Komatsu 930E-3 Dump Truck Shop Manual CEBM008401 – PDF DOWNLOAD

Description

Komatsu 930E-3 Dump Truck Shop Manual CEBM008401 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-3 Dump Truck Shop Manual CEBM008401 – PDF DOWNLOAD

Language : English
Pages :960
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E-3 Dump Truck Shop Manual CEBM008401 – PDF DOWNLOAD

SERIAL NUMBERS A30304 – A30309

FOREWORD

This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.

• All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
• For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model.
• The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

Komatsu 930E-3 Dump Truck Shop Manual CEBM008401 – PDF DOWNLOAD

SERIAL NUMBERS A30304 – A30309

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 55
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 61
STORAGE AND IDLE MACHINE PREPARATION 63
Short Term Idle Periods 63
PREPARATION FOR STORAGE 64
REMOVAL FROM STORAGE 65
RECONDITIONING AN IDLE VEHICLE 67
ENGINE OPERATION 70
After The Engine Has Started 71
ENGINE STORAGE 72
Preparing Engine For Storage 72
Temporary Storage (30 Days Or Less) 72
Extended Storage (more Than 30 Days) 72
RESTORING AN ENGINE AFTER EXTENDED STORAGE 74
ELECTRIC DRIVE TRUCKS 75
Storage Instructions and Procedures 75
Placing Equipment Into Storage 75
Storing A Truck That Is Operational 75
Storing A Truck That Is Not Operational 76
Storing A Major Component 76
Periodic Inspections 77
Placing Equipment Into Service After Storage 77
When A Truck Is Operational 77
When A Truck Is Not Operational 77
For The First Hour 78
SECTION B – STRUCTURES – INDEX 79
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 81
STRUCTURAL COMPONENTS 83
Preparation 83
GRILLE, HOOD AND LADDER 84
Removal 84
Installation 84
DECKS 85
RIGHT DECK AND COMPONENTS 85
Removal 85
Installation 86
LEFT DECK 86
Removal 86
Installation 86
CENTER DECK 86
SECTION B3 – DUMP BODY – INDEX 87
DUMP BODY 89
Removal 89
Installation 90
BODY PADS 91
Adjustment 91
BODY GUIDE 92
HOIST LIMIT SWITCH 92
BODY UP SWITCH 92
BODY-UP RETENTION CABLE 92
ROCK EJECTORS 93
Rock Ejectors 93
Inspection 93
SECTION B4 – FUEL TANK – INDEX 95
FUEL TANK 97
Removal 98
Installation 98
Repair 98
Cleaning 98
FUEL GAUGE SENDER 99
Removal 99
Installation 99
LOW FUEL SWITCH 99
WIGGINS QUICK FILL FUEL SYSTEM100
FUEL RECEIVER100
TANK BREATHER VALVE100
Removal100
Installation100
Disassembly100
Assembly100
LEFT SIDE FILL101
SECTION C – ENGINE – INDEX103
SECTION C2 – POWER MODULE – INDEX105
POWER MODULE107
Preparation107
Preparation for Removal108
Removal – Power Module111
Installation – Power Module113
Hookup – Power Module113
SECTION C3 – COOLING SYSTEM – INDEX115
COOLING SYSTEM117
RADIATOR117
Removal – Radiator117
Installation – Radiator119
RADIATOR FILLING PROCEDURE120
RADIATOR REPAIR120
Internal Inspection120
External Cleaning120
Disassembly121
Cleaning and Inspection122
Assembly122
Pressure Testing123
Additional Service Information123
COOLANT SYSTEM TROUBLESHOOTING124
SECTION C4 – POWERTRAIN – INDEX125
POWER TRAIN127
ALTERNATOR127
Removal – Alternator127
ENGINE/ALTERNATOR MATING129
General Instructions129
Measuring Procedure129
Joining The Alternator and Engine131
ENGINE132
Removal132
Service132
Installation132
SECTION C5 – AIR CLEANERS – INDEX133
AIR CLEANERS135
AIR CLEANERS135
Operation135
General Service Information135
FILTER ELEMENT REPLACEMENT136
Main Filter Element Cleaning137
Precleaner Section138
Cleaning Precleaner Tubes138
AIR INTAKE TROUBLESHOOTING139
SECTION C7 – FAN CLUTCH – INDEX141
FAN CLUTCH143
REMOVAL & INSTALLATION TOOLING143
FAN CLUTCH – DISASSEMBLY146
CLEANING AND INSPECTION156
ASSEMBLY – FAN CLUTCH160
TEST PROCEDURE174
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX175
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX177
24VDC ELECTRIC SUPPLY SYSTEM179
ELECTRICAL SYSTEM DESCRIPTION179
BATTERIES179
Maintenance and Service179
Troubleshooting179
BATTERY SUPPLY SYSTEM181
24VDC Batter Charging Alternator181
Battery Box181
Batter Control Box182
Battery Disconnect Switches182
24VDC Auxiliary Battery Connectors182
24VDC to 12VDC Converter183
Isolation Diodes183
Engine Starter Relay183
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX185
24 VDC ELECTRICAL SYSTEM COMPONENTS187
TRUCK SHUTDOWN PROCEDURE187
24 VDC ELECTRICAL SYSTEM COMPONENTS187
Brake Warning Buzzer (BWB)187
AUXILIARY CONTROL CABINET COMPONENTS187
Fuse Block 1 & 2188
Power Distribution Terminals188
PULSE VOLTAGE MODULATOR188
5 Minute Idle Timer Components190
5 Minute Idle Timer190
5 Minute Idle Circuit Test190
Tail Light Resistor Diode Assemblies190
Engine Starter Failure Delay Timer190
Lubrication System Timer192
Auto Lube Delay Timer192
Barometric Pressure Transducer192
Kontrol Power Relay192
Alarm Indicating Device (AID) System194
Temperature and Latch195
Hot Switch Inverter195
Hot Switch Inverter Card (Slot 4) (Not Used)195
Oil Level195
Temperature195
Diode Matrix (Without Sound)195
Diode Matrix (With Sound)195
Lamp Test196
Diode Board – DB1196
Diode Testing196
RELAY BOARDS197
Relay Boards RB1, RB3, RB4, RB5197
Service197
Relay Board Identification198
RELAY BOARD FUNCTIONS199
Relay Board 1 (RB1)199
Relay Board 3 (RB3)199
Relay Board 6, 7 & 8 (RB6, RB7, RB8)200
Installing Additional Circuits200
BODY-UP SWITCH201
Operation201
Adjustment201
Service201
HOIST LIMIT SWITCH202
Operation202
Adjustment202
Service202
FUSE BLOCKS203
CIRCUIT BREAKERS203
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX205
BATTERY CHARGING ALTERNATOR207
ELECTRICAL SYSTEM DESCRIPTION207
BATTERY207
Maintenance and Service207
Troubleshooting207
BATTERY CHARGING SYSTEM (Niehoff)209
General Description209
TROUBLESHOOTING PROCEDURES (On-Truck)209
Equipment Required:209
Preliminary Checks210
Test Setup210
Test Procedure210
Regulator Bypass Test211
ON VEHICLE TROUBLESHOOTING GUIDE213
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage213
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:213
CHARGE VOLT AND AMP VALUES214
DEFINITIONS214
ADVANCED SYSTEM TROUBLESHOOTING215
Static Test – Engine OFF, Key ON, Battery Switch ON215
Go To Alternator215
Go To Regulator (If Required)216
Go To Regulator Connector On The Alternator216
ALTERNATOR OVERHAUL217
ALTERNATOR DIMENSIONS217
ALTERNATOR SPECIFICATIONS218
SERVICE PARTS219
ON-VEHICLE TEST221
Equipment:221
Preliminary Checks:221
Test Set-up221
Test Procedure221
ON-VEHICLE TEST222
Bypass Test:222
BENCH TEST223
STATIC TESTS224
Regulator Tests224
Control Box Tests225
ALTERNATOR DISASSEMBLY227
ASSEMBLY- ALTERNATOR232
BF4822 STATOR SERVICE TOOL INSTRUCTIONS241
Stator Removal And Replacement241
Stator Installation242
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX245
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX247
ELECTRICAL PROPULSION SYSTEM COMPONENTS249
GENERAL SYSTEM DESCRIPTION249
SYSTEM COMPONENTS251
Propulsion System Controller(PSC)251
Truck Control Interface (TCI)251
Diagnostic Information Display253
DID Panel Event Codes253
PSC SOFTWARE FUNCTIONS277
Input Processing277
STATE MANAGEMENT277
State Machine277
DC Link State280
Powering the Link280
De-Powering the Link280
Control Functions280
ALTERNATOR FIELD CONTROL281
Desired Three-Phase Voltage281
Desired DC Link Voltage281
Self-load281
Propel Torque Control282
Retard Torque Control282
Wheel Slide Control282
Resistor Grid Control283
Chopper Voltage Control283
EVENT PROCESSING283
Event Detection283
Power On Tests283
Initiated Tests284
Periodic Tests284
EVENT RESTRICTIONS284
EVENT LOGGING AND STORAGE284
Event History Buffer285
Data Packs285
To Record and Save a Data Pack to a Floppy Disk285
Event Reset286
SERIAL DATA COMMUNICATIONS287
PSC – PTU Communications Processing287
Inverter Communications Processing287
OUTPUT PROCESSING288
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS288
Fast Start288
Engine Shutdown/Engine Not Running288
Limp Home Mode288
Entering/Exiting Limp Home Mode288
PROPULSION SYSTEM COMPONENT ABBREVIATIONS289
ELECTRONIC ACCELERATOR AND RETARD PEDALS301
Removal301
Installation301
Disassembly301
Assembly301
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX303
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE305
AC DRIVE SYSTEM MAINTENANCE305
TRUCK SHUTDOWN PROCEDURES305
NORMAL TRUCK SHUTDOWN PROCEDURE306
SHUTDOWN AFTER SYSTEM FAILURE307
SYSTEM CHECKOUT308
Battery and Control Checks of System WITH Battery Power OFF308
Battery and Control Circuit Checks of System With Battery Power ON311
Checks with Key Switch OFF312
CPU Battery Checks314
MEMORY BACKUP BATTERY REPLACEMENT314
TCI PROGRAMMING315
PSC PROGRAMMING315
INVERTER PROGRAMMING316
TCI CHECKOUT316
Modular Mining Communication Port317
TCI Input Checks318
TCI Digital Output Tests320
TCI Digital Input Tests322
PSC Checkout Procedure324
PSC Digital Input Checks328
Miscellaneous Checks329
A3PV Panel329
LINKV Panel329
Thermistor Checks329
17FM384 Panel Check329
Pedal Percentages and Meter Calibration330
Meter Calibration Procedure330
Reprogram With Serial Numbers and Pedal Percentages332
LOAD TESTING334
Preload Checks334
ADDITIONAL TRUCK CHECKS336
On-Board Load Testing338
Preparation338
Initiate Loadbox Test341
Manual Offset HP Output Adjustment343
TROUBLESHOOTING345
PVM Optimum Load Curve Handshaking Troubleshooting345
MISCELLANEOUS COMPONENT REPAIR346
Troubleshooting Phase Modules and Chopper Modules346
Phase Module Removal and Snubber Resistor Replacement346
Snubber Resistor Installation347
Phase Module Installation347
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING348
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING351
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING352
IGBT TROUBLESHOOTING353
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX355
SECTION G2 – TIRES AND RIMS – INDEX357
TIRES AND RIMS359
WHEEL STUD MAINTENANCE360
FRONT TIRES AND RIMS361
Removal361
Installation362
REAR TIRES AND RIMS363
Removal363
Installation364
RIM365
Tire Removal365
Tire Installation366
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX369
FRONT WHEEL HUB AND SPINDLE371
WHEEL HUB AND SPINDLE ASSEMBLY371
Preparation371
Removal371
Installation – Wheel Hub and Spindle Assembly374
Disassembly – Wheel Hub and Spindle Assembly375
Cleaning and Inspection – Wheel Hub and Spindle Assembly375
Assembly – Wheel Hub and Spindle Assembly377
Wheel Bearing Adjustment:377
Brake Installation378
Seal Assembly Gap Check379
STEERING CYLINDERS AND TIE ROD380
Spherical Bearing Wear Limits380
Removal – Steering Cylinder and Tie Rod381
Installation – Steering Cylinder and Tie Rod382
Bearing Replacement382
TOE-IN ADJUSTMENT383
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX385
REAR AXLE HOUSING ATTACHMENT387
PIVOT PIN387
Removal387
Installation388
PIVOT EYE BEARING389
Removal389
Installation389
PIVOT EYE REPAIR389
Removal389
Disassembly389
Assembly390
Installation390
ANTI-SWAY BAR390
Removal390
Installation391
Disassembly391
Cleaning and Inspection391
Assembly391
SECTION G5 – REAR AXLE HOUSING – INDEX393
REAR AXLE HOUSING395
REAR AXLE HOUSING395
Preparation395
Removal395
Cleaning and Inspection – Rear Axle Housing397
Installation – Rear Axle Housing397
WHEEL MOTOR398
Preparation398
Removal398
Cleaning and Inspection – Wheel Motor399
Installation – Wheel Motor400
WHEEL MOTOR GEAR OIL403
Filtering Requirements403
Particle Size Analysis403
Flushing403
Oil Sample Analysis404
ELEMENT SPECIFICATION CHARTS405
SECTION H – HYDRAIR II SUSPENSIONS – INDEX409
SECTION H2 – FRONT SUSPENSIONS – INDEX411
FRONT SUSPENSION413
Removal413
Installation – Front Suspension414
“Turn-Of-The-Nut” Tightening Procedure417
MINOR REPAIRS (LOWER BEARING & SEALS)418
Removal – Bearing Retainer418
Installation – Bearing Retainer418
MAJOR SUSPENSION REBUILD420
Disassembly420
Assembly420
SECTION H3 – REAR SUSPENSIONS – INDEX423
REAR SUSPENSIONS425
Removal425
Installation – Rear Suspension427
Disassembly – Rear Suspension428
Cleaning and Inspection – Rear Suspension428
Assembly – Rear Suspension428
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX431
SUSPENSION OILING AND CHARGING PROCEDURE433
GENERAL433
EQUIPMENT LIST433
Hydrair® Charging Kit433
Installation of Charging Kit433
Removal of Charging Kit434
Support Blocks For Oiling And Charging Dimensions434
FRONT SUSPENSION435
Front Suspension Oiling435
Front Suspension Nitrogen Charging436
REAR SUSPENSION437
Rear Suspension Oiling437
Rear Suspension Nitrogen Charging438
OIL AND NITROGEN SPECIFICATIONS CHART440
SECTION J – BRAKE CIRCUIT – INDEX441
SECTION J2 – BRAKE CIRCUIT – INDEX443
BRAKE CIRCUIT445
SERVICE BRAKE CIRCUIT445
SECONDARY BRAKING AND AUTOMATIC APPLY447
PARKING BRAKE CIRCUIT447
Normal Operation (key switch on, engine running)447
BRAKE LOCK CIRCUIT448
WARNING CIRCUIT448
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX451
BRAKE CIRCUIT COMPONENT SERVICE453
BRAKE VALVE453
Rebuild Criteria453
Removal454
Installation454
Disassembly455
Cleaning and Inspection458
Assembly458
Actuator Base Threaded Inserts458
Boot and Cap458
Valve Body Seal Installation458
Regulator Sleeve O-Ring Installation459
Actuator Plunger O-ring Installation459
Assembly of Valve459
DIFFERENTIAL PRESSURE SWITCH461
Disassembly461
Cleaning and Inspection461
Assembly461
VALVE BENCH TEST AND ADJUSTMENT462
Test Set Up Procedure463
Brake Valve Output Pressure Adjustment463
Differential Pressure Switch Adjustment463
Final Test and Adjustment464
Installation Of Brake Pedal Actuator Assembly to Brake Valve465
Installation of Retard Pedal To Brake Pedal465
DUAL RELAY VALVE467
Removal467
Installation467
Disassembly469
Cleaning and Inspection469
Assembly469
DIFFERENTIAL PRESSURE SWITCH470
Disassembly470
Cleaning and Inspection470
Assembly470
VALVE TEST AND ADJUSTMENT471
Test Set Up Procedure472
Relay Valve Output Pressure Adjustment472
Differential Pressure Switch Adjustment473
BRAKE MANIFOLD474
Removal474
Installation475
Disassembly475
Cleaning and Inspection475
Assembly475
BRAKE ACCUMULATORS476
Brake Accumulator Bleeddown Procedure476
BRAKE ACCUMULATOR REPAIR477
Removal477
Installation477
Disassembly478
Cleaning and Inspection479
Assembly479
ACCUMULATOR CHARGING PROCEDURE481
Temperature During Precharge482
Precharge Maintenance483
Recharging Accumulators483
Accumulator Storage procedures484
Bladder Storage Procedures484
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)485
Removal485
Installation485
Disassembly and Adjustment485
Potentiometer Check487
Assembly487
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX489
BRAKE CIRCUIT CHECK-OUT PROCEDURE491
REQUIRED EQUIPMENT493
INITIAL SYSTEM SET-UP494
BRAKE SYSTEM CHECKOUT495
Failure Modes Check-Out496
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART498
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET501
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET502
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX503
WET DISC BRAKE ASSEMBLY505
OPERATION505
MAINTENANCE506
Brake Disc Wear Indicator506
Removal/Installation – Wet Disc Brake Assembly506
BRAKE REBUILD508
Disassembly508
Cleaning and Inspection511
Assembly512
Floating Ring Seal Assembly/Installation515
WET DISC BRAKE BLEEDING PROCEDURE518
SECTION J7 – PARKING BRAKE – INDEX519
PARKING BRAKE521
OPERATION521
MAINTENANCE522
Inspection – Parking Brake522
Removal – Parking Brake522
Installation – Parking Brake523
Disassembly – Parking Brake524
Cleaning and Inspection – Parking Brake524
Assembly – Parking Brake524
PARKING BRAKE BLEEDING PROCEDURE526
SECTION L – HYDRAULIC SYSTEM – INDEX527
SECTION L2 – HYDRAULIC SYSTEM – INDEX529
HYDRAULIC SYSTEM531
HYDRAULIC PUMP MODULE531
HOIST CIRCUIT OPERATION532
STEERING CIRCUIT OPERATION534
DISC BRAKE COOLING SYSTEM536
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX539
HYDRAULIC SYSTEM COMPONENT REPAIR541
HOIST PUMP541
Removal541
Installation543
INSPECTION OF PARTS548
Assembly548
HYDRAULIC TANK554
Filling Instructions554
Removal554
Installation555
HYDRAULIC TANK STRAINERS555
Removal555
Inspect and Clean555
Installation555
HYDRAULIC TANK BREATHERS556
SECTION L4 – STEERING CIRCUIT – INDEX557
STEERING CIRCUIT559
COMPONENT DESCRIPTION560
Steering Control Unit560
Bleeddown Manifold Valve561
Bleeddown Solenoid561
Relief Valves563
Hoist Limit Solenoid563
Accumulators563
Low Precharge Warning Switch563
High Pressure Filter563
Quick Disconnect Ports563
Flow Amplifier564
FLOW AMPLIFIER SYSTEM OPERATION566
No Steer566
Steering Left568
Steering Right570
No Steer, External Shock Load572
STEERING PUMP574
Operation574
PRINCIPLE OF OPERATION576
Full Pump Volume:576
Half Pump Volume:576
Neutral Position:576
Steering Pump577
SECTION L5 – STEERING CONTROL UNIT – INDEX579
STEERING CONTROL UNIT581
Removal581
Spline Inspection581
Installation582
STEERING CONTROL UNIT REBUILD582
Disassembly582
Cleaning and Inspection – Steering Control Unit583
Assembly – Steering Control Unit585
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX589
STEERING CIRCUIT COMPONENT REPAIR591
BLEEDDOWN MANIFOLD VALVE591
Removal591
Installation591
FLOW AMPLIFIER593
Removal593
Installation593
FLOW AMPLIFIER REBUILD593
Disassembly596
Assembly597
STEERING CYLINDERS598
Disassembly599
Piston Seal & Bearing Installation599
Cylinder Assembly599
Test599
STEERING AND BRAKE PUMP600
Removal600
Installation600
Disassembly602
Control Piston Group602
Valve Plate Group602
Rotating Group605
Swashblock Group605
Driveshaft Group605
Inspection605
Control Piston Group605
Valve Plate Group605
Rotating Group605
Swashblock Group607
Driveshaft Group608
Compensator Block and Unloader Module608
Stroke Adjuster Assembly608
Assembly608
Swashblock Group608
Driveshaft Group609
Rotating Group609
Valve Plate Group610
STEERING ACCUMULATORS611
Removal611
Installation611
Disassembly612
Cleaning and Inspection612
Assembly613
Leak Testing615
Charging Procedure616
Temperature During Precharge617
Precharge Maintenance618
Accumulator Storage procedures619
Bladder Storage Procedures619
TROUBLESHOOTING CHART620
SECTION L7 – HOIST CIRCUIT – INDEX625
HOIST CIRCUIT627
HOIST CIRCUIT OPERATION627
COMPONENT DESCRIPTION628
Hydraulic Tank628
Hydraulic Pump628
High Pressure Filters628
Hoist Valve628
Inlet Sections – Hoist Valve628
Spool Sections – Hoist Valve629
Hoist Pilot Valve629
Bleeddown Manifold630
Hoist-up Limit Solenoid630
Pilot Operated Check Valve630
Overcenter Manifold630
HOIST CIRCUIT OPERATION631
Float Position Of Pilot Valve With Truck Body On Frame632
Power Up Operation634
Hold Operation636
Power Down Operation638
Float Operation640
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX643
HOIST CIRCUIT COMPONENT REPAIR645
HOIST VALVE645
Removal645
Installation646
O-Ring Replacement646
INLET SECTION647
Disassembly647
Cleaning and Inspection648
Assembly648
REAR SPOOL SECTION (Work Ports)648
Disassembly648
Cleaning and Inspection650
Assembly650
FRONT SPOOL SECTION (Tank Ports)651
Disassembly651
Cleaning and Inspection651
Assembly651
HOIST PILOT VALVE653
Removal653
Installation653
Disassembly654
Cleaning and Inspection655
Assembly655
HOIST CYLINDERS656
Removal656
Installation657
Disassembly659
Cleaning and Inspection660
Assembly – Quill and Cylinder661
Quill Installation661
Installation Of Check Balls And Plugs In Quill662
Assembly of Cylinder663
OVERCENTER VALVE MANIFOLD664
DISABLED TRUCK DUMPING PROCEDURE665
Hookup665
Raising the Body665
Lowering the Body665
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX667
HYDRAULIC SYSTEM FILTERS669
HOIST CIRCUIT FILTER669
Filter Element Replacement669
Removal – Hoist Circuit Filter670
Installation – Hoist Circuit Filter670
Indicator Switch – Hoist Circuit Filter670
STEERING CIRCUIT FILTER671
Filter Element Replacement671
Removal – Steering Circuit Filter672
Installation – Steering Circuit Filter672
Indicator Switch – Steering Circuit Filter672
INDICATOR SWITCH672
Test Procedure672
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX675
HYDRAULIC CHECK-OUT PROCEDURE677
GENERAL INFORMATION677
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE677
Equipment Requirements678
Pump Pressure Control Adjustments678
Steering Control Valve and Flow Amplifier Leakage Test679
Bleeddown Manifold Leakage Test679
STEERING/BRAKE PUMP STROKE ADJUSTMENT680
SHOCK AND SUCTION VALVES681
Equipment Requirements681
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES682
Equipment Requirements682
Pressure Gauge Locations682
Brake Cooling Circuit Test682
Power Up Relief Pressure Test683
Adjustment683
Power Down Relief Pressure Test684
Hoist Counterbalance Valve Adjustment Preparation685
Counterbalance Valve Pressure Check685
Counterbalance Valve Adjustment686
Preparation687
Flushing Procedure687
Filter Element Replacement688
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET688
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET690
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX691
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX693
FIRE CONTROL SYSTEM (MANUAL)695
Operation695
Inspection and Maintenance695
Recharging Procedures696
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1697
Control Module697
Actuator698
Linear Detection Wire698
Power Wire698
Test Kit698
Squib698
Securing the Detection Wire699
Preliminary Test Before Final Hook-Up699
Installation Procedure for Squib701
Placing the Electric Detection & Actuation System Into Service701
INSPECTION AND MAINTENANCE SCHEDULES702
Daily702
Normal Maintenance Based On Actual Operating Hours702
IN CASE OF FIRE703
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM705
SECTION M8 – SPECIAL TOOLS707
SECTION M20 – PAYLOAD METER III – INDEX713
OPERATION SECTION717
Introduction717
Data Summary717
Data Gathering717
COMPONENT DESCRIPTION718
System Diagram718
Suspension Pressure Sensors718
Inclinometer718
Operator Display718
Operator Switch719
Speed Input719
Body-Up Switch719
Brake Lock Switch719
Payload Meter719
Communications Ports719
Keyswitch Input720
Payload Meter Power720
Load Lights720
Wiring and Termination721
TCI Outputs721
OPERATOR’S DISPLAY AND SWITCH722
Reading the Speedometer722
Reading the Load Display722
Using the Operator ID722
Using the Load and Ton Counter722
Total Ton Counter722
Total Load Counter723
Clearing the Counters723
Viewing Live Sensor Data723
Other Display Messages723
PAYLOAD OPERATION & CALCULATION724
Description of Haul Cycle States724
Haul Cycle Description724
Load Calculation725
Carry Back725
Measurement Accuracy725
SOURCES FOR PAYLOAD ERROR725
Payload Error725
Loading Conditions726
Pressure Sensors726
Swingloads726
Speed and Distance726
HAUL CYCLE DATA726
Haul Cycle Data727
Haul Cycle Warning Flags728
M: Haul Cycle Too Long729
N: Sensor Input Error729
Frame Torque Data729
Sprung Weight Data729
Maximum Speed Data729
Alarm Records729
Fault Code Data730
PC SOFTWARE OVERVIEW731
PC Overview731
System Configuration731
Installing the PLMIII Software731
DOWNLOADING DATA732
PLM III SYSTEM CONFIGURATION733
Starting Communications733
Displayed Payload Units733
Time Units733
Connection Menu733
Connecting to the Payload Meter734
Configure the Payload Meter734
Setting the Date and Time734
Setting the Truck Type735
Setting the Gauge Display Units735
Setting the Frame Serial Number735
Setting the Truck Number735
Setting the Komatsu Distributor735
Setting the Komatsu Customer735
Clean Truck Tare736
Inclinometer Calibration736
DATA ANALYSIS737
Creating a Query737
Sorting on Truck Unit Number737
Sorting on Truck Type737
Sorting on Date Range738
Sorting on Time Range738
Payload Detail Screen739
Creating Reports739
Summary – one page report740
Detailed – multi-page report740
Creating Graphs741
Exporting Data741
CSV Export741
Compressed742
Importing Data743
Deleting Haul Cycle Records743
Viewing Alarms744
Deleting Alarm Records744
TROUBLESHOOTING SECTION745
TROUBLESHOOTING745
Viewing Active Alarms745
Real-Time Data Display745
Testing the Payload Lights745
Creating Log Files of Inputs746
Daily Inspections746
Periodic Maintenance746
Abnormal Displays at Power-Up747
No Payload Display When Keyswitch is Turned ON748
No Display on Speedometer749
No Display on Operator Display749
No Communications With PC750
Load Lights Don’t Light During Loading751
Load Lights Remain ON752
Load Lights Remain ON During Dumping752
Display Doesn’t Clear When The Load Is Dumped752
Calibration Problems753
Alarm 1 – Left Front Pressure High754
Alarm 2 – Left Front Pressure Low754
Troubleshoot Wiring to Left Front Suspension754
Alarm 3 – Right Front Pressure High755
Alarm 4 – Right Front Pressure Low755
Troubleshoot Wiring to Right Front Suspension755
Alarm 5 -Left Rear Pressure High756
Alarm 6 – Left Rear Pressure Low756
Troubleshoot Wiring to Left Rear Suspension756
Alarm 7 – Right Rear Pressure High757
Alarm 8 – Right Rear Pressure Low757
Troubleshoot Wiring to Right Rear Suspension757
Alarm 9 – Inclinometer High758
Alarm 10 – Inclinometer Low758
Troubleshoot Inclinometer Wiring758
Alarm 13 – Body Up Input Failure759
Alarm 16 – Memory Write Failure760
Alarm 17 – Memory Read Failure760
Alarm 18761
Alarm 19761
Alarm 22761
Operator Switch Doesn’t Work762
Alarm 26 – User Switch Fault – SELECT762
Alarm 27 – User Switch Fault – SET762
Connector Map763
Connectors764
PLMIII CHECK OUT PROCEDURE765
General Description765
Tools Required765
Checkout Procedure765
PLMIII CHECKOUT PROCEDURE CONFIRMATION769
Flashburn Programming769
Confirmation Checklist771
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX773
RESERVE ENGINE OIL SYSTEM775
Operation776
LED Monitor Light776
Tank Fill Control (Optional)777
Filling Procedure (Remote fill feature)777
SERVICE778
Every 10 Hours, or once each shift:778
Every 500 Hours:778
Changing Oil778
TROUBLESHOOTING779
Circuit Breaker or Fuse779
SYSTEM ELECTRICAL SCHEMATICS780
SECTION N – CAB COMPONENTS – INDEX781
SECTION N2 – TRUCK CAB – INDEX783
TRUCK CAB785
Description785
Preparation786
Removal – Cab786
Installation – Cab788
CAB DOOR788
Removal788
Installation788
Door Adjustment789
Door Jamb Bolt Adjustment789
Door Handle Plunger Adjustment790
Door Glass Replacement791
Door Window Regulator Replacement795
Door Handle or Latch Assembly Replacement795
Door and Door Hinge Seal Replacement796
Door Opening Seal Removal796
Installation796
GLASS REPLACEMENT797
Adhesive Bonded Windows797
Replacement Procedure797
Windshield And Rear Glass798
Removal798
Installation799
SECTION N3 – CAB COMPONENTS – INDEX801
CAB COMPONENTS803
WINDSHIELD WIPERS803
Wiper Motor Replacement803
Removal803
Installation803
Wiper Arm803
Removal803
Installation804
Wiper Linkage Replacement804
Removal804
Installation804
WINDSHIELD WASHER805
Operation805
Service805
OPERATOR SEAT806
Adjustment806
Seat Removal806
Seat Installation806
SECTION N4 – OPERATOR COMFORT – INDEX807
OPERATOR COMFORT809
HEATER / AIR CONDITIONER809
Operation809
Heater/Air Conditioner Vents809
COMPONENTS810
Circuit Breakers810
Relays810
Heater Core810
Fan Motor And Speed Control811
Actuators811
Filter811
Service811
AIR CONDITIONING SYSTEM813
Environmental Impact813
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES814
PRINCIPLES OF REFRIGERATION814
Air Conditioning814
Refrigeration – The Act Of Cooling815
The Refrigeration Cycle815
AIR CONDITIONER SYSTEM COMPONENTS816
Compressor (Refrigerant Pump)816
Service Valves816
Condenser816
Receiver-Drier816
Expansion Block Valve817
Accumulator817
Evaporator817
ELECTRICAL CIRCUIT818
Thermostat818
Compressor Clutch818
Trinary™ Switch819
SYSTEM SERVICING820
SERVICE TOOLS AND EQUIPMENT821
Recovery/Recycle Station821
Leak Detector821
Service Valves822
Vacuum Pump822
Manifold Gauge Set823
Installing Manifold Gauge Set824
Purging Air From Service Hoses824
SYSTEM PERFORMANCE TEST825
SYSTEM OIL826
Handling and Reusing PAG Oil826
Oil Quantity826
Checking System Oil826
REFRIGERANT827
Recycled Refrigerant827
Reclaimed Refrigerant827
Refrigerant Quantity827
R-134a Refrigerant Containers827
SYSTEM LEAK TESTING828
Electronic Leak Detector828
Tracer Dyes828
Soap and Water828
RECOVERING AND RECYCLING THE REFRIGERANT829
Performing the Recovery Cycle829
Performing the Recycling Procedure829
Evacuating and Charging the A/C System829
SYSTEM REPAIR830
System Flushing830
COMPONENT REPLACEMENT830
Hoses and Fittings830
Lines830
Expansion Valve831
Receiver-Drier831
Thermostat831
Compressor831
Accumulator831
Clutch832
Servicing the Compressor Clutch832
Pulley Removal834
Clutch Coil Check835
Pulley Installation835
Clutch Assembly Installation835
EVACUATING THE SYSTEM837
CHARGING THE A/C SYSTEM839
TROUBLESHOOTING840
Preliminary Checks840
Diagnosis Of Gauge Readings And System Performance840
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS841
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM847
SECTION N5 – OPERATOR CAB CONTROLS – INDEX849
OPERATOR CAB CONTROLS851
STEERING COLUMN851
Removal851
Steering Column Inspection851
Installation851
STEERING WHEEL AND CONTROLS853
Horn Button853
Telescope Lock Ring853
Tilt Wheel Lever853
Turn Signal/Headlight Dimmer853
DYNAMIC RETARDING853
Retarder Control Lever854
Dynamic Retarder/Service Brake Pedal854
Accelerator (Throttle) Pedal854
Starting on a Grade With a Loaded Truck854
GRADE/SPEED RETARD CHART855
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS856
Heater/Air Conditioner Vents856
INSTRUMENT PANEL857
OVERHEAD PANEL AND DISPLAYS857
CENTER CONSOLE858
F-N-R Selector Switch858
Hoist Control Lever859
Raising The Dump Body859
Lowering The Dump Body:859
Ash Tray859
Lighter859
LH Window Control Switch859
RH Window Control Switch859
Engine Shutdown Switch859
Override/Fault Reset Switch860
Retard Speed Control (RSC) Switch860
Retard Speed Control (RSC) Adjust Dial860
Data Store Button861
Engine Control System861
Service Engine Light (Blue)861
Engine Diagnostics Download Port861
Payload Meter861
TCI Download Port861
PSC Download Port861
PAYLOAD METER861
INSTRUMENT PANEL AND INDICATOR LIGHTS863
CONTROL SYMBOLS863
INSTRUMENT PANEL863
PANEL GAUGES, INDICATORS, AND CONTROLS865
Key Switch865
Starting865
Cold Weather Starting865
Normal Engine Shutdown865
Engine Shutdown Switch with 5 Minute Idle Timer Delay866
Fog Lights (Optional)866
Ladder Light Switch866
Manual Backup Switch866
Panel Illumination Lights867
Cab/Air Conditioner Vents867
Rotating Beacon Light Switch (Optional)867
Heated Mirror Switch (Optional)867
Wheel Brake Lock Control867
Parking Brake Control867
Tachometer868
Right Turn Signal Indicator868
High Beam Indicator868
Left Turn Signal Indicator868
Speedometer / Payload Meter868
Voltmeter868
Engine Oil Pressure Gauge868
Water Temperature Gauge868
Fuel Gauge868
AC Drive System Temperature Gauge869
Hydraulic Oil Temperature Gauge869
Hourmeter869
Rest Switch869
Light Switch870
Windshield Wiper and Washer870
Panel Light Dimmer870
Payload Meter Switch870
OVERHEAD STATUS / WARNING INDICATORS871
STATUS / WARNING INDICATOR LIGHT SYMBOLS872
Hazard Warning Lights877
Lamp Test Switch877
Link-On Warning Light877
SECTION P – LUBRICATION AND SERVICE – INDEX879
SECTION P2 – LUBRICATION AND SERVICE – INDEX881
LUBRICATION AND SERVICE883
930E SERVICE CAPACITIES883
HYDRAULIC TANK SERVICE883
Adding Oil883
WHEEL MOTOR SERVICE883
COOLANT LEVEL CHECK884
RADIATOR FILLING PROCEDURE884
RESERVE ENGINE OIL SYSTEM (Optional)884
Reserve Oil Tank Filling Procedure (Remote fill)884
LUBRICATION CHART885
10 HOUR (DAILY) INSPECTION886
50 HOUR LUBRICATION AND MAINTENANCE CHECKS889
100 HOUR LUBRICATION AND MAINTENANCE CHECKS890
250 HOUR LUBRICATION AND MAINTENANCE CHECKS891
500 HOUR LUBRICATION AND MAINTENANCE CHECKS894
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS895
5000 HOUR MAINTENANCE CHECKS896
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX897
AUTOMATIC LUBRICATION SYSTEM899
GENERAL DESCRIPTION899
SYSTEM COMPONENTS901
Filter901
Hydraulic Motor and Pump901
Grease Reservoir901
Pressure Reducing Valve901
Flow Control Valve901
Solenoid Valve901
Vent Valve901
Lubrication Cycle Timer901
Time Delay Module901
Pump Cutoff Pressure Switch (NO 2500 psi [17 237 kPa])901
Grease Pressure Failure Switch (NO 2000 psi [13 789 kPa])901
Pressure Gauge901
Injectors901
SYSTEM OPERATION902
Normal Operation902
Pressure Failure Detection Circuits903
GENERAL INSTRUCTIONS904
Lubricant Requirements904
System Priming904
LUBRICANT PUMP904
Pump Housing Oil Level904
Pump Pressure Control904
Lubrication Cycle Timer Check905
Lubrication Cycle Timer Adjustment905
FILTER ASSEMBLY905
SYSTEM CHECKOUT906
INJECTORS (SL-1 Series “H”))906
Injector Specifications906
Injector Adjustment906
INJECTOR OPERATION907
PUMP REBUILD908
Disassembly908
Cleaning and Inspection910
Assembly910
SYSTEM TROUBLESHOOTING CHART912
PREVENTATIVE MAINTENANCE PROCEDURES915
Daily Lubrication System Inspection915
250 Hour Inspection915
1000 Hour Inspection915
SECTION Q ALPHABETICAL INDEX917
SECTION R – SYSTEM SCHEMATICS – INDEX921
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358923
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359924
ELECTRICAL SCHEMATIC – XS1300925

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24