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Komatsu 930E-3 Dump Truck Shop Manual A30364-A30461 – PDF DOWNLOAD
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Komatsu 930E-3 Dump Truck Shop Manual
SERIAL NUMBERS: A30364 – A30461
Book Code: CEBM015700
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Description
Komatsu 930E-3 Dump Truck Shop Manual
FILE DETAILS:
Komatsu 930E-3 Dump Truck Shop Manual
Language : English
Pages : 1043
Downloadable : Yes
File Type : PDF
Size: 31.4MB
Book Code: CEBM015700
DESCRIPTION:
Komatsu 930E-3 Dump Truck Shop Manual
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 per- sonnel should read and understand the materials in this manual before perfomiing maintenance andlor 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 gen- eral infomiation. 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 othemise.
- 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 Mm) torque. All torque specifications have ae10% tolerance unless otherwise specified. A Product Identification plate is nomially located on the truck frame in front of the right side front wheel and desig- nates 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 man- ufacturing bfll 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-3 Dump Truck Shop Manual
MAIN MENU................................................................................. 0 COVER..................................................................................... 0 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 & 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 - INDEX.................... 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 PSC 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 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING.............................. 424 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING.............................. 427 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING...................................... 428 IGBT TROUBLESHOOTING.......................................................... 429 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX........................................ 431 SECTION G2 - TIRES AND RIMS - INDEX................................................... 433 TIRES AND RIMS.................................................................... 435 WHEEL STUD MAINTENANCE........................................................ 436 FRONT TIRES AND RIMS.......................................................... 437 Removal................................................................... 437 Installation.............................................................. 438 REAR TIRES AND RIMS........................................................... 439 Removal................................................................... 439 Installation.............................................................. 440 RIM........................................................................... 441 Tire Removal.............................................................. 441 Tire Installation......................................................... 442 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...................................... 445 FRONT WHEEL HUB AND SPINDLE....................................................... 447 WHEEL HUB AND SPINDLE ASSEMBLY................................................ 447 Preparation............................................................... 447 Removal................................................................... 447 Installation - Wheel Hub and Spindle Assembly............................. 450 Disassembly - Wheel Hub and Spindle Assembly.............................. 451 Cleaning and Inspection - Wheel Hub and Spindle Assembly.................. 451 Assembly - Wheel Hub and Spindle Assembly................................. 453 Wheel Bearing Adjustment:................................................. 453 Brake Installation........................................................ 454 Seal Assembly Gap Check................................................... 455 STEERING CYLINDERS AND TIE ROD................................................ 456 Spherical Bearing Wear Limits............................................. 456 Removal - Steering Cylinder and Tie Rod................................... 457 Installation - Steering Cylinder and Tie Rod.............................. 458 Bearing Replacement....................................................... 458 TOE-IN ADJUSTMENT............................................................. 459 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX..................................... 461 REAR AXLE HOUSING ATTACHMENT...................................................... 463 PIVOT PIN..................................................................... 463 Removal................................................................... 463 Installation.............................................................. 464 PIVOT EYE BEARING............................................................. 465 Removal................................................................... 465 Installation.............................................................. 465 PIVOT EYE REPAIR.............................................................. 465 Removal................................................................... 465 Disassembly............................................................... 465 Assembly.................................................................. 466 Installation.............................................................. 466 ANTI-SWAY BAR................................................................. 466 Removal................................................................... 466 Installation.............................................................. 467 Disassembly............................................................... 467 Cleaning and Inspection................................................... 467 Assembly.................................................................. 467 SECTION G5 - REAR AXLE HOUSING - INDEX................................................ 469 REAR AXLE HOUSING................................................................. 471 REAR AXLE HOUSING............................................................. 471 Preparation............................................................... 471 Removal................................................................... 471 Cleaning and Inspection - Rear Axle Housing............................... 473 Installation - Rear Axle Housing.......................................... 473 WHEEL MOTOR................................................................... 474 Preparation............................................................... 474 Removal................................................................... 474 Cleaning and Inspection - Wheel Motor..................................... 475 Installation - Wheel Motor................................................ 476 WHEEL MOTOR GEAR OIL.......................................................... 479 Filtering Requirements.................................................... 479 Particle Size Analysis.................................................... 479 Flushing.................................................................. 479 Oil Sample Analysis....................................................... 480 ELEMENT SPECIFICATION CHARTS.................................................. 481 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................ 485 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................ 487 FRONT SUSPENSION.................................................................. 489 Removal....................................................................... 489 Installation - Front Suspension............................................... 490 "Turn-Of-The-Nut" Tightening Procedure........................................ 493 MINOR REPAIRS (LOWER BEARING & SEALS)......................................... 494 Removal - Bearing Retainer................................................ 494 Installation - Bearing Retainer........................................... 494 MAJOR SUSPENSION REBUILD...................................................... 496 Disassembly............................................................... 496 Assembly.................................................................. 496 SECTION H3 - REAR SUSPENSIONS - INDEX................................................. 499 REAR SUSPENSIONS.................................................................. 501 SUSPENSION CYLINDER........................................................... 502 Removal................................................................... 502 Installation - Rear Suspension............................................ 504 Disassembly - Rear Suspension............................................. 504 Cleaning and Inspection - Rear Suspension................................. 504 Assembly - Rear Suspension................................................ 505 SUSPENSION PRESSURE TEST...................................................... 507 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX......................... 509 SUSPENSION OILING AND CHARGING PROCEDURE.......................................... 511 GENERAL....................................................................... 511 EQUIPMENT LIST................................................................ 511 Hydrair® Charging Kit..................................................... 511 Installation of Charging Kit.............................................. 511 Removal of Charging Kit................................................... 512 Support Blocks For Oiling And Charging Dimensions......................... 512 FRONT SUSPENSION.............................................................. 513 Front Suspension Oiling................................................... 513 Front Suspension Nitrogen Charging........................................ 514 REAR SUSPENSION............................................................... 515 Rear Suspension Oiling.................................................... 515 Rear Suspension Nitrogen Charging......................................... 517 OIL AND NITROGEN SPECIFICATIONS CHART............................................. 518 SECTION J - BRAKE CIRCUIT - INDEX......................................................... 519 SECTION J2 - BRAKE CIRCUIT - INDEX.................................................... 521 BRAKE CIRCUIT..................................................................... 523 SERVICE BRAKE CIRCUIT......................................................... 523 SECONDARY BRAKING AND AUTOMATIC APPLY......................................... 525 PARKING BRAKE CIRCUIT......................................................... 525 Normal Operation (key switch on, engine running).......................... 525 BRAKE LOCK CIRCUIT............................................................ 526 WARNING CIRCUIT............................................................... 526 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.................................. 529 BRAKE CIRCUIT COMPONENT SERVICE................................................... 531 BRAKE VALVE................................................................... 531 Rebuild Criteria.......................................................... 531 Removal................................................................... 532 Installation.............................................................. 532 Disassembly............................................................... 533 Cleaning and Inspection................................................... 536 Assembly.................................................................. 536 Actuator Base Threaded Inserts............................................ 536 Boot and Cap.............................................................. 536 Valve Body Seal Installation.............................................. 536 Regulator Sleeve O-Ring Installation...................................... 537 Actuator Plunger O-ring Installation...................................... 537 Assembly of Valve......................................................... 537 DIFFERENTIAL PRESSURE SWITCH.................................................. 539 Disassembly............................................................... 539 Cleaning and Inspection................................................... 539 Assembly.................................................................. 539 VALVE BENCH TEST AND ADJUSTMENT............................................... 540 Test Set Up Procedure..................................................... 541 Brake Valve Output Pressure Adjustment.................................... 541 Differential Pressure Switch Adjustment................................... 541 Final Test and Adjustment................................................. 542 Installation Of Brake Pedal Actuator Assembly to Brake Valve.............. 543 Installation of Retard Pedal To Brake Pedal............................... 543 DUAL RELAY VALVE.............................................................. 545 Removal................................................................... 545 Installation.............................................................. 545 Disassembly............................................................... 547 Cleaning and Inspection................................................... 547 Assembly.................................................................. 547 DIFFERENTIAL PRESSURE SWITCH.................................................. 548 Disassembly............................................................... 548 Cleaning and Inspection................................................... 548 Assembly.................................................................. 548 VALVE TEST AND ADJUSTMENT..................................................... 549 Test Set Up Procedure..................................................... 550 Relay Valve Output Pressure Adjustment.................................... 550 Differential Pressure Switch Adjustment................................... 551 BRAKE MANIFOLD................................................................ 552 Removal................................................................... 552 Installation.............................................................. 553 Disassembly............................................................... 553 Cleaning and Inspection................................................... 553 Assembly.................................................................. 553 BRAKE ACCUMULATORS............................................................ 554 Brake Accumulator Bleeddown Procedure..................................... 554 BRAKE ACCUMULATOR REPAIR...................................................... 555 Removal................................................................... 555 Installation.............................................................. 555 Disassembly............................................................... 556 Cleaning and Inspection................................................... 557 Assembly.................................................................. 557 ACCUMULATOR CHARGING PROCEDURE................................................ 559 Temperature During Precharge.............................................. 560 Precharge Maintenance..................................................... 561 Recharging Accumulators................................................... 561 Accumulator Storage procedures............................................ 562 Bladder Storage Procedures................................................ 562 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).................................. 563 Removal....................................................................... 563 Installation.................................................................. 563 Disassembly and Adjustment.................................................... 563 Potentiometer Check........................................................... 565 Assembly...................................................................... 565 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................ 567 BRAKE CIRCUIT CHECK-OUT PROCEDURE................................................. 569 REQUIRED EQUIPMENT............................................................ 571 INITIAL SYSTEM SET-UP......................................................... 572 BRAKE SYSTEM CHECKOUT......................................................... 573 Failure Modes Check-Out................................................... 574 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART............................... 576 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................. 579 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................. 580 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX.......................................... 581 WET DISC BRAKE ASSEMBLY........................................................... 583 OPERATION..................................................................... 583 MAINTENANCE................................................................... 584 Brake Disc Wear Indicator................................................. 584 Removal/Installation - Wet Disc Brake Assembly............................ 584 BRAKE REBUILD................................................................. 586 Disassembly............................................................... 586 Cleaning and Inspection................................................... 589 Assembly.................................................................. 590 Floating Ring Seal Assembly/Installation.................................. 593 WET DISC BRAKE BLEEDING PROCEDURE............................................. 596 SECTION J7 - PARKING BRAKE - INDEX.................................................... 597 PARKING BRAKE..................................................................... 599 OPERATION..................................................................... 599 MAINTENANCE................................................................... 600 Inspection - Parking Brake................................................ 600 Removal - Parking Brake................................................... 600 Installation - Parking Brake.............................................. 601 Disassembly - Parking Brake............................................... 602 Cleaning and Inspection - Parking Brake................................... 602 Assembly - Parking Brake.................................................. 602 PARKING BRAKE BLEEDING PROCEDURE.............................................. 604 SECTION L - HYDRAULIC SYSTEM - INDEX...................................................... 605 SECTION L2 - HYDRAULIC SYSTEM - INDEX................................................. 607 HYDRAULIC SYSTEM.................................................................. 609 HYDRAULIC PUMP MODULE......................................................... 609 HOIST CIRCUIT OPERATION....................................................... 610 STEERING CIRCUIT OPERATION.................................................... 612 DISC BRAKE COOLING SYSTEM..................................................... 614 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................ 617 HYDRAULIC SYSTEM COMPONENT REPAIR................................................. 619 HOIST PUMP.................................................................... 619 Removal................................................................... 619 Installation.............................................................. 621 INSPECTION OF PARTS........................................................... 626 Assembly.................................................................. 626 HYDRAULIC TANK................................................................ 632 Filling Instructions...................................................... 632 Removal................................................................... 632 Installation.............................................................. 633 HYDRAULIC TANK STRAINERS...................................................... 633 Removal................................................................... 633 Inspect and Clean......................................................... 633 Installation.............................................................. 633 HYDRAULIC TANK BREATHERS...................................................... 634 SECTION L4 - STEERING CIRCUIT - INDEX................................................. 635 STEERING CIRCUIT.................................................................. 637 COMPONENT DESCRIPTION......................................................... 638 Steering Control Unit..................................................... 638 Bleeddown Manifold Valve.................................................. 639 Bleeddown Solenoid........................................................ 639 Relief Valves............................................................. 641 Hoist Limit Solenoid...................................................... 641 Accumulators.............................................................. 641 Low Precharge Warning Switch.............................................. 641 High Pressure Filter...................................................... 641 Quick Disconnect Ports.................................................... 641 Flow Amplifier............................................................ 642 FLOW AMPLIFIER SYSTEM OPERATION............................................... 644 No Steer.................................................................. 644 Steering Left............................................................. 646 Steering Right............................................................ 648 No Steer, External Shock Load............................................. 650 STEERING PUMP................................................................. 652 Operation................................................................. 652 PRINCIPLE OF OPERATION........................................................ 654 Full Pump Volume:......................................................... 654 Half Pump Volume:......................................................... 654 Neutral Position:......................................................... 654 Steering Pump............................................................. 655 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................ 657 STEERING CONTROL UNIT............................................................. 659 Removal....................................................................... 659 Spline Inspection............................................................. 659 Installation.................................................................. 660 STEERING CONTROL UNIT REBUILD................................................. 660 Disassembly............................................................... 660 Cleaning and Inspection - Steering Control Unit........................... 661 Assembly - Steering Control Unit.......................................... 663 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................ 667 STEERING CIRCUIT COMPONENT REPAIR................................................. 669 BLEEDDOWN MANIFOLD VALVE...................................................... 669 Removal................................................................... 669 Installation.............................................................. 669 FLOW AMPLIFIER................................................................ 671 Removal................................................................... 671 Installation.............................................................. 671 FLOW AMPLIFIER REBUILD........................................................ 671 Disassembly............................................................... 674 Assembly.................................................................. 675 STEERING CYLINDERS............................................................ 676 Disassembly............................................................... 677 Piston Seal & Bearing Installation........................................ 677 Cylinder Assembly......................................................... 677 Test...................................................................... 677 STEERING AND BRAKE PUMP....................................................... 678 Removal................................................................... 678 Installation.............................................................. 678 Disassembly............................................................... 680 Control Piston Group...................................................... 680 Valve Plate Group......................................................... 680 Rotating Group............................................................ 683 Swashblock Group.......................................................... 683 Driveshaft Group.......................................................... 683 Inspection................................................................ 683 Control Piston Group...................................................... 683 Valve Plate Group......................................................... 683 Rotating Group............................................................ 683 Swashblock Group.......................................................... 685 Driveshaft Group.......................................................... 686 Compensator Block and Unloader Module..................................... 686 Stroke Adjuster Assembly.................................................. 686 Assembly.................................................................. 686 Swashblock Group.......................................................... 686 Driveshaft Group.......................................................... 687 Rotating Group............................................................ 687 Valve Plate Group......................................................... 688 STEERING ACCUMULATORS......................................................... 689 Removal................................................................... 689 Installation.............................................................. 689 Disassembly............................................................... 690 Cleaning and Inspection................................................... 690 Assembly.................................................................. 691 Leak Testing.............................................................. 693 Charging Procedure........................................................ 694 Temperature During Precharge.............................................. 695 Precharge Maintenance..................................................... 696 Accumulator Storage procedures............................................ 697 Bladder Storage Procedures................................................ 697 TROUBLESHOOTING CHART............................................................. 698 SECTION L7 - HOIST CIRCUIT - INDEX.................................................... 703 HOIST CIRCUIT..................................................................... 705 HOIST CIRCUIT OPERATION....................................................... 705 COMPONENT DESCRIPTION......................................................... 706 Hydraulic Tank............................................................ 706 Hydraulic Pump............................................................ 706 High Pressure Filters..................................................... 706 Hoist Valve............................................................... 706 Inlet Sections - Hoist Valve.............................................. 706 Spool Sections - Hoist Valve.............................................. 707 Hoist Pilot Valve......................................................... 707 Bleeddown Manifold........................................................ 708 Hoist-up Limit Solenoid................................................... 708 Pilot Operated Check Valve................................................ 708 Overcenter Manifold....................................................... 708 HOIST CIRCUIT OPERATION........................................................... 709 Float Position Of Pilot Valve With Truck Body On Frame........................ 710 Power Up Operation............................................................ 712 Hold Operation................................................................ 714 Power Down Operation.......................................................... 716 Float Operation............................................................... 718 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX................................... 721 HOIST CIRCUIT COMPONENT REPAIR.................................................... 723 HOIST VALVE................................................................... 723 Removal................................................................... 723 Installation.............................................................. 724 O-Ring Replacement........................................................ 724 INLET SECTION................................................................. 725 Disassembly............................................................... 725 Cleaning and Inspection................................................... 726 Assembly.................................................................. 726 REAR SPOOL SECTION (Work Ports)............................................... 726 Disassembly............................................................... 726 Cleaning and Inspection................................................... 728 Assembly.................................................................. 728 FRONT SPOOL SECTION (Tank Ports).............................................. 729 Disassembly............................................................... 729 Cleaning and Inspection................................................... 729 Assembly.................................................................. 729 HOIST PILOT VALVE............................................................. 731 Removal................................................................... 731 Installation.............................................................. 731 Disassembly............................................................... 732 Cleaning and Inspection................................................... 733 Assembly.................................................................. 733 HOIST CYLINDERS............................................................... 734 Removal................................................................... 734 Installation.............................................................. 735 Disassembly............................................................... 737 Cleaning and Inspection................................................... 738 Assembly - Quill and Cylinder............................................. 739 Quill Installation........................................................ 739 Installation Of Check Balls And Plugs In Quill............................ 740 Assembly of Cylinder...................................................... 741 OVERCENTER VALVE MANIFOLD..................................................... 742 DISABLED TRUCK DUMPING PROCEDURE.............................................. 743 Hookup.................................................................... 743 Raising the Body.......................................................... 743 Lowering the Body......................................................... 743 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX......................................... 745 HYDRAULIC SYSTEM FILTERS.......................................................... 747 HOIST CIRCUIT FILTER.......................................................... 747 Filter Element Replacement................................................ 747 Removal - Hoist Circuit Filter............................................ 748 Installation - Hoist Circuit Filter....................................... 748 Indicator Switch - Hoist Circuit Filter................................... 748 STEERING CIRCUIT FILTER....................................................... 749 Filter Element Replacement................................................ 749 Removal - Steering Circuit Filter......................................... 750 Installation - Steering Circuit Filter.................................... 750 Indicator Switch - Steering Circuit Filter................................ 750 INDICATOR SWITCH.............................................................. 750 Test Procedure............................................................ 750 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX................................... 753 HYDRAULIC CHECK-OUT PROCEDURE..................................................... 755 GENERAL INFORMATION........................................................... 755 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE............................. 755 Equipment Requirements.................................................... 756 Pump Pressure Control Adjustments......................................... 756 Steering Control Valve and Flow Amplifier Leakage Test.................... 757 Bleeddown Manifold Leakage Test........................................... 757 STEERING/BRAKE PUMP STROKE ADJUSTMENT......................................... 758 SHOCK AND SUCTION VALVES...................................................... 759 Equipment Requirements.................................................... 759 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES................. 760 Equipment Requirements.................................................... 760 Pressure Gauge Locations.................................................. 760 Brake Cooling Circuit Test................................................ 760 Power Up Relief Pressure Test............................................. 761 Adjustment................................................................ 761 Power Down Relief Pressure Test........................................... 762 Hoist Counterbalance Valve Adjustment Preparation......................... 763 Counterbalance Valve Pressure Check....................................... 763 Counterbalance Valve Adjustment........................................... 764 Preparation............................................................... 765 Flushing Procedure........................................................ 765 Filter Element Replacement................................................ 766 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET............................. 766 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................ 768 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX............................................. 769 SECTION M2 - FIRE CONTROL SYSTEM - INDEX ............................................. 771 FIRE CONTROL SYSTEM (MANUAL)...................................................... 773 Operation..................................................................... 773 Inspection and Maintenance.................................................... 773 Recharging Procedures......................................................... 774 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1...................... 775 Control Module................................................................ 775 Actuator...................................................................... 776 Linear Detection Wire......................................................... 776 Power Wire.................................................................... 776 Test Kit...................................................................... 776 Squib......................................................................... 776 Securing the Detection Wire................................................... 777 Preliminary Test Before Final Hook-Up......................................... 777 Installation Procedure for Squib.............................................. 779 Placing the Electric Detection & Actuation System Into Service................ 779 INSPECTION AND MAINTENANCE SCHEDULES.......................................... 780 Daily..................................................................... 780 Normal Maintenance Based On Actual Operating Hours........................ 780 IN CASE OF FIRE............................................................... 781 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM..................................... 783 SECTION M8 - SPECIAL TOOLS............................................................ 785 SECTION M20 - PAYLOAD METER III - INDEX............................................... 791 OPERATION SECTION................................................................. 795 Introduction.................................................................. 795 Data Summary.............................................................. 795 Data Gathering............................................................ 795 COMPONENT DESCRIPTION......................................................... 796 System Diagram............................................................ 796 Suspension Pressure Sensors............................................... 796 Inclinometer.............................................................. 796 Operator Display.......................................................... 796 Operator Switch........................................................... 797 Speed Input............................................................... 797 Body-Up Switch............................................................ 797 Brake Lock Switch......................................................... 797 Payload Meter............................................................. 797 Communications Ports...................................................... 797 Keyswitch Input........................................................... 798 Payload Meter Power....................................................... 798 Load Lights............................................................... 798 Wiring and Termination.................................................... 799 TCI Outputs............................................................... 799 OPERATOR’S DISPLAY AND SWITCH................................................. 800 Reading the Speedometer................................................... 800 Reading the Load Display.................................................. 800 Using the Operator ID..................................................... 800 Using the Load and Ton Counter............................................ 800 Total Ton Counter......................................................... 800 Total Load Counter........................................................ 801 Clearing the Counters..................................................... 801 Viewing Live Sensor Data.................................................. 801 Other Display Messages.................................................... 801 PAYLOAD OPERATION & CALCULATION............................................... 802 Description of Haul Cycle States.......................................... 802 Haul Cycle Description.................................................... 802 Load Calculation.......................................................... 803 Carry Back................................................................ 803 Measurement Accuracy...................................................... 803 SOURCES FOR PAYLOAD ERROR..................................................... 803 Payload Error............................................................. 803 Loading Conditions........................................................ 804 Pressure Sensors.......................................................... 804 Swingloads................................................................ 804 Speed and Distance........................................................ 804 HAUL CYCLE DATA............................................................... 804 Haul Cycle Data........................................................... 805 Haul Cycle Warning Flags.................................................. 806 M: Haul Cycle Too Long.................................................... 807 N: Sensor Input Error..................................................... 807 Frame Torque Data......................................................... 807 Sprung Weight Data........................................................ 807 Maximum Speed Data........................................................ 807 Alarm Records............................................................. 807 Fault Code Data........................................................... 808 PC SOFTWARE OVERVIEW.......................................................... 809 PC Overview............................................................... 809 System Configuration...................................................... 809 Installing the PLMIII Software............................................ 809 DOWNLOADING DATA.............................................................. 810 PLM III SYSTEM CONFIGURATION.................................................. 811 Starting Communications................................................... 811 Displayed Payload Units................................................... 811 Time Units................................................................ 811 Connection Menu........................................................... 811 Connecting to the Payload Meter........................................... 812 Configure the Payload Meter............................................... 812 Setting the Date and Time................................................. 812 Setting the Truck Type.................................................... 813 Setting the Gauge Display Units........................................... 813 Setting the Frame Serial Number........................................... 813 Setting the Truck Number.................................................. 813 Setting the Komatsu Distributor........................................... 813 Setting the Komatsu Customer.............................................. 813 Clean Truck Tare.......................................................... 814 Inclinometer Calibration.................................................. 814 DATA ANALYSIS................................................................. 815 Creating a Query.......................................................... 815 Sorting on Truck Unit Number.............................................. 815 Sorting on Truck Type..................................................... 815 Sorting on Date Range..................................................... 816 Sorting on Time Range..................................................... 816 Payload Detail Screen..................................................... 817 Creating Reports.......................................................... 817 Summary - one page report................................................. 818 Detailed - multi-page report.............................................. 818 Creating Graphs........................................................... 819 Exporting Data............................................................ 819 CSV Export................................................................ 819 Compressed................................................................ 820 Importing Data............................................................ 821 Deleting Haul Cycle Records............................................... 821 Viewing Alarms............................................................ 822 Deleting Alarm Records.................................................... 822 TROUBLESHOOTING SECTION........................................................... 823 TROUBLESHOOTING............................................................... 823 Viewing Active Alarms..................................................... 823 Real-Time Data Display.................................................... 823 Testing the Payload Lights................................................ 823 Creating Log Files of Inputs.............................................. 824 Daily Inspections......................................................... 824 Periodic Maintenance...................................................... 824 Abnormal Displays at Power-Up............................................. 825 No Payload Display When Keyswitch is Turned ON............................ 826 No Display on Speedometer................................................. 827 No Display on Operator Display............................................ 827 No Communications With PC................................................. 828 Load Lights Don’t Light During Loading.................................... 829 Load Lights Remain ON..................................................... 830 Load Lights Remain ON During Dumping...................................... 830 Display Doesn't Clear When The Load Is Dumped............................. 830 Calibration Problems...................................................... 831 Alarm 1 - Left Front Pressure High........................................ 832 Alarm 2 - Left Front Pressure Low......................................... 832 Troubleshoot Wiring to Left Front Suspension.............................. 832 Alarm 3 - Right Front Pressure High....................................... 833 Alarm 4 - Right Front Pressure Low........................................ 833 Troubleshoot Wiring to Right Front Suspension............................. 833 Alarm 5 -Left Rear Pressure High.......................................... 834 Alarm 6 - Left Rear Pressure Low.......................................... 834 Troubleshoot Wiring to Left Rear Suspension............................... 834 Alarm 7 - Right Rear Pressure High........................................ 835 Alarm 8 - Right Rear Pressure Low......................................... 835 Troubleshoot Wiring to Right Rear Suspension.............................. 835 Alarm 9 - Inclinometer High............................................... 836 Alarm 10 - Inclinometer Low............................................... 836 Troubleshoot Inclinometer Wiring.......................................... 836 Alarm 13 - Body Up Input Failure.......................................... 837 Alarm 16 - Memory Write Failure........................................... 838 Alarm 17 - Memory Read Failure............................................ 838 Alarm 18.................................................................. 839 Alarm 19.................................................................. 839 Alarm 22.................................................................. 839 Operator Switch Doesn't Work.............................................. 840 Alarm 26 - User Switch Fault - SELECT..................................... 840 Alarm 27 - User Switch Fault - SET........................................ 840 Connector Map............................................................. 841 Connectors................................................................ 842 PLMIII CHECK OUT PROCEDURE........................................................ 843 General Description........................................................... 843 Tools Required................................................................ 843 Checkout Procedure............................................................ 843 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................ 847 Flashburn Programming..................................................... 847 Confirmation Checklist.................................................... 849 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX....................................... 851 RESERVE ENGINE OIL SYSTEM......................................................... 853 Operation..................................................................... 853 LED Monitor Light............................................................. 854 Tank Fill Control (Optional).................................................. 854 Filling Procedure (Remote fill feature)....................................... 854 SERVICE....................................................................... 855 Every 10 Hours, or once each shift:....................................... 855 Every 500 Hours:.......................................................... 855 Changing Oil.............................................................. 855 TROUBLESHOOTING............................................................... 856 Circuit Breaker or Fuse................................................... 856 SYSTEM ELECTRICAL SCHEMATICS.................................................. 857 SECTION N - CAB COMPONENTS - INDEX........................................................ 859 SECTION N2 - TRUCK CAB - INDEX........................................................ 861 TRUCK CAB......................................................................... 863 Description................................................................... 863 Preparation................................................................... 864 Removal - Cab................................................................. 864 Installation - Cab............................................................ 866 CAB DOOR...................................................................... 866 Removal................................................................... 866 Installation.............................................................. 866 Door Adjustment........................................................... 867 Door Jamb Bolt Adjustment................................................. 867 Door Handle Plunger Adjustment............................................ 868 Door Glass Replacement.................................................... 869 Door Window Regulator Replacement......................................... 873 Door Handle or Latch Assembly Replacement................................. 873 Door and Door Hinge Seal Replacement...................................... 874 Door Opening Seal Removal................................................. 874 Installation.............................................................. 874 GLASS REPLACEMENT............................................................. 875 Adhesive Bonded Windows................................................... 875 Replacement Procedure..................................................... 875 Windshield And Rear Glass................................................. 876 Removal................................................................... 876 Installation.............................................................. 877 SECTION N3 - CAB COMPONENTS - INDEX................................................... 879 CAB COMPONENTS.................................................................... 881 WINDSHIELD WIPERS............................................................. 881 Wiper Motor Replacement................................................... 881 Removal................................................................... 881 Installation.............................................................. 881 Wiper Arm................................................................. 881 Removal................................................................... 881 Installation.............................................................. 882 Wiper Linkage Replacement................................................. 882 Removal................................................................... 882 Installation.............................................................. 882 WINDSHIELD WASHER............................................................. 883 Operation................................................................. 883 Service................................................................... 883 OPERATOR SEAT................................................................. 884 Adjustment................................................................ 884 Seat Removal.............................................................. 884 Seat Installation......................................................... 884 SECTION N4 - OPERATOR COMFORT - INDEX................................................. 885 OPERATOR COMFORT.................................................................. 887 HEATER / AIR CONDITIONER...................................................... 887 Operation................................................................. 887 Heater/Air Conditioner Vents.............................................. 887 COMPONENTS.................................................................... 888 Circuit Breakers.......................................................... 888 Relays.................................................................... 888 Heater Core............................................................... 888 Fan Motor And Speed Control............................................... 889 Actuators................................................................. 889 Cab Air Filter............................................................ 889 AIR CONDITIONING SYSTEM........................................................... 891 Environmental Impact.......................................................... 891 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES..................................... 892 PRINCIPLES OF REFRIGERATION................................................... 892 Air Conditioning.......................................................... 892 Refrigeration - The Act Of Cooling........................................ 893 The Refrigeration Cycle................................................... 893 AIR CONDITIONER SYSTEM COMPONENTS............................................. 894 Compressor (Refrigerant Pump)............................................. 894 Service Valves............................................................ 894 Condenser................................................................. 894 Receiver-Drier............................................................ 894 Expansion Block Valve..................................................... 895 Accumulator............................................................... 895 Evaporator................................................................ 895 ELECTRICAL CIRCUIT............................................................ 896 Thermostat................................................................ 896 Compressor Clutch......................................................... 896 Trinary™ Switch........................................................... 897 SYSTEM SERVICING.............................................................. 898 SERVICE TOOLS AND EQUIPMENT................................................... 899 Recovery/Recycle Station.................................................. 899 Leak Detector............................................................. 899 Service Valves............................................................ 900 Vacuum Pump............................................................... 900 Manifold Gauge Set........................................................ 901 Installing Manifold Gauge Set............................................. 902 Purging Air From Service Hoses............................................ 902 SYSTEM PERFORMANCE TEST....................................................... 903 SYSTEM OIL.................................................................... 904 Handling and Reusing PAG Oil.............................................. 904 Oil Quantity.............................................................. 904 Checking System Oil....................................................... 904 REFRIGERANT................................................................... 905 Recycled Refrigerant...................................................... 905 Reclaimed Refrigerant..................................................... 905 Refrigerant Quantity...................................................... 905 R-134a Refrigerant Containers............................................. 905 SYSTEM LEAK TESTING........................................................... 906 Electronic Leak Detector.................................................. 906 Tracer Dyes............................................................... 906 Soap and Water............................................................ 906 RECOVERING AND RECYCLING THE REFRIGERANT...................................... 907 Performing the Recovery Cycle............................................. 907 Performing the Recycling Procedure........................................ 907 Evacuating and Charging the A/C System.................................... 907 SYSTEM REPAIR................................................................. 908 System Flushing........................................................... 908 COMPONENT REPLACEMENT......................................................... 908 Hoses and Fittings........................................................ 908 Lines..................................................................... 908 Expansion Valve........................................................... 909 Receiver-Drier............................................................ 909 Thermostat................................................................ 909 Compressor................................................................ 909 Accumulator............................................................... 909 Clutch.................................................................... 910 Servicing the Compressor Clutch........................................... 910 Pulley Removal............................................................ 912 Clutch Coil Check......................................................... 913 Pulley Installation....................................................... 913 Clutch Assembly Installation.............................................. 913 EVACUATING THE SYSTEM......................................................... 915 CHARGING THE A/C SYSTEM....................................................... 917 TROUBLESHOOTING................................................................... 918 Preliminary Checks............................................................ 918 Diagnosis Of Gauge Readings And System Performance............................ 918 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.................................... 919 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.................................. 925 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................ 927 OPERATOR CAB CONTROLS............................................................. 929 STEERING COLUMN............................................................... 929 Removal................................................................... 929 Steering Column Inspection................................................ 929 Installation.............................................................. 929 STEERING WHEEL AND CONTROLS................................................... 931 Horn Button............................................................... 931 Telescope Lock Ring....................................................... 931 Tilt Wheel Lever.......................................................... 931 Multi-Function Turn Signal Switch......................................... 931 DYNAMIC RETARDING............................................................. 932 Retarder Control Lever.................................................... 932 Dynamic Retarder/Service Brake Pedal...................................... 932 Accelerator (Throttle) Pedal.............................................. 933 Starting on a Grade With a Loaded Truck................................... 933 GRADE/SPEED RETARD CHART...................................................... 933 INSTRUMENT PANEL.............................................................. 935 OVERHEAD PANEL AND DISPLAYS................................................... 935 CENTER CONSOLE................................................................ 936 F-N-R Selector Switch..................................................... 936 Hoist Control Lever....................................................... 937 Raising The Dump Body..................................................... 937 Lowering The Dump Body.................................................... 937 Ash Tray.................................................................. 937 Lighter................................................................... 937 L.H. Window Control Switch................................................ 937 R.H. Window Control Switch................................................ 937 Engine Shutdown Switch.................................................... 937 Override/Fault Reset Switch............................................... 938 Retard Speed Control (RSC) Switch......................................... 938 Retard Speed Control (RSC) Adjust Dial.................................... 938 Data Store Button......................................................... 939 Engine Control System..................................................... 939 Service Engine Light...................................................... 939 Engine Diagnostics Download Port.......................................... 939 Payload Meter............................................................. 939 TCI Download Port......................................................... 939 PSC Download Port......................................................... 939 Payload Meter............................................................. 939 INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 941 CONTROL SYMBOLS............................................................... 941 INSTRUMENT PANEL.............................................................. 941 PANEL GAUGES, INDICATORS, AND CONTROLS............................................ 943 Key Switch.................................................................... 943 Starting...................................................................... 943 Cold Weather Starting......................................................... 943 Normal Engine Shutdown........................................................ 943 Engine Shutdown Switch with 5 Minute Idle Timer Delay......................... 944 Fog Lights (Optional)......................................................... 944 Ladder Light Switch........................................................... 944 Manual Backup Switch.......................................................... 944 Panel Illumination Lights..................................................... 945 Cab/Air Conditioner Vents..................................................... 945 Rotating Beacon Light Switch (Optional)....................................... 945 Heated Mirror Switch (Optional)............................................... 945 Wheel Brake Lock Control...................................................... 945 Parking Brake Control......................................................... 945 Tachometer.................................................................... 946 Right Turn Signal Indicator................................................... 946 High Beam Indicator........................................................... 946 Left Turn Signal Indicator.................................................... 946 Speedometer / Payload Meter................................................... 946 Voltmeter..................................................................... 946 Engine Oil Pressure Gauge..................................................... 946 Water Temperature Gauge....................................................... 946 Fuel Gauge.................................................................... 946 AC Drive System Temperature Gauge............................................. 947 Hydraulic Oil Temperature Gauge............................................... 947 Hourmeter..................................................................... 947 Rest Switch................................................................... 947 Light Switch.................................................................. 948 Windshield Wiper and Washer................................................... 948 Panel Light Dimmer............................................................ 948 Payload Meter Switch.......................................................... 948 OVERHEAD STATUS / WARNING INDICATORS.......................................... 949 STATUS / WARNING INDICATOR LIGHT SYMBOLS...................................... 950 Hazard Warning Lights..................................................... 955 Lamp Test Switch.......................................................... 955 Link-On Warning Light..................................................... 955 SECTION P - LUBRICATION AND SERVICE - INDEX............................................... 957 SECTION P2 - LUBRICATION AND SERVICE - INDEX.......................................... 959 LUBRICATION AND SERVICE........................................................... 961 930E SERVICE CAPACITIES....................................................... 961 HYDRAULIC TANK SERVICE........................................................ 961 Adding Oil................................................................ 961 WHEEL MOTOR SERVICE........................................................... 961 COOLANT LEVEL CHECK........................................................... 962 RADIATOR FILLING PROCEDURE.................................................... 962 RESERVE ENGINE OIL SYSTEM (Optional).......................................... 962 Reserve Oil Tank Filling Procedure (Remote fill).......................... 962 LUBRICATION CHART............................................................. 963 10 HOUR (DAILY) INSPECTION.................................................... 964 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 967 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 968 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 969 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 972 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS................................. 973 5000 HOUR MAINTENANCE CHECKS.................................................. 974 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX..................................... 975 AUTOMATIC LUBRICATION SYSTEM...................................................... 977 GENERAL DESCRIPTION........................................................... 977 SYSTEM COMPONENTS............................................................. 979 Filter.................................................................... 979 Hydraulic Motor and Pump.................................................. 979 Grease Reservoir.......................................................... 979 Pressure Reducing Valve................................................... 979 Flow Control Valve........................................................ 979 Solenoid Valve............................................................ 979 Vent Valve................................................................ 979 Lubrication Cycle Timer................................................... 979 Time Delay Module......................................................... 979 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]).................. 979 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])............... 979 Pressure Gauge............................................................ 979 Injectors................................................................. 979 SYSTEM OPERATION.............................................................. 980 Normal Operation.......................................................... 980 Pressure Failure Detection Circuits....................................... 981 GENERAL INSTRUCTIONS.......................................................... 982 Lubricant Requirements.................................................... 982 System Priming............................................................ 982 LUBRICANT PUMP................................................................ 982 Pump Housing Oil Level.................................................... 982 Pump Pressure Control..................................................... 982 Lubrication Cycle Timer Check............................................. 983 Lubrication Cycle Timer Adjustment........................................ 983 FILTER ASSEMBLY............................................................... 983 SYSTEM CHECKOUT............................................................... 984 INJECTORS (SL-1 Series “H”)).................................................. 984 Injector Specifications................................................... 984 Injector Adjustment....................................................... 984 INJECTOR OPERATION............................................................ 985 PUMP REBUILD.................................................................. 986 Disassembly............................................................... 986 Cleaning and Inspection................................................... 988 Assembly.................................................................. 988 SYSTEM TROUBLESHOOTING CHART...................................................... 990 PREVENTATIVE MAINTENANCE PROCEDURES............................................... 993 Daily Lubrication System Inspection........................................... 993 250 Hour Inspection........................................................... 993 1000 Hour Inspection.......................................................... 993 SECTION Q - ALPHABETICAL INDEX............................................................ 995 SECTION R - SYSTEM SCHEMATIC - INDEX...................................................... 999 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH358..............................................1001 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH359..................................1002 ELECTRICAL SCHEMATIC - XS1300.........................................................1003 VHMS ELECTRICAL SCHEMATIC.............................................................1037
KOMATSU 930E-3 DUMP TRUCK SHOP MANUAL A30364-A30461 – PDF DOWNLOAD:
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