
PL MODE -LOAD CALCULATION TIMING683
FINAL GEAR RATIO SELECTION684
BATTERY REPLACEMENT PROCEDURE685
Replacing the Battery685
After Replacing the Battery686
SUSPENSION PRESSURE SENSOR686
Removal686
Installation687
INCLINOMETER687
Removal687
Installation687
Adjustment687
PAYLOAD METER BACK PANEL688
CONNECTIONS689
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE690
PAYLOAD CIRCUIT NUMBERS691
TROUBLESHOOTING692
COMMON PROBLEMS692
Suspension Charging692
Symptom Table693
Missing Body-Up Signal693
Missing Speed Signal694
F-18: Alternator R-Terminal, Oil Pressure Signals694
Shorted 18v Sensor Power Supply (930E)694
FAULT TREE DIAGNOSIS695
Payload Lights Won’t Illuminate695
Red, Amber or Green Payload Light Does Not Illuminate696
Cannot Download – PC Communications697
PC Communications Configuration698
FCAL: Payload Meter Won’t Calibrate699
F-20: Sensor Power Fault700
F-21, F-25: Left Front Pressure Sensor702
F-22, F-26: Right Front Pressure Sensor702
F-23, F-27: Left Rear Pressure Sensor702
F-24, F-28: Right Rear Pressure Sensor702
F-31, F-32: Inclinometer704
Body Up Input706
Brake Lock Input707
Speed Signal708
Adjusting the Speed Sensor708
CONNECTORS AND PRESSURE SENSORS710
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM713
Menu Functions716
Using Scope716
Log File Information716
Connections to Payload Meter II™717
USING SCOPE718
Monitoring Inputs Using Scope718
Monitoring Suspension Charging Using Scope718
Pressure Sensor Dummy Loads721
GAIN ADJUSTMENT WORKSHEET722
SECTION N – CAB COMPONENTS – INDEX723
SECTION N2 TRUCK CAB – INDEX725
TRUCK CAB727
Description727
Preparation728
Removal – Cab728
Installation – Cab730
CAB DOOR730
Removal730
Installation730
Door Adjustment731
Door Jamb Bolt Adjustment731
Door Handle Plunger Adjustment732
Door Glass Replacement733
Door Window Regulator Replacement737
Door Handle or Latch Assembly Replacement737
Door and Door Hinge Seal Replacement738
Door Opening Seal Removal738
Installation738
GLASS REPLACEMENT739
Adhesive Bonded Windows739
Replacement Procedure739
Windshield And Rear Glass740
Removal740
Installation741
SECTION N3 – CAB COMPONENTS – INDEX743
CAB COMPONENTS745
WINDSHIELD WIPERS745
Wiper Motor Replacement745
Removal745
Installation745
Wiper Arm Replacement745
Removal745
Installation746
Wiper Linkage Replacement746
Removal746
Installation746
WINDSHIELD WASHER747
Operation747
Service747
OPERATOR SEAT748
Adjustment748
Removal748
Installation748
SECTION N4 – OPERATOR COMFORT – INDEX749
OPERATOR COMFORT751
HEATER/AIR CONDITIONER751
Operation751
HEATER COMPONENTS752
Circuit Breakers752
Heater Water Control Solenoid752
Test753
Heater Coil753
Fan Motor And Speed Control754
Actuators754
Filter754
AIR CONDITIONING SYSTEM756
Environmental Impact756
OPERATOR CAB AIR CONDITIONING757
PRINCIPLES OF REFRIGERATION757
Air Conditioning757
Refrigeration – The Act Of Cooling758
The Refrigeration Cycle758
AIR CONDITIONER SYSTEM COMPONENTS759
Compressor (Refrigerant Pump)759
Service Valves759
Condenser759
Receiver-Drier759
Expansion Block Valve760
Evaporator760
ELECTRICAL CIRCUIT761
Thermostat761
Compressor Clutch761
Trinary™ Switch762
SYSTEM SERVICING763
SYSTEM OIL764
Handling and Reusing PAG Oil764
Oil Quantity764
Replacing Oil After Servicing the System764
Setting Up a New Compressor764
REFRIGERANT765
Recycled Refrigerant765
Reclaimed Refrigerant765
Refrigerant Quantity765
R-134a Refrigerant Containers765
SERVICE TOOLS AND EQUIPMENT766
Recovery/Recycle Station766
Leak Detector766
Service Valves767
Vacuum Pump767
Manifold Gauge Set768
Installing Manifold Gauge Set769
Purging Air From Service Hoses770
Stabilizing the AC System771
SYSTEM PERFORMANCE TEST771
SYSTEM LEAK TESTING772
Electronic Leak Detector772
Tracer Dyes772
Soap and Water772
SYSTEM REPAIR773
System Cleaning773
Hoses and Fittings773
Lines773
Expansion Valve773
Receiver-Drier774
Thermostat774
Compressor774
Clutch774
Servicing the Compressor Clutch775
Pulley Removal777
Clutch Coil Check777
Pulley Installation777
Clutch Assembly Installation778
RECOVERING AND RECYCLING THE REFRIGERANT779
Performing the Recovery Cycle779
Performing the Recycling Procedure779
Evacuating and Charging the AC System779
EVACUATING THE SYSTEM780
CHARGING THE AC SYSTEM781
TROUBLESHOOTING782
Pre-Diagnosis Checks782
Preparing For Diagnosis782
Preliminary Steps782
System Performance Test782
Diagnosis Of Gauge Readings And System Performance783
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS784
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM790
SECTION N5 OPERATOR CAB CONTROLS – INDEX791
OPERATOR CAB CONTROLS793
STEERING COLUMN793
Removal793
Installation793
STEERING WHEEL AND CONTROLS795
Horn Button795
Telescope Lock Ring795
Tilt Wheel Lever795
Turn Signal/Headlight Dimmer795
DYNAMIC RETARDING795
Dynamic Retarder Control Lever796
Dynamic Retarder/Service Brake Pedal796
Accelerator (Throttle) Pedal796
Starting on a Grade With a Loaded Truck796
GRADE/SPEED RETARD CHART797
INSTRUMENT PANEL798
OVERHEAD PANEL AND DISPLAYS798
F-N-R SELECTOR SWITCH799
HOIST CONTROL LEVER800
OVERRIDE /FAULT RESET SWITCH801
10, FIGURE 5-5 – BLANK801
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH801
RETARD SPEED CONTROL (RSC) ADJUST DIAL801
TCI DOWNLOAD PORT802
PASSENGER SEAT802
INSTRUMENT PANEL AND INDICATOR LIGHTS803
CONTROL SYMBOLS803
INSTRUMENT PANEL (Figure 5-5)803
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-5)805
KEY SWITCH805
Starting805
Cold Weather Starting805
Normal Engine Shutdown805
PARKING BRAKE CONTROL807
AC DRIVE SYSTEM TEMPERATURE GAUGE809
STATUS / WARNING INDICATOR LIGHT SYMBOLS812
SECTION P – LUBRICATION AND SERVICE – INDEX819
SECTION P2 – LUBRICATION AND SERVICE – INDEX821
LUBRICATION AND SERVICE823
930E SERVICE CAPACITIES823
HYDRAULIC TANK SERVICE823
Adding Oil823
WHEEL MOTOR SERVICE823
COOLANT LEVEL CHECK824
RADIATOR FILLING PROCEDURE824
LUBRICATION CHART825
10 HOUR (DAILY) INSPECTION826
50 HOUR LUBRICATION AND MAINTENANCE CHECKS829
100 HOUR LUBRICATION AND MAINTENANCE CHECKS830
250 HOUR LUBRICATION AND MAINTENANCE CHECKS831
500 HOUR LUBRICATION AND MAINTENANCE CHECKS834
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS835
2500 HOUR MAINTENANCE CHECKS836
5000 HOUR MAINTENANCE CHECKS836
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX837
LINCOLN AUTOMATIC LUBRICATION SYSTEM839
System Components839
System Operation841
GENERAL INSTRUCTIONS842
Lubricant Required for System842
System Priming842
SYSTEM CHECKOUT842
24 VDC SOLID STATE TIMER CHECK843
24 VDC Solid State Timer Adjustment843
INJECTORS (SL-1 Series “H”)844
Injector Specifications844
Injector Adjustment844
INJECTOR OPERATION845
PUMP CYCLE TIMER (FLASHER TIMER)846
Pump Cycle Timer (Flasher Timer) Installation846
Pump Cycle Timer (Flasher Timer) Adjustment:846
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (NC)846
PRESSURE REDUCER ADJUSTMENT848
TROUBLESHOOTING CHART849
Preventative Maintenance Procedures852
Daily Lubrication System Inspection852
250 Hour Inspection852
SECTION Q ALPHABETICAL INDEX853
SECTION R – SYSTEM SCHEMATICS – INDEX857
HYDRAULIC BRAKE SYSTEM SCHEMATIC859
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC860
ELECTRICAL SCHEMATIC861

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24