John Deere / Bell B30C Articulated Dump Truck Operation & Test Service Manual (TM1813)
Complete Operation & Test manual for John Deere / Bell B30C Articulated Dump Truck, with all the shop information to maintain, diagnose, and service like professional mechanics.
John Deere / Bell B30C Articulated Dump Truck workshop Diagnosis & Test manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Total Pages: 1,056 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
tm1813 - B30C Articulated Dump Truck Operation and Tests Technical Manual.pdf
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MAIN SECTIONS
Foreword
Technical Information Feedback Form
Machine Number Identification
General Information
Safety Information
General Specification
Torque Values
Fuels and Lubricants
Operational Checkout Procedure
Operational Checkout Procedure
Engine
Theory of Operation
Diagnose Engine Malfunctions
Adjustments
Tests
Electrical System
System Information
System Diagrams
Sub-System Diagnostics
References
Power Train
Theory of Operation
Diagnostic Information
Adjustments
Tests
Pneumatic System
Theory of Operation
Diagnostic Information
Tests
Hydraulic System
Theory of Operation
Diagnostic Information
Tests
Heater and Air Conditioner
Theory of Operation
Diagnostic Information
Adjustments
Tests
TABLE OF CONTENTS....1
Section 9000: General Information....19
Group 01: Safety Information....19
Handle Fluids Safely-Avoid Fires....22
Prevent Battery Explosions....23
Prepare for Emergencies....24
Prevent Acid Burns....25
Handle Chemical Products Safely....27
Avoid High-Pressure Fluids....28
Park Machine Safely....29
Support Machine Properly....30
Wear Protective Clothing....31
Work in Clean Area....32
Service Machines Safely....33
Work In Ventilated Area....34
Illuminate Work Area Safely....35
Replace Safety Signs....36
Use Proper Lifting Equipment....37
Remove Paint Before Welding or Heating....38
Avoid Heating Near Pressurized Fluid Lines....39
Service Tires Safely....40
Avoid Harmful Asbestos Dust....41
Practice Safe Maintenance....42
Use Proper Tools....44
Dispose of Waste Properly....45
Live With Safety....46
Group 02: General Specification....19
Articulated Dump Truck....48
Articulated Dump Truck Specifications....49
Engine Specifications....51
Travel Speeds....52
Drain and Refill Capacities....53
Group 03: Torque Values....19
Hardware Torque Specifications....55
Metric Bolt and Cap Screw Torque Values....56
Additional Metric Cap Screw Torque Values....58
Unified Inch Bolt and Cap Screw Torque Values....60
Metric Cap Screw and Nut Torque Values....62
Imperial and SAE (Inch) Cap Screw and Nut Torque Values....63
Check Oil Lines and Fittings....64
Service Recommendations for O-Ring Boss Fittings....66
Service Recommendations For Flat Face O-Ring Seal Fittings....68
Service Recommendations for Metric Series Four Bolt Flange Fitting....70
Service Recommendations For Inch Series Four Bolt Flange Fittings....72
Group 04: Fuels and Lubricants....20
Diesel Fuel....75
Lubricity of Diesel Fuels....76
Low Sulfur Diesel Fuel Conditioner....77
Diesel Fuel Storage....78
Fuel Tank....79
Do Not Use Galvanized Containers....80
Diesel Engine Oil....81
Transmission and Hydraulic Oil....82
Multipurpose Lubricant (Axles and Final Drives)....83
Grease....84
Oil Filters....85
Lubricant Storage....86
Alternative and Synthetic Lubricants....87
Mixing of Lubricants....88
Section 9005: Operational Checkout Procedure....89
Group 10: Operational Checkout Procedure....89
Operational Checkout....200
Section 9010: Engine....310
Group 05: Theory of Operation....310
OM442 Engine Sectional View....315
Engine Operation....318
Lubrication System Operation....319
Fuel System Component Location....320
Fuel Injection Pump Operation....322
Fuel Injection Pump Operation....322
Fuel Injection Nozzle Operation....323
Mechanical Governor Operation....325
Starting Engine-Mechanical Governor....327
Engine Running at Slow Idle-Mechanical Governor....329
Engine Running at Medium Speed-Mechanical Governor....330
Engine Running at Full Load Rated Speed-Mechanical Governor....331
Stopping the Engine-Mechanical Governor....333
Aneroid Operation....335
Cooling System Operation....337
Crankcase Ventilation System Operation....339
Cold Weather Start System Operation....340
Group 15: Diagnose Engine Malfunctions....350
Diagnose Engine Malfunctions....350
Group 20: Adjustments....310
JT05801 Clamp-On Electronic Tachometer Installation....897
Slow and Fast Idle Adjustment....360
Throttle Position Sensor Adjustment....362
Exhaust Brake Valve Adjustment....365
Bleed the Fuel System....370
Alternator and Water Pump Belts Adjustment....371
Mechanical Fuel Shutoff Adjustment (Machine No. -478832.00)....374
Fuel Shutoff Solenoid Adjustment (Machine No. 478832.01- )....375
Injection Pump Timing Adjustment....376
Group 25: Tests....310
JT05801 Clamp-On Electronic Tachometer Installation....897
Fuel Line Leakage Test....381
Fuel Injection Nozzles Test....382
Engine Compression Test....388
Inspect Thermostat and Test Operating Temperature....390
Fuel Supply Pump Test....392
Radiator Cap and Cooling System Pressure Test....395
Air Intake System Leakage TestThis will need to be revised for dump truck; Bob Simon will look at it.....398
Viscous Drive Fan Check....400
Section 9015: Electrical System....402
Group 05: System Information....402
Electrical System Visual Inspection....407
Electrical Circuit Malfunctions....408
High Resistance Circuit....410
Open Circuit....412
Grounded Circuit....414
Shorted Circuit....416
Sensor Circuit Shorted to Power....418
Sensor Circuit Shorted to Itself....420
Sensor Circuit Shorted to Ground....422
Multimeter....424
Seven Step Electrical Test Procedure....425
Schematic, Wiring Diagram, and Component Location Information....427
Reading a System Functional Schematic....428
Reading a Wiring Diagram....430
Reading a Component Location Diagram....432
Reading a Connector End View Diagram....434
Electrical Schematic Symbols....435
Group 10: System Diagrams....402
Explanation of Wire Markings....439
Component Identification Table....440
Functional Schematic and Component Location Legend....442
Functional Schematic Section Legend....448
Power, Starting, Charging and Display Module System Functional Schematic....449
Transmission System Functional Schematic....450
Flasher, Turn Signal, Horn, and Light System Functional Schematic....451
Brake Light, Exhaust Brake, and Indicator Light System Functional Schematic....452
Body, Park Brake, Radio and 12 Volt, Reverse Lights, Cooling Fan, and Unloader Valve System Functional Schematic....453
Air Conditioning, Inter-Axle Lock, Dome Light, Wiper/Washer, and Rotating Beacon System Functional Schematic....454
Cab Harness (W5) Wiring Diagram (1 of 5)....455
Cab Harness (W5) Wiring Diagram (2 of 5)....456
Cab Harness (W5) Wiring Diagram (3 of 5)....457
Cab Harness (W5) Wiring Diagram (4 of 5)....458
Cab Harness (W5) Wiring Diagram (5 of 5)....459
Cab Harness (W5) Component Location (1 of 4)....460
Cab Harness (W5) Instrument Panel Component Location (2 of 4)....461
Cab Harness (W5) Dash Panel Component Location (3 of 4)....462
Cab Harness (W5) Breaker Panel Component Location (4 of 4)....463
Engine Harness (W6) Wiring Diagram....464
Engine Harness (W6) Component Location....465
Cold Start Harness (W7) Wiring Diagram....466
Cold Start Harness (W7) Component Location....467
Front Light Harness (W8) Wiring Diagram....468
Front Light Harness (W8) Component Location....469
Cab-to-Hydraulic Manifold Block Harness (W9) Wiring Diagram....470
Cab-to-Hydraulic Manifold Block Harness (W9) Component Location....471
Rear Chassis Harness (W10) Wiring Diagram....472
Rear Chassis Harness (W10) Component Location....473
Transmission Control Harness (W13) Wiring Diagram (1 of 2)....474
Transmission Control Harness (W13) Wiring Diagram (2 of 2)....475
Transmission Control Harness (W13) Component Location....476
Cab-to-Transmission Harness (W15) Wiring Diagram....477
Cab-to-Transmission Harness (W15) Component Location....478
Roof Harness (W22) Wiring Diagram....479
Roof Harness (W22) Component Location....480
Group 15: Sub-System Diagnostics....403
Power Circuit Operational Information....482
Power Circuit Theory of Operation....483
Power Circuit Schematic....484
Starting and Charging Circuit Operational Information....491
Starting and Charging Circuit Theory of Operation....492
Starting and Charging Circuit Schematic....494
Display Module Circuit Operational Information....503
Display Module Circuit Theory of Operation....504
Display Module Circuit Schematic....506
Transmission Circuit Operational Information....511
Transmission Circuit Theory of Operation....512
Transmission Circuit Schematic....513
Flasher, Turn Signal, and Horn Circuit Operational Information....522
Flasher, Turn Signal, and Horn Circuit Theory of Operation....523
Flasher, Turn Signal, and Horn Circuit Schematic....526
Light Circuit Operational Information....535
Light Circuit Theory of Operation....536
Light Circuit Schematic....538
Brake Light Circuit Operational Information....548
Brake Light Circuit Theory of Operation....549
Brake Light Circuit Schematic....550
Exhaust Brake Circuit Operational Information....554
Exhaust Brake Circuit Theory of Operation....555
Exhaust Brake Circuit Schematic....556
Indicator Light Circuit Operational Information....561
Indicator Light Circuit Theory of Operation....562
Indicator Light Circuit Schematic....566
Body Circuit Operational Information....580
Body Circuit Theory of Operation....581
Body Circuit Schematic....582
Park Brake Circuit Operational Information....586
Park Brake Circuit Theory of Operation....587
Park Brake Circuit Schematic....588
Radio and 12V Circuit Operational Information (Machine No. -478832.01)....592
Radio and 12V Circuit Theory of Operation (Machine No. -478832.01)....593
Radio and 12V Circuit Schematic (Machine No. -478832.01)....594
Radio and 12 Volt Circuit Operational Information (Machine No. 478832.02- )....599
Radio and 12 Volt Circuit Theory of Operation (Machine No. 478832.02- )....600
Radio and 12 Volt Circuit Schematic (Machine No. 478832.02- )....601
Reverse Light Circuit Operational Information....606
Reverse Light Circuit Theory of Operation....607
Reverse Light Circuit Schematic....608
Cooling Fan Circuit Operational Information....611
Cooling Fan Circuit Theory of Operation....612
Cooling Fan Circuit Schematic....613
Unloader Valve Circuit Operational Information....615
Unloader Valve Circuit Theory of Operation....616
Unloader Valve Circuit Schematic....617
Air Conditioning Circuit Operational Information....619
Air Conditioning Circuit Theory of Operation....620
Air Conditioning Circuit Schematic....622
Inter-Axle Lock Circuit Operational Information....629
Inter-Axle Lock Circuit Theory of Operation....630
Inter-Axle Lock Schematic....631
Dome Light Circuit Operational Information....634
Dome Light Circuit Theory of Operation....635
Dome Light Circuit Schematic....636
Wiper/Washer Circuit Operational Information....639
Wiper/Washer Circuit Theory of Operation....640
Wiper/Washer Circuit Schematic....641
Rotating Beacon Circuit Operational Information....645
Rotating Beacon Circuit Theory of Operation....646
Rotating Beacon Circuit Schematic....647
Group 20: References....405
Battery Operation....653
Battery Specifications....655
Diagnose Battery Malfunctions....656
Check Battery Electrolyte Level and Terminals....657
Procedure for Testing Batteries....660
Using Booster Batteries-24 Volt System....661
Replacing Batteries....663
Adding 12 or 24 Volt Accessories....664
Adjusting Headlights....665
Section 9020: Power Train....667
Group 05: Theory of Operation....667
Transmission Side View....670
Transmission Front View....671
Transmission Rear View....672
Transmission Control Valve Test Points....673
Transmission Clutch Engagement And Solenoids Activated....674
Power Train Component Location....708
Transmission Cross Sectional Diagram....676
Torque Converter Operation....678
Inter-Axle Lock Operation....679
Limited Slip Differential Operation....681
Transmission Operation-1st Speed Forward....683
Transmission Operation-4th Speed Forward....684
Transmission Operation-First Gear Reverse....685
Transmission Filter Bypass Valve....686
Transmission Control Valve Components....688
Transmission Pressure Regulating Circuit....689
Transmission Modulation Circuit....690
Transmission Clutch Modulation....692
Group 15: Diagnostic Information....667
Diagnostic Procedure....882
Diagnose Power Train System Malfunctions....695
Diagnose Service Brake Malfunctions....702
Diagnose Park Brake Malfunctions....703
Diagnose Differential and Axle Malfunctions....705
Diagnose Drive Line Malfunctions....707
Power Train Component Location....708
Transmission Control Circuit-First Forward....709
Group 20: Adjustments....667
Service Brake Pad and Disk Thickness Check....713
Park Brake Pad and Disk Thickness Check....715
Park Brake Adjustment....717
Group 25: Tests....668
Transmission Warm Up Procedure....722
Tachometer....723
Park Brake Test (Machine No. -478832.02)....724
Park Brake Test (Machine No. 479832.00- )....727
Transmission System Pressure Test....730
Transmission Pump Flow Test....732
Transmission Clutch Pressure Test....734
Transmission System Leakage Test....737
Transmission Lube Pressure Test....741
Converter-In Pressure Test....744
Converter-Out Pressure Test....746
Converter Relief Pressure Test....748
Converter-Out Flow Test....751
Transmission Oil Cooler Restriction Test....753
Torque Converter Stall Test....756
Torque Converter Stator Test....759
Torque Converter Lockup Test....761
List of Service Codes....764
Section 9022: Pneumatic System....766
Group 05: Theory of Operation....766
Pneumatic System Operation....769
Pneumatic System Supply Circuit Operation....770
Air Drier and Unloader Valve Operation....772
Inter-Axle Lock Circuit Operation....775
Engine Accelerator Circuit Operation....776
Accelerator Valve Operation....777
Park Brake Circuit Operation (Machine No. -478832.02)....779
Park Brake Circuit Operation (Machine No. 479832.00-)....781
Park Brake Valve Operation (Machine No. -478832.02)....783
Park Brake Valve Operation (Machine No. 479832.00-)....786
Exhaust Brake and Hydraulic Retarder Circuit Operation....789
Front Suspension Leveling Circuit Operation....791
Body Control Circuit Operation....793
Air Suspension Seat Circuit Operation....794
Pneumatic System Legend....795
Pneumatic System Schematic Diagram (Machine No. -478832.02)....796
Pneumatic System Schematic Diagram (Machine No. 479832.00- )....798
Group 15: Diagnostic Information....766
Diagnostic Procedure....882
Diagnose Pneumatic System Malfunctions....802
Pneumatic System Component Location (Machine No. -478832.02)....807
Pneumatic System Schematic (Machine No. -478832.02)....809
Pneumatic System Component Location (Machine No. 479832.00- )....811
Pneumatic System Schematic (Machine No. 479832.00- )....813
Group 25: Tests....766
JT05801 Clamp-On Electronic Tachometer Installation....897
JT02156A Digital Pressure And Temperature Analyzer Installation....899
Unloader Valve Pressure Test and Adjustment....818
Park Brake Valve Pressure Test (Machine No. -478832.02)....822
Park Brake Valve Pressure Test (Machine No. 479832.00- )....826
Engine Accelerator Circuit Pressure Test....830
Section 9025: Hydraulic System....834
Group 05: Theory of Operation....834
Articulated Dump Truck Hydraulic System Overview....837
Articulated Dump Truck Hydraulic System Operation....838
Main Hydraulic Pump Operation....841
Main Hydraulic Pump Load Sense Operation....843
Hydraulic System Manifold Operation....852
Body Control Valve Operation....865
Brake Accumulator Charge Circuit Operation....867
Service Brake Valve Operation....871
Steering and Secondary Steering System Operation....873
Steering Valve Operation....876
Secondary Steering Hydraulic Pump Operation....879
Group 15: Diagnostic Information....834
Diagnostic Procedure....882
Diagnose Hydraulic System Malfunctions....883
Diagnose Steering System Malfunctions....886
Diagnose Service Brake System Malfunctions....889
Hydraulic System Circuit Symbols....890
Hydraulic System Component Location....891
Hydraulic System Schematic....893
Group 25: Tests....834
JT05801 Clamp-On Electronic Tachometer Installation....897
JT05800 Digital Thermometer Installation....898
JT02156A Digital Pressure And Temperature Analyzer Installation....899
Hydraulic Oil Filter Inspection Procedure....900
Hydraulic Oil Cleanup Procedure Using Portable Filter Caddy....901
Hydraulic System Warm-Up Procedure....903
Cycle Time Test....904
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment-(S.N. -200152)....907
Main Hydraulic Pump Residual and Compensator Valves Test and Adjustment-(S.N. 200153- )....913
Body Lower Circuit Relief Valve Test....919
Body Raise Circuit Relief Valve Test....923
Brake Accumulator Pressure Reducing Valve Test and Adjustment....928
Brake Accumulator Charge Valve Band Test and Adjustment....934
Brake Low Pressure Switch and Brake Accumulator Test....939
Service Brake Valve Test....944
Secondary Steering Hydraulic Pump Residual and Compensator Valves Test and Adjustment (S.N. -200152)....948
Secondary Steering Hydraulic Pump Residual and Compensator Valves Test and Adjustment (S.N. 200153- )....961
Steering Load Sense Relief Valve Test and Adjustment....974
Steering Cylinder Leakage Test....977
Section 9031: Heater and Air Conditioner....980
Group 05: Theory of Operation....980
Proper R134a Refrigerant Handling....1037
R134a Refrigerant Cautions....1038
R134a Refrigerant Operation....985
Air Conditioner Compressor Operation....987
Vapor Condenser Operation....988
Receiver-Dryer Operation....989
Expansion Valve Operation....991
Thermocouple Operation....993
Temperature Control Operation....994
Evaporator Operation....995
Heater Core Operation....996
High/Low Pressure Switch Operation....997
Heater and Air Conditioner Electrical Circuit Operation....998
Heater and Air Conditioner Circuit Schematic....999
Group 15: Diagnostic Information....980
Diagnose Air Conditioner Malfunctions....1004
Diagnose Heater System Malfunctions....1007
Heater and Air Conditioner Component Location....1009
Group 20: Adjustments....980
Proper R134a Refrigerant Handling....1037
R134a Refrigerant Cautions....1038
R134a Refrigerant Oil Charge Check....1014
Compressor R134a Refrigerant Oil Removal....1015
R134a Refrigerant Oil Component Charge....1016
R134a Refrigerant Recovery, Recycling, and Charging Station Installation Procedure....1019
Recover R134a System....1021
Evacuate R134a System....1023
Charge R134a System....1026
Air Conditioner Compressor Belt Tension Check and Adjustment....1028
R134A Air Conditioner System Cleaning Procedures....1030
Purge R134a Air Conditioner System....1031
Flush R134a Air Conditioner System....1032
Group 25: Tests....981
Proper R134a Refrigerant Handling....1037
R134a Refrigerant Cautions....1038
Refrigerant Hoses and Tubing Inspection....1039
R134a Air Conditioner System Test....1040
Operating Pressure Diagnostic Chart....1050
Pressure Diagnostic Chart....1050
Thermocouple Test....1051
Leak Testing R134a Air Conditioner System....1053
John Deere / Bell B30C Articulated Dump Truck Operation & Test Service Manual (TM1813)
