Download Komatsu 930E Dump Truck Shop Manual CEBM010200 PDF

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Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD

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Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD

Language : English
Pages :903
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD

SERIAL NUMBERS A30019, A30026 thru A30119
w/DDC 4000 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 CEBM010200 – PDF DOWNLOAD

SERIAL NUMBERS A30019, A30026 thru A30119
w/DDC 4000 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
Preparation for Removal112
Power Module Removal115
Power Module Installation117
Power Module Hookup117
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)119
SECTION C3 – COOLING SYSTEM – INDEX121
COOLING SYSTEM123
COOLING SYSTEM DESCRIPTION123
Coolant Flow123
RADIATOR124
Removal124
RADIATOR REPAIR126
Internal Inspection126
External Cleaning126
Disassembly127
Cleaning and Inspection128
Assembly128
Pressure Testing129
Additional Service Information129
Installation130
RADIATOR FILL PROCEDURE130
Radiator Pressure Regulator Valve131
COOLING SYSTEM TROUBLESHOOTING131
SECTION C4 – POWERTRAIN – INDEX133
POWER TRAIN135
ALTERNATOR REMOVAL PROCEDURE135
Removal (MTU/DDC 4000 Engine)135
ENGINE/ALTERNATOR MATING137
General Instructions137
MEASURING PROCEDURE137
Joining Alternator and MTU/DDC Engine139
ENGINE140
Removal140
Service140
Installation140
SECTION C5 – AIR CLEANERS – INDEX141
AIR CLEANERS143
AIR CLEANERS143
Operation143
General Service Information143
FILTER ELEMENT REPLACEMENT144
Main Filter Element Cleaning145
Precleaner Section146
Cleaning Precleaner Tubes146
AIR INTAKE TROUBLESHOOTING147
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX149
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX151
24VDC ELECTRIC SUPPLY SYSTEM153
ELECTRICAL SYSTEM DESCRIPTION153
BATTERIES153
Maintenance and Service153
Troubleshooting153
BATTERY SUPPLY SYSTEM155
24VDC Battery Charging Alternator155
Battery Box155
Battery Control Box155
System Battery Starter Disconnect Relay155
Battery Disconnect Switches156
24VDC Auxiliary Battery Connectors156
Battery Equalizer157
Troubleshooting157
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX159
24 VDC ELECTRICAL SYSTEM COMPONENTS161
PASSENGER SEAT BASE COMPARTMENT161
TRUCK SHUTDOWN PROCEDURE161
COMPONENTS161
Tail Light Resistor Diode Assemblies161
5 Minute Idle Timer Components161
Inclinometer163
Brake Warning Buzzer (BWB)163
Alarm Indicating Device (AID) System163
ELECTRICAL INTERFACE CABINET166
Lubrication System Timer166
Barometric Pressure Transducer166
Special Interface Module166
Power Distribution Terminals166
Truck Control Interface Panel166
Control Power Relay166
Circuit Breaker Panel166
Diode Board – DB1168
Diode Testing168
RELAY BOARDS169
Relay Boards – RB1, RB2, RB3, RB4, RB5169
Service169
Relay Board Identification170
Relay Board Functions171
Relay Board 6 (RB6)172
BODY-UP SWITCH173
Operation173
Adjustment173
Service173
HOIST LIMIT SWITCH174
Operation174
Adjustment174
Service174
SECTION D5 – DDEC ELECTRONIC ENGINE CONTROL – INDEX177
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE179
COMPONENT DESCRIPTION180
Electronic Control Module180
Electronic Unit Nozzles182
System Sensors and Operator Inputs182
ENGINE PROTECTION SYSTEM183
DIAGNOSTICS184
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX185
BATTERY CHARGING ALTERNATOR187
ELECTRICAL SYSTEM DESCRIPTION187
BATTERY187
Maintenance and Service187
Troubleshooting187
BATTERY CHARGING SYSTEM (Niehoff)189
General Description189
TROUBLESHOOTING PROCEDURES (On-Truck)189
Equipment Required:189
Preliminary Checks190
Test Setup190
Test Procedure190
Regulator Bypass Test191
ON VEHICLE TROUBLESHOOTING GUIDE193
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage193
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:193
CHARGE VOLT AND AMP VALUES194
DEFINITIONS194
ADVANCED SYSTEM TROUBLESHOOTING195
Static Test – Engine OFF, Key ON, Battery Switch ON195
Go To Alternator195
Go To Regulator (If Required)196
Go To Regulator Connector On The Alternator196
ALTERNATOR OVERHAUL197
ALTERNATOR DIMENSIONS197
ALTERNATOR SPECIFICATIONS198
SERVICE PARTS199
ON-VEHICLE TEST201
Equipment:201
Preliminary Checks:201
Test Set-up201
Test Procedure201
ON-VEHICLE TEST202
Bypass Test:202
BENCH TEST203
STATIC TESTS204
Regulator Tests204
Control Box Tests205
ALTERNATOR DISASSEMBLY207
ASSEMBLY- ALTERNATOR212
BF4822 STATOR SERVICE TOOL INSTRUCTIONS221
Stator Removal And Replacement221
Stator Installation222
SECTION E – ELECTRICAL PROPULSION – INDEX225
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX227
ELECTRICAL PROPULSION SYSTEM COMPONENTS229
GENERAL SYSTEM DESCRIPTION229
SYSTEM COMPONENTS231
Auxiliary Blower System231
Propulsion System Controller (PSC)231
TRUCK CONTROL INTERFACE PANEL (TCI)232
Diagnostic Information Display233
DID PANEL EVENT CODES233
PSC SOFTWARE FUNCTIONS258
Input Processing258
STATE MANAGEMENT258
State Machine258
Transitions Between States259
DC Link State261
Powering the Link261
De-Powering the Link261
Control Functions261
Engine Control261
ALTERNATOR FIELD CONTROL262
Desired Three-Phase Voltage262
Desired DC Link Voltage262
Self-load262
Propel Torque Control263
Retard Torque Control263
Wheel Slide Control263
Resistor Grid Control264
Chopper Voltage Control264
AUXILIARY BLOWER CONTROL264
EVENT PROCESSING264
Event Detection264
Power On Tests264
Initiated Tests265
Periodic Tests265
EVENT RESTRICTIONS265
EVENT LOGGING AND STORAGE265
Event History Buffer266
Data Packs266
To Record and Save a Data Pack to a Floppy Disk266
Event Reset267
SERIAL DATA COMMUNICATIONS268
PSC – TCI Communications processing268
PSC – PTU Communications Processing268
Inverter Communications Processing268
OUTPUT PROCESSING269
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS269
Fast Start269
Engine Shutdown/Engine Not Running269
Limp Home Mode269
Entering/Exiting Limp Home Mode269
PROPULSION SYSTEM COMPONENT ABBREVIATIONS270
ELECTRONIC ACCELERATOR AND RETARD PEDALS280
Removal280
Installation280
Disassembly280
Assembly280
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX281
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE283
AC DRIVE SYSTEM MAINTENANCE283
TRUCK SHUTDOWN PROCEDURES283
NORMAL TRUCK SHUTDOWN PROCEDURE284
SHUTDOWN AFTER SYSTEM FAILURE285
SYSTEM CHECKOUT286
Battery and Control Checks of System WITH Battery Power OFF286
Battery and Control Circuit Checks of System With Battery Power ON289
Checks with Key Switch OFF290
CPU Battery Checks292
MEMORY BACKUP BATTERY REPLACEMENT292
TCI PROGRAMMING293
PSC PROGRAMMING293
INVERTER PROGRAMMING294
TCI CHECKOUT294
Modular Mining Communication Port295
TCI Input Checks296
TCI Digital Output Tests298
TCI Digital Input Tests300
PSC Checkout Procedure302
PSC Digital Input Checks306
Miscellaneous Checks307
A3PV Panel307
LINKV Panel307
Thermistor Checks307
17FM384 Panel Check307
Pedal Percentages and Meter Calibration308
Meter Calibration Procedure308
Reprogram With Serial Numbers and Pedal Percentages310
LOAD TESTING312
Preload Checks312
ADDITIONAL TRUCK CHECKS314
On-Board Load Testing316
Preparation316
Initiate Loadbox Test319
Manual Offset HP Output Adjustment321
TROUBLESHOOTING323
PVM Optimum Load Curve Handshaking Troubleshooting323
MISCELLANEOUS COMPONENT REPAIR324
Troubleshooting Phase Modules and Chopper Modules324
Phase Module Removal and Snubber Resistor Replacement324
Snubber Resistor Installation325
Phase Module Installation325
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING326
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING329
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING330
IGBT TROUBLESHOOTING331
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX333
SECTION G2 – TIRES AND RIMS – INDEX335
TIRES AND RIMS337
FRONT TIRES AND RIMS338
Removal338
Installation339
REAR TIRES AND RIMS339
Removal339
Installation340
RIM341
Tire Removal341
Tire Installation342
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX343
FRONT WHEEL HUB AND SPINDLE345
WHEEL HUB AND SPINDLE ASSEMBLY345
Preparation345
Removal345
Installation348
Disassembly349
Cleaning and Inspection349
Assembly351
Wheel Bearing Adjustment:351
Brake Installation352
Seal Assembly Gap Check:353
STEERING CYLINDERS AND TIE ROD354
Spherical Bearing Wear Limits354
Removal355
Installation356
Bearing Replacement356
TOE-IN ADJUSTMENT357
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX359
REAR AXLE HOUSING ATTACHMENT361
PIVOT PIN361
Removal361
Installation361
PIVOT EYE BEARING362
Disassembly362
PIVOT EYE REPAIR363
Removal363
Disassembly363
Assembly363
Installation363
ANTI-SWAY BAR364
Removal364
Installation364
Disassembly364
Assembly364
SECTION G5 – REAR AXLE HOUSING – INDEX365
REAR AXLE HOUSING367
REAR AXLE HOUSING367
PREPARATION367
Removal367
Cleaning and Inspection369
Installation369
WHEEL MOTOR370
Preparation370
Removal370
Cleaning and Inspection371
Installation372
WHEEL MOTOR GEAR OIL375
Filtering Requirements375
Particle Size Analysis375
Flushing375
Oil Sample Analysis376
ELEMENT SPECIFICATION CHARTS377
SECTION H – HYDRAIR II SUSPENSIONS – INDEX381
SECTION H2 – FRONT SUSPENSION – INDEX383
FRONT SUSPENSION385
Removal385
Installation386
“TURN-OF-THE-NUT” Tightening Procedure388
MINOR REPAIR ONLY (LOWER BEARING & SEALS)389
Lower Bearing Removal389
Lower Bearing Installation389
MAJOR SUSPENSION REBUILD391
Disassembly391
Assembly391
SECTION H3 – REAR SUSPENSIONS – INDEX393
REAR SUSPENSIONS395
Removal395
Installation397
Disassembly398
Cleaning and Inspection398
Assembly398
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX401
SUSPENSION OILING AND CHARGING PROCEDURE403
GENERAL403
EQUIPMENT LIST403
Hydrair® Charging Kit403
Installation of Charging Kit403
Removal of Charging Kit404
Support Blocks For Oiling And Charging Dimensions404
FRONT SUSPENSION405
Front Suspension Oiling405
Front Suspension Nitrogen Charging406
REAR SUSPENSION407
Rear Suspension Oiling407
Rear Suspension Nitrogen Charging408
OIL AND NITROGEN SPECIFICATIONS CHART410
SECTION J – BRAKE CIRCUIT – INDEX411
SECTION J2 – BRAKE CIRCUIT – INDEX413
BRAKE CIRCUIT415
SERVICE BRAKE CIRCUIT415
SECONDARY BRAKING AND AUTOMATIC APPLY417
PARKING BRAKE CIRCUIT417
BRAKE LOCK CIRCUIT418
WARNING CIRCUIT418
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX421
BRAKE CIRCUIT COMPONENT SERVICE423
BRAKE VALVE423
Rebuild Criteria423
Removal – Brake Valve424
Installation – Brake Valve424
Disassembly – Brake Valve425
Cleaning and Inspection – Brake Valve428
Assembly – Actuator Base Threaded Inserts428
Assembly – Boot and Cap428
Installation – Valve Body Seal428
Installation – Regulator Sleeve O-Ring429
Installation – Actuator Plunger O-ring429
Assembly – Brake Valve429
DIFFERENTIAL PRESSURE SWITCH431
Disassembly431
Cleaning and Inspection431
Assembly431
VALVE BENCH TEST AND ADJUSTMENT432
Test Set Up Procedure433
Adjustment – Brake Valve Output Pressure433
Adjustment – Differential Pressure Switch433
Final Test and Adjustment434
Installation – Brake Pedal Actuator Assembly to Brake Valve435
Installation – Retard Pedal To Brake Pedal435
DUAL RELAY VALVE437
Removal437
Installation437
Disassembly – Dual Relay Valve439
Cleaning and Inspection – Dual Relay Valve439
Assembly – Dual Relay Valve439
DIFFERENTIAL PRESSURE SWITCH440
Disassembly440
Cleaning and Inspection440
Assembly440
VALVE TEST AND ADJUSTMENT441
Test Set Up Procedure442
Adjustment – Brake Valve Output Pressure442
Adjustment – Differential Pressure Switch443
HYDRAULIC BRAKE ACCUMULATORS444
Brake Accumulator Bleed Down Procedure444
ACCUMULUTOR – HYDRAULIC COMPONENTS CABINET444
Removal444
Installation444
Disassembly444
Cleaning and Inspection – Accumulator445
Assembly – Accumulator446
Charging Procedure – Accumulator447
ACCUMULATORS – FRAME MOUNTED448
Removal448
Installation448
Disassembly – Accumulator449
Cleaning and Inspection – Accumulator449
Assembly – Accumulator450
Testing – Accumulator450
ACCUMULATOR CHARGING PROCEDURE (Frame Mounted Brake Accumulators)451
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)452
Removal – Retarder Control Lever452
Installation – Retarder Control Lever452
Disassembly and Adjustment – Retarder Control Lever453
Potentiometer Check – Retarder Control Lever453
Assembly – Retarder Control Lever453
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX455
BRAKE CIRCUIT CHECK-OUT PROCEDURE457
EQUIPMENT REQUIRED459
INITIAL SYSTEM SET-UP460
BRAKE SYSTEM CHECKOUT461
Failure Modes Check-Out462
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING465
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET469
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX471
WET DISC BRAKE ASSEMBLY473
Operation473
MAINTENANCE474
Brake Disc Wear Indicator474
Removal/Installation474
BRAKE REBUILD476
Disassembly476
Cleaning and Inspection479
Assembly480
Floating Ring Seal Assembly/Installation483
WET DISC BRAKE BLEEDING PROCEDURE486
SECTION J7 – PARKING BRAKE – INDEX487
PARKING BRAKE489
OPERATION489
MAINTENANCE490
Inspection – Parking Brake490
Removal – Parking Brake490
Installation – Parking Brake491
Disassembly – Parking Brake492
Cleaning and Inspection – Parking Brake492
Assembly – Parking Brake492
PARKING BRAKE BLEEDING PROCEDURE494
SECTION L – HYDRAULIC SYSTEM – INDEX495
SECTION L2 – HYDRAULIC SYSTEM – INDEX497
HYDRAULIC SYSTEM499
Hoist Circuit Operation500
Steering Circuit Operation502
Disc Brake Cooling System504
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX507
HYDRAULIC SYSTEM COMPONENT REPAIR509
HOIST PUMP509
Removal509
Installation511
Disassembly512
Inspection Of Parts516
Assembly516
TROUBLESHOOTING GUIDE521
HYDRAULIC TANK522
Filling Instructions522
Removal522
Installation523
HYDRAULIC TANK STRAINERS523
Removal523
Inspect and Clean523
Installation523
Hydraulic Tank Breathers524
SECTION L4 – STEERING CIRCUIT – INDEX525
STEERING CIRCUIT527
STEERING CIRCUIT OPERATION527
COMPONENT DESCRIPTION528
Steering Control Valve528
Bleeddown Manifold Valve529
Bleeddown Solenoids529
Accumulators530
Low Precharge Warning Switch530
High Pressure Filter530
Flow Amplifier530
FLOW AMPLIFIER SYSTEM OPERATION532
No Steer532
Steering Left534
Steering Right536
No Steer, External Shock Load538
STEERING PUMP540
Operation540
High Altitude Operation540
PRINCIPLE OF OPERATION542
Steering Pump543
SECTION L5 – STEERING CONTROL UNIT – INDEX545
STEERING CONTROL UNIT547
Removal547
Installation547
STEERING CONTROL UNIT REBUILD548
Disassembly548
Cleaning and Inspection – Steering Control Unit549
Assembly – Steering Control Unit551
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX555
STEERING CIRCUIT COMPONENT REPAIR557
BLEEDDOWN MANIFOLD VALVE557
Removal557
Installation557
ACCUMULATORS558
Removal558
Installation558
Disassembly559
Cleaning and Inspection559
Assembly560
Testing560
STEERING ACCUMULATOR CHARGING PROCEDURE561
FLOW AMPLIFIER562
Removal562
Installation562
Flow Amplifier Rebuild562
Disassembly564
Assembly565
STEERING CYLINDERS566
Disassembly567
Piston Seal & Bearing Installation567
Cylinder Assembly567
Test567
STEERING AND BRAKE PUMP568
Removal568
Installation568
Disassembly570
Control Piston Group570
Valve Plate Group570
Rotating Group573
Swashblock Group573
Driveshaft Group573
Inspection573
Control Piston Group573
Valve Plate Group573
Rotating Group573
Swashblock Group575
Driveshaft Group576
Compensator Block and Unloader Module576
Stroke Adjuster Assembly576
Assembly576
Swashblock Group576
Driveshaft Group577
Rotating Group577
Control Piston Group577
Valve Plate Group578
TROUBLESHOOTING579
SECTION L7 – HOIST CIRCUIT – INDEX585
HOIST CIRCUIT587
HOIST CIRCUIT OPERATION587
COMPONENT DESCRIPTION588
Hydraulic Tank588
Hydraulic Pump588
High Pressure Filters588
Hoist Valve588
Inlet Sections588
Spool Sections589
Work Ports (Rear) Spool Section589
Tank Ports (Front) Spool Section589
Hoist Pilot Valve589
Hoist Up Limit Solenoid590
Pilot Operated Check Valve590
Snubber Valve590
Counterbalance Valve590
HOIST CIRCUIT OPERATION590
POWER UP OPERATION (Figure 7-5)592
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX601
HOIST CIRCUIT COMPONENT REPAIR603
HOIST VALVE603
Removal603
Installation604
O-Ring Replacement604
INLET SECTION605
Disassembly605
Cleaning and Inspection606
Assembly606
REAR SPOOL SECTION (Work Ports)606
Disassembly606
Cleaning and Inspection608
Assembly608
FRONT SPOOL SECTION (Tank Ports)609
Disassembly609
Cleaning and Inspection609
Assembly609
HOIST PILOT VALVE611
Removal611
Installation611
Disassembly612
Cleaning and Inspection613
Assembly613
Hoist Up Limit Solenoid614
HOIST CYLINDERS614
Removal614
Installation615
Disassembly617
Cleaning and Inspection618
Quill and Cylinder – Assembly619
Quill Installation619
Installation Of Check Balls And Plugs In Quill620
Assembly of Cylinder621
DISABLED TRUCK DUMPING PROCEDURE622
Hookup622
Raising the Body:622
Lowering the Body:622
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX623
HYDRAULIC SYSTEM FILTERS625
HOIST CIRCUIT FILTER625
Filter Element Replacement625
Removal – Hoist Circuit Filter626
Installation – Hoist Circuit Filter626
Indicator Switch – Hoist Circuit Filter626
STEERING CIRCUIT FILTER627
Filter Element Replacement627
Removal – Steering Circuit Filter628
Installation – Steering Circuit Filter628
Indicator Switch – Steering Circuit Filter628
INDICATOR SWITCH628
Test Procedure628
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX631
HYDRAULIC CHECK-OUT PROCEDURE633
GENERAL INFORMATION633
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE633
Equipment Requirements634
Pump Pressure Control Adjustments634
Steering Control Valve and Flow Amplifier Leakage Test635
Bleeddown Manifold Leakage Test635
Steering / Brake Pump Stroke Adjustment636
Shock And Suction Valves637
Equipment Requirements637
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES638
Equipment Requirements638
Pressure Checks638
Brake Cooling Circuit Test638
Power Up Relief Pressure Test639
Adjustment639
Power Down Relief Pressure Test640
Adjustment640
Hoist Counterbalance Valve Adjustment641
HYDRAULIC SYSTEM FLUSHING PROCEDURE642
Preparation642
Flushing Procedure642
Filter Element Replacement643
930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET645
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX647
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX649
FIRE CONTROL SYSTEM (MANUAL)651
Operation651
Inspection and Maintenance651
Recharging Procedures652
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1653
Control Module653
Actuator654
Linear Detection Wire654
Power Wire654
Test Kit654
Squib654
Securing the Detection Wire655
Preliminary Test Before Final Hook-Up655
Installation Procedure for Squib657
Placing the Electric Detection & Actuation System Into Service657
INSPECTION AND MAINTENANCE SCHEDULES658
Daily658
Normal Maintenance Based On Actual Operating Hours658
IN CASE OF FIRE659
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM661
SECTION M8 – SPECIAL TOOLS 663
SECTION M20 – PAYLOAD METER II – INDEX671
GENERAL INFORMATION673
Haul Cycles673
LIGHTS, SWITCHES AND COMPONENTS674
TIPS FOR OPERATION675
EXTERNAL DISPLAY LIGHTS675
THEORY OF OPERATION676
Basic Description676
Inclinometer676
Linkage Factor676
Gain Factor677
Brake Lock677
Sources of Error677
Typical Data From Service Check Mode677
Example Calculation of Payload678
Viewing Payload Calculation Inputs678
Checking the Gain679
Adjusting the Gain679
TYPES OF DATA STORED680
Cycle Data680
Engine ON/OFF Data681
Fault Codes and Warning Data681
Engine Operation682
Total Payload and Total Number of Cycles682
Other Data682
OPERATOR FUNCTIONS683
Using the Operator Load Counter683
Viewing the Operator Load Counter683
Clearing the Operator Load Counter683
Dimming the Lights on the Display683
INITIAL SETUP OF PAYLOAD METER684
Switch Settings684
Checking the Operator Check Mode685
Checking the Service Check Mode685
Checking the Gt setting:686
Checking the Inclinometer Settings686
Calibrating a Truck686
DISPLAYS AT START-UP687
Normal Operation687
SETUP AND MAINTENANCE688
Setting The Speed Limit688
Setting the Option Code688
Setting The Machine ID Code689
Setting The Operator ID Code689
Setting The Time and Date689
DOWNLOAD OF INFORMATION690
DISPLAY OF FAULT CODES690
Monitoring Input Signals694
Service Check Mode694
UP FACTOR – PAYLOAD CALCULATION GAIN695
PL MODE -LOAD CALCULATION TIMING695
FINAL GEAR RATIO SELECTION696
BATTERY REPLACEMENT PROCEDURE697
Replacing the Battery697
After Replacing the Battery698
SUSPENSION PRESSURE SENSOR698
Removal698
Installation699
INCLINOMETER699
Removal699
Installation699
Adjustment699
PAYLOAD METER BACK PANEL700
CONNECTIONS701
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE702
PAYLOAD CIRCUIT NUMBERS703
TROUBLESHOOTING704
COMMON PROBLEMS704
Suspension Charging704
Symptom Table705
Missing Body-Up Signal705
Missing Speed Signal706
F-18: Alternator R-Terminal, Oil Pressure Signals706
Shorted 18v Sensor Power Supply (930E)706
FAULT TREE DIAGNOSIS707
Payload Lights Won’t Illuminate707
Red, Amber or Green Payload Light Does Not Illuminate708
Cannot Download – PC Communications709
PC Communications Configuration710
FCAL: Payload Meter Won’t Calibrate711
F-20: Sensor Power Fault712
F-21, F-25: Left Front Pressure Sensor714
F-22, F-26: Right Front Pressure Sensor714
F-23, F-27: Left Rear Pressure Sensor714
F-24, F-28: Right Rear Pressure Sensor714
F-31, F-32: Inclinometer716
Body Up Input718
Brake Lock Input719
Speed Signal720
Adjusting the Speed Sensor720
CONNECTORS AND PRESSURE SENSORS722
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM725
Menu Functions728
Using Scope728
Log File Information728
Connections to Payload Meter II™729
USING SCOPE730
Monitoring Inputs Using Scope730
Monitoring Suspension Charging Using Scope730
Pressure Sensor Dummy Loads733
GAIN ADJUSTMENT WORKSHEET734
SECTION N – CAB COMPONENTS – INDEX735
SECTION N2 – TRUCK CAB – INDEX737
TRUCK CAB739
Description739
Preparation740
Removal – Cab740
Installation – Cab742
CAB DOOR742
Removal742
Installation742
Door Adjustment743
Door Jamb Bolt Adjustment743
Door Handle Plunger Adjustment744
Door Glass Replacement745
Door Window Regulator Replacement749
Door Handle or Latch Assembly Replacement749
Door and Door Hinge Seal Replacement750
Door Opening Seal Removal750
Installation750
GLASS REPLACEMENT751
Adhesive Bonded Windows751
Replacement Procedure751
Windshield And Rear Glass752
Removal752
Installation753
SECTION N3 – CAB COMPONENTS – INDEX755
CAB COMPONENTS757
WINDSHIELD WIPERS757
Wiper Motor Replacement757
Removal757
Installation757
Wiper Arm Replacement757
Removal757
Installation758
Wiper Linkage Replacement758
Removal758
Installation758
WINDSHIELD WASHER759
Operation759
Service759
OPERATOR SEAT760
Adjustment760
Removal760
Installation760
SECTION N4 – OPERATOR COMFORT – INDEX761
OPERATOR COMFORT763
HEATER/AIR CONDITIONER763
Operation763
HEATER COMPONENTS764
Circuit Breakers764
Heater Control Components764
Heater Coil764
Fan Motor And Speed Control765
Actuators765
Filter765
AIR CONDITIONING SYSTEM767
Environmental Impact767
OPERATOR CAB AIR CONDITIONING768
PRINCIPLES OF REFRIGERATION768
Air Conditioning768
Refrigeration – The Act Of Cooling769
The Refrigeration Cycle769
AIR CONDITIONER SYSTEM COMPONENTS770
Compressor (Refrigerant Pump)770
Service Valves770
Condenser770
Receiver-Drier770
Expansion Block Valve771
Evaporator771
ELECTRICAL CIRCUIT772
Thermostat772
Compressor Clutch772
Trinary™ Switch773
SYSTEM SERVICING774
SYSTEM OIL775
Handling and Reusing PAG Oil775
Oil Quantity775
Replacing Oil After Servicing the System775
Setting Up a New Compressor775
REFRIGERANT776
Recycled Refrigerant776
Reclaimed Refrigerant776
Refrigerant Quantity776
R-134a Refrigerant Containers776
SERVICE TOOLS AND EQUIPMENT777
Recovery/Recycle Station777
Leak Detector777
Service Valves778
Vacuum Pump778
Manifold Gauge Set779
Installing Manifold Gauge Set780
Purging Air From Service Hoses781
Stabilizing the AC System782
SYSTEM PERFORMANCE TEST782
SYSTEM LEAK TESTING783
Electronic Leak Detector783
Tracer Dyes783
Soap and Water783
SYSTEM REPAIR784
System Cleaning784
Hoses and Fittings784
Lines784
Expansion Valve784
Receiver-Drier785
Thermostat785
Compressor785
Clutch785
Servicing the Compressor Clutch786
Pulley Removal788
Clutch Coil Check788
Pulley Installation788
Clutch Assembly Installation789
RECOVERING AND RECYCLING THE REFRIGERANT790
Performing the Recovery Cycle790
Performing the Recycling Procedure790
Evacuating and Charging the AC System790
EVACUATING THE SYSTEM791
CHARGING THE AC SYSTEM792
TROUBLESHOOTING793
Pre-Diagnosis Checks793
Preparing For Diagnosis793
Preliminary Steps793
System Performance Test793
Diagnosis Of Gauge Readings And System Performance794
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS795
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM801
SECTION N5 – OPERATOR CAB CONTROLS – INDEX803
OPERATOR CAB CONTROLS805
STEERING COLUMN805
Removal805
Installation805
STEERING WHEEL AND CONTROLS807
DYNAMIC RETARDING807
RETARDER CONTROL LEVER808
DYNAMIC RETARDER/SERVICE BRAKE PEDAL808
ACCELERATOR (THROTTLE) PEDAL808
Starting on a Grade With a Loaded Truck808
GRADE/SPEED RETARD CHART809
HEATER / AIR CONDITIONER VENTS810
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS810
DEFROSTER VENT CONTROL SWITCH810
HEAT VENT CONTROL SWITCH810
FAN CONTROL KNOB810
AIR CONDITIONER CONTROL KNOB810
OUTSIDE/INSIDE AIR CONTROL SWITCH810
SELECTION CONTROL SWITCH810
HEATER/AIR CONDITIONER VENTS810
INSTRUMENT PANEL811
OVERHEAD PANEL AND DISPLAYS811
F-N-R SELECTOR SWITCH812
HOIST CONTROL LEVER813
OVERRIDE /FAULT RESET SWITCH814
10, FIGURE 5-5 – BLANK814
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH814
RETARD SPEED CONTROL (RSC) ADJUST DIAL814
TCI DOWNLOAD PORT815
PASSENGER SEAT815
INSTRUMENT PANEL AND INDICATOR LIGHTS817
CONTROL SYMBOLS817
INSTRUMENT PANEL (Figure 5-6)817
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)819
KEY SWITCH819
Starting819
Cold Weather Starting819
Normal Engine Shutdown819
Operation820
PARKING BRAKE CONTROL821
AC DRIVE SYSTEM TEMPERATURE GAUGE823
STATUS / WARNING INDICATOR LIGHT SYMBOLS826
SECTION P – LUBRICATION AND SERVICE – INDEX833
SECTION P2 – LUBRICATION AND SERVCIE – INDEX835
LUBRICATION AND SERVICE837
930E SERVICE CAPACITIES837
HYDRAULIC TANK SERVICE837
Adding Oil837
WHEEL MOTOR SERVICE837
COOLANT LEVEL CHECK838
RADIATOR FILLING PROCEDURE838
LUBRICATION CHART839
10 HOUR (DAILY) INSPECTION840
50 HOUR LUBRICATION AND MAINTENANCE CHECKS843
100 HOUR LUBRICATION AND MAINTENANCE CHECKS844
250 HOUR LUBRICATION AND MAINTENANCE CHECKS845
500 HOUR LUBRICATION AND MAINTENANCE CHECKS848
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS849
2500 HOUR MAINTENANCE CHECKS850
5000 HOUR MAINTENANCE CHECKS850
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX851
LINCOLN AUTOMATIC LUBRICATION SYSTEM853
System Components853
System Operation855
GENERAL INSTRUCTIONS856
Lubricant Required for System856
System Priming856
SYSTEM CHECKOUT856
24 VDC SOLID STATE TIMER CHECK857
24 VDC Solid State Timer Adjustment857
INJECTORS (SL-1 Series “H”)858
Injector Specifications858
Injector Adjustment858
INJECTOR OPERATION859
PUMP CYCLE TIMER (FLASHER TIMER)860
Pump Cycle Timer (Flasher Timer) Installation860
Pump Cycle Timer (Flasher Timer) Adjustment:860
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (NC)860
PRESSURE REDUCER ADJUSTMENT862
TROUBLESHOOTING CHART863
Preventative Maintenance Procedures866
Daily Lubrication System Inspection866
250 Hour Inspection866
SECTION Q ALPHABETICAL INDEX867
SECTION R – SYSTEM SCHEMATICS871
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH341873
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH348874
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC875
ELECTRICAL SCHEMATIC876
24 VOLT ELECTRICAL SCHEMATIC889

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24