Komatsu 930E-3 Dump Truck Shop Manual CEBM014501 PDF

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Komatsu 930E-3 Dump Truck Shop Manual CEBM014501 – PDF DOWNLOAD

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Komatsu 930E-3 Dump Truck Shop Manual CEBM014501 – PDF DOWNLOAD 

Language : English
Pages : 964
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 930E-3 Dump Truck Shop Manual CEBM014501 – PDF DOWNLOAD 

SERIAL NUMBERS A30329 – A30363

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.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• 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.

TABLE OF CONTENTS:

Komatsu 930E-3 Dump Truck Shop Manual CEBM014501 – PDF DOWNLOAD 

SERIAL NUMBERS A30329 – A30363

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 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 E – ELECTRICAL PROPULSION SYSTEM – INDEX 247
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 249
ELECTRICAL PROPULSION SYSTEM COMPONENTS 251
GENERAL SYSTEM DESCRIPTION 251
SYSTEM COMPONENTS 253
Propulsion System Controller(PSC) 253
Truck Control Interface (TCI) 253
Diagnostic Information Display 255
DID Panel Event Codes 255
PSC SOFTWARE FUNCTIONS 279
Input Processing 279
STATE MANAGEMENT 279
State Machine 279
DC Link State 282
Powering the Link 282
De-Powering the Link 282
Control Functions 282
ALTERNATOR FIELD CONTROL 283
Desired Three-Phase Voltage 283
Desired DC Link Voltage 283
Self-load 283
Propel Torque Control 284
Retard Torque Control 284
Wheel Slide Control 284
Resistor Grid Control 285
Chopper Voltage Control 285
EVENT PROCESSING 285
Event Detection 285
Power On Tests 285
Initiated Tests 286
Periodic Tests 286
EVENT RESTRICTIONS 286
EVENT LOGGING AND STORAGE 286
Event History Buffer 287
Data Packs 287
To Record and Save a Data Pack to a Floppy Disk 287
Event Reset 288
SERIAL DATA COMMUNICATIONS 289
PSC – PTU Communications Processing 289
Inverter Communications Processing 289
OUTPUT PROCESSING 290
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 290
Fast Start 290
Engine Shutdown/Engine Not Running 290
Limp Home Mode 290
Entering/Exiting Limp Home Mode 290
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 291
ELECTRONIC ACCELERATOR AND RETARD PEDALS 303
Removal 303
Installation 303
Disassembly 303
Assembly 303
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 305
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 307
AC DRIVE SYSTEM MAINTENANCE 307
TRUCK SHUTDOWN PROCEDURES 307
NORMAL TRUCK SHUTDOWN PROCEDURE 308
SHUTDOWN AFTER SYSTEM FAILURE 309
SYSTEM CHECKOUT 310
Battery and Control Checks of System WITH Battery Power OFF 310
Battery and Control Circuit Checks of System With Battery Power ON 313
Checks with Key Switch OFF 314
CPU Battery Checks 316
MEMORY BACKUP BATTERY REPLACEMENT 316
TCI PROGRAMMING 317
PSC PROGRAMMING 317
INVERTER PROGRAMMING 318
TCI CHECKOUT 318
Modular Mining Communication Port 319
TCI Input Checks 320
TCI Digital Output Tests 322
TCI Digital Input Tests 324
PSC Checkout Procedure 326
PSC Digital Input Checks 330
Miscellaneous Checks 331
A3PV Panel 331
LINKV Panel 331
Thermistor Checks 331
17FM384 Panel Check 331
Pedal Percentages and Meter Calibration 332
Meter Calibration Procedure 332
Reprogram With Serial Numbers and Pedal Percentages 334
LOAD TESTING 336
Preload Checks 336
ADDITIONAL TRUCK CHECKS 338
On-Board Load Testing 340
Preparation 340
Initiate Loadbox Test 343
Manual Offset HP Output Adjustment 345
TROUBLESHOOTING 347
PVM Optimum Load Curve Handshaking Troubleshooting 347
MISCELLANEOUS COMPONENT REPAIR 348
Troubleshooting Phase Modules and Chopper Modules 348
Phase Module Removal and Snubber Resistor Replacement 348
Snubber Resistor Installation 349
Phase Module Installation 349
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 350
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 353
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 354
IGBT TROUBLESHOOTING 355
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 357
SECTION G2 – TIRES AND RIMS – INDEX 359
TIRES AND RIMS 361
WHEEL STUD MAINTENANCE 362
FRONT TIRES AND RIMS 363
Removal 363
Installation 364
REAR TIRES AND RIMS 365
Removal 365
Installation 366
RIM 367
Tire Removal 367
Tire Installation 368
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 371
FRONT WHEEL HUB AND SPINDLE 373
WHEEL HUB AND SPINDLE ASSEMBLY 373
Preparation 373
Removal 373
Installation – Wheel Hub and Spindle Assembly 376
Disassembly – Wheel Hub and Spindle Assembly 377
Cleaning and Inspection – Wheel Hub and Spindle Assembly 377
Assembly – Wheel Hub and Spindle Assembly 379
Wheel Bearing Adjustment: 379
Brake Installation 380
Seal Assembly Gap Check 381
STEERING CYLINDERS AND TIE ROD 382
Spherical Bearing Wear Limits 382
Removal – Steering Cylinder and Tie Rod 383
Installation – Steering Cylinder and Tie Rod 384
Bearing Replacement 384
TOE-IN ADJUSTMENT 385
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 387
REAR AXLE HOUSING ATTACHMENT 389
PIVOT PIN 389
Removal 389
Installation 390
PIVOT EYE BEARING 391
Removal 391
Installation 391
PIVOT EYE REPAIR 391
Removal 391
Disassembly 391
Assembly 392
Installation 392
ANTI-SWAY BAR 392
Removal 392
Installation 393
Disassembly 393
Cleaning and Inspection 393
Assembly 393
SECTION G5 – REAR AXLE HOUSING – INDEX 395
REAR AXLE HOUSING 397
REAR AXLE HOUSING 397
Preparation 397
Removal 397
Cleaning and Inspection – Rear Axle Housing 399
Installation – Rear Axle Housing 399
WHEEL MOTOR 400
Preparation 400
Removal 400
Cleaning and Inspection – Wheel Motor 401
Installation – Wheel Motor 402
WHEEL MOTOR GEAR OIL 405
Filtering Requirements 405
Particle Size Analysis 405
Flushing 405
Oil Sample Analysis 406
ELEMENT SPECIFICATION CHARTS 407
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 411
SECTION H2 – FRONT SUSPENSIONS – INDEX 413
FRONT SUSPENSION 415
Removal 415
Installation – Front Suspension 416
“Turn-Of-The-Nut” Tightening Procedure 419
MINOR REPAIRS (LOWER BEARING & SEALS) 420
Removal – Bearing Retainer 420
Installation – Bearing Retainer 420
MAJOR SUSPENSION REBUILD 422
Disassembly 422
Assembly 422
SECTION H3 – REAR SUSPENSIONS – INDEX 425
REAR SUSPENSIONS 427
SUSPENSION CYLINDER 428
Removal 428
Installation – Rear Suspension 430
Disassembly – Rear Suspension 430
Cleaning and Inspection – Rear Suspension 430
Assembly – Rear Suspension 431
SUSPENSION PRESSURE TEST 433
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 435
SUSPENSION OILING AND CHARGING PROCEDURE 437
GENERAL 437
EQUIPMENT LIST 437
Hydrair® Charging Kit 437
Installation of Charging Kit 437
Removal of Charging Kit 438
Support Blocks For Oiling And Charging Dimensions 438
FRONT SUSPENSION 439
Front Suspension Oiling 439
Front Suspension Nitrogen Charging 440
REAR SUSPENSION 441
Rear Suspension Oiling 441
Rear Suspension Nitrogen Charging 443
OIL AND NITROGEN SPECIFICATIONS CHART 444
SECTION J – BRAKE CIRCUIT – INDEX 445
SECTION J2 – BRAKE CIRCUIT – INDEX 447
BRAKE CIRCUIT 449
SERVICE BRAKE CIRCUIT 449
SECONDARY BRAKING AND AUTOMATIC APPLY 451
PARKING BRAKE CIRCUIT 451
Normal Operation (key switch on, engine running) 451
BRAKE LOCK CIRCUIT 452
WARNING CIRCUIT 452
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 455
BRAKE CIRCUIT COMPONENT SERVICE 457
BRAKE VALVE 457
Rebuild Criteria 457
Removal 458
Installation 458
Disassembly 459
Cleaning and Inspection 462
Assembly 462
Actuator Base Threaded Inserts 462
Boot and Cap 462
Valve Body Seal Installation 462
Regulator Sleeve O-Ring Installation 463
Actuator Plunger O-ring Installation 463
Assembly of Valve 463
DIFFERENTIAL PRESSURE SWITCH 465
Disassembly 465
Cleaning and Inspection 465
Assembly 465
VALVE BENCH TEST AND ADJUSTMENT 466
Test Set Up Procedure 467
Brake Valve Output Pressure Adjustment 467
Differential Pressure Switch Adjustment 467
Final Test and Adjustment 468
Installation Of Brake Pedal Actuator Assembly to Brake Valve 469
Installation of Retard Pedal To Brake Pedal 469
DUAL RELAY VALVE 471
Removal 471
Installation 471
Disassembly 473
Cleaning and Inspection 473
Assembly 473
DIFFERENTIAL PRESSURE SWITCH 474
Disassembly 474
Cleaning and Inspection 474
Assembly 474
VALVE TEST AND ADJUSTMENT 475
Test Set Up Procedure 476
Relay Valve Output Pressure Adjustment 476
Differential Pressure Switch Adjustment 477
BRAKE MANIFOLD 478
Removal 478
Installation 479
Disassembly 479
Cleaning and Inspection 479
Assembly 479
BRAKE ACCUMULATORS 480
Brake Accumulator Bleeddown Procedure 480
BRAKE ACCUMULATOR REPAIR 481
Removal 481
Installation 481
Disassembly 482
Cleaning and Inspection 483
Assembly 483
ACCUMULATOR CHARGING PROCEDURE 485
Temperature During Precharge 486
Precharge Maintenance 487
Recharging Accumulators 487
Accumulator Storage procedures 488
Bladder Storage Procedures 488
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 489
Removal 489
Installation 489
Disassembly and Adjustment 489
Potentiometer Check 491
Assembly 491
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 493
BRAKE CIRCUIT CHECK-OUT PROCEDURE 495
REQUIRED EQUIPMENT 497
INITIAL SYSTEM SET-UP 498
BRAKE SYSTEM CHECKOUT 499
Failure Modes Check-Out 500
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 502
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 505
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 506
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 507
WET DISC BRAKE ASSEMBLY 509
OPERATION 509
MAINTENANCE 510
Brake Disc Wear Indicator 510
Removal/Installation – Wet Disc Brake Assembly 510
BRAKE REBUILD 512
Disassembly 512
Cleaning and Inspection 515
Assembly 516
Floating Ring Seal Assembly/Installation 519
WET DISC BRAKE BLEEDING PROCEDURE 522
SECTION J7 – PARKING BRAKE – INDEX 523
PARKING BRAKE 525
OPERATION 525
MAINTENANCE 526
Inspection – Parking Brake 526
Removal – Parking Brake 526
Installation – Parking Brake 527
Disassembly – Parking Brake 528
Cleaning and Inspection – Parking Brake 528
Assembly – Parking Brake 528
PARKING BRAKE BLEEDING PROCEDURE 530
SECTION L – HYDRAULIC SYSTEM – INDEX 531
SECTION L2 – HYDRAULIC SYSTEM – INDEX 533
HYDRAULIC SYSTEM 535
HYDRAULIC PUMP MODULE 535
HOIST CIRCUIT OPERATION 536
STEERING CIRCUIT OPERATION 538
DISC BRAKE COOLING SYSTEM 540
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 543
HYDRAULIC SYSTEM COMPONENT REPAIR 545
HOIST PUMP 545
Removal 545
Installation 547
INSPECTION OF PARTS 552
Assembly 552
HYDRAULIC TANK 558
Filling Instructions 558
Removal 558
Installation 559
HYDRAULIC TANK STRAINERS 559
Removal 559
Inspect and Clean 559
Installation 559
HYDRAULIC TANK BREATHERS 560
SECTION L4 – STEERING CIRCUIT – INDEX 561
STEERING CIRCUIT 563
COMPONENT DESCRIPTION 564
Steering Control Unit 564
Bleeddown Manifold Valve 565
Bleeddown Solenoid 565
Relief Valves 567
Hoist Limit Solenoid 567
Accumulators 567
Low Precharge Warning Switch 567
High Pressure Filter 567
Quick Disconnect Ports 567
Flow Amplifier 568
FLOW AMPLIFIER SYSTEM OPERATION 570
No Steer 570
Steering Left 572
Steering Right 574
No Steer, External Shock Load 576
STEERING PUMP 578
Operation 578
PRINCIPLE OF OPERATION 580
Full Pump Volume: 580
Half Pump Volume: 580
Neutral Position: 580
Steering Pump 581
SECTION L5 – STEERING CONTROL UNIT – INDEX 583
STEERING CONTROL UNIT 585
Removal 585
Spline Inspection 585
Installation 586
STEERING CONTROL UNIT REBUILD 586
Disassembly 586
Cleaning and Inspection – Steering Control Unit 587
Assembly – Steering Control Unit 589
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 593
STEERING CIRCUIT COMPONENT REPAIR 595
BLEEDDOWN MANIFOLD VALVE 595
Removal 595
Installation 595
FLOW AMPLIFIER 597
Removal 597
Installation 597
FLOW AMPLIFIER REBUILD 597
Disassembly 600
Assembly 601
STEERING CYLINDERS 602
Disassembly 603
Piston Seal & Bearing Installation 603
Cylinder Assembly 603
Test 603
STEERING AND BRAKE PUMP 604
Removal 604
Installation 604
Disassembly 606
Control Piston Group 606
Valve Plate Group 606
Rotating Group 609
Swashblock Group 609
Driveshaft Group 609
Inspection 609
Control Piston Group 609
Valve Plate Group 609
Rotating Group 609
Swashblock Group 611
Driveshaft Group 612
Compensator Block and Unloader Module 612
Stroke Adjuster Assembly 612
Assembly 612
Swashblock Group 612
Driveshaft Group 613
Rotating Group 613
Valve Plate Group 614
STEERING ACCUMULATORS 615
Removal 615
Installation 615
Disassembly 616
Cleaning and Inspection 616
Assembly 617
Leak Testing 619
Charging Procedure 620
Temperature During Precharge 621
Precharge Maintenance 622
Accumulator Storage procedures 623
Bladder Storage Procedures 623
TROUBLESHOOTING CHART 624
SECTION L7 – HOIST CIRCUIT – INDEX 629
HOIST CIRCUIT 631
HOIST CIRCUIT OPERATION 631
COMPONENT DESCRIPTION 632
Hydraulic Tank 632
Hydraulic Pump 632
High Pressure Filters 632
Hoist Valve 632
Inlet Sections – Hoist Valve 632
Spool Sections – Hoist Valve 633
Hoist Pilot Valve 633
Bleeddown Manifold 634
Hoist-up Limit Solenoid 634
Pilot Operated Check Valve 634
Overcenter Manifold 634
HOIST CIRCUIT OPERATION 635
Float Position Of Pilot Valve With Truck Body On Frame 636
Power Up Operation 638
Hold Operation 640
Power Down Operation 642
Float Operation 644
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 647
HOIST CIRCUIT COMPONENT REPAIR 649
HOIST VALVE 649
Removal 649
Installation 650
O-Ring Replacement 650
INLET SECTION 651
Disassembly 651
Cleaning and Inspection 652
Assembly 652
REAR SPOOL SECTION (Work Ports) 652
Disassembly 652
Cleaning and Inspection 654
Assembly 654
FRONT SPOOL SECTION (Tank Ports) 655
Disassembly 655
Cleaning and Inspection 655
Assembly 655
HOIST PILOT VALVE 657
Removal 657
Installation 657
Disassembly 658
Cleaning and Inspection 659
Assembly 659
HOIST CYLINDERS 660
Removal 660
Installation 661
Disassembly 663
Cleaning and Inspection 664
Assembly – Quill and Cylinder 665
Quill Installation 665
Installation Of Check Balls And Plugs In Quill 666
Assembly of Cylinder 667
OVERCENTER VALVE MANIFOLD 668
DISABLED TRUCK DUMPING PROCEDURE 669
Hookup 669
Raising the Body 669
Lowering the Body 669
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 671
HYDRAULIC SYSTEM FILTERS 673
HOIST CIRCUIT FILTER 673
Filter Element Replacement 673
Removal – Hoist Circuit Filter 674
Installation – Hoist Circuit Filter 674
Indicator Switch – Hoist Circuit Filter 674
STEERING CIRCUIT FILTER 675
Filter Element Replacement 675
Removal – Steering Circuit Filter 676
Installation – Steering Circuit Filter 676
Indicator Switch – Steering Circuit Filter 676
INDICATOR SWITCH 676
Test Procedure 676
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 679
HYDRAULIC CHECK-OUT PROCEDURE 681
GENERAL INFORMATION 681
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 681
Equipment Requirements 682
Pump Pressure Control Adjustments 682
Steering Control Valve and Flow Amplifier Leakage Test 683
Bleeddown Manifold Leakage Test 683
STEERING/BRAKE PUMP STROKE ADJUSTMENT 684
SHOCK AND SUCTION VALVES 685
Equipment Requirements 685
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 686
Equipment Requirements 686
Pressure Gauge Locations 686
Brake Cooling Circuit Test 686
Power Up Relief Pressure Test 687
Adjustment 687
Power Down Relief Pressure Test 688
Hoist Counterbalance Valve Adjustment Preparation 689
Counterbalance Valve Pressure Check 689
Counterbalance Valve Adjustment 690
Preparation 691
Flushing Procedure 691
Filter Element Replacement 692
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 693
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 694
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 695
SECTION M2 – FIRE CONTROL SYSTEM – INDEX 697
FIRE CONTROL SYSTEM (MANUAL) 699
Operation 699
Inspection and Maintenance 699
Recharging Procedures 700
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 701
Control Module 701
Actuator 702
Linear Detection Wire 702
Power Wire 702
Test Kit 702
Squib 702
Securing the Detection Wire 703
Preliminary Test Before Final Hook-Up 703
Installation Procedure for Squib 705
Placing the Electric Detection & Actuation System Into Service 705
INSPECTION AND MAINTENANCE SCHEDULES 706
Daily 706
Normal Maintenance Based On Actual Operating Hours 706
IN CASE OF FIRE 707
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 709
SECTION M8 – SPECIAL TOOLS 711
SECTION M20 – PAYLOAD METER III – INDEX 717
OPERATION SECTION 721
Introduction 721
Data Summary 721
Data Gathering 721
COMPONENT DESCRIPTION 722
System Diagram 722
Suspension Pressure Sensors 722
Inclinometer 722
Operator Display 722
Operator Switch 723
Speed Input 723
Body-Up Switch 723
Brake Lock Switch 723
Payload Meter 723
Communications Ports 723
Keyswitch Input 724
Payload Meter Power 724
Load Lights 724
Wiring and Termination 725
TCI Outputs 725
OPERATOR’S DISPLAY AND SWITCH 726
Reading the Speedometer 726
Reading the Load Display 726
Using the Operator ID 726
Using the Load and Ton Counter 726
Total Ton Counter 726
Total Load Counter 727
Clearing the Counters 727
Viewing Live Sensor Data 727
Other Display Messages 727
PAYLOAD OPERATION & CALCULATION 728
Description of Haul Cycle States 728
Haul Cycle Description 728
Load Calculation 729
Carry Back 729
Measurement Accuracy 729
SOURCES FOR PAYLOAD ERROR 729
Payload Error 729
Loading Conditions 730
Pressure Sensors 730
Swingloads 730
Speed and Distance 730
HAUL CYCLE DATA 730
Haul Cycle Data 731
Haul Cycle Warning Flags 732
M: Haul Cycle Too Long 733
N: Sensor Input Error 733
Frame Torque Data 733
Sprung Weight Data 733
Maximum Speed Data 733
Alarm Records 733
Fault Code Data 734
PC SOFTWARE OVERVIEW 735
PC Overview 735
System Configuration 735
Installing the PLMIII Software 735
DOWNLOADING DATA 736
PLM III SYSTEM CONFIGURATION 737
Starting Communications 737
Displayed Payload Units 737
Time Units 737
Connection Menu 737
Connecting to the Payload Meter 738
Configure the Payload Meter 738
Setting the Date and Time 738
Setting the Truck Type 739
Setting the Gauge Display Units 739
Setting the Frame Serial Number 739
Setting the Truck Number 739
Setting the Komatsu Distributor 739
Setting the Komatsu Customer 739
Clean Truck Tare 740
Inclinometer Calibration 740
DATA ANALYSIS 741
Creating a Query 741
Sorting on Truck Unit Number 741
Sorting on Truck Type 741
Sorting on Date Range 742
Sorting on Time Range 742
Payload Detail Screen 743
Creating Reports 743
Summary – one page report 744
Detailed – multi-page report 744
Creating Graphs 745
Exporting Data 745
CSV Export 745
Compressed 746
Importing Data 747
Deleting Haul Cycle Records 747
Viewing Alarms 748
Deleting Alarm Records 748
TROUBLESHOOTING SECTION 749
TROUBLESHOOTING 749
Viewing Active Alarms 749
Real-Time Data Display 749
Testing the Payload Lights 749
Creating Log Files of Inputs 750
Daily Inspections 750
Periodic Maintenance 750
Abnormal Displays at Power-Up 751
No Payload Display When Keyswitch is Turned ON 752
No Display on Speedometer 753
No Display on Operator Display 753
No Communications With PC 754
Load Lights Don’t Light During Loading 755
Load Lights Remain ON 756
Load Lights Remain ON During Dumping 756
Display Doesn’t Clear When The Load Is Dumped 756
Calibration Problems 757
Alarm 1 – Left Front Pressure High 758
Alarm 2 – Left Front Pressure Low 758
Troubleshoot Wiring to Left Front Suspension 758
Alarm 3 – Right Front Pressure High 759
Alarm 4 – Right Front Pressure Low 759
Troubleshoot Wiring to Right Front Suspension 759
Alarm 5 -Left Rear Pressure High 760
Alarm 6 – Left Rear Pressure Low 760
Troubleshoot Wiring to Left Rear Suspension 760
Alarm 7 – Right Rear Pressure High 761
Alarm 8 – Right Rear Pressure Low 761
Troubleshoot Wiring to Right Rear Suspension 761
Alarm 9 – Inclinometer High 762
Alarm 10 – Inclinometer Low 762
Troubleshoot Inclinometer Wiring 762
Alarm 13 – Body Up Input Failure 763
Alarm 16 – Memory Write Failure 764
Alarm 17 – Memory Read Failure 764
Alarm 18 765
Alarm 19 765
Alarm 22 765
Operator Switch Doesn’t Work 766
Alarm 26 – User Switch Fault – SELECT 766
Alarm 27 – User Switch Fault – SET 766
Connector Map 767
Connectors 768
PLMIII CHECK OUT PROCEDURE 769
General Description 769
Tools Required 769
Checkout Procedure 769
PLMIII CHECKOUT PROCEDURE CONFIRMATION 773
Flashburn Programming 773
Confirmation Checklist 775
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 777
RESERVE ENGINE OIL SYSTEM 779
Operation 779
LED Monitor Light 780
Tank Fill Control (Optional) 780
Filling Procedure (Remote fill feature) 780
SERVICE 781
Every 10 Hours, or once each shift: 781
Every 500 Hours: 781
Changing Oil 781
TROUBLESHOOTING 782
Circuit Breaker or Fuse 782
SYSTEM ELECTRICAL SCHEMATICS 783
SECTION N – CAB COMPONENTS – INDEX 785
SECTION N2 – TRUCK CAB – INDEX 787
TRUCK CAB 789
Description 789
Preparation 790
Removal – Cab 790
Installation – Cab 792
CAB DOOR 792
Removal 792
Installation 792
Door Adjustment 793
Door Jamb Bolt Adjustment 793
Door Handle Plunger Adjustment 794
Door Glass Replacement 795
Door Window Regulator Replacement 799
Door Handle or Latch Assembly Replacement 799
Door and Door Hinge Seal Replacement 800
Door Opening Seal Removal 800
Installation 800
GLASS REPLACEMENT 801
Adhesive Bonded Windows 801
Replacement Procedure 801
Windshield And Rear Glass 802
Removal 802
Installation 803
SECTION N3 – CAB COMPONENTS – INDEX 805
CAB COMPONENTS 807
WINDSHIELD WIPERS 807
Wiper Motor Replacement 807
Removal 807
Installation 807
Wiper Arm 807
Removal 807
Installation 808
Wiper Linkage Replacement 808
Removal 808
Installation 808
WINDSHIELD WASHER 809
Operation 809
Service 809
OPERATOR SEAT 810
Adjustment 810
Seat Removal 810
Seat Installation 810
SECTION N4 – OPERATOR COMFORT – INDEX 811
OPERATOR COMFORT 813
HEATER / AIR CONDITIONER 813
Operation 813
Heater/Air Conditioner Vents 813
COMPONENTS 814
Circuit Breakers 814
Relays 814
Heater Core 814
Fan Motor And Speed Control 815
Actuators 815
Cab Air Filter 815
AIR CONDITIONING SYSTEM 817
Environmental Impact 817
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 818
PRINCIPLES OF REFRIGERATION 818
Air Conditioning 818
Refrigeration – The Act Of Cooling 819
The Refrigeration Cycle 819
AIR CONDITIONER SYSTEM COMPONENTS 820
Compressor (Refrigerant Pump) 820
Service Valves 820
Condenser 820
Receiver-Drier 820
Expansion Block Valve 821
Accumulator 821
Evaporator 821
ELECTRICAL CIRCUIT 822
Thermostat 822
Compressor Clutch 822
Trinary™ Switch 823
SYSTEM SERVICING 824
SERVICE TOOLS AND EQUIPMENT 825
Recovery/Recycle Station 825
Leak Detector 825
Service Valves 826
Vacuum Pump 826
Manifold Gauge Set 827
Installing Manifold Gauge Set 828
Purging Air From Service Hoses 828
SYSTEM PERFORMANCE TEST 829
SYSTEM OIL 830
Handling and Reusing PAG Oil 830
Oil Quantity 830
Checking System Oil 830
REFRIGERANT 831
Recycled Refrigerant 831
Reclaimed Refrigerant 831
Refrigerant Quantity 831
R-134a Refrigerant Containers 831
SYSTEM LEAK TESTING 832
Electronic Leak Detector 832
Tracer Dyes 832
Soap and Water 832
RECOVERING AND RECYCLING THE REFRIGERANT 833
Performing the Recovery Cycle 833
Performing the Recycling Procedure 833
Evacuating and Charging the A/C System 833
SYSTEM REPAIR 834
System Flushing 834
COMPONENT REPLACEMENT 834
Hoses and Fittings 834
Lines 834
Expansion Valve 835
Receiver-Drier 835
Thermostat 835
Compressor 835
Accumulator 835
Clutch 836
Servicing the Compressor Clutch 836
Pulley Removal 838
Clutch Coil Check 839
Pulley Installation 839
Clutch Assembly Installation 839
EVACUATING THE SYSTEM 841
CHARGING THE A/C SYSTEM 843
TROUBLESHOOTING 844
Preliminary Checks 844
Diagnosis Of Gauge Readings And System Performance 844
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 845
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 851
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 853
OPERATOR CAB CONTROLS 855
STEERING COLUMN 855
Removal 855
Steering Column Inspection 855
Installation 855
STEERING WHEEL AND CONTROLS 857
Horn Button 857
Telescope Lock Ring 857
Tilt Wheel Lever 857
Multi-Function Turn Signal Switch 857
DYNAMIC RETARDING 858
Retarder Control Lever 858
Dynamic Retarder/Service Brake Pedal 858
Accelerator (Throttle) Pedal 859
Starting on a Grade With a Loaded Truck 859
GRADE/SPEED RETARD CHART 859
INSTRUMENT PANEL 861
OVERHEAD PANEL AND DISPLAYS 861
CENTER CONSOLE 862
F-N-R Selector Switch 862
Hoist Control Lever 863
Raising The Dump Body 863
Lowering The Dump Body 863
Ash Tray 863
Lighter 863
L H Window Control Switch 863
R H Window Control Switch 863
Engine Shutdown Switch 863
Override/Fault Reset Switch 864
Retard Speed Control (RSC) Switch 864
Retard Speed Control (RSC) Adjust Dial 864
Data Store Button 865
Engine Control System 865
Service Engine Light 865
Engine Diagnostics Download Port 865
Payload Meter 865
TCI Download Port 865
PSC Download Port 865
Payload Meter 865
INSTRUMENT PANEL AND INDICATOR LIGHTS 867
CONTROL SYMBOLS 867
INSTRUMENT PANEL 867
PANEL GAUGES, INDICATORS, AND CONTROLS 869
Key Switch 869
Starting 869
Cold Weather Starting 869
Normal Engine Shutdown 869
Engine Shutdown Switch with 5 Minute Idle Timer Delay 870
Fog Lights (Optional) 870
Ladder Light Switch 870
Manual Backup Switch 870
Panel Illumination Lights 871
Cab/Air Conditioner Vents 871
Rotating Beacon Light Switch (Optional) 871
Heated Mirror Switch (Optional) 871
Wheel Brake Lock Control 871
Parking Brake Control 871
Tachometer 872
Right Turn Signal Indicator 872
High Beam Indicator 872
Left Turn Signal Indicator 872
Speedometer / Payload Meter 872
Voltmeter 872
Engine Oil Pressure Gauge 872
Water Temperature Gauge 872
Fuel Gauge 872
AC Drive System Temperature Gauge 873
Hydraulic Oil Temperature Gauge 873
Hourmeter 873
Rest Switch 873
Light Switch 874
Windshield Wiper and Washer 874
Panel Light Dimmer 874
Payload Meter Switch 874
OVERHEAD STATUS / WARNING INDICATORS 875
STATUS / WARNING INDICATOR LIGHT SYMBOLS 876
Hazard Warning Lights 881
Lamp Test Switch 881
Link-On Warning Light 881
SECTION P – LUBRICATION AND SERVICE – INDEX 883
SECTION P2 – LUBRICATION AND SERVICE – INDEX 885
LUBRICATION AND SERVICE 887
930E SERVICE CAPACITIES 887
HYDRAULIC TANK SERVICE 887
Adding Oil 887
WHEEL MOTOR SERVICE 887
COOLANT LEVEL CHECK 888
RADIATOR FILLING PROCEDURE 888
RESERVE ENGINE OIL SYSTEM (Optional) 888
Reserve Oil Tank Filling Procedure (Remote fill) 888
LUBRICATION CHART 889
10 HOUR (DAILY) INSPECTION 890
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 893
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 894
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 895
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 898
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 899
5000 HOUR MAINTENANCE CHECKS 900
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 901
AUTOMATIC LUBRICATION SYSTEM 903
GENERAL DESCRIPTION 903
SYSTEM COMPONENTS 905
Filter 905
Hydraulic Motor and Pump 905
Grease Reservoir 905
Pressure Reducing Valve 905
Flow Control Valve 905
Solenoid Valve 905
Vent Valve 905
Lubrication Cycle Timer 905
Time Delay Module 905
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 905
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 905
Pressure Gauge 905
Injectors 905
SYSTEM OPERATION 906
Normal Operation 906
Pressure Failure Detection Circuits 907
GENERAL INSTRUCTIONS 908
Lubricant Requirements 908
System Priming 908
LUBRICANT PUMP 908
Pump Housing Oil Level 908
Pump Pressure Control 908
Lubrication Cycle Timer Check 909
Lubrication Cycle Timer Adjustment 909
FILTER ASSEMBLY 909
SYSTEM CHECKOUT 910
INJECTORS (SL-1 Series “H”)) 910
Injector Specifications 910
Injector Adjustment 910
INJECTOR OPERATION 911
PUMP REBUILD 912
Disassembly 912
Cleaning and Inspection 914
Assembly 914
SYSTEM TROUBLESHOOTING CHART 916
PREVENTATIVE MAINTENANCE PROCEDURES 919
Daily Lubrication System Inspection 919
250 Hour Inspection 919
1000 Hour Inspection 919
SECTION Q ALPHABETICAL INDEX 921
SECTION R – SYSTEM SCHEMATIC – INDEX 925
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 927
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 928
ELECTRICAL SCHEMATIC – XS1300 929

S.V 15/12/24