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Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
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Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
SERIAL NUMBERS A30301 thru A30303
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Description
Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
Language : English
Pages :937
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
SERIAL NUMBERS A30301 thru A30303
FOREWORD
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
- For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model.
- The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu 930E-2 Dump Truck Shop Manual CEBM012401 – PDF DOWNLOAD
SERIAL NUMBERS A30301 thru A30303
MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – MAJOR COMPONENT DESCRIPTION 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
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 55
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 61
STORAGE AND IDLE MACHINE PREPARATION 63
Short Term Idle Periods 63
PREPARATION FOR STORAGE 64
REMOVAL FROM STORAGE 65
RECONDITIONING AN IDLE VEHICLE 67
ENGINE OPERATION 70
After The Engine Has Started 71
ENGINE STORAGE 72
Preparing Engine For Storage 72
Temporary Storage (30 Days Or Less) 72
Extended Storage (more Than 30 Days) 72
RESTORING AN ENGINE AFTER EXTENDED STORAGE 74
ELECTRIC DRIVE TRUCKS 75
Storage Instructions and Procedures 75
Placing Equipment Into Storage 75
Storing A Truck That Is Operational 75
Storing A Truck That Is Not Operational 76
Storing A Major Component 76
Periodic Inspections 77
Placing Equipment Into Service After Storage 77
When A Truck Is Operational 77
When A Truck Is Not Operational 77
For The First Hour 78
SECTION B – STRUCTURES – INDEX 79
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 81
STRUCTURAL COMPONENTS 83
Preparation 83
GRILLE, HOOD AND LADDER 84
Removal 84
Installation 84
DECKS 85
RIGHT DECK AND COMPONENTS 85
Removal 85
Installation 86
LEFT DECK 86
Removal 86
Installation 86
CENTER DECK 86
SECTION B3 – DUMP BODY – INDEX 87
DUMP BODY 89
Removal 89
Installation 90
BODY PADS 91
Adjustment 91
BODY GUIDE 92
HOIST LIMIT SWITCH 92
BODY UP SWITCH 92
BODY-UP RETENTION CABLE 92
ROCK EJECTORS 93
Rock Ejectors (Type I) 93
Inspection 93
Rock Ejectors (Type II) 94
Inspection 94
SECTION B4 – FUEL TANK – INDEX 95
FUEL TANK 97
Removal 98
Installation 98
Repair 98
Cleaning 98
FUEL GAUGE SENDER 99
Removal 99
Installation 99
LOW FUEL SWITCH 99
WIGGINS QUICK FILL FUEL SYSTEM100
FUEL RECEIVER100
TANK BREATHER VALVE100
Removal100
Installation100
Disassembly100
Assembly100
LEFT SIDE FILL101
SECTION C – ENGINE – INDEX103
SECTION C2 – POWER MODULE – INDEX105
POWER MODULE107
Preparation107
Preparation for Removal108
Removal – Power Module111
Installation – Power Module113
Hookup – Power Module113
SECTION C3 – COOLING SYSTEM – INDEX115
COOLING SYSTEM117
RADIATOR117
Removal – Radiator117
RADIATOR REPAIR119
Internal Inspection119
External Cleaning119
Disassembly120
Cleaning and Inspection121
Assembly121
Pressure Testing122
Additional Service Information122
Installation – Radiator123
RADIATOR FILLING PROCEDURE124
COOLANT SYSTEM TROUBLESHOOTING124
SECTION C4 – POWER TRAIN – INDEX125
POWER TRAIN127
ALTERNATOR127
Removal – Alternator127
ENGINE/ALTERNATOR MATING129
General Instructions129
Measuring Procedure129
Joining The Alternator and Engine131
ENGINE132
Removal132
Service132
Installation132
SECTION C5 – AIR CLEANERS – INDEX133
AIR CLEANERS135
AIR CLEANERS135
Operation135
General Service Information135
FILTER ELEMENT REPLACEMENT136
Main Filter Element Cleaning137
Precleaner Section138
Cleaning Precleaner Tubes138
AIR INTAKE TROUBLESHOOTING139
SECTION C7 – FAN CLUTCH – INDEX141
FAN CLUTCH143
REMOVAL & INSTALLATION TOOLING143
FAN CLUTCH – DISASSEMBLY146
CLEANING AND INSPECTION156
ASSEMBLY – FAN CLUTCH160
TEST PROCEDURE174
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX175
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX177
24VDC ELECTRIC SUPPLY SYSTEM179
ELECTRICAL SYSTEM DESCRIPTION179
BATTERIES179
Maintenance and Service179
Troubleshooting179
BATTERY SUPPLY SYSTEM181
24VDC Battery Charging Alternator181
Battery Box181
Battery Control Box181
Isolation Diodes181
Battery Disconnect Switches182
24VDC Auxiliary Battery Connectors182
Battery Equalizer182
Troubleshooting183
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX185
24 VDC ELECTRICAL SYSTEM COMPONENTS187
PASSENGER SEAT BASE COMPARTMENT187
TRUCK SHUTDOWN PROCEDURE187
COMPONENTS187
Tail Light Resistor Diode Assemblies187
5 Minute Idle Timer Components187
5 Minute Idle Timer189
5 Minute Idle Relay189
5 Minute Idle Contactor189
5 Minute Idle Circuit Test189
Inclinometer189
Brake Warning Buzzer (BWB)189
Alarm Indicating Device (AID) System189
Coolant Level/Flasher189
Temperature and Latch Card190
Hot Switch Inverter Card190
Hot Switch Inverter Card (Slot 4) (Not Used)191
Oil Level Card191
Temperature Card191
Diode Matrix (Without Sound) Card191
Diode Matrix (With Sound) Card191
Lamp Test Switch191
Electrical Interface Cabinet192
Lubrication System Timer192
Lincoln Lube Delay Timer192
Barometric Pressure Transducer192
Pulse Voltage Modulator192
Power Distribution Terminals192
Truck Control Interface Panel192
Kontrol Power Relay192
Circuit Breaker Panel192
Diode Board – DB1194
Diode Testing194
Relay Boards195
Relay Boards: RB1, RB2, RB3, RB4, RB5195
Service195
Relay Board Identification196
Relay Board Functions197
Installing Additional Circuits198
Body Up Switch199
Operation199
Adjustment199
Service199
Hoist Limit Switch200
Operation200
Adjustment200
Service200
CIRCUIT BREAKER CHART201
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX203
BATTERY CHARGING ALTERNATOR205
ELECTRICAL SYSTEM DESCRIPTION205
BATTERY205
Maintenance and Service205
Troubleshooting205
BATTERY CHARGING SYSTEM (Niehoff)207
General Description207
TROUBLESHOOTING PROCEDURES (On-Truck)207
Equipment Required:207
Preliminary Checks208
Test Setup208
Test Procedure208
Regulator Bypass Test209
ON VEHICLE TROUBLESHOOTING GUIDE211
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage211
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:211
CHARGE VOLT AND AMP VALUES212
DEFINITIONS212
ADVANCED SYSTEM TROUBLESHOOTING213
Static Test – Engine OFF, Key ON, Battery Switch ON213
Go To Alternator213
Go To Regulator (If Required)214
Go To Regulator Connector On The Alternator214
ALTERNATOR OVERHAUL215
ALTERNATOR DIMENSIONS215
ALTERNATOR SPECIFICATIONS216
SERVICE PARTS217
ON-VEHICLE TEST219
Equipment:219
Preliminary Checks:219
Test Set-up219
Test Procedure219
ON-VEHICLE TEST220
Bypass Test:220
BENCH TEST221
STATIC TESTS222
Regulator Tests222
Control Box Tests223
ALTERNATOR DISASSEMBLY225
ASSEMBLY- ALTERNATOR230
BF4822 STATOR SERVICE TOOL INSTRUCTIONS239
Stator Removal And Replacement239
Stator Installation240
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX243
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX245
ELECTRICAL PROPULSION SYSTEM COMPONENTS247
GENERAL SYSTEM DESCRIPTION247
SYSTEM COMPONENTS249
Auxiliary Blower System249
Propulsion System Controller (PSC)249
TRUCK CONTROL INTERFACE PANEL (TCI)250
Diagnostic Information Display251
DID PANEL EVENT CODES251
PSC SOFTWARE FUNCTIONS276
Input Processing276
STATE MANAGEMENT276
State Machine276
Transitions Between States277
DC Link State279
Powering the Link279
De-Powering the Link279
Control Functions279
Engine Control279
ALTERNATOR FIELD CONTROL280
Desired Three-Phase Voltage280
Desired DC Link Voltage280
Self-load280
Propel Torque Control281
Retard Torque Control281
Wheel Slide Control281
Resistor Grid Control282
Chopper Voltage Control282
AUXILIARY BLOWER CONTROL282
EVENT PROCESSING282
Event Detection282
Power On Tests282
Initiated Tests283
Periodic Tests283
EVENT RESTRICTIONS283
EVENT LOGGING AND STORAGE283
Event History Buffer284
Data Packs284
To Record and Save a Data Pack to a Floppy Disk284
Event Reset285
SERIAL DATA COMMUNICATIONS286
PSC – TCI Communications processing286
PSC – PTU Communications Processing286
Inverter Communications Processing286
OUTPUT PROCESSING287
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS287
Fast Start287
Engine Shutdown/Engine Not Running287
Limp Home Mode287
Entering/Exiting Limp Home Mode287
PROPULSION SYSTEM COMPONENT ABBREVIATIONS288
ELECTRONIC ACCELERATOR AND RETARD PEDALS298
Removal298
Installation298
Disassembly298
Assembly298
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX299
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE301
AC DRIVE SYSTEM MAINTENANCE301
TRUCK SHUTDOWN PROCEDURES301
NORMAL TRUCK SHUTDOWN PROCEDURE302
SHUTDOWN AFTER SYSTEM FAILURE303
SYSTEM CHECKOUT304
Battery and Control Checks of System WITH Battery Power OFF304
Battery and Control Circuit Checks of System With Battery Power ON307
Checks with Key Switch OFF308
CPU Battery Checks310
MEMORY BACKUP BATTERY REPLACEMENT310
TCI PROGRAMMING311
PSC PROGRAMMING311
INVERTER PROGRAMMING312
TCI CHECKOUT312
Modular Mining Communication Port313
TCI Input Checks314
TCI Digital Output Tests316
TCI Digital Input Tests318
PSC Checkout Procedure320
PSC Digital Input Checks324
Miscellaneous Checks325
A3PV Panel325
LINKV Panel325
Thermistor Checks325
17FM384 Panel Check325
Pedal Percentages and Meter Calibration326
Meter Calibration Procedure326
Reprogram With Serial Numbers and Pedal Percentages328
LOAD TESTING330
Preload Checks330
ADDITIONAL TRUCK CHECKS332
On-Board Load Testing334
Preparation334
Initiate Loadbox Test337
Manual Offset HP Output Adjustment339
TROUBLESHOOTING341
PVM Optimum Load Curve Handshaking Troubleshooting341
MISCELLANEOUS COMPONENT REPAIR342
Troubleshooting Phase Modules and Chopper Modules342
Phase Module Removal and Snubber Resistor Replacement342
Snubber Resistor Installation343
Phase Module Installation343
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING344
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING347
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING348
IGBT TROUBLESHOOTING349
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX351
SECTION G2 – TIRES AND RIMS – INDEX353
TIRES AND RIMS355
WHEEL STUD MAINTENANCE356
FRONT TIRES AND RIMS357
Removal357
Installation358
REAR TIRES AND RIMS359
Removal359
Installation360
RIM361
Tire Removal361
Tire Installation362
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX365
FRONT WHEEL HUB AND SPINDLE367
WHEEL HUB AND SPINDLE ASSEMBLY367
Preparation367
Removal367
Installation – Wheel Hub and Spindle Assembly370
Disassembly – Wheel Hub and Spindle Assembly371
Cleaning and Inspection – Wheel Hub and Spindle Assembly371
Assembly – Wheel Hub and Spindle Assembly373
Wheel Bearing Adjustment:373
Brake Installation374
Seal Assembly Gap Check375
STEERING CYLINDERS AND TIE ROD376
Spherical Bearing Wear Limits376
Removal – Steering Cylinder and Tie Rod377
Installation – Steering Cylinder and Tie Rod378
Bearing Replacement378
TOE-IN ADJUSTMENT379
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX381
REAR AXLE HOUSING ATTACHMENT383
PIVOT PIN383
Removal383
Installation383
PIVOT EYE BEARING384
Disassembly384
Assembly384
PIVOT EYE REPAIR385
Removal385
Disassembly385
Assembly385
Installation385
ANTI-SWAY BAR386
Removal386
Installation386
Disassembly386
Cleaning and Inspection386
Assembly386
SECTION G5 – REAR AXLE HOUSING – INDEX387
REAR AXLE HOUSING389
REAR AXLE HOUSING389
Preparation389
Removal389
Cleaning and Inspection – Rear Axle Housing391
Installation – Rear Axle Housing391
WHEEL MOTOR392
Preparation392
Removal392
Cleaning and Inspection – Wheel Motor393
Installation – Wheel Motor394
WHEEL MOTOR GEAR OIL397
Filtering Requirements397
Particle Size Analysis397
Flushing397
Oil Sample Analysis398
ELEMENT SPECIFICATION CHARTS399
SECTION H – HYDRAIR II SUSPENSIONS – INDEX403
SECTION H2 – FRONT SUSPENSIONS – INDEX405
FRONT SUSPENSION407
Removal407
Installation – Front Suspension408
“Turn-Of-The-Nut” Tightening Procedure411
MINOR REPAIRS (LOWER BEARING & SEALS)412
Removal – Bearing Retainer412
Installation – Bearing Retainer412
MAJOR SUSPENSION REBUILD414
Disassembly414
Assembly414
SECTION H3 – REAR SUSPENSIONS – INDEX417
REAR SUSPENSIONS419
Removal419
Installation – Rear Suspension421
Disassembly – Rear Suspension422
Cleaning and Inspection – Rear Suspension422
Assembly – Rear Suspension422
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX425
SUSPENSION OILING AND CHARGING PROCEDURE427
GENERAL427
EQUIPMENT LIST427
Hydrair® Charging Kit427
Installation of Charging Kit427
Removal of Charging Kit428
Support Blocks For Oiling And Charging Dimensions428
FRONT SUSPENSION429
Front Suspension Oiling429
Front Suspension Nitrogen Charging430
REAR SUSPENSION431
Rear Suspension Oiling431
Rear Suspension Nitrogen Charging432
OIL AND NITROGEN SPECIFICATIONS CHART434
SECTION J – BRAKE CIRCUIT – INDEX435
SECTION J2 – BRAKE CIRCUIT – INDEX437
BRAKE CIRCUIT439
SERVICE BRAKE CIRCUIT439
SECONDARY BRAKING AND AUTOMATIC APPLY441
PARKING BRAKE CIRCUIT441
BRAKE LOCK CIRCUIT442
WARNING CIRCUIT442
Rear Axle Brake Lines444
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX445
BRAKE CIRCUIT COMPONENT SERVICE447
BRAKE VALVE447
Rebuild Criteria447
Removal448
Installation448
DISASSEMBLY449
Cleaning and Inspection452
ASSEMBLY452
Actuator Base Threaded Inserts452
Boot and Cap452
Valve Body Seal Installation452
Regulator Sleeve O-Ring Installation453
Actuator Plunger O-ring Installation453
Assembly of Valve453
DIFFERENTIAL PRESSURE SWITCH455
Disassembly455
Cleaning and Inspection455
Assembly455
VALVE BENCH TEST AND ADJUSTMENT456
Test Set Up Procedure457
Brake Valve Output Pressure Adjustment457
Differential Pressure Switch Adjustment457
Final Test and Adjustment458
Installation Of Brake Pedal Actuator Assembly to Brake Valve459
Installation of Retard Pedal To Brake Pedal459
DUAL RELAY VALVE461
Removal461
Installation461
Disassembly463
Cleaning and Inspection463
Assembly463
DIFFERENTIAL PRESSURE SWITCH464
Disassembly464
Cleaning and Inspection464
Assembly464
VALVE TEST AND ADJUSTMENT465
Test Set Up Procedure466
Brake Valve Output Pressure Adjustment466
Differential Pressure Switch Adjustment467
BRAKE MANIFOLD468
Removal468
Installation469
Disassembly469
Cleaning and Inspection469
Assembly469
HYDRAULIC BRAKE ACCUMULATORS470
Brake Accumulator Bleed Down Procedure470
ACCUMULATORS – BRAKE CABINET470
Removal470
Installation470
Disassembly470
Cleaning and Inspection472
Assembly472
ACCUMULATORS – FRAME MOUNTED474
Removal474
Installation474
Disassembly475
Cleaning and Inspection476
Assembly476
ACCUMULATOR CHARGING PROCEDURE478
Temperature During Precharge480
Precharge Maintenance480
ACCUMULATOR STORAGE481
Installing A Bladder Accumulator From Storage481
Bladder Storage Procedures481
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)482
Removal482
Installation482
Disassembly and Adjustment482
Potentiometer Check484
Assembly484
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX485
BRAKE CIRCUIT CHECK-OUT PROCEDURE487
EQUIPMENT REQUIRED489
INITIAL SYSTEM SET-UP490
BRAKE SYSTEM CHECKOUT491
Failure Modes Check-Out492
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING495
CHECK-OUT PROCEDURE499
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX501
WET DISC BRAKE ASSEMBLY503
OPERATION503
MAINTENANCE504
Brake Disc Wear Indicator504
Removal/Installation – Wet Disc Brake Assembly504
BRAKE REBUILD506
Disassembly506
Cleaning and Inspection509
Assembly510
Floating Ring Seal Assembly/Installation513
WET DISC BRAKE BLEEDING PROCEDURE516
SECTION J7 – PARKING BRAKE – INDEX517
PARKING BRAKE519
OPERATION519
MAINTENANCE520
Inspection – Parking Brake520
Removal – Parking Brake520
Installation – Parking Brake521
Disassembly – Parking Brake522
Cleaning and Inspection – Parking Brake522
Assembly – Parking Brake522
PARKING BRAKE BLEEDING PROCEDURE524
SECTION L – HYDRAULIC SYSTEM – INDEX525
SECTION L2 – HYDRAULIC SYSTEM – INDEX527
HYDRAULIC SYSTEM529
HYDRAULIC PUMP MODULE529
HOIST CIRCUIT OPERATION530
STEERING CIRCUIT OPERATION532
DISC BRAKE COOLING SYSTEM534
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX537
HYDRAULIC SYSTEM COMPONENT REPAIR539
HOIST PUMP539
Removal539
Installation541
INSPECTION OF PARTS546
Assembly546
HYDRAULIC TANK552
Filling Instructions552
Removal552
Installation553
HYDRAULIC TANK STRAINERS553
Removal553
Inspect and Clean553
Installation553
HYDRAULIC TANK BREATHERS554
SECTION L4 – STEERING CIRCUIT – INDEX555
STEERING CIRCUIT557
COMPONENT DESCRIPTION558
Steering Control Unit558
Bleeddown Manifold Valve559
Bleeddown Solenoid559
Relief Valves561
Hoist Limit Solenoid561
Accumulators561
Low Precharge Warning Switch561
High Pressure Filter561
Quick Disconnect Ports561
Flow Amplifier562
FLOW AMPLIFIER SYSTEM OPERATION564
No Steer564
Steering Left566
Steering Right568
No Steer, External Shock Load570
STEERING PUMP572
Operation572
PRINCIPLE OF OPERATION574
Full Pump Volume:574
Half Pump Volume:574
Neutral Position:574
Steering Pump575
SECTION L5 – STEERING CONTROL UNIT – INDEX577
STEERING CONTROL UNIT579
Removal579
Installation579
STEERING CONTROL UNIT REBUILD580
Disassembly580
Cleaning and Inspection – Steering Control Unit581
Assembly – Steering Control Unit583
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX587
STEERING CIRCUIT COMPONENT REPAIR589
BLEEDDOWN MANIFOLD VALVE589
Removal589
Installation589
FLOW AMPLIFIER590
Removal590
Installation590
FLOW AMPLIFIER REBUILD590
Disassembly592
Assembly593
STEERING CYLINDERS594
Disassembly595
Piston Seal & Bearing Installation595
Cylinder Assembly595
Test595
STEERING AND BRAKE PUMP596
Removal596
Installation596
Disassembly598
Control Piston Group598
Valve Plate Group598
Rotating Group601
Swashblock Group601
Driveshaft Group601
Inspection601
Control Piston Group601
Valve Plate Group601
Rotating Group601
Swashblock Group603
Driveshaft Group604
Compensator Block and Unloader Module604
Stroke Adjuster Assembly604
Assembly604
Swashblock Group604
Driveshaft Group605
Rotating Group605
Valve Plate Group606
STEERING ACCUMULATORS607
Removal607
Installation607
Disassembly608
Cleaning and Inspection609
Steering Accumulator Charging Procedure611
TROUBLESHOOTING CHART612
SECTION L7 – HOIST CIRCUIT – INDEX617
HOIST CIRCUIT619
HOIST CIRCUIT OPERATION619
COMPONENT DESCRIPTION620
Hydraulic Tank620
Hydraulic Pump620
High Pressure Filters620
Hoist Valve620
Inlet Sections – Hoist Valve620
Spool Sections – Hoist Valve621
Hoist Pilot Valve621
Bleeddown Manifold622
Hoist-up Limit Solenoid622
Pilot Operated Check Valve622
Overcenter Manifold622
HOIST CIRCUIT OPERATION623
Float Position Of Pilot Valve With Truck Body On Frame624
Power Up Operation626
Hold Operation628
Power Down Operation630
Float Operation632
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX635
HOIST CIRCUIT COMPONENT REPAIR637
HOIST VALVE637
Removal637
Installation638
O-Ring Replacement638
INLET SECTION639
Disassembly639
Cleaning and Inspection640
Assembly640
REAR SPOOL SECTION (Work Ports)640
Disassembly640
Cleaning and Inspection642
Assembly642
FRONT SPOOL SECTION (Tank Ports)643
Disassembly643
Cleaning and Inspection643
Assembly643
HOIST PILOT VALVE645
Removal645
Installation645
Disassembly646
Cleaning and Inspection647
Assembly647
HOIST CYLINDERS648
Removal648
Installation649
Disassembly651
Cleaning and Inspection652
Assembly – Quill and Cylinder653
Quill Installation653
Installation Of Check Balls And Plugs In Quill654
Assembly of Cylinder655
OVERCENTER VALVE MANIFOLD656
DISABLED TRUCK DUMPING PROCEDURE657
Hookup657
Raising the Body657
Lowering the Body657
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX659
HYDRAULIC SYSTEM FILTERS661
HOIST CIRCUIT FILTER661
Filter Element Replacement661
Removal – Hoist Circuit Filter662
Installation – Hoist Circuit Filter662
Indicator Switch – Hoist Circuit Filter662
STEERING CIRCUIT FILTER663
Filter Element Replacement663
Removal – Steering Circuit Filter664
Installation – Steering Circuit Filter664
Indicator Switch – Steering Circuit Filter664
INDICATOR SWITCH664
Test Procedure664
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX667
HYDRAULIC CHECK-OUT PROCEDURE669
GENERAL INFORMATION669
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE669
Equipment Requirements670
Pump Pressure Control Adjustments670
Steering Control Unit and Flow Amplifier Leakage Test671
Bleeddown Manifold Leakage Test671
STEERING/BRAKE PUMP STROKE ADJUSTMENT672
SHOCK AND SUCTION VALVES673
Equipment Requirements673
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES674
Equipment Requirements674
Pressure Gauge Locations674
Brake Cooling Circuit Test674
Power Up Relief Pressure Test675
Adjustment675
Power Down Relief Pressure Test676
Hoist Counterbalance Valve Adjustment Preparation677
Counterbalance Valve Pressure Check677
Counterbalance Valve Adjustment678
Preparation679
Flushing Procedure679
Filter Element Replacement680
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET681
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET682
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX683
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX685
FIRE CONTROL SYSTEM (MANUAL)687
Operation687
Inspection and Maintenance687
Recharging Procedures688
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1689
Control Module689
Actuator690
Linear Detection Wire690
Power Wire690
Test Kit690
Squib690
Securing the Detection Wire691
Preliminary Test Before Final Hook-Up691
Installation Procedure for Squib693
Placing the Electric Detection & Actuation System Into Service693
INSPECTION AND MAINTENANCE SCHEDULES694
Daily694
Normal Maintenance Based On Actual Operating Hours694
IN CASE OF FIRE695
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM697
SECTION M8 – SPECIAL TOOLS699
SECTION M20 – PAYLOAD METER III – INDEX705
OPERATION SECTION709
Introduction709
Data Summary709
Data Gathering709
COMPONENT DESCRIPTION710
System Diagram710
Suspension Pressure Sensors710
Inclinometer710
Operator Display710
Operator Switch711
Speed Input711
Body-Up Switch711
Brake Lock Switch711
Payload Meter711
Communications Ports711
Keyswitch Input712
Payload Meter Power712
Load Lights712
Wiring and Termination713
TCI Outputs713
OPERATOR’S DISPLAY AND SWITCH714
Reading the Speedometer714
Reading the Load Display714
Using the Operator ID714
Using the Load and Ton Counter714
Total Ton Counter714
Total Load Counter715
Clearing the Counters715
Viewing Live Sensor Data715
Other Display Messages715
PAYLOAD OPERATION & CALCULATION716
Description of Haul Cycle States716
Haul Cycle Description716
Load Calculation717
Carry Back717
Measurement Accuracy717
SOURCES FOR PAYLOAD ERROR717
Payload Error717
Loading Conditions718
Pressure Sensors718
Swingloads718
Speed and Distance718
HAUL CYCLE DATA718
Haul Cycle Data719
Haul Cycle Warning Flags720
M: Haul Cycle Too Long721
N: Sensor Input Error721
Frame Torque Data721
Sprung Weight Data721
Maximum Speed Data721
Alarm Records721
Fault Code Data722
PC SOFTWARE OVERVIEW723
PC Overview723
System Configuration723
Installing the PLMIII Software723
DOWNLOADING DATA724
PLM III SYSTEM CONFIGURATION725
Starting Communications725
Displayed Payload Units725
Time Units725
Connection Menu725
Connecting to the Payload Meter726
Configure the Payload Meter726
Setting the Date and Time726
Setting the Truck Type727
Setting the Gauge Display Units727
Setting the Frame Serial Number727
Setting the Truck Number727
Setting the Komatsu Distributor727
Setting the Komatsu Customer727
Clean Truck Tare728
Inclinometer Calibration728
DATA ANALYSIS729
Creating a Query729
Sorting on Truck Unit Number729
Sorting on Truck Type729
Sorting on Date Range730
Sorting on Time Range730
Payload Detail Screen731
Creating Reports731
Summary – one page report732
Detailed – multi-page report732
Creating Graphs733
Exporting Data733
CSV Export733
Compressed734
Importing Data735
Deleting Haul Cycle Records735
Viewing Alarms736
Deleting Alarm Records736
TROUBLESHOOTING SECTION737
TROUBLESHOOTING737
Viewing Active Alarms737
Real-Time Data Display737
Testing the Payload Lights737
Creating Log Files of Inputs738
Daily Inspections738
Periodic Maintenance738
Abnormal Displays at Power-Up739
No Payload Display When Keyswitch is Turned ON740
No Display on Speedometer741
No Display on Operator Display741
No Communications With PC742
Load Lights Don’t Light During Loading743
Load Lights Remain ON744
Load Lights Remain ON During Dumping744
Display Doesn’t Clear When The Load Is Dumped744
Calibration Problems745
Alarm 1 – Left Front Pressure High746
Alarm 2 – Left Front Pressure Low746
Troubleshoot Wiring to Left Front Suspension746
Alarm 3 – Right Front Pressure High747
Alarm 4 – Right Front Pressure Low747
Troubleshoot Wiring to Right Front Suspension747
Alarm 5 -Left Rear Pressure High748
Alarm 6 – Left Rear Pressure Low748
Troubleshoot Wiring to Left Rear Suspension748
Alarm 7 – Right Rear Pressure High749
Alarm 8 – Right Rear Pressure Low749
Troubleshoot Wiring to Right Rear Suspension749
Alarm 9 – Inclinometer High750
Alarm 10 – Inclinometer Low750
Troubleshoot Inclinometer Wiring750
Alarm 13 – Body Up Input Failure751
Alarm 16 – Memory Write Failure752
Alarm 17 – Memory Read Failure752
Alarm 18753
Alarm 19753
Alarm 22753
Operator Switch Doesn’t Work754
Alarm 26 – User Switch Fault – SELECT754
Alarm 27 – User Switch Fault – SET754
Connector Map755
Connectors756
PLMIII CHECK OUT PROCEDURE757
General Description757
Tools Required757
Checkout Procedure757
PLMIII CHECKOUT PROCEDURE CONFIRMATION761
Flashburn Programming761
Confirmation Checklist763
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX765
RESERVE ENGINE OIL SYSTEM767
Operation768
LED Monitor Light768
Tank Fill Control (Optional)769
Filling Procedure (Remote fill feature)769
SERVICE770
Every 10 Hours, or once each shift:770
Every 500 Hours:770
Changing Oil770
TROUBLESHOOTING771
Circuit Breaker or Fuse771
SYSTEM ELECTRICAL SCHEMATICS772
SECTION N – CAB COMPONENTS – INDEX773
SECTION N2 – TRUCK CAB – INDEX775
TRUCK CAB777
Description777
Preparation778
Removal – Cab778
Installation – Cab780
CAB DOOR780
Removal780
Installation780
Door Adjustment781
Door Jamb Bolt Adjustment781
Door Handle Plunger Adjustment782
Door Glass Replacement783
Door Window Regulator Replacement787
Door Handle or Latch Assembly Replacement787
Door and Door Hinge Seal Replacement788
Door Opening Seal Removal788
Installation788
GLASS REPLACEMENT789
Adhesive Bonded Windows789
Replacement Procedure789
Windshield And Rear Glass790
Removal790
Installation791
SECTION N3 – CAB COMPONENTS – INDEX793
CAB COMPONENTS795
WINDSHIELD WIPERS795
Wiper Motor Replacement795
Removal795
Installation795
Wiper Arm Replacement795
Removal795
Installation796
Wiper Linkage Replacement796
Removal796
Installation796
WINDSHIELD WASHER797
Operation797
Service797
OPERATOR COMFORT798
OPERATOR SEAT798
Adjustment798
SECTION N4 – OPERATOR COMFORT – INDEX799
OPERATOR COMFORT801
HEATER / AIR CONDITIONER801
Operation801
Heater/Air Conditioner Vents801
COMPONENTS802
Circuit Breakers802
Relays802
Heater Core802
Fan Motor And Speed Control803
Actuators803
Filter803
Service803
AIR CONDITIONING SYSTEM805
Environmental Impact805
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES806
PRINCIPLES OF REFRIGERATION806
Air Conditioning806
Refrigeration – The Act Of Cooling807
The Refrigeration Cycle807
AIR CONDITIONER SYSTEM COMPONENTS808
Compressor (Refrigerant Pump)808
Service Valves808
Condenser808
Receiver-Drier808
Expansion Block Valve809
Accumulator809
Evaporator809
ELECTRICAL CIRCUIT810
Thermostat810
Compressor Clutch810
Trinary™ Switch811
SYSTEM SERVICING812
SERVICE TOOLS AND EQUIPMENT813
Recovery/Recycle Station813
Leak Detector813
Service Valves814
Vacuum Pump814
Manifold Gauge Set815
Installing Manifold Gauge Set816
Purging Air From Service Hoses816
SYSTEM PERFORMANCE TEST817
SYSTEM OIL818
Handling and Reusing PAG Oil818
Oil Quantity818
Checking System Oil818
REFRIGERANT819
Recycled Refrigerant819
Reclaimed Refrigerant819
Refrigerant Quantity819
R-134a Refrigerant Containers819
SYSTEM LEAK TESTING820
Electronic Leak Detector820
Tracer Dyes820
Soap and Water820
RECOVERING AND RECYCLING THE REFRIGERANT821
Performing the Recovery Cycle821
Performing the Recycling Procedure821
Evacuating and Charging the A/C System821
SYSTEM REPAIR822
System Flushing822
COMPONENT REPLACEMENT822
Hoses and Fittings822
Lines822
Expansion Valve823
Receiver-Drier823
Thermostat823
Compressor823
Accumulator823
Clutch824
Servicing the Compressor Clutch824
Pulley Removal826
Clutch Coil Check827
Pulley Installation827
Clutch Assembly Installation827
EVACUATING THE SYSTEM829
CHARGING THE A/C SYSTEM831
TROUBLESHOOTING832
Preliminary Checks832
Diagnosis Of Gauge Readings And System Performance832
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS833
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM839
SECTION N5 – OPERATOR CAB CONTROLS – INDEX841
OPERATOR CAB CONTROLS843
STEERING COLUMN843
Removal843
Steering Column Inspection843
Installation843
STEERING WHEEL AND CONTROLS845
Horn Button845
Telescope Lock Ring845
Tilt Wheel Lever845
Turn Signal/Headlight Dimmer845
DYNAMIC RETARDING845
Retarder Control Lever846
Dynamic Retarder/Service Brake Pedal846
Accelerator (Throttle) Pedal846
Starting on a Grade With a Loaded Truck846
GRADE/SPEED RETARD CHART847
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS848
Heater/Air Conditioner Vents848
INSTRUMENT PANEL849
OVERHEAD PANEL AND DISPLAYS849
CENTER CONSOLE850
F-N-R Selector Switch850
Hoist Control Lever851
Raising The Dump Body851
Lowering The Dump Body851
Ash Tray851
Lighter851
LH Window Control Switch851
RH Window Control Switch851
Engine Shutdown Switch851
Override/Fault Reset Switch852
Retard Speed Control (RSC) Switch852
Retard Speed Control (RSC) Adjust Dial852
PSC Download Port853
Engine Diagnostics Download Port853
Engine Control System853
TCI Download Port853
Passenger Seat853
PAYLOAD METER853
Payload Meter Download Connector853
INSTRUMENT PANEL AND INDICATOR LIGHTS855
CONTROL SYMBOLS855
INSTRUMENT PANEL855
PANEL GAUGES, INDICATORS, AND CONTROLS857
Key Switch857
Starting857
Cold Weather Starting857
Normal Engine Shutdown857
Engine Shutdown Switch with 5 Minute Idle Timer Delay858
Fog Lights (Optional)858
Ladder Light Switch858
Manual Backup Switch858
Panel Illumination Lights859
Cab/Air Conditioner Vents859
Rotating Beacon Light Switch (Optional)859
Heated Mirror Switch (Optional)859
Wheel Brake Lock Control859
Parking Brake Control859
Tachometer860
Right Turn Signal Indicator860
High Beam Indicator860
Left Turn Signal Indicator860
Speedometer860
Voltmeter860
Engine Oil Pressure Gauge860
Water Temperature Gauge860
Fuel Gauge860
AC Drive System Temperature Gauge861
Hydraulic Oil Temperature Gauge861
Hourmeter861
Rest Switch861
Light Switch862
Windshield Wiper and Washer862
Panel Light Dimmer862
OVERHEAD STATUS / WARNING INDICATORS863
STATUS / WARNING INDICATOR LIGHT SYMBOLS864
Hazard Warning Lights869
Lamp Test Switch869
Link-On Warning Light869
SECTION P – LUBRICATION AND SERVICE – INDEX871
SECTION P2 – LUBRICATION AND SERVICE – INDEX873
LUBRICATION AND SERVICE875
930E SERVICE CAPACITIES875
HYDRAULIC TANK SERVICE875
Adding Oil875
WHEEL MOTOR SERVICE875
COOLANT LEVEL CHECK876
RADIATOR FILLING PROCEDURE876
RESERVE ENGINE OIL SYSTEM (Optional)876
Reserve Oil Tank Filling Procedure (Remote fill)876
LUBRICATION CHART877
10 HOUR (DAILY) INSPECTION878
50 HOUR LUBRICATION AND MAINTENANCE CHECKS881
100 HOUR LUBRICATION AND MAINTENANCE CHECKS882
250 HOUR LUBRICATION AND MAINTENANCE CHECKS883
500 HOUR LUBRICATION AND MAINTENANCE CHECKS886
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS887
5000 HOUR MAINTENANCE CHECKS888
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX889
AUTOMATIC LUBRICATION SYSTEM891
GENERAL DESCRIPTION891
SYSTEM COMPONENTS893
SYSTEM OPERATION894
Normal Operation894
Pressure Failure Detection Circuits895
INJECTOR OPERATION896
GENERAL INSTRUCTIONS897
LUBRICANT REQUIREMENTS897
System Priming897
LUBRICANT PUMP897
Pump Housing Oil Level897
Pump Pressure Control897
Pressure Control Valve Adjustment897
INJECTORS (SL-1 Series “H”))898
Injector Specifications898
Injector Adjustment898
SYSTEM CHECKOUT898
Lubrication Cycle Timer Check899
Lubrication Cycle Timer Adjustment899
FILTER ASSEMBLY899
PUMP REBUILD900
Disassembly900
Cleaning and Inspection900
Assembly902
SYSTEM TROUBLESHOOTING CHART903
PREVENTATIVE MAINTENANCE PROCEDURES906
Daily Lubrication System Inspection906
250 Hour Inspection906
1000 Hour Inspection906
SECTION Q ALPHABETICAL INDEX907
SECTION R – SYSTEM SCHEMATICS – INDEX911
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH347913
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH357914
PLM III ELECTRICAL SYSTEM SCHEMATIC – HE479915
PLM III HOOK-UP WIRING – HE483916
ELECTRICAL SCHEMATIC – XS0500917
IMAGES PREVIEW OF THE MANUAL:
S.M 15/12/24
