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Komatsu DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
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Komatsu DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
SERIAL NUMBERS
A30171, A30318, A30319, A30322
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Description
Komatsu DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
FILE DETAILS:
Komatsu DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
Language : English
Pages :1035
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
SERIAL NUMBERS
A30171, A30318, A30319, A30322
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 DUMP TRUCK 930E-3SE Shop Manual CEBM013702 – PDF DOWNLOAD
SERIAL NUMBERS
A30171, A30318, A30319, A30322
MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 57
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 63
STORAGE AND IDLE MACHINE PREPARATION 65
Short Term Idle Periods 65
PREPARATION FOR STORAGE 66
REMOVAL FROM STORAGE 67
RECONDITIONING AN IDLE VEHICLE 69
ENGINE OPERATION 72
After The Engine Has Started 73
ENGINE STORAGE 74
Preparing Engine For Storage 74
Temporary Storage (30 Days Or Less) 74
Extended Storage (more Than 30 Days) 74
RESTORING AN ENGINE AFTER EXTENDED STORAGE 76
ELECTRIC DRIVE TRUCKS 77
Storage Instructions and Procedures 77
Placing Equipment Into Storage 77
Storing A Truck That Is Operational 77
Storing A Truck That Is Not Operational 78
Storing A Major Component 78
Periodic Inspections 79
Placing Equipment Into Service After Storage 79
When A Truck Is Operational 79
When A Truck Is Not Operational 79
For The First Hour 80
SECTION B – STRUCTURES – INDEX 81
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 83
STRUCTURAL COMPONENTS 85
Preparation 85
GRILLE, HOOD AND LADDER 86
Removal 86
Installation 86
DECKS 87
RIGHT DECK AND COMPONENTS 87
Removal 87
Installation 88
LEFT DECK 88
Removal 88
Installation 88
CENTER DECK 88
SECTION B3 – DUMP BODY – INDEX 89
DUMP BODY 91
Removal 91
Installation 92
BODY PADS 93
Adjustment 93
BODY GUIDE 94
HOIST LIMIT SWITCH 94
BODY UP SWITCH 94
BODY-UP RETENTION CABLE 94
ROCK EJECTORS 95
Rock Ejectors 95
Inspection 95
SECTION B4 – FUEL TANK – INDEX 97
FUEL TANK 99
Removal 100
Installation 100
Repair 100
Cleaning 100
FUEL GAUGE SENDER 101
Removal 101
Installation 101
LOW FUEL SWITCH 101
WIGGINS QUICK FILL FUEL SYSTEM 102
FUEL RECEIVER 102
TANK BREATHER VALVE 102
Removal 102
Installation 102
Disassembly 102
Assembly 102
LEFT SIDE FILL 103
SECTION C – ENGINE – INDEX 105
SECTION C2 – POWER MODULE – INDEX 107
POWER MODULE 109
Preparation 109
Preparation for Removal 110
Removal – Power Module 113
Installation – Power Module 115
Hookup – Power Module 115
SECTION C3 – COOLING SYSTEM – INDEX 117
COOLING SYSTEM 119
RADIATOR 119
Removal – Radiator 119
Installation – Radiator 121
RADIATOR FILLING PROCEDURE 122
RADIATOR REPAIR 122
Internal Inspection 122
External Cleaning 122
Disassembly 123
Cleaning and Inspection 124
Assembly 124
Pressure Testing 125
Additional Service Information 125
COOLANT SYSTEM TROUBLESHOOTING 126
SECTION C4 – POWERTRAIN – INDEX 127
POWER TRAIN 129
ALTERNATOR 129
Removal – Alternator 129
ENGINE/ALTERNATOR MATING 131
General Instructions 131
Measuring Procedure 131
Joining The Alternator and Engine 133
ENGINE 134
Removal 134
Service 134
Installation 134
SECTION C5 – AIR CLEANERS – INDEX 135
AIR CLEANERS 137
AIR CLEANERS 137
Operation 137
General Service Information 137
FILTER ELEMENT REPLACEMENT 138
Main Filter Element Cleaning 139
Precleaner Section 140
Cleaning Precleaner Tubes 140
AIR INTAKE TROUBLESHOOTING 141
SECTION C7 – FAN CLUTCH – INDEX 143
FAN CLUTCH 145
REMOVAL & INSTALLATION TOOLING 145
FAN CLUTCH – DISASSEMBLY 148
CLEANING AND INSPECTION 158
ASSEMBLY – FAN CLUTCH 162
TEST PROCEDURE 176
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX 177
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 179
24VDC ELECTRIC SUPPLY SYSTEM 181
ELECTRICAL SYSTEM DESCRIPTION 181
BATTERIES 181
Maintenance and Service 181
Troubleshooting 181
BATTERY SUPPLY SYSTEM 183
24VDC Batter Charging Alternator 183
Battery Box 183
Batter Control Box 184
Battery Disconnect Switches 184
24VDC Auxiliary Battery Connectors 184
24VDC to 12VDC Converter 185
Isolation Diodes 185
Engine Starter Relay 185
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX 187
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
TRUCK SHUTDOWN PROCEDURE 189
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
Brake Warning Buzzer (BWB) 189
AUXILIARY CONTROL CABINET COMPONENTS 189
Fuse Block 1 & 2 190
Power Distribution Terminals 190
PULSE VOLTAGE MODULATOR 190
5 Minute Idle Timer Components 192
5 Minute Idle Timer 192
5 Minute Idle Circuit Test 192
Tail Light Resistor Diode Assemblies 192
Engine Starter Failure Delay Timer 192
Lubrication System Timer 194
Auto Lube Delay Timer 194
Barometric Pressure Transducer 194
Kontrol Power Relay 194
Alarm Indicating Device (AID) System 196
Temperature and Latch 197
Hot Switch Inverter 197
Hot Switch Inverter Card (Slot 4) (Not Used) 197
Oil Level 197
Temperature 197
Diode Matrix (Without Sound) 197
Diode Matrix (With Sound) 197
Lamp Test 198
Diode Board – DB1 198
Diode Testing 198
RELAY BOARDS 199
Relay Boards RB1, RB3, RB4, RB5 199
Service 199
Relay Board Identification 200
RELAY BOARD FUNCTIONS 201
Relay Board 1 (RB1) 201
Relay Board 3 (RB3) 201
Relay Board 6, 7 & 8 (RB6, RB7, RB8) 202
Installing Additional Circuits 202
BODY-UP SWITCH 203
Operation 203
Adjustment 203
Service 203
HOIST LIMIT SWITCH 204
Operation 204
Adjustment 204
Service 204
FUSE BLOCKS 205
CIRCUIT BREAKERS 205
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX 207
BATTERY CHARGING ALTERNATOR 209
ELECTRICAL SYSTEM DESCRIPTION 209
BATTERY 209
Maintenance and Service 209
Troubleshooting 209
BATTERY CHARGING SYSTEM (Niehoff) 211
General Description 211
TROUBLESHOOTING PROCEDURES (On-Truck) 211
Equipment Required: 211
Preliminary Checks 212
Test Setup 212
Test Procedure 212
Regulator Bypass Test 213
ON VEHICLE TROUBLESHOOTING GUIDE 215
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 215
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 215
CHARGE VOLT AND AMP VALUES 216
DEFINITIONS 216
ADVANCED SYSTEM TROUBLESHOOTING 217
Static Test – Engine OFF, Key ON, Battery Switch ON 217
Go To Alternator 217
Go To Regulator (If Required) 218
Go To Regulator Connector On The Alternator 218
ALTERNATOR OVERHAUL 219
ALTERNATOR DIMENSIONS 219
ALTERNATOR SPECIFICATIONS 220
SERVICE PARTS 221
ON-VEHICLE TEST 223
Equipment: 223
Preliminary Checks: 223
Test Set-up 223
Test Procedure 223
ON-VEHICLE TEST 224
Bypass Test: 224
BENCH TEST 225
STATIC TESTS 226
Regulator Tests 226
Control Box Tests 227
ALTERNATOR DISASSEMBLY 229
ASSEMBLY- ALTERNATOR 234
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 243
Stator Removal And Replacement 243
Stator Installation 244
SECTION D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 – VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT AND TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
ICP PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 425
SECTION G2 – TIRES AND RIMS – INDEX 427
TIRES AND RIMS 429
WHEEL STUD MAINTENANCE 430
FRONT TIRES AND RIMS 431
Removal 431
Installation 432
REAR TIRES AND RIMS 433
Removal 433
Installation 434
RIM 435
Tire Removal 435
Tire Installation 436
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 439
FRONT WHEEL HUB AND SPINDLE 441
WHEEL HUB AND SPINDLE ASSEMBLY 441
Preparation 441
Removal 441
Installation – Wheel Hub and Spindle Assembly 444
Disassembly – Wheel Hub and Spindle Assembly 445
Cleaning and Inspection – Wheel Hub and Spindle Assembly 445
Assembly – Wheel Hub and Spindle Assembly 447
Wheel Bearing Adjustment: 447
Brake Installation 448
Seal Assembly Gap Check 449
STEERING CYLINDERS AND TIE ROD 450
Spherical Bearing Wear Limits 450
Removal – Steering Cylinder and Tie Rod 451
Installation – Steering Cylinder and Tie Rod 452
Bearing Replacement 452
TOE-IN ADJUSTMENT 453
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 455
REAR AXLE HOUSING ATTACHMENT 457
PIVOT PIN 457
Removal 457
Installation 458
PIVOT EYE BEARING 459
Removal 459
Installation 459
PIVOT EYE REPAIR 459
Removal 459
Disassembly 459
Assembly 460
Installation 460
ANTI-SWAY BAR 460
Removal 460
Installation 461
Disassembly 461
Cleaning and Inspection 461
Assembly 461
SECTION G5 – REAR AXLE HOUSING – INDEX 463
REAR AXLE HOUSING 465
REAR AXLE HOUSING 465
Preparation 465
Removal 465
Cleaning and Inspection – Rear Axle Housing 467
Installation – Rear Axle Housing 467
WHEEL MOTOR 468
Preparation 468
Removal 468
Cleaning and Inspection – Wheel Motor 469
Installation – Wheel Motor 470
WHEEL MOTOR GEAR OIL 473
Filtering Requirements 473
Particle Size Analysis 473
Flushing 473
Oil Sample Analysis 474
ELEMENT SPECIFICATION CHARTS 475
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 479
SECTION H2 – FRONT SUSPENSIONS – INDEX 481
FRONT SUSPENSION 483
Removal 483
Installation – Front Suspension 484
“Turn-Of-The-Nut” Tightening Procedure 487
MINOR REPAIRS (LOWER BEARING & SEALS) 488
Removal – Bearing Retainer 488
Installation – Bearing Retainer 488
MAJOR SUSPENSION REBUILD 490
Disassembly 490
Assembly 490
SECTION H3 – REAR SUSPENSIONS – INDEX 493
REAR SUSPENSIONS 495
Removal 495
Installation – Rear Suspension 497
Disassembly – Rear Suspension 498
Cleaning and Inspection – Rear Suspension 498
Assembly – Rear Suspension 498
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 501
SUSPENSION OILING AND CHARGING PROCEDURE 503
GENERAL 503
EQUIPMENT LIST 503
Hydrair® Charging Kit 503
Installation of Charging Kit 503
Removal of Charging Kit 504
Support Blocks For Oiling And Charging Dimensions 504
FRONT SUSPENSION 505
Front Suspension Oiling 505
Front Suspension Nitrogen Charging 506
REAR SUSPENSION 507
Rear Suspension Oiling 507
Rear Suspension Nitrogen Charging 508
OIL AND NITROGEN SPECIFICATIONS CHART 510
SECTION J – BRAKE CIRCUIT – INDEX 511
SECTION J2 – BRAKE CIRCUIT – INDEX 513
BRAKE CIRCUIT 515
SERVICE BRAKE CIRCUIT 515
SECONDARY BRAKING AND AUTOMATIC APPLY 517
PARKING BRAKE CIRCUIT 517
Normal Operation (key switch on, engine running) 517
BRAKE LOCK CIRCUIT 518
WARNING CIRCUIT 518
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 521
BRAKE CIRCUIT COMPONENT SERVICE 523
BRAKE VALVE 523
Rebuild Criteria 523
Removal 524
Installation 524
Disassembly 525
Cleaning and Inspection 528
Assembly 528
Actuator Base Threaded Inserts 528
Boot and Cap 528
Valve Body Seal Installation 528
Regulator Sleeve O-Ring Installation 529
Actuator Plunger O-ring Installation 529
Assembly of Valve 529
DIFFERENTIAL PRESSURE SWITCH 531
Disassembly 531
Cleaning and Inspection 531
Assembly 531
VALVE BENCH TEST AND ADJUSTMENT 532
Test Set Up Procedure 533
Brake Valve Output Pressure Adjustment 533
Differential Pressure Switch Adjustment 533
Final Test and Adjustment 534
Installation Of Brake Pedal Actuator Assembly to Brake Valve 535
Installation of Retard Pedal To Brake Pedal 535
DUAL RELAY VALVE 537
Removal 537
Installation 537
Disassembly 539
Cleaning and Inspection 539
Assembly 539
DIFFERENTIAL PRESSURE SWITCH 540
Disassembly 540
Cleaning and Inspection 540
Assembly 540
VALVE TEST AND ADJUSTMENT 541
Test Set Up Procedure 542
Relay Valve Output Pressure Adjustment 542
Differential Pressure Switch Adjustment 543
BRAKE MANIFOLD 544
Removal 544
Installation 545
Disassembly 545
Cleaning and Inspection 545
Assembly 545
BRAKE ACCUMULATORS 546
Brake Accumulator Bleeddown Procedure 546
BRAKE ACCUMULATOR REPAIR 547
Removal 547
Installation 547
Disassembly 548
Cleaning and Inspection 549
Assembly 549
ACCUMULATOR CHARGING PROCEDURE 551
Temperature During Precharge 552
Precharge Maintenance 553
Recharging Accumulators 553
Accumulator Storage procedures 554
Bladder Storage Procedures 554
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 555
Removal 555
Installation 555
Disassembly and Adjustment 555
Potentiometer Check 557
Assembly 557
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 559
BRAKE CIRCUIT CHECK-OUT PROCEDURE 561
REQUIRED EQUIPMENT 563
INITIAL SYSTEM SET-UP 564
BRAKE SYSTEM CHECKOUT 565
Failure Modes Check-Out 566
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 568
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 571
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 572
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 573
WET DISC BRAKE ASSEMBLY 575
OPERATION 575
MAINTENANCE 576
Brake Disc Wear Indicator 576
Removal/Installation – Wet Disc Brake Assembly 576
BRAKE REBUILD 578
Disassembly 578
Cleaning and Inspection 581
Assembly 582
Floating Ring Seal Assembly/Installation 585
WET DISC BRAKE BLEEDING PROCEDURE 588
SECTION J7 – PARKING BRAKE – INDEX 589
PARKING BRAKE 591
OPERATION 591
MAINTENANCE 592
Inspection – Parking Brake 592
Removal – Parking Brake 592
Installation – Parking Brake 593
Disassembly – Parking Brake 594
Cleaning and Inspection – Parking Brake 594
Assembly – Parking Brake 594
PARKING BRAKE BLEEDING PROCEDURE 596
SECTION L – HYDRAULIC SYSTEM – INDEX 597
SECTION L2 – HYDRAULIC SYSTEM – INDEX 599
HYDRAULIC SYSTEM 601
HYDRAULIC PUMP MODULE 601
HOIST CIRCUIT OPERATION 602
STEERING CIRCUIT OPERATION 604
DISC BRAKE COOLING SYSTEM 606
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 609
HYDRAULIC SYSTEM COMPONENT REPAIR 611
HOIST PUMP 611
Removal 611
Installation 613
INSPECTION OF PARTS 618
Assembly 618
HYDRAULIC TANK 624
Filling Instructions 624
Removal 624
Installation 625
HYDRAULIC TANK STRAINERS 625
Removal 625
Inspect and Clean 625
Installation 625
HYDRAULIC TANK BREATHERS 626
SECTION L4 – STEERING CIRCUIT – INDEX 627
STEERING CIRCUIT 629
COMPONENT DESCRIPTION 630
Steering Control Unit 630
Bleeddown Manifold Valve 631
Bleeddown Solenoid 631
Relief Valves 633
Hoist Limit Solenoid 633
Accumulators 633
Low Precharge Warning Switch 633
High Pressure Filter 633
Quick Disconnect Ports 633
Flow Amplifier 634
FLOW AMPLIFIER SYSTEM OPERATION 636
No Steer 636
Steering Left 638
Steering Right 640
No Steer, External Shock Load 642
STEERING PUMP 644
Operation 644
PRINCIPLE OF OPERATION 646
Full Pump Volume: 646
Half Pump Volume: 646
Neutral Position: 646
Steering Pump 647
SECTION L5 – STEERING CONTROL UNIT – INDEX 649
STEERING CONTROL UNIT 651
Removal 651
Spline Inspection 651
Installation 652
STEERING CONTROL UNIT REBUILD 652
Disassembly 652
Cleaning and Inspection – Steering Control Unit 653
Assembly – Steering Control Unit 655
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 659
STEERING CIRCUIT COMPONENT REPAIR 661
BLEEDDOWN MANIFOLD VALVE 661
Removal 661
Installation 661
FLOW AMPLIFIER 663
Removal 663
Installation 663
FLOW AMPLIFIER REBUILD 663
Disassembly 666
Assembly 667
STEERING CYLINDERS 668
Disassembly 669
Piston Seal & Bearing Installation 669
Cylinder Assembly 669
Test 669
STEERING AND BRAKE PUMP 670
Removal 670
Installation 670
Disassembly 672
Control Piston Group 672
Valve Plate Group 672
Rotating Group 675
Swashblock Group 675
Driveshaft Group 675
Inspection 675
Control Piston Group 675
Valve Plate Group 675
Rotating Group 675
Swashblock Group 677
Driveshaft Group 678
Compensator Block and Unloader Module 678
Stroke Adjuster Assembly 678
Assembly 678
Swashblock Group 678
Driveshaft Group 679
Rotating Group 679
Valve Plate Group 680
STEERING ACCUMULATORS 681
Removal 681
Installation 681
Disassembly 682
Cleaning and Inspection 682
Assembly 683
Leak Testing 685
Charging Procedure 686
Temperature During Precharge 687
Precharge Maintenance 688
Accumulator Storage procedures 689
Bladder Storage Procedures 689
TROUBLESHOOTING CHART 690
SECTION L7 – HOIST CIRCUIT – INDEX 695
HOIST CIRCUIT 697
HOIST CIRCUIT OPERATION 697
COMPONENT DESCRIPTION 698
Hydraulic Tank 698
Hydraulic Pump 698
High Pressure Filters 698
Hoist Valve 698
Inlet Sections – Hoist Valve 698
Spool Sections – Hoist Valve 699
Hoist Pilot Valve 699
Bleeddown Manifold 700
Hoist-up Limit Solenoid 700
Pilot Operated Check Valve 700
Overcenter Manifold 700
HOIST CIRCUIT OPERATION 701
Float Position Of Pilot Valve With Truck Body On Frame 702
Power Up Operation 704
Hold Operation 706
Power Down Operation 708
Float Operation 710
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 713
HOIST CIRCUIT COMPONENT REPAIR 715
HOIST VALVE 715
Removal 715
Installation 716
O-Ring Replacement 716
INLET SECTION 717
Disassembly 717
Cleaning and Inspection 718
Assembly 718
REAR SPOOL SECTION (Work Ports) 718
Disassembly 718
Cleaning and Inspection 720
Assembly 720
FRONT SPOOL SECTION (Tank Ports) 721
Disassembly 721
Cleaning and Inspection 721
Assembly 721
HOIST PILOT VALVE 723
Removal 723
Installation 723
Disassembly 724
Cleaning and Inspection 725
Assembly 725
HOIST CYLINDERS 726
Removal 726
Installation 727
Disassembly 729
Cleaning and Inspection 730
Assembly – Quill and Cylinder 731
Quill Installation 731
Installation Of Check Balls And Plugs In Quill 732
Assembly of Cylinder 733
OVERCENTER VALVE MANIFOLD 734
DISABLED TRUCK DUMPING PROCEDURE 735
Hookup 735
Raising the Body 735
Lowering the Body 735
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 737
HYDRAULIC SYSTEM FILTERS 739
HOIST CIRCUIT FILTER 739
Filter Element Replacement 739
Removal – Hoist Circuit Filter 740
Installation – Hoist Circuit Filter 740
Indicator Switch – Hoist Circuit Filter 740
STEERING CIRCUIT FILTER 741
Filter Element Replacement 741
Removal – Steering Circuit Filter 742
Installation – Steering Circuit Filter 742
Indicator Switch – Steering Circuit Filter 742
INDICATOR SWITCH 742
Test Procedure 742
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 745
HYDRAULIC CHECK-OUT PROCEDURE 747
GENERAL INFORMATION 747
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 747
Equipment Requirements 748
Pump Pressure Control Adjustments 748
Steering Control Valve and Flow Amplifier Leakage Test 749
Bleeddown Manifold Leakage Test 749
STEERING/BRAKE PUMP STROKE ADJUSTMENT 750
SHOCK AND SUCTION VALVES 751
Equipment Requirements 751
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 752
Equipment Requirements 752
Pressure Gauge Locations 752
Brake Cooling Circuit Test 752
Power Up Relief Pressure Test 753
Adjustment 753
Power Down Relief Pressure Test 754
Hoist Counterbalance Valve Adjustment Preparation 755
Counterbalance Valve Pressure Check 755
Counterbalance Valve Adjustment 756
HYDRAULIC SYSTEM FLUSHING PROCEDURE 757
Preparation 757
Flushing Procedure 757
Filter Element Replacement 758
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 759
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 760
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 761
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX 763
FIRE CONTROL SYSTEM (MANUAL) 765
Operation 765
Inspection and Maintenance 765
Recharging Procedures 766
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 767
Control Module 767
Actuator 768
Linear Detection Wire 768
Power Wire 768
Test Kit 768
Squib 768
Securing the Detection Wire 769
Preliminary Test Before Final Hook-Up 769
Installation Procedure for Squib 771
Placing the Electric Detection & Actuation System Into Service 771
INSPECTION AND MAINTENANCE SCHEDULES 772
Daily 772
Normal Maintenance Based On Actual Operating Hours 772
IN CASE OF FIRE 773
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 775
SECTION M8 – SPECIAL TOOLS 777
SECTION M20 – PAYLOAD METER III – INDEX 783
OPERATION SECTION 787
Introduction 787
Data Summary 787
Data Gathering 787
COMPONENT DESCRIPTION 788
System Diagram 788
Suspension Pressure Sensors 788
Inclinometer 788
Operator Display 788
Operator Switch 789
Speed Input 789
Body-Up Switch 789
Brake Lock Switch 789
Payload Meter 789
Communications Ports 789
Keyswitch Input 790
Payload Meter Power 790
Load Lights 790
Wiring and Termination 791
TCI Outputs 791
OPERATOR’S DISPLAY AND SWITCH 792
Reading the Speedometer 792
Reading the Load Display 792
Using the Operator ID 792
Using the Load and Ton Counter 792
Total Ton Counter 792
Total Load Counter 793
Clearing the Counters 793
Viewing Live Sensor Data 793
Other Display Messages 793
PAYLOAD OPERATION & CALCULATION 794
Description of Haul Cycle States 794
Haul Cycle Description 794
Load Calculation 795
Carry Back 795
Measurement Accuracy 795
SOURCES FOR PAYLOAD ERROR 795
Payload Error 795
Loading Conditions 796
Pressure Sensors 796
Swingloads 796
Speed and Distance 796
HAUL CYCLE DATA 796
Haul Cycle Data 797
Haul Cycle Warning Flags 798
M: Haul Cycle Too Long 799
N: Sensor Input Error 799
Frame Torque Data 799
Sprung Weight Data 799
Maximum Speed Data 799
Alarm Records 799
Fault Code Data 800
PC SOFTWARE OVERVIEW 801
PC Overview 801
System Configuration 801
Installing the PLMIII Software 801
DOWNLOADING DATA 802
PLM III SYSTEM CONFIGURATION 803
Starting Communications 803
Displayed Payload Units 803
Time Units 803
Connection Menu 803
Connecting to the Payload Meter 804
Configure the Payload Meter 804
Setting the Date and Time 804
Setting the Truck Type 805
Setting the Gauge Display Units 805
Setting the Frame Serial Number 805
Setting the Truck Number 805
Setting the Komatsu Distributor 805
Setting the Komatsu Customer 805
Clean Truck Tare 806
Inclinometer Calibration 806
DATA ANALYSIS 807
Creating a Query 807
Sorting on Truck Unit Number 807
Sorting on Truck Type 807
Sorting on Date Range 808
Sorting on Time Range 808
Payload Detail Screen 809
Creating Reports 809
Summary – one page report 810
Detailed – multi-page report 810
Creating Graphs 811
Exporting Data 811
CSV Export 811
Compressed 812
Importing Data 813
Deleting Haul Cycle Records 813
Viewing Alarms 814
Deleting Alarm Records 814
TROUBLESHOOTING SECTION 815
TROUBLESHOOTING 815
Viewing Active Alarms 815
Real-Time Data Display 815
Testing the Payload Lights 815
Creating Log Files of Inputs 816
Daily Inspections 816
Periodic Maintenance 816
Abnormal Displays at Power-Up 817
No Payload Display When Keyswitch is Turned ON 818
No Display on Speedometer 819
No Display on Operator Display 819
No Communications With PC 820
Load Lights Don’t Light During Loading 821
Load Lights Remain ON 822
Load Lights Remain ON During Dumping 822
Display Doesn’t Clear When The Load Is Dumped 822
Calibration Problems 823
Alarm 1 – Left Front Pressure High 824
Alarm 2 – Left Front Pressure Low 824
Troubleshoot Wiring to Left Front Suspension 824
Alarm 3 – Right Front Pressure High 825
Alarm 4 – Right Front Pressure Low 825
Troubleshoot Wiring to Right Front Suspension 825
Alarm 5 -Left Rear Pressure High 826
Alarm 6 – Left Rear Pressure Low 826
Troubleshoot Wiring to Left Rear Suspension 826
Alarm 7 – Right Rear Pressure High 827
Alarm 8 – Right Rear Pressure Low 827
Troubleshoot Wiring to Right Rear Suspension 827
Alarm 9 – Inclinometer High 828
Alarm 10 – Inclinometer Low 828
Troubleshoot Inclinometer Wiring 828
Alarm 13 – Body Up Input Failure 829
Alarm 16 – Memory Write Failure 830
Alarm 17 – Memory Read Failure 830
Alarm 18 831
Alarm 19 831
Alarm 22 831
Operator Switch Doesn’t Work 832
Alarm 26 – User Switch Fault – SELECT 832
Alarm 27 – User Switch Fault – SET 832
Connector Map 833
Connectors 834
PLMIII CHECK OUT PROCEDURE 835
General Description 835
Tools Required 835
Checkout Procedure 835
PLMIII CHECKOUT PROCEDURE CONFIRMATION 839
Flashburn Programming 839
Confirmation Checklist 841
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 843
RESERVE ENGINE OIL SYSTEM 845
Operation 845
LED Monitor Light 846
Tank Fill Control (Optional) 846
Filling Procedure (Remote fill feature) 846
SERVICE 847
Every 10 Hours, or once each shift: 847
Every 500 Hours: 847
Changing Oil 847
TROUBLESHOOTING 848
Circuit Breaker or Fuse 848
SYSTEM ELECTRICAL SCHEMATICS 849
SECTION N – CAB COMPONENTS – INDEX 851
SECTION N2 – TRUCK CAB – INDEX 853
TRUCK CAB 855
Description 855
Preparation 856
Removal – Cab 856
Installation – Cab 858
CAB DOOR 858
Removal 858
Installation 858
Door Adjustment 859
Door Jamb Bolt Adjustment 859
Door Handle Plunger Adjustment 860
Door Glass Replacement 861
Door Window Regulator Replacement 865
Door Handle or Latch Assembly Replacement 865
Door and Door Hinge Seal Replacement 866
Door Opening Seal Removal 866
Installation 866
GLASS REPLACEMENT 867
Adhesive Bonded Windows 867
Replacement Procedure 867
Windshield And Rear Glass 868
Removal 868
Installation 869
SECTION N3 – CAB COMPONENTS – INDEX 871
CAB COMPONENTS 873
WINDSHIELD WIPERS 873
Wiper Motor Replacement 873
Removal 873
Installation 873
Wiper Arm 873
Removal 873
Installation 874
Wiper Linkage Replacement 874
Removal 874
Installation 874
WINDSHIELD WASHER 875
Operation 875
Service 875
OPERATOR SEAT 876
Adjustment 876
Seat Removal 876
Seat Installation 876
SECTION N4 – OPERATOR COMFORT – INDEX 877
OPERATOR COMFORT 879
HEATER / AIR CONDITIONER 879
Operation 879
Heater/Air Conditioner Vents 879
COMPONENTS 880
Circuit Breakers 880
Relays 880
Heater Core 880
Fan Motor And Speed Control 881
Actuators 881
Cab Air Filter 881
AIR CONDITIONING SYSTEM 883
Environmental Impact 883
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 884
PRINCIPLES OF REFRIGERATION 884
Air Conditioning 884
Refrigeration – The Act Of Cooling 885
The Refrigeration Cycle 885
AIR CONDITIONER SYSTEM COMPONENTS 886
Compressor (Refrigerant Pump) 886
Service Valves 886
Condenser 886
Receiver-Drier 886
Expansion Block Valve 887
Accumulator 887
Evaporator 887
ELECTRICAL CIRCUIT 888
Thermostat 888
Compressor Clutch 888
Trinary™ Switch 889
SYSTEM SERVICING 890
SERVICE TOOLS AND EQUIPMENT 891
Recovery/Recycle Station 891
Leak Detector 891
Service Valves 892
Vacuum Pump 892
Manifold Gauge Set 893
Installing Manifold Gauge Set 894
Purging Air From Service Hoses 894
SYSTEM PERFORMANCE TEST 895
SYSTEM OIL 896
Handling and Reusing PAG Oil 896
Oil Quantity 896
Checking System Oil 896
REFRIGERANT 897
Recycled Refrigerant 897
Reclaimed Refrigerant 897
Refrigerant Quantity 897
R-134a Refrigerant Containers 897
SYSTEM LEAK TESTING 898
Electronic Leak Detector 898
Tracer Dyes 898
Soap and Water 898
RECOVERING AND RECYCLING THE REFRIGERANT 899
Performing the Recovery Cycle 899
Performing the Recycling Procedure 899
Evacuating and Charging the A/C System 899
SYSTEM REPAIR 900
System Flushing 900
COMPONENT REPLACEMENT 900
Hoses and Fittings 900
Lines 900
Expansion Valve 901
Receiver-Drier 901
Thermostat 901
Compressor 901
Accumulator 901
Clutch 902
Servicing the Compressor Clutch 902
Pulley Removal 904
Clutch Coil Check 905
Pulley Installation 905
Clutch Assembly Installation 905
EVACUATING THE SYSTEM 907
CHARGING THE A/C SYSTEM 909
TROUBLESHOOTING 910
Preliminary Checks 910
Diagnosis Of Gauge Readings And System Performance 910
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 911
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 917
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 919
OPERATOR CAB CONTROLS 919
OPERATOR CAB CONTROLS 921
STEERING COLUMN 921
Removal 921
Steering Column Inspection 921
Installation 921
STEERING WHEEL AND CONTROLS 923
Horn Button 923
Telescope Lock Ring 923
Tilt Wheel Lever 923
Turn Signal/Headlight Dimmer 923
DYNAMIC RETARDING 923
Retarder Control Lever 924
Dynamic Retarder/Service Brake Pedal 924
Accelerator (Throttle) Pedal 924
Starting on a Grade With a Loaded Truck 924
GRADE/SPEED RETARD CHART 925
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 926
Heater/Air Conditioner Vents 926
INSTRUMENT PANEL 927
OVERHEAD PANEL AND DISPLAYS 927
CENTER CONSOLE 928
F-N-R Selector Switch 928
Hoist Control Lever 929
Raising The Dump Body 929
Lowering The Dump Body: 929
Ash Tray 929
Lighter 929
LH Window Control Switch 929
RH Window Control Switch 929
Engine Shutdown Switch 929
Override/Fault Reset Switch 930
Retard Speed Control (RSC) Switch 930
Retard Speed Control (RSC) Adjust Dial 930
Data Store Button 931
Engine Control System 931
Service Engine Light (Blue) 931
Engine Diagnostics Download Port 931
Payload Meter 931
TCI Download Port 931
PSC Download Port 931
PAYLOAD METER 931
INSTRUMENT PANEL AND INDICATOR LIGHTS 933
CONTROL SYMBOLS 933
INSTRUMENT PANEL 933
PANEL GAUGES, INDICATORS, AND CONTROLS 935
Key Switch 935
Starting 935
Cold Weather Starting 935
Normal Engine Shutdown 935
Engine Shutdown Switch with 5 Minute Idle Timer Delay 936
Fog Lights (Optional) 936
Ladder Light Switch 936
Manual Backup Switch 936
Panel Illumination Lights 937
Cab/Air Conditioner Vents 937
Rotating Beacon Light Switch (Optional) 937
Heated Mirror Switch (Optional) 937
Wheel Brake Lock Control 937
Parking Brake Control 937
Tachometer 938
Right Turn Signal Indicator 938
High Beam Indicator 938
Left Turn Signal Indicator 938
Speedometer / Payload Meter 938
Voltmeter 938
Engine Oil Pressure Gauge 938
Water Temperature Gauge 938
Fuel Gauge 938
AC Drive System Temperature Gauge 939
Hydraulic Oil Temperature Gauge 939
Hourmeter 939
Rest Switch 939
Light Switch 940
Windshield Wiper and Washer 940
Panel Light Dimmer 940
Payload Meter Switch 940
OVERHEAD STATUS / WARNING INDICATORS 941
STATUS / WARNING INDICATOR LIGHT SYMBOLS 942
Hazard Warning Lights 947
Lamp Test Switch 947
Link-On Warning Light 947
SECTION P – LUBRICATION AND SERVICE – INDEX 949
SECTION P2 – LUBRICATION AND SERVICE – INDEX 951
LUBRICATION AND SERVICE 953
930E SERVICE CAPACITIES 953
HYDRAULIC TANK SERVICE 953
Adding Oil 953
WHEEL MOTOR SERVICE 953
COOLANT LEVEL CHECK 954
RADIATOR FILLING PROCEDURE 954
RESERVE ENGINE OIL SYSTEM (Optional) 954
Reserve Oil Tank Filling Procedure (Remote fill) 954
LUBRICATION CHART 955
10 HOUR (DAILY) INSPECTION 956
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 959
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 961
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 964
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 965
5000 HOUR MAINTENANCE CHECKS 966
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 967
AUTOMATIC LUBRICATION SYSTEM 969
GENERAL DESCRIPTION 969
SYSTEM COMPONENTS 971
Filter 971
Hydraulic Motor and Pump 971
Grease Reservoir 971
Pressure Reducing Valve 971
Flow Control Valve 971
Solenoid Valve 971
Vent Valve 971
Lubrication Cycle Timer 971
Time Delay Module 971
Pump Cutoff Pressure Switch (NO 2500 psi [17 237 kPa]) 971
Grease Pressure Failure Switch (NO 2000 psi [13 789 kPa]) 971
Pressure Gauge 971
Injectors 971
SYSTEM OPERATION 972
Normal Operation 972
Pressure Failure Detection Circuits 973
GENERAL INSTRUCTIONS 974
Lubricant Requirements 974
System Priming 974
LUBRICANT PUMP 974
Pump Housing Oil Level 974
Pump Pressure Control 974
Lubrication Cycle Timer Check 975
Lubrication Cycle Timer Adjustment 975
FILTER ASSEMBLY 975
SYSTEM CHECKOUT 976
INJECTORS (SL-1 Series “H”)) 976
Injector Specifications 976
Injector Adjustment 976
INJECTOR OPERATION 977
PUMP REBUILD 978
Disassembly 978
Cleaning and Inspection 980
Assembly 980
SYSTEM TROUBLESHOOTING CHART 982
PREVENTATIVE MAINTENANCE PROCEDURES 985
Daily Lubrication System Inspection 985
250 Hour Inspection 985
1000 Hour Inspection 985
SECTION Q ALPHABETICAL INDEX 987
SECTION R – SYSTEM SCHEMATICS – INDEX 991
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 993
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 994
ELECTRICAL SCHEMATIC – XS1300 995
EL1130 – VHMS ELECTRICAL SCHEMATIC1029
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 57
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 63
STORAGE AND IDLE MACHINE PREPARATION 65
Short Term Idle Periods 65
PREPARATION FOR STORAGE 66
REMOVAL FROM STORAGE 67
RECONDITIONING AN IDLE VEHICLE 69
ENGINE OPERATION 72
After The Engine Has Started 73
ENGINE STORAGE 74
Preparing Engine For Storage 74
Temporary Storage (30 Days Or Less) 74
Extended Storage (more Than 30 Days) 74
RESTORING AN ENGINE AFTER EXTENDED STORAGE 76
ELECTRIC DRIVE TRUCKS 77
Storage Instructions and Procedures 77
Placing Equipment Into Storage 77
Storing A Truck That Is Operational 77
Storing A Truck That Is Not Operational 78
Storing A Major Component 78
Periodic Inspections 79
Placing Equipment Into Service After Storage 79
When A Truck Is Operational 79
When A Truck Is Not Operational 79
For The First Hour 80
SECTION B – STRUCTURES – INDEX 81
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 83
STRUCTURAL COMPONENTS 85
Preparation 85
GRILLE, HOOD AND LADDER 86
Removal 86
Installation 86
DECKS 87
RIGHT DECK AND COMPONENTS 87
Removal 87
Installation 88
LEFT DECK 88
Removal 88
Installation 88
CENTER DECK 88
SECTION B3 – DUMP BODY – INDEX 89
DUMP BODY 91
Removal 91
Installation 92
BODY PADS 93
Adjustment 93
BODY GUIDE 94
HOIST LIMIT SWITCH 94
BODY UP SWITCH 94
BODY-UP RETENTION CABLE 94
ROCK EJECTORS 95
Rock Ejectors 95
Inspection 95
SECTION B4 – FUEL TANK – INDEX 97
FUEL TANK 99
Removal 100
Installation 100
Repair 100
Cleaning 100
FUEL GAUGE SENDER 101
Removal 101
Installation 101
LOW FUEL SWITCH 101
WIGGINS QUICK FILL FUEL SYSTEM 102
FUEL RECEIVER 102
TANK BREATHER VALVE 102
Removal 102
Installation 102
Disassembly 102
Assembly 102
LEFT SIDE FILL 103
SECTION C – ENGINE – INDEX 105
SECTION C2 – POWER MODULE – INDEX 107
POWER MODULE 109
Preparation 109
Preparation for Removal 110
Removal – Power Module 113
Installation – Power Module 115
Hookup – Power Module 115
SECTION C3 – COOLING SYSTEM – INDEX 117
COOLING SYSTEM 119
RADIATOR 119
Removal – Radiator 119
Installation – Radiator 121
RADIATOR FILLING PROCEDURE 122
RADIATOR REPAIR 122
Internal Inspection 122
External Cleaning 122
Disassembly 123
Cleaning and Inspection 124
Assembly 124
Pressure Testing 125
Additional Service Information 125
COOLANT SYSTEM TROUBLESHOOTING 126
SECTION C4 – POWERTRAIN – INDEX 127
POWER TRAIN 129
ALTERNATOR 129
Removal – Alternator 129
ENGINE/ALTERNATOR MATING 131
General Instructions 131
Measuring Procedure 131
Joining The Alternator and Engine 133
ENGINE 134
Removal 134
Service 134
Installation 134
SECTION C5 – AIR CLEANERS – INDEX 135
AIR CLEANERS 137
AIR CLEANERS 137
Operation 137
General Service Information 137
FILTER ELEMENT REPLACEMENT 138
Main Filter Element Cleaning 139
Precleaner Section 140
Cleaning Precleaner Tubes 140
AIR INTAKE TROUBLESHOOTING 141
SECTION C7 – FAN CLUTCH – INDEX 143
FAN CLUTCH 145
REMOVAL & INSTALLATION TOOLING 145
FAN CLUTCH – DISASSEMBLY 148
CLEANING AND INSPECTION 158
ASSEMBLY – FAN CLUTCH 162
TEST PROCEDURE 176
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX 177
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 179
24VDC ELECTRIC SUPPLY SYSTEM 181
ELECTRICAL SYSTEM DESCRIPTION 181
BATTERIES 181
Maintenance and Service 181
Troubleshooting 181
BATTERY SUPPLY SYSTEM 183
24VDC Batter Charging Alternator 183
Battery Box 183
Batter Control Box 184
Battery Disconnect Switches 184
24VDC Auxiliary Battery Connectors 184
24VDC to 12VDC Converter 185
Isolation Diodes 185
Engine Starter Relay 185
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX 187
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
TRUCK SHUTDOWN PROCEDURE 189
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
Brake Warning Buzzer (BWB) 189
AUXILIARY CONTROL CABINET COMPONENTS 189
Fuse Block 1 & 2 190
Power Distribution Terminals 190
PULSE VOLTAGE MODULATOR 190
5 Minute Idle Timer Components 192
5 Minute Idle Timer 192
5 Minute Idle Circuit Test 192
Tail Light Resistor Diode Assemblies 192
Engine Starter Failure Delay Timer 192
Lubrication System Timer 194
Auto Lube Delay Timer 194
Barometric Pressure Transducer 194
Kontrol Power Relay 194
Alarm Indicating Device (AID) System 196
Temperature and Latch 197
Hot Switch Inverter 197
Hot Switch Inverter Card (Slot 4) (Not Used) 197
Oil Level 197
Temperature 197
Diode Matrix (Without Sound) 197
Diode Matrix (With Sound) 197
Lamp Test 198
Diode Board – DB1 198
Diode Testing 198
RELAY BOARDS 199
Relay Boards RB1, RB3, RB4, RB5 199
Service 199
Relay Board Identification 200
RELAY BOARD FUNCTIONS 201
Relay Board 1 (RB1) 201
Relay Board 3 (RB3) 201
Relay Board 6, 7 & 8 (RB6, RB7, RB8) 202
Installing Additional Circuits 202
BODY-UP SWITCH 203
Operation 203
Adjustment 203
Service 203
HOIST LIMIT SWITCH 204
Operation 204
Adjustment 204
Service 204
FUSE BLOCKS 205
CIRCUIT BREAKERS 205
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX 207
BATTERY CHARGING ALTERNATOR 209
ELECTRICAL SYSTEM DESCRIPTION 209
BATTERY 209
Maintenance and Service 209
Troubleshooting 209
BATTERY CHARGING SYSTEM (Niehoff) 211
General Description 211
TROUBLESHOOTING PROCEDURES (On-Truck) 211
Equipment Required: 211
Preliminary Checks 212
Test Setup 212
Test Procedure 212
Regulator Bypass Test 213
ON VEHICLE TROUBLESHOOTING GUIDE 215
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 215
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 215
CHARGE VOLT AND AMP VALUES 216
DEFINITIONS 216
ADVANCED SYSTEM TROUBLESHOOTING 217
Static Test – Engine OFF, Key ON, Battery Switch ON 217
Go To Alternator 217
Go To Regulator (If Required) 218
Go To Regulator Connector On The Alternator 218
ALTERNATOR OVERHAUL 219
ALTERNATOR DIMENSIONS 219
ALTERNATOR SPECIFICATIONS 220
SERVICE PARTS 221
ON-VEHICLE TEST 223
Equipment: 223
Preliminary Checks: 223
Test Set-up 223
Test Procedure 223
ON-VEHICLE TEST 224
Bypass Test: 224
BENCH TEST 225
STATIC TESTS 226
Regulator Tests 226
Control Box Tests 227
ALTERNATOR DISASSEMBLY 229
ASSEMBLY- ALTERNATOR 234
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 243
Stator Removal And Replacement 243
Stator Installation 244
SECTION D11 – VHMS COMPONENTS 247
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 249
VHMS BASIC FEATURES 249
Gather Data 249
Convert and Record Data 250
Communicate Data to Off-Board Systems 250
USING THE VHMS SYSTEM 251
Turning the VHMS System ON 251
Normal VHMS Operation 252
Turning the VHMS System OFF 252
Downloading from the VHMS controller 252
VHMS DATA ITEMS 253
Fault Codes 253
Machine History 253
VHMS History 253
Snapshots 253
Manual Snapshots 255
Trends 255
Histogram (Load Map) Data 257
Haul Cycle Data 257
Alarm and Snapshot Triggers 259
Satellite Features 261
VHMS DIAGNOSTIC FEATURES 261
Fault History 261
VHMS LED Digits 261
VHMS COMPONENTS 262
VHMS Controller 262
Removal 262
Installation 263
OrbComm Controller 263
Removal 263
Installation 264
Interface Module 264
Removal 265
Installation 265
Temperature Sensors 266
Pressure Sensors 267
SECTION D12 – VHMS SOFTWARE 269
VHMS SOFTWARE 271
NECESSARY SOFTWARE 271
NECESSARY TOOLS 271
VHMS TOOL BOX INSTALLATION 272
VHMS SETTING TOOL INSTALLATION 272
VHMS INITIALIZATION PROCEDURE 272
Preliminary Checks 272
Initialization Steps 273
Select Operation 273
VHMS Setting Function 273
Machine Information Setting(1) 273
Machine Information Setting(2) 273
Date & Time Setting 274
GCC Setting 274
Setting Summary 274
VHMS SNAPSHOT PROCEDURE 275
VHMS DOWNLOAD 275
VHMS FTP UPLOAD 276
LOCATION OF DOWNLOAD FILES 277
INSTALLING FLASHBURN PROGRAM 278
INSTALLING APPLICATION CODE INTO INTERFACE MODULE 278
INSTALLING VHMS WATCHER PROGRAM 279
INSTALLING VHMS WATCHER DATA FILES 279
WHEN REPLACING A VHMS CONTROLLER 279
To Set: Date & Time; Satellite; Payload Meter 282
Review Setting Information 283
SECTION D13 – VHMS CHECKOUT AND TROUBLESHOOTING 285
VHMS CHECKOUT & TROUBLESHOOTING 287
VHMS CHECKOUT PROCEDURE 287
General 287
Structure and Purpose 288
Necessary Equipment: 288
VHMS SYSTEM CHECKOUT 288
Preliminary 288
Checking Inputs To The Interface Module 289
Checking Outputs From The Interface Module 292
VHMS CONTROLLER CHECKOUT 292
TROUBLESHOOTING 293
Communications Networks 293
Coaxial Cable 293
VHMS COMPONENTS 294
VHMS Controller 294
OrbComm Controller 295
Interface Module 295
FAULT CODES 296
Fault History 296
VHMS LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 301
FAULT TREE ANALYSIS 307
Unable to connect to VHMS from laptop PC 307
Flashing Error Code N4-23 (PLM III Communications Fault) 308
Flashing Error Code N4-22 (Engine Communications Fault) 309
No Data Received By WebCARE 310
Coaxial Cable Troubleshooting 311
SECTION D14 – VHMS FORMS 313
VHMS FORMS 315
VHMS INITIALIZATION CHECK LIST 315
VHMS DATA DOWNLOAD 316
VHMS INITIALIZATION FORM 316
VHMS INITIALIZATION CHECK LIST 317
VHMS INITIALIZATION FORM 319
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 321
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller(PSC) 327
Truck Control Interface (TCI) 327
Diagnostic Information Display 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 353
Input Processing 353
STATE MANAGEMENT 353
State Machine 353
DC Link State 356
Powering the Link 356
De-Powering the Link 356
Control Functions 356
ALTERNATOR FIELD CONTROL 357
Desired Three-Phase Voltage 357
Desired DC Link Voltage 357
Self-load 357
Propel Torque Control 358
Retard Torque Control 358
Wheel Slide Control 358
Resistor Grid Control 359
Chopper Voltage Control 359
EVENT PROCESSING 359
Event Detection 359
Power On Tests 359
Initiated Tests 360
Periodic Tests 360
EVENT RESTRICTIONS 360
EVENT LOGGING AND STORAGE 360
Event History Buffer 361
Data Packs 361
To Record and Save a Data Pack to a Floppy Disk 361
Event Reset 362
SERIAL DATA COMMUNICATIONS 363
PSC – PTU Communications Processing 363
Inverter Communications Processing 363
OUTPUT PROCESSING 364
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 364
Fast Start 364
Engine Shutdown/Engine Not Running 364
Limp Home Mode 364
Entering/Exiting Limp Home Mode 364
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 365
ELECTRONIC ACCELERATOR AND RETARD PEDALS 377
Removal 377
Installation 377
Disassembly 377
Assembly 377
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 379
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 381
AC DRIVE SYSTEM MAINTENANCE 381
TRUCK SHUTDOWN PROCEDURES 381
NORMAL TRUCK SHUTDOWN PROCEDURE 382
SHUTDOWN AFTER SYSTEM FAILURE 383
SYSTEM CHECKOUT 384
Battery and Control Checks of System WITH Battery Power OFF 384
Battery and Control Circuit Checks of System With Battery Power ON 387
Checks with Key Switch OFF 388
CPU Battery Checks 390
MEMORY BACKUP BATTERY REPLACEMENT 390
TCI PROGRAMMING 391
ICP PROGRAMMING 391
INVERTER PROGRAMMING 392
TCI CHECKOUT 392
Modular Mining Communication Port 393
TCI Input Checks 394
TCI Digital Output Tests 396
TCI Digital Input Tests 398
PSC Checkout Procedure 400
PSC Digital Input Checks 404
Miscellaneous Checks 405
A3PV Panel 405
LINKV Panel 405
Thermistor Checks 405
17FM384 Panel Check 405
Pedal Percentages and Meter Calibration 406
Meter Calibration Procedure 406
Reprogram With Serial Numbers and Pedal Percentages 408
LOAD TESTING 410
Preload Checks 410
ADDITIONAL TRUCK CHECKS 412
On-Board Load Testing 414
Preparation 414
Initiate Loadbox Test 417
Manual Offset HP Output Adjustment 419
TROUBLESHOOTING 421
PVM Optimum Load Curve Handshaking Troubleshooting 421
MISCELLANEOUS COMPONENT REPAIR 422
Troubleshooting Phase Modules and Chopper Modules 422
Phase Module Removal and Snubber Resistor Replacement 422
Snubber Resistor Installation 423
Phase Module Installation 423
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 425
SECTION G2 – TIRES AND RIMS – INDEX 427
TIRES AND RIMS 429
WHEEL STUD MAINTENANCE 430
FRONT TIRES AND RIMS 431
Removal 431
Installation 432
REAR TIRES AND RIMS 433
Removal 433
Installation 434
RIM 435
Tire Removal 435
Tire Installation 436
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 439
FRONT WHEEL HUB AND SPINDLE 441
WHEEL HUB AND SPINDLE ASSEMBLY 441
Preparation 441
Removal 441
Installation – Wheel Hub and Spindle Assembly 444
Disassembly – Wheel Hub and Spindle Assembly 445
Cleaning and Inspection – Wheel Hub and Spindle Assembly 445
Assembly – Wheel Hub and Spindle Assembly 447
Wheel Bearing Adjustment: 447
Brake Installation 448
Seal Assembly Gap Check 449
STEERING CYLINDERS AND TIE ROD 450
Spherical Bearing Wear Limits 450
Removal – Steering Cylinder and Tie Rod 451
Installation – Steering Cylinder and Tie Rod 452
Bearing Replacement 452
TOE-IN ADJUSTMENT 453
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 455
REAR AXLE HOUSING ATTACHMENT 457
PIVOT PIN 457
Removal 457
Installation 458
PIVOT EYE BEARING 459
Removal 459
Installation 459
PIVOT EYE REPAIR 459
Removal 459
Disassembly 459
Assembly 460
Installation 460
ANTI-SWAY BAR 460
Removal 460
Installation 461
Disassembly 461
Cleaning and Inspection 461
Assembly 461
SECTION G5 – REAR AXLE HOUSING – INDEX 463
REAR AXLE HOUSING 465
REAR AXLE HOUSING 465
Preparation 465
Removal 465
Cleaning and Inspection – Rear Axle Housing 467
Installation – Rear Axle Housing 467
WHEEL MOTOR 468
Preparation 468
Removal 468
Cleaning and Inspection – Wheel Motor 469
Installation – Wheel Motor 470
WHEEL MOTOR GEAR OIL 473
Filtering Requirements 473
Particle Size Analysis 473
Flushing 473
Oil Sample Analysis 474
ELEMENT SPECIFICATION CHARTS 475
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 479
SECTION H2 – FRONT SUSPENSIONS – INDEX 481
FRONT SUSPENSION 483
Removal 483
Installation – Front Suspension 484
“Turn-Of-The-Nut” Tightening Procedure 487
MINOR REPAIRS (LOWER BEARING & SEALS) 488
Removal – Bearing Retainer 488
Installation – Bearing Retainer 488
MAJOR SUSPENSION REBUILD 490
Disassembly 490
Assembly 490
SECTION H3 – REAR SUSPENSIONS – INDEX 493
REAR SUSPENSIONS 495
Removal 495
Installation – Rear Suspension 497
Disassembly – Rear Suspension 498
Cleaning and Inspection – Rear Suspension 498
Assembly – Rear Suspension 498
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 501
SUSPENSION OILING AND CHARGING PROCEDURE 503
GENERAL 503
EQUIPMENT LIST 503
Hydrair® Charging Kit 503
Installation of Charging Kit 503
Removal of Charging Kit 504
Support Blocks For Oiling And Charging Dimensions 504
FRONT SUSPENSION 505
Front Suspension Oiling 505
Front Suspension Nitrogen Charging 506
REAR SUSPENSION 507
Rear Suspension Oiling 507
Rear Suspension Nitrogen Charging 508
OIL AND NITROGEN SPECIFICATIONS CHART 510
SECTION J – BRAKE CIRCUIT – INDEX 511
SECTION J2 – BRAKE CIRCUIT – INDEX 513
BRAKE CIRCUIT 515
SERVICE BRAKE CIRCUIT 515
SECONDARY BRAKING AND AUTOMATIC APPLY 517
PARKING BRAKE CIRCUIT 517
Normal Operation (key switch on, engine running) 517
BRAKE LOCK CIRCUIT 518
WARNING CIRCUIT 518
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 521
BRAKE CIRCUIT COMPONENT SERVICE 523
BRAKE VALVE 523
Rebuild Criteria 523
Removal 524
Installation 524
Disassembly 525
Cleaning and Inspection 528
Assembly 528
Actuator Base Threaded Inserts 528
Boot and Cap 528
Valve Body Seal Installation 528
Regulator Sleeve O-Ring Installation 529
Actuator Plunger O-ring Installation 529
Assembly of Valve 529
DIFFERENTIAL PRESSURE SWITCH 531
Disassembly 531
Cleaning and Inspection 531
Assembly 531
VALVE BENCH TEST AND ADJUSTMENT 532
Test Set Up Procedure 533
Brake Valve Output Pressure Adjustment 533
Differential Pressure Switch Adjustment 533
Final Test and Adjustment 534
Installation Of Brake Pedal Actuator Assembly to Brake Valve 535
Installation of Retard Pedal To Brake Pedal 535
DUAL RELAY VALVE 537
Removal 537
Installation 537
Disassembly 539
Cleaning and Inspection 539
Assembly 539
DIFFERENTIAL PRESSURE SWITCH 540
Disassembly 540
Cleaning and Inspection 540
Assembly 540
VALVE TEST AND ADJUSTMENT 541
Test Set Up Procedure 542
Relay Valve Output Pressure Adjustment 542
Differential Pressure Switch Adjustment 543
BRAKE MANIFOLD 544
Removal 544
Installation 545
Disassembly 545
Cleaning and Inspection 545
Assembly 545
BRAKE ACCUMULATORS 546
Brake Accumulator Bleeddown Procedure 546
BRAKE ACCUMULATOR REPAIR 547
Removal 547
Installation 547
Disassembly 548
Cleaning and Inspection 549
Assembly 549
ACCUMULATOR CHARGING PROCEDURE 551
Temperature During Precharge 552
Precharge Maintenance 553
Recharging Accumulators 553
Accumulator Storage procedures 554
Bladder Storage Procedures 554
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 555
Removal 555
Installation 555
Disassembly and Adjustment 555
Potentiometer Check 557
Assembly 557
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 559
BRAKE CIRCUIT CHECK-OUT PROCEDURE 561
REQUIRED EQUIPMENT 563
INITIAL SYSTEM SET-UP 564
BRAKE SYSTEM CHECKOUT 565
Failure Modes Check-Out 566
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 568
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 571
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 572
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 573
WET DISC BRAKE ASSEMBLY 575
OPERATION 575
MAINTENANCE 576
Brake Disc Wear Indicator 576
Removal/Installation – Wet Disc Brake Assembly 576
BRAKE REBUILD 578
Disassembly 578
Cleaning and Inspection 581
Assembly 582
Floating Ring Seal Assembly/Installation 585
WET DISC BRAKE BLEEDING PROCEDURE 588
SECTION J7 – PARKING BRAKE – INDEX 589
PARKING BRAKE 591
OPERATION 591
MAINTENANCE 592
Inspection – Parking Brake 592
Removal – Parking Brake 592
Installation – Parking Brake 593
Disassembly – Parking Brake 594
Cleaning and Inspection – Parking Brake 594
Assembly – Parking Brake 594
PARKING BRAKE BLEEDING PROCEDURE 596
SECTION L – HYDRAULIC SYSTEM – INDEX 597
SECTION L2 – HYDRAULIC SYSTEM – INDEX 599
HYDRAULIC SYSTEM 601
HYDRAULIC PUMP MODULE 601
HOIST CIRCUIT OPERATION 602
STEERING CIRCUIT OPERATION 604
DISC BRAKE COOLING SYSTEM 606
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 609
HYDRAULIC SYSTEM COMPONENT REPAIR 611
HOIST PUMP 611
Removal 611
Installation 613
INSPECTION OF PARTS 618
Assembly 618
HYDRAULIC TANK 624
Filling Instructions 624
Removal 624
Installation 625
HYDRAULIC TANK STRAINERS 625
Removal 625
Inspect and Clean 625
Installation 625
HYDRAULIC TANK BREATHERS 626
SECTION L4 – STEERING CIRCUIT – INDEX 627
STEERING CIRCUIT 629
COMPONENT DESCRIPTION 630
Steering Control Unit 630
Bleeddown Manifold Valve 631
Bleeddown Solenoid 631
Relief Valves 633
Hoist Limit Solenoid 633
Accumulators 633
Low Precharge Warning Switch 633
High Pressure Filter 633
Quick Disconnect Ports 633
Flow Amplifier 634
FLOW AMPLIFIER SYSTEM OPERATION 636
No Steer 636
Steering Left 638
Steering Right 640
No Steer, External Shock Load 642
STEERING PUMP 644
Operation 644
PRINCIPLE OF OPERATION 646
Full Pump Volume: 646
Half Pump Volume: 646
Neutral Position: 646
Steering Pump 647
SECTION L5 – STEERING CONTROL UNIT – INDEX 649
STEERING CONTROL UNIT 651
Removal 651
Spline Inspection 651
Installation 652
STEERING CONTROL UNIT REBUILD 652
Disassembly 652
Cleaning and Inspection – Steering Control Unit 653
Assembly – Steering Control Unit 655
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 659
STEERING CIRCUIT COMPONENT REPAIR 661
BLEEDDOWN MANIFOLD VALVE 661
Removal 661
Installation 661
FLOW AMPLIFIER 663
Removal 663
Installation 663
FLOW AMPLIFIER REBUILD 663
Disassembly 666
Assembly 667
STEERING CYLINDERS 668
Disassembly 669
Piston Seal & Bearing Installation 669
Cylinder Assembly 669
Test 669
STEERING AND BRAKE PUMP 670
Removal 670
Installation 670
Disassembly 672
Control Piston Group 672
Valve Plate Group 672
Rotating Group 675
Swashblock Group 675
Driveshaft Group 675
Inspection 675
Control Piston Group 675
Valve Plate Group 675
Rotating Group 675
Swashblock Group 677
Driveshaft Group 678
Compensator Block and Unloader Module 678
Stroke Adjuster Assembly 678
Assembly 678
Swashblock Group 678
Driveshaft Group 679
Rotating Group 679
Valve Plate Group 680
STEERING ACCUMULATORS 681
Removal 681
Installation 681
Disassembly 682
Cleaning and Inspection 682
Assembly 683
Leak Testing 685
Charging Procedure 686
Temperature During Precharge 687
Precharge Maintenance 688
Accumulator Storage procedures 689
Bladder Storage Procedures 689
TROUBLESHOOTING CHART 690
SECTION L7 – HOIST CIRCUIT – INDEX 695
HOIST CIRCUIT 697
HOIST CIRCUIT OPERATION 697
COMPONENT DESCRIPTION 698
Hydraulic Tank 698
Hydraulic Pump 698
High Pressure Filters 698
Hoist Valve 698
Inlet Sections – Hoist Valve 698
Spool Sections – Hoist Valve 699
Hoist Pilot Valve 699
Bleeddown Manifold 700
Hoist-up Limit Solenoid 700
Pilot Operated Check Valve 700
Overcenter Manifold 700
HOIST CIRCUIT OPERATION 701
Float Position Of Pilot Valve With Truck Body On Frame 702
Power Up Operation 704
Hold Operation 706
Power Down Operation 708
Float Operation 710
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 713
HOIST CIRCUIT COMPONENT REPAIR 715
HOIST VALVE 715
Removal 715
Installation 716
O-Ring Replacement 716
INLET SECTION 717
Disassembly 717
Cleaning and Inspection 718
Assembly 718
REAR SPOOL SECTION (Work Ports) 718
Disassembly 718
Cleaning and Inspection 720
Assembly 720
FRONT SPOOL SECTION (Tank Ports) 721
Disassembly 721
Cleaning and Inspection 721
Assembly 721
HOIST PILOT VALVE 723
Removal 723
Installation 723
Disassembly 724
Cleaning and Inspection 725
Assembly 725
HOIST CYLINDERS 726
Removal 726
Installation 727
Disassembly 729
Cleaning and Inspection 730
Assembly – Quill and Cylinder 731
Quill Installation 731
Installation Of Check Balls And Plugs In Quill 732
Assembly of Cylinder 733
OVERCENTER VALVE MANIFOLD 734
DISABLED TRUCK DUMPING PROCEDURE 735
Hookup 735
Raising the Body 735
Lowering the Body 735
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 737
HYDRAULIC SYSTEM FILTERS 739
HOIST CIRCUIT FILTER 739
Filter Element Replacement 739
Removal – Hoist Circuit Filter 740
Installation – Hoist Circuit Filter 740
Indicator Switch – Hoist Circuit Filter 740
STEERING CIRCUIT FILTER 741
Filter Element Replacement 741
Removal – Steering Circuit Filter 742
Installation – Steering Circuit Filter 742
Indicator Switch – Steering Circuit Filter 742
INDICATOR SWITCH 742
Test Procedure 742
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 745
HYDRAULIC CHECK-OUT PROCEDURE 747
GENERAL INFORMATION 747
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 747
Equipment Requirements 748
Pump Pressure Control Adjustments 748
Steering Control Valve and Flow Amplifier Leakage Test 749
Bleeddown Manifold Leakage Test 749
STEERING/BRAKE PUMP STROKE ADJUSTMENT 750
SHOCK AND SUCTION VALVES 751
Equipment Requirements 751
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 752
Equipment Requirements 752
Pressure Gauge Locations 752
Brake Cooling Circuit Test 752
Power Up Relief Pressure Test 753
Adjustment 753
Power Down Relief Pressure Test 754
Hoist Counterbalance Valve Adjustment Preparation 755
Counterbalance Valve Pressure Check 755
Counterbalance Valve Adjustment 756
HYDRAULIC SYSTEM FLUSHING PROCEDURE 757
Preparation 757
Flushing Procedure 757
Filter Element Replacement 758
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 759
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 760
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 761
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX 763
FIRE CONTROL SYSTEM (MANUAL) 765
Operation 765
Inspection and Maintenance 765
Recharging Procedures 766
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 767
Control Module 767
Actuator 768
Linear Detection Wire 768
Power Wire 768
Test Kit 768
Squib 768
Securing the Detection Wire 769
Preliminary Test Before Final Hook-Up 769
Installation Procedure for Squib 771
Placing the Electric Detection & Actuation System Into Service 771
INSPECTION AND MAINTENANCE SCHEDULES 772
Daily 772
Normal Maintenance Based On Actual Operating Hours 772
IN CASE OF FIRE 773
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 775
SECTION M8 – SPECIAL TOOLS 777
SECTION M20 – PAYLOAD METER III – INDEX 783
OPERATION SECTION 787
Introduction 787
Data Summary 787
Data Gathering 787
COMPONENT DESCRIPTION 788
System Diagram 788
Suspension Pressure Sensors 788
Inclinometer 788
Operator Display 788
Operator Switch 789
Speed Input 789
Body-Up Switch 789
Brake Lock Switch 789
Payload Meter 789
Communications Ports 789
Keyswitch Input 790
Payload Meter Power 790
Load Lights 790
Wiring and Termination 791
TCI Outputs 791
OPERATOR’S DISPLAY AND SWITCH 792
Reading the Speedometer 792
Reading the Load Display 792
Using the Operator ID 792
Using the Load and Ton Counter 792
Total Ton Counter 792
Total Load Counter 793
Clearing the Counters 793
Viewing Live Sensor Data 793
Other Display Messages 793
PAYLOAD OPERATION & CALCULATION 794
Description of Haul Cycle States 794
Haul Cycle Description 794
Load Calculation 795
Carry Back 795
Measurement Accuracy 795
SOURCES FOR PAYLOAD ERROR 795
Payload Error 795
Loading Conditions 796
Pressure Sensors 796
Swingloads 796
Speed and Distance 796
HAUL CYCLE DATA 796
Haul Cycle Data 797
Haul Cycle Warning Flags 798
M: Haul Cycle Too Long 799
N: Sensor Input Error 799
Frame Torque Data 799
Sprung Weight Data 799
Maximum Speed Data 799
Alarm Records 799
Fault Code Data 800
PC SOFTWARE OVERVIEW 801
PC Overview 801
System Configuration 801
Installing the PLMIII Software 801
DOWNLOADING DATA 802
PLM III SYSTEM CONFIGURATION 803
Starting Communications 803
Displayed Payload Units 803
Time Units 803
Connection Menu 803
Connecting to the Payload Meter 804
Configure the Payload Meter 804
Setting the Date and Time 804
Setting the Truck Type 805
Setting the Gauge Display Units 805
Setting the Frame Serial Number 805
Setting the Truck Number 805
Setting the Komatsu Distributor 805
Setting the Komatsu Customer 805
Clean Truck Tare 806
Inclinometer Calibration 806
DATA ANALYSIS 807
Creating a Query 807
Sorting on Truck Unit Number 807
Sorting on Truck Type 807
Sorting on Date Range 808
Sorting on Time Range 808
Payload Detail Screen 809
Creating Reports 809
Summary – one page report 810
Detailed – multi-page report 810
Creating Graphs 811
Exporting Data 811
CSV Export 811
Compressed 812
Importing Data 813
Deleting Haul Cycle Records 813
Viewing Alarms 814
Deleting Alarm Records 814
TROUBLESHOOTING SECTION 815
TROUBLESHOOTING 815
Viewing Active Alarms 815
Real-Time Data Display 815
Testing the Payload Lights 815
Creating Log Files of Inputs 816
Daily Inspections 816
Periodic Maintenance 816
Abnormal Displays at Power-Up 817
No Payload Display When Keyswitch is Turned ON 818
No Display on Speedometer 819
No Display on Operator Display 819
No Communications With PC 820
Load Lights Don’t Light During Loading 821
Load Lights Remain ON 822
Load Lights Remain ON During Dumping 822
Display Doesn’t Clear When The Load Is Dumped 822
Calibration Problems 823
Alarm 1 – Left Front Pressure High 824
Alarm 2 – Left Front Pressure Low 824
Troubleshoot Wiring to Left Front Suspension 824
Alarm 3 – Right Front Pressure High 825
Alarm 4 – Right Front Pressure Low 825
Troubleshoot Wiring to Right Front Suspension 825
Alarm 5 -Left Rear Pressure High 826
Alarm 6 – Left Rear Pressure Low 826
Troubleshoot Wiring to Left Rear Suspension 826
Alarm 7 – Right Rear Pressure High 827
Alarm 8 – Right Rear Pressure Low 827
Troubleshoot Wiring to Right Rear Suspension 827
Alarm 9 – Inclinometer High 828
Alarm 10 – Inclinometer Low 828
Troubleshoot Inclinometer Wiring 828
Alarm 13 – Body Up Input Failure 829
Alarm 16 – Memory Write Failure 830
Alarm 17 – Memory Read Failure 830
Alarm 18 831
Alarm 19 831
Alarm 22 831
Operator Switch Doesn’t Work 832
Alarm 26 – User Switch Fault – SELECT 832
Alarm 27 – User Switch Fault – SET 832
Connector Map 833
Connectors 834
PLMIII CHECK OUT PROCEDURE 835
General Description 835
Tools Required 835
Checkout Procedure 835
PLMIII CHECKOUT PROCEDURE CONFIRMATION 839
Flashburn Programming 839
Confirmation Checklist 841
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 843
RESERVE ENGINE OIL SYSTEM 845
Operation 845
LED Monitor Light 846
Tank Fill Control (Optional) 846
Filling Procedure (Remote fill feature) 846
SERVICE 847
Every 10 Hours, or once each shift: 847
Every 500 Hours: 847
Changing Oil 847
TROUBLESHOOTING 848
Circuit Breaker or Fuse 848
SYSTEM ELECTRICAL SCHEMATICS 849
SECTION N – CAB COMPONENTS – INDEX 851
SECTION N2 – TRUCK CAB – INDEX 853
TRUCK CAB 855
Description 855
Preparation 856
Removal – Cab 856
Installation – Cab 858
CAB DOOR 858
Removal 858
Installation 858
Door Adjustment 859
Door Jamb Bolt Adjustment 859
Door Handle Plunger Adjustment 860
Door Glass Replacement 861
Door Window Regulator Replacement 865
Door Handle or Latch Assembly Replacement 865
Door and Door Hinge Seal Replacement 866
Door Opening Seal Removal 866
Installation 866
GLASS REPLACEMENT 867
Adhesive Bonded Windows 867
Replacement Procedure 867
Windshield And Rear Glass 868
Removal 868
Installation 869
SECTION N3 – CAB COMPONENTS – INDEX 871
CAB COMPONENTS 873
WINDSHIELD WIPERS 873
Wiper Motor Replacement 873
Removal 873
Installation 873
Wiper Arm 873
Removal 873
Installation 874
Wiper Linkage Replacement 874
Removal 874
Installation 874
WINDSHIELD WASHER 875
Operation 875
Service 875
OPERATOR SEAT 876
Adjustment 876
Seat Removal 876
Seat Installation 876
SECTION N4 – OPERATOR COMFORT – INDEX 877
OPERATOR COMFORT 879
HEATER / AIR CONDITIONER 879
Operation 879
Heater/Air Conditioner Vents 879
COMPONENTS 880
Circuit Breakers 880
Relays 880
Heater Core 880
Fan Motor And Speed Control 881
Actuators 881
Cab Air Filter 881
AIR CONDITIONING SYSTEM 883
Environmental Impact 883
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 884
PRINCIPLES OF REFRIGERATION 884
Air Conditioning 884
Refrigeration – The Act Of Cooling 885
The Refrigeration Cycle 885
AIR CONDITIONER SYSTEM COMPONENTS 886
Compressor (Refrigerant Pump) 886
Service Valves 886
Condenser 886
Receiver-Drier 886
Expansion Block Valve 887
Accumulator 887
Evaporator 887
ELECTRICAL CIRCUIT 888
Thermostat 888
Compressor Clutch 888
Trinary™ Switch 889
SYSTEM SERVICING 890
SERVICE TOOLS AND EQUIPMENT 891
Recovery/Recycle Station 891
Leak Detector 891
Service Valves 892
Vacuum Pump 892
Manifold Gauge Set 893
Installing Manifold Gauge Set 894
Purging Air From Service Hoses 894
SYSTEM PERFORMANCE TEST 895
SYSTEM OIL 896
Handling and Reusing PAG Oil 896
Oil Quantity 896
Checking System Oil 896
REFRIGERANT 897
Recycled Refrigerant 897
Reclaimed Refrigerant 897
Refrigerant Quantity 897
R-134a Refrigerant Containers 897
SYSTEM LEAK TESTING 898
Electronic Leak Detector 898
Tracer Dyes 898
Soap and Water 898
RECOVERING AND RECYCLING THE REFRIGERANT 899
Performing the Recovery Cycle 899
Performing the Recycling Procedure 899
Evacuating and Charging the A/C System 899
SYSTEM REPAIR 900
System Flushing 900
COMPONENT REPLACEMENT 900
Hoses and Fittings 900
Lines 900
Expansion Valve 901
Receiver-Drier 901
Thermostat 901
Compressor 901
Accumulator 901
Clutch 902
Servicing the Compressor Clutch 902
Pulley Removal 904
Clutch Coil Check 905
Pulley Installation 905
Clutch Assembly Installation 905
EVACUATING THE SYSTEM 907
CHARGING THE A/C SYSTEM 909
TROUBLESHOOTING 910
Preliminary Checks 910
Diagnosis Of Gauge Readings And System Performance 910
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 911
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 917
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 919
OPERATOR CAB CONTROLS 919
OPERATOR CAB CONTROLS 921
STEERING COLUMN 921
Removal 921
Steering Column Inspection 921
Installation 921
STEERING WHEEL AND CONTROLS 923
Horn Button 923
Telescope Lock Ring 923
Tilt Wheel Lever 923
Turn Signal/Headlight Dimmer 923
DYNAMIC RETARDING 923
Retarder Control Lever 924
Dynamic Retarder/Service Brake Pedal 924
Accelerator (Throttle) Pedal 924
Starting on a Grade With a Loaded Truck 924
GRADE/SPEED RETARD CHART 925
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 926
Heater/Air Conditioner Vents 926
INSTRUMENT PANEL 927
OVERHEAD PANEL AND DISPLAYS 927
CENTER CONSOLE 928
F-N-R Selector Switch 928
Hoist Control Lever 929
Raising The Dump Body 929
Lowering The Dump Body: 929
Ash Tray 929
Lighter 929
LH Window Control Switch 929
RH Window Control Switch 929
Engine Shutdown Switch 929
Override/Fault Reset Switch 930
Retard Speed Control (RSC) Switch 930
Retard Speed Control (RSC) Adjust Dial 930
Data Store Button 931
Engine Control System 931
Service Engine Light (Blue) 931
Engine Diagnostics Download Port 931
Payload Meter 931
TCI Download Port 931
PSC Download Port 931
PAYLOAD METER 931
INSTRUMENT PANEL AND INDICATOR LIGHTS 933
CONTROL SYMBOLS 933
INSTRUMENT PANEL 933
PANEL GAUGES, INDICATORS, AND CONTROLS 935
Key Switch 935
Starting 935
Cold Weather Starting 935
Normal Engine Shutdown 935
Engine Shutdown Switch with 5 Minute Idle Timer Delay 936
Fog Lights (Optional) 936
Ladder Light Switch 936
Manual Backup Switch 936
Panel Illumination Lights 937
Cab/Air Conditioner Vents 937
Rotating Beacon Light Switch (Optional) 937
Heated Mirror Switch (Optional) 937
Wheel Brake Lock Control 937
Parking Brake Control 937
Tachometer 938
Right Turn Signal Indicator 938
High Beam Indicator 938
Left Turn Signal Indicator 938
Speedometer / Payload Meter 938
Voltmeter 938
Engine Oil Pressure Gauge 938
Water Temperature Gauge 938
Fuel Gauge 938
AC Drive System Temperature Gauge 939
Hydraulic Oil Temperature Gauge 939
Hourmeter 939
Rest Switch 939
Light Switch 940
Windshield Wiper and Washer 940
Panel Light Dimmer 940
Payload Meter Switch 940
OVERHEAD STATUS / WARNING INDICATORS 941
STATUS / WARNING INDICATOR LIGHT SYMBOLS 942
Hazard Warning Lights 947
Lamp Test Switch 947
Link-On Warning Light 947
SECTION P – LUBRICATION AND SERVICE – INDEX 949
SECTION P2 – LUBRICATION AND SERVICE – INDEX 951
LUBRICATION AND SERVICE 953
930E SERVICE CAPACITIES 953
HYDRAULIC TANK SERVICE 953
Adding Oil 953
WHEEL MOTOR SERVICE 953
COOLANT LEVEL CHECK 954
RADIATOR FILLING PROCEDURE 954
RESERVE ENGINE OIL SYSTEM (Optional) 954
Reserve Oil Tank Filling Procedure (Remote fill) 954
LUBRICATION CHART 955
10 HOUR (DAILY) INSPECTION 956
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 959
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 960
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 961
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 964
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 965
5000 HOUR MAINTENANCE CHECKS 966
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 967
AUTOMATIC LUBRICATION SYSTEM 969
GENERAL DESCRIPTION 969
SYSTEM COMPONENTS 971
Filter 971
Hydraulic Motor and Pump 971
Grease Reservoir 971
Pressure Reducing Valve 971
Flow Control Valve 971
Solenoid Valve 971
Vent Valve 971
Lubrication Cycle Timer 971
Time Delay Module 971
Pump Cutoff Pressure Switch (NO 2500 psi [17 237 kPa]) 971
Grease Pressure Failure Switch (NO 2000 psi [13 789 kPa]) 971
Pressure Gauge 971
Injectors 971
SYSTEM OPERATION 972
Normal Operation 972
Pressure Failure Detection Circuits 973
GENERAL INSTRUCTIONS 974
Lubricant Requirements 974
System Priming 974
LUBRICANT PUMP 974
Pump Housing Oil Level 974
Pump Pressure Control 974
Lubrication Cycle Timer Check 975
Lubrication Cycle Timer Adjustment 975
FILTER ASSEMBLY 975
SYSTEM CHECKOUT 976
INJECTORS (SL-1 Series “H”)) 976
Injector Specifications 976
Injector Adjustment 976
INJECTOR OPERATION 977
PUMP REBUILD 978
Disassembly 978
Cleaning and Inspection 980
Assembly 980
SYSTEM TROUBLESHOOTING CHART 982
PREVENTATIVE MAINTENANCE PROCEDURES 985
Daily Lubrication System Inspection 985
250 Hour Inspection 985
1000 Hour Inspection 985
SECTION Q ALPHABETICAL INDEX 987
SECTION R – SYSTEM SCHEMATICS – INDEX 991
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 993
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 994
ELECTRICAL SCHEMATIC – XS1300 995
EL1130 – VHMS ELECTRICAL SCHEMATIC1029
IMAGES PREVIEW OF THE MANUAL:
S.M 25/12/24
