Komatsu 930E-3 Dump Truck Shop Manual CEBM013301 – PDF DOWNLOAD 

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Komatsu 930E-3 Dump Truck Shop Manual CEBM013301 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-3 Dump Truck Shop Manual CEBM013301 – PDF DOWNLOAD 

Language : English
Pages : 962
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-3 Dump Truck Shop Manual CEBM013301 – PDF DOWNLOAD 

Serial Number A30310 thru A30328

COVER 1
CONTENTS 2
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 27
LIST OF LUBRICANT AND WATER 29
10 STRUCTURE AND FUNCTION 31
RADIATOR AND OIL COOLER 32
ENGINE CONTROL 33
PTO (COUPLING) 34
POWER TRAIN 35
SWING CIRCLE 36
SWING MACHINERY 37
TRACK FRAME 38
TRACK SHOE 39
HYDRAULIC CIRCUIT DIAGRAM 40
HYDRAULIC TANK 45
HYDRAULIC PUMP 46
CONTROL VALVE 66
CLSS 77
SWING MOTOR 123
CENTER SWIVEL JOINT 126
TRAVEL MOTOR 127
VALVE CONTROL 135
WORK EQUIPMENT・SWING PPC VALVE 137
TRAVEL PPC VALVE 141
SERVICE PPC VALVE 145
SAFETY LOCK VALVE 148
PPC ACCUMULATOR 148
STRAIGHT-TRAVEL SYSTEM 149
SOLENOID VALVE 150
ACCUMULATOR FOR BREAKER 154
ADDITIONAL FILTER FOR BREAKER 155
WORK EQUIPMENT 156
AIR CONDITIONER 157
ACTUAL ELERICAL WIRING DIAGRAM 158
ELECTRICAL CIRCUIT DIAGRAM 162
ELECTRIC CONTROL SYSTEM 167
MACHINE MONITOR SYSTEM 172
SENSORS 175
20 TESTING AND ADJUSTING 177
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 178
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 179
STANDARD VALUE TABLE FOR ELECTRICAL PARTS 187
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 189
MEASURING ENGINE SPEED 190
MEASURING EXHAUST COLOR 191
ADJUSTING VALVE CLEARANCE 192
MEASURING BLOW-BY PRESSURE 193
TESTING AND ADJUSTING FUEL INJECTION TIMING 194
MEASURING ENGINE OIL PRESSURE 195
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 196
ADJUSTING FUEL CONTROL LEVER 197
ADJUSTING ENGINE SPEED SENSOR 199
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT 200
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) 202
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE 204
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE 207
TESTING SOLENOID VALVE OUTPUT PRESSURE 209
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE 211
TESTING TRAVEL DEVIATION 212
MEASURING OIL LEAKAGE 213
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 215
TESTING CLEARANCE OF SWING CIRCLE BEARING 216
TESTING AND ADJUSTING TRACK SHOE TENSION 217
MEASURING WEAR OF SPROCKET 218
BLEEDING AIR 219
TROUBLESHOOTING 221
POINTS TO REMEMBER WHEN TROUBLESHOOTING 222
SEQUENCE OF EVENTS IN TROUBLESHOOTING 223
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 224
CHECKS BEFORE TROUBLESHOOTING 232
CONNECTOR TYPES AND MOUNTING LOCATIONS 233
CONNECTOR ARRANGEMENT DIAGRAM 235
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 237
METHOD OF USING JUDGEMENT TABLE 247
METHOD OF USING TROUBLESHOOTING CHARTS 249
TROUBLESHOOTING OF ENGINE (S MODE) 251
METHOD OF USING TROUBLESHOOTING CHART 252
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 256
S-2 ENGINE DOES NOT START 258
1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 258
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 259
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 260
S-4 ENDINE STOPS DURING OPERATIONS 261
S-5 ENGINE DOES NOT ROTATES SMOOTHLY (HUNTING) 262
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER) 263
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 264
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 265
S-9 OIL BECOMES CONTAMINATED QUICKLY 266
S-10 FUEL CONSUMPTION IS EXCESSIVE 267
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 268
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 269
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 270
S-14 WATER TEMPERTURE BECOMES TOO HIGH (OVERHEATING) 271
S-15 ABNORMAL NOISE IS MADE 272
S-16 VIBRATION IS EXCESSIVE 273
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 274
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS 275
E MODE RELATED ELECTRIC CIRCUIT DIAGRAM 277
E-1 ABNORMALITY IN PC-EPC SYSTEM 280
a) SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER 280
b) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 281
E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM 283
a) WORK EQUIPMENT, SWING, TRAVEL DO NOT MOVE EVEN WHEN SAFETY LOCK IS PLACED AT FREE 283
b) WORK EQUIPMENT, SWING, TRAVEL MOVE EVEN WHEN SAFETY LOCK IS PLACED AT LOCK 283
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM 286
a) SWING DOES NOT MOVE EVEN WHEN SWING LOCK SWITCH IS PLACED AT FREE 286
b) SWING MOVES EVEN WHEN SWING LOCK SWITCH IS PLACED AT LOCK 286
E-4 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM 288
a) MACHINE DOES NOT TRAVEL AT HIGH SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT HI 288
b) MACHINE DOES NOT TRAVEL AT LOW SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT LO 288
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START) 290
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 293
TABLE OF FAILURE MODES AND CAUSES 294
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER 296
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS 296
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE 297
H-4 ABNORMALITY NOISE GENERATED (AROUND PUMP) 297
H-5 FINE CONTROL ABLITY IS POOR OR RESPONSE IS POOR 298
H-6 BOOM IS SLOW OR LACKS POWER 299
H-7 ARM IS SLOW OR LACKS POWER 299
H-8 BUCKET IS SLOW OR LACKS POWER 301
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL) 301
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET) 302
H-11 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW 302
H-12 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW 303
H-13 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 303
H-14 IN WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY 303
H-15 TRAVEL DEVIATION 304
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL 304
b) DEVIATION IS EXCESSIVE WHEN STARTING 304
H-16 TRAVEL SPEED IS SLOW 305
H-17 STEERING IS DIFFERENT TO TURN OR LACKS POWER 306
H-18 TRAVEL SPEED DOES NOT SWITCH 308
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY) 308
H-20 DOES NOT SWING 309
a) DOES NOT SWING TO EITHER LEFT OR RIGHT 309
b) DOES NOT SWING IN ONE DIRECTION 309
H-21 SWING ACCELERATION IS POOR 310
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING 312
a) ONE DIRECTION ONLY 312
b) BOTH DIRECTIONS 312
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) 313
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING 313
H-25 EXCESSIVE HYDRULIC DRIFT OF SWING 314
a) WHEN SWING LOCK SWITCH IS OFF 314
b) WHEN SWING LOCK SWITCH IS AT LOCK 314
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 315
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM 316
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (3 SECOND SELF CHECK IS ALSO NOT CARRIED OUT) 317
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECOND), LAMPS DO NOT GO OUT 317
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS 318
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP) 318
b) SWING LOCK OR PREHEATING LAMPS DO NOT LIGHT UP (GAUGE LAMPS ALL LIGHT UP) 318
c) BATTERY CHARGE LAMP DOES NOT LIGHT UP 318
d) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP 318
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP 319
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP 319
M-6 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP 320
M-7 WHEN SWING LOCK IS TURNED ON, SWING LOCK PILOT LAMP DOES NOT LIGHT UP 320
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL) 321
M-9 WHEN ENGINE IS RUNNING, BATTERY CHARGE CAUTION LAMP LIGHTS UP 321
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 322
a) AFTER ENGINE IS STARTED, ONLY LOWEST LEVEL LAMP (WHITE RANGE) LIGHTS UP AND LEVEL DOES NOT RISE 322
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NO OVERHEATING) 322
c) GAUGE GOES OUT 322
M-11 ABNORMALITY IN FUEL GAUGE 324
a) ALL SEGMENTS OF GAUGE GO OUT 324
b) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL 324
c) EVEN WHEN FUEL TANK IS FILED, GAUGE DOES NOT DISPLAY FULL 324
M-12 DEFETIVE OPERATION OF ALARM BUZZER 326
a) BUZZER DOES NOT SOUND 326
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP 326
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE 327
a) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP 327
b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP 327
M-14 NIGHT LIGHTING DOES NOT LIGHT UP 328
a) GAUGE LIGHTING DOES NOT LIGHT UP 328
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY) 328
M-15 HEATER DOES NOT WORK (MACHINES WITH HEATER) 329
a) BOTH LO AND HI DO NOT WORK 329
b) ONLY LO DOES NOT WORK 329
c) ONLY HI DOES NOT WORK 329
30 DISASSEMBLY AND ASSEMBLY 331
METHOD OF USING MANUAL 333
PRECAUTIONS WHEN CARRYING OUT OPERATION 334
SPECIAL TOOL LIST 336
SKETCHES OF SPECIAL TOOLS 340
STARTING MOTOR 342
REMOVAL AND INSTALLATION 342
ALTERNATOR 343
REMOVAL AND INSTALLATION 343
AIR CONDITIONER COMPRESSOR 345
REMOVAL AND INSTALLATION 345
CONDENSER 346
REMOVAL AND INSTALLATION 346
ENGINE OIL COOLER 347
REMOVAL AND INSTALLATION 347
FUEL INJECTION PUMP 348
REMOVAL 348
INSTALLATION 350
WATER PUMP 352
REMOVAL AND INSTALLATION 352
NOZZLE HOLDER 353
REMOVAL AND INSTALLATION 353
TURBOCHARGER 354
REMOVAL AND INSTALLATION 354
THERMOSTAT 355
REMOVAL AND INSTALLATION 355
CYLINDER HEAD 356
REMOVAL 356
INSTALLATION 361
ENGINE, MAIN PUMP 364
REMOVAL 364
INSTALLATION 368
HYDRAULIC COOLER 369
REMOVAL AND INSTALLATION 369
RADIATOR, HYDRAULIC COOLER 370
REMOVAL 370
INSTALLATION 371
FUEL TANK 372
REMOVAL AND INSTALLATION 372
CENTER SWIVEL JOINT 373
REMOVAL AND INSTALLATION 373
DISASSEMBLY AND ASSEMBLY 374
SPROCKET 375
REMOVAL AND INSTALLATION 375
TRAVEL MOTOR 376
REMOVAL AND INSTALLATION 376
SWING MACHINERY, SWING MOTOR 377
REMOVAL AND INSTALLATION 377
SWING MOTOR 378
REMOVAL AND INSTALLATION 378
DISASSEMBLY 379
ASSEMBLY 383
SWING MACHINERY 391
DISASSEMBLY 391
ASSEMBLY 394
REVOLVING FRAME 398
REMOVAL 398
INSTALLATION 399
SWING CIRCLE 400
REMOVAL AND INSTALLATION 400
IDLER, RECOIL SPRING 401
REMOVAL AND INSTALLATION 401
IDLER 402
DISASSEMBLY 402
ASSEMBLY 403
RECOIL SPRING 405
DISASSEMBLY 405
ASSEMBLY 406
TRACK ROLLER 407
REMOVAL AND INSTALLATION 407
DISASSEMBLY 408
ASSEMBLY 409
CARRIER ROLLER 411
REMOVAL AND INSTALLATION 411
TRACK SHOE 412
REMOVAL AND INSTALLATION 412
HYDRAULIC TANK 413
REMOVAL 413
INSTALLATION 414
CONTROL PUMP 415
REMOVAL AND INSTALLATION 415
MAIN PUMP 416
REMOVAL 416
INSTALLATION 417
DISASSEMBLY 418
ASSEMBLY 428
MAIN PUMP INPUT SHAFT OIL SEAL 440
REMOVAL AND INSTALLATION 440
CONTROL VALVE 441
REMOVAL 441
INSTALLATION 442
DISASSEMBLY 443
ASSEMBLY 448
LS SELECT VALVE 454
DISASSEMBLY AND ASSEMBLY 454
PC-EPC VALVE 455
REMOVAL AND INSTALLATION 455
PC VALVE 456
REMOVAL AND INSTALLATION 456
LS VALVE 457
REMOVAL AND INSTALLATION 457
SOLENOID VALVE 458
REMOVAL AND INSTALLATION 458
PPC VALVE 460
REMOVAL AND INSTALLATION 460
WORK EQUIPMENT RIGHT SIDE PPC VALVE 461
REMOVAL AND INSTALLATION 461
WORK EQUIPMENT, SWING PPC VALVE 462
DISASSEMBLY 462
ASSEMBLY 463
TRAVEL PPC VALVE 464
REMOVAL AND INSTALLATION 464
DISASSEMBLY 465
ASSEMBLY 466
BOOM CYLINDER 467
REMOVAL 467
INSTALLATION 468
ARM CYLINDER 469
REMOVAL 469
INSTALLATION 470
BUCKET CYLINDER 471
REMOVAL 471
INSTALLATION 472
HYDRAULIC CYLINDER 473
DISASSEMBLY 473
ASSEMBLY 476
WORK EQUIPMENT 480
REMOVAL 480
INSTALLATION 481
BUCKET 482
REMOVAL 482
INSTALLATION 483
ARM 484
REMOVAL 484
INSTALLATION 485
BUCKET, ARM 486
REMOVAL 486
INSTALLATION 487
BOOM 488
REMOVAL 488
INSTALLATION 489
OPERATOR’S CAB 490
REMOVAL AND INSTALLATION 490
COUNTERWEIGHT 491
REMOVAL AND INSTALLATION 491
MONITOR 492
REMOVAL AND INSTALLATION 492
40 MAINTENANCE STANDARD 493
SWING MACHINERY 494
SWING CIRCLE 496
TRACK FRAME 497
IDLER 498
CARRIER ROLLER 499
TRACK ROLLER 500
SPROCKET 501
TRACK SHOE 502
HYDRAULIC PUMP 509
CONTROL VALVE 511
SWING MOTOR 521
TRAVEL MOTOR 522
CENTER SWIVEL JOINT 523
WORK EQUIPMENT・SWING PPC VALVE 524
TRAVEL PPC VALVE 525
SERVICE PPC VALVE 526
HYDRAULIC CYLINDER 527
WORK EQUIPMENT 529
DIMENSION OF WORK EQUIPMENT 531
90 OTHER 535
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO 57449-60967 536
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO 60968 AND UP 537
ELECTRICAL CIRCUIT GIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO 57499-60967 538
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO 57499-60967 539
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO 60968 AND UP 540
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO 60968 AND UP 541

DESCRIPTION:

Komatsu 930E-3 Dump Truck Shop Manual CEBM013301 – PDF DOWNLOAD 

Serial Number A30310 thru A30328

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 per- sonnel 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 accom- plishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other gen- eral 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 detall of the truck. Disassembly should be cared 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 operators 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 Nm) torque. All torque specifications have 10% tolerance unless otherwise specified
• A Product Identification plate is normally 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 (1.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 bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
  The Gross Vehicle Weight (GWW) is what determines the load on the drive train, frame, tires, and other compo- nents.
• The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which Includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.

S.V 24/12/24