Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU 930E-3 DUMP TRUCK Shop Manual SERIAL NUMBERS A30304 – A30309 -PDF Download
Original price was: $55.00.$28.95Current price is: $28.95.
KOMATSU 930E-3 DUMP TRUCK Shop Repair Manual
SERIAL NUMBERS: A30304 – A30309
Pub Number:CEBM008401
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU 930E-3 DUMP TRUCK Shop Manual SERIAL NUMBERS A30304 – A30309
KOMATSU 930E-3 DUMP TRUCK SHOP MANUAL SERIAL NUMBERS A30304 – A30309 -PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 930E-3 DUMP TRUCK Shop Manual 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 SYSTEM....................................................100 FUEL RECEIVER.................................................................100 TANK BREATHER VALVE...........................................................100 Removal...................................................................100 Installation..............................................................100 Disassembly...............................................................100 Assembly..................................................................100 LEFT SIDE FILL................................................................101 SECTION C - ENGINE - INDEX................................................................103 SECTION C2 - POWER MODULE - INDEX.....................................................105 POWER MODULE......................................................................107 Preparation...................................................................107 Preparation for Removal.......................................................108 Removal - Power Module........................................................111 Installation - Power Module...................................................113 Hookup - Power Module.........................................................113 SECTION C3 - COOLING SYSTEM - INDEX...................................................115 COOLING SYSTEM....................................................................117 RADIATOR......................................................................117 Removal - Radiator........................................................117 Installation - Radiator...................................................119 RADIATOR FILLING PROCEDURE....................................................120 RADIATOR REPAIR...............................................................120 Internal Inspection.......................................................120 External Cleaning.........................................................120 Disassembly...............................................................121 Cleaning and Inspection...................................................122 Assembly..................................................................122 Pressure Testing..........................................................123 Additional Service Information............................................123 COOLANT SYSTEM TROUBLESHOOTING................................................124 SECTION C4 - POWERTRAIN - INDEX.......................................................125 POWER TRAIN.......................................................................127 ALTERNATOR....................................................................127 Removal - Alternator......................................................127 ENGINE/ALTERNATOR MATING......................................................129 General Instructions......................................................129 Measuring Procedure.......................................................129 Joining The Alternator and Engine.........................................131 ENGINE........................................................................132 Removal...................................................................132 Service...................................................................132 Installation..............................................................132 SECTION C5 - AIR CLEANERS - INDEX.....................................................133 AIR CLEANERS......................................................................135 AIR CLEANERS..................................................................135 Operation.................................................................135 General Service Information...............................................135 FILTER ELEMENT REPLACEMENT....................................................136 Main Filter Element Cleaning..............................................137 Precleaner Section........................................................138 Cleaning Precleaner Tubes.................................................138 AIR INTAKE TROUBLESHOOTING....................................................139 SECTION C7 - FAN CLUTCH - INDEX.......................................................141 FAN CLUTCH........................................................................143 REMOVAL & INSTALLATION TOOLING................................................143 FAN CLUTCH - DISASSEMBLY......................................................146 CLEANING AND INSPECTION.......................................................156 ASSEMBLY - FAN CLUTCH.........................................................160 TEST PROCEDURE................................................................174 SECTION D - ELECTRICAL SYSTEM (24VDC NON-PROPULSION) - INDEX..............................175 SECTION D2 - 24VDC ELECTRIC SUPPLY SYSTEM - INDEX.....................................177 24VDC ELECTRIC SUPPLY SYSTEM......................................................179 ELECTRICAL SYSTEM DESCRIPTION.................................................179 BATTERIES.................................................................179 Maintenance and Service...................................................179 Troubleshooting...........................................................179 BATTERY SUPPLY SYSTEM.........................................................181 24VDC Batter Charging Alternator..........................................181 Battery Box...............................................................181 Batter Control Box........................................................182 Battery Disconnect Switches...............................................182 24VDC Auxiliary Battery Connectors........................................182 24VDC to 12VDC Converter..................................................183 Isolation Diodes..........................................................183 Engine Starter Relay......................................................183 SECTION D3 - 24VDC ELECTRICAL SYSTEM COMPONENTS - INDEX...............................185 24 VDC ELECTRICAL SYSTEM COMPONENTS...............................................187 TRUCK SHUTDOWN PROCEDURE......................................................187 24 VDC ELECTRICAL SYSTEM COMPONENTS...........................................187 Brake Warning Buzzer (BWB)................................................187 AUXILIARY CONTROL CABINET COMPONENTS..........................................187 Fuse Block 1 & 2..........................................................188 Power Distribution Terminals..............................................188 PULSE VOLTAGE MODULATOR...................................................188 5 Minute Idle Timer Components............................................190 5 Minute Idle Timer.......................................................190 5 Minute Idle Circuit Test................................................190 Tail Light Resistor Diode Assemblies......................................190 Engine Starter Failure Delay Timer........................................190 Lubrication System Timer..................................................192 Auto Lube Delay Timer.....................................................192 Barometric Pressure Transducer............................................192 Kontrol Power Relay.......................................................192 Alarm Indicating Device (AID) System......................................194 Temperature and Latch.....................................................195 Hot Switch Inverter.......................................................195 Hot Switch Inverter Card (Slot 4) (Not Used)..............................195 Oil Level.................................................................195 Temperature...............................................................195 Diode Matrix (Without Sound)..............................................195 Diode Matrix (With Sound).................................................195 Lamp Test.................................................................196 Diode Board - DB1.........................................................196 Diode Testing.............................................................196 RELAY BOARDS..................................................................197 Relay Boards RB1, RB3, RB4, RB5...........................................197 Service...................................................................197 Relay Board Identification................................................198 RELAY BOARD FUNCTIONS.........................................................199 Relay Board 1 (RB1).......................................................199 Relay Board 3 (RB3).......................................................199 Relay Board 6, 7 & 8 (RB6, RB7, RB8)......................................200 Installing Additional Circuits............................................200 BODY-UP SWITCH................................................................201 Operation.................................................................201 Adjustment................................................................201 Service...................................................................201 HOIST LIMIT SWITCH............................................................202 Operation.................................................................202 Adjustment................................................................202 Service...................................................................202 FUSE BLOCKS...................................................................203 CIRCUIT BREAKERS..............................................................203 SECTION D10 - BATTERY CHARGING ALTERNATOR - INDEX.....................................205 BATTERY CHARGING ALTERNATOR.......................................................207 ELECTRICAL SYSTEM DESCRIPTION.................................................207 BATTERY.......................................................................207 Maintenance and Service...................................................207 Troubleshooting...........................................................207 BATTERY CHARGING SYSTEM (Niehoff).............................................209 General Description.......................................................209 TROUBLESHOOTING PROCEDURES (On-Truck).........................................209 Equipment Required:.......................................................209 Preliminary Checks........................................................210 Test Setup................................................................210 Test Procedure............................................................210 Regulator Bypass Test.....................................................211 ON VEHICLE TROUBLESHOOTING GUIDE..................................................213 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage....213 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................213 CHARGE VOLT AND AMP VALUES....................................................214 DEFINITIONS...................................................................214 ADVANCED SYSTEM TROUBLESHOOTING...................................................215 Static Test - Engine OFF, Key ON, Battery Switch ON...........................215 Go To Alternator..............................................................215 Go To Regulator (If Required).................................................216 Go To Regulator Connector On The Alternator...................................216 ALTERNATOR OVERHAUL...............................................................217 ALTERNATOR DIMENSIONS.........................................................217 ALTERNATOR SPECIFICATIONS.....................................................218 SERVICE PARTS.................................................................219 ON-VEHICLE TEST...............................................................221 Equipment:................................................................221 Preliminary Checks:.......................................................221 Test Set-up...............................................................221 Test Procedure............................................................221 ON-VEHICLE TEST...............................................................222 Bypass Test:..............................................................222 BENCH TEST....................................................................223 STATIC TESTS..................................................................224 Regulator Tests...........................................................224 Control Box Tests.........................................................225 ALTERNATOR DISASSEMBLY........................................................227 ASSEMBLY- ALTERNATOR..........................................................232 BF4822 STATOR SERVICE TOOL INSTRUCTIONS...........................................241 Stator Removal And Replacement................................................241 Stator Installation...........................................................242 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX..........................................245 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX..........................247 ELECTRICAL PROPULSION SYSTEM COMPONENTS...........................................249 GENERAL SYSTEM DESCRIPTION....................................................249 SYSTEM COMPONENTS.............................................................251 Propulsion System Controller(PSC).........................................251 Truck Control Interface (TCI).............................................251 Diagnostic Information Display............................................253 DID Panel Event Codes.....................................................253 PSC SOFTWARE FUNCTIONS........................................................277 Input Processing..........................................................277 STATE MANAGEMENT..............................................................277 State Machine.............................................................277 DC Link State.............................................................280 Powering the Link.........................................................280 De-Powering the Link......................................................280 Control Functions.........................................................280 ALTERNATOR FIELD CONTROL......................................................281 Desired Three-Phase Voltage...............................................281 Desired DC Link Voltage...................................................281 Self-load.................................................................281 Propel Torque Control.....................................................282 Retard Torque Control.....................................................282 Wheel Slide Control.......................................................282 Resistor Grid Control.....................................................283 Chopper Voltage Control...................................................283 EVENT PROCESSING..............................................................283 Event Detection...........................................................283 Power On Tests............................................................283 Initiated Tests...........................................................284 Periodic Tests............................................................284 EVENT RESTRICTIONS............................................................284 EVENT LOGGING AND STORAGE.....................................................284 Event History Buffer......................................................285 Data Packs................................................................285 To Record and Save a Data Pack to a Floppy Disk...........................285 Event Reset...............................................................286 SERIAL DATA COMMUNICATIONS....................................................287 PSC - PTU Communications Processing.......................................287 Inverter Communications Processing........................................287 OUTPUT PROCESSING.............................................................288 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS......................................288 Fast Start................................................................288 Engine Shutdown/Engine Not Running........................................288 Limp Home Mode............................................................288 Entering/Exiting Limp Home Mode...........................................288 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.....................................289 ELECTRONIC ACCELERATOR AND RETARD PEDALS......................................301 Removal...................................................................301 Installation..............................................................301 Disassembly...............................................................301 Assembly..................................................................301 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE - INDEX....................303 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.....................................305 AC DRIVE SYSTEM MAINTENANCE...................................................305 TRUCK SHUTDOWN PROCEDURES.....................................................305 NORMAL TRUCK SHUTDOWN PROCEDURE...............................................306 SHUTDOWN AFTER SYSTEM FAILURE.................................................307 SYSTEM CHECKOUT...............................................................308 Battery and Control Checks of System WITH Battery Power OFF...............308 Battery and Control Circuit Checks of System With Battery Power ON........311 Checks with Key Switch OFF................................................312 CPU Battery Checks........................................................314 MEMORY BACKUP BATTERY REPLACEMENT.............................................314 TCI PROGRAMMING...............................................................315 PSC PROGRAMMING...............................................................315 INVERTER PROGRAMMING..........................................................316 TCI CHECKOUT..................................................................316 Modular Mining Communication Port.........................................317 TCI Input Checks..........................................................318 TCI Digital Output Tests..................................................320 TCI Digital Input Tests...................................................322 PSC Checkout Procedure....................................................324 PSC Digital Input Checks..................................................328 Miscellaneous Checks......................................................329 A3PV Panel................................................................329 LINKV Panel...............................................................329 Thermistor Checks.........................................................329 17FM384 Panel Check.......................................................329 Pedal Percentages and Meter Calibration...................................330 Meter Calibration Procedure...............................................330 Reprogram With Serial Numbers and Pedal Percentages.......................332 LOAD TESTING..................................................................334 Preload Checks............................................................334 ADDITIONAL TRUCK CHECKS.......................................................336 On-Board Load Testing.....................................................338 Preparation...............................................................338 Initiate Loadbox Test.....................................................341 Manual Offset HP Output Adjustment........................................343 TROUBLESHOOTING...................................................................345 PVM Optimum Load Curve Handshaking Troubleshooting............................345 MISCELLANEOUS COMPONENT REPAIR................................................346 Troubleshooting Phase Modules and Chopper Modules.........................346 Phase Module Removal and Snubber Resistor Replacement.....................346 Snubber Resistor Installation.............................................347 Phase Module Installation.................................................347 AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING..............................348 AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING..............................351 AUXILLIARY SNUBBER PANEL TROUBLESHOOTING......................................352 IGBT TROUBLESHOOTING..........................................................353 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX........................................355 SECTION G2 - TIRES AND RIMS - INDEX...................................................357 TIRES AND RIMS....................................................................359 WHEEL STUD MAINTENANCE........................................................360 FRONT TIRES AND RIMS..........................................................361 Removal...................................................................361 Installation..............................................................362 REAR TIRES AND RIMS...........................................................363 Removal...................................................................363 Installation..............................................................364 RIM...........................................................................365 Tire Removal..............................................................365 Tire Installation.........................................................366 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX......................................369 FRONT WHEEL HUB AND SPINDLE.......................................................371 WHEEL HUB AND SPINDLE ASSEMBLY................................................371 Preparation...............................................................371 Removal...................................................................371 Installation - Wheel Hub and Spindle Assembly.............................374 Disassembly - Wheel Hub and Spindle Assembly..............................375 Cleaning and Inspection - Wheel Hub and Spindle Assembly..................375 Assembly - Wheel Hub and Spindle Assembly.................................377 Wheel Bearing Adjustment:.................................................377 Brake Installation........................................................378 Seal Assembly Gap Check...................................................379 STEERING CYLINDERS AND TIE ROD................................................380 Spherical Bearing Wear Limits.............................................380 Removal - Steering Cylinder and Tie Rod...................................381 Installation - Steering Cylinder and Tie Rod..............................382 Bearing Replacement.......................................................382 TOE-IN ADJUSTMENT.............................................................383 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX.....................................385 REAR AXLE HOUSING ATTACHMENT......................................................387 PIVOT PIN.....................................................................387 Removal...................................................................387 Installation..............................................................388 PIVOT EYE BEARING.............................................................389 Removal...................................................................389 Installation..............................................................389 PIVOT EYE REPAIR..............................................................389 Removal...................................................................389 Disassembly...............................................................389 Assembly..................................................................390 Installation..............................................................390 ANTI-SWAY BAR.................................................................390 Removal...................................................................390 Installation..............................................................391 Disassembly...............................................................391 Cleaning and Inspection...................................................391 Assembly..................................................................391 SECTION G5 - REAR AXLE HOUSING - INDEX................................................393 REAR AXLE HOUSING.................................................................395 REAR AXLE HOUSING.............................................................395 Preparation...............................................................395 Removal...................................................................395 Cleaning and Inspection - Rear Axle Housing...............................397 Installation - Rear Axle Housing..........................................397 WHEEL MOTOR...................................................................398 Preparation...............................................................398 Removal...................................................................398 Cleaning and Inspection - Wheel Motor.....................................399 Installation - Wheel Motor................................................400 WHEEL MOTOR GEAR OIL..........................................................403 Filtering Requirements....................................................403 Particle Size Analysis....................................................403 Flushing..................................................................403 Oil Sample Analysis.......................................................404 ELEMENT SPECIFICATION CHARTS..................................................405 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................409 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................411 FRONT SUSPENSION..................................................................413 Removal.......................................................................413 Installation - Front Suspension...............................................414 "Turn-Of-The-Nut" Tightening Procedure........................................417 MINOR REPAIRS (LOWER BEARING & SEALS).........................................418 Removal - Bearing Retainer................................................418 Installation - Bearing Retainer...........................................418 MAJOR SUSPENSION REBUILD......................................................420 Disassembly...............................................................420 Assembly..................................................................420 SECTION H3 - REAR SUSPENSIONS - INDEX.................................................423 REAR SUSPENSIONS..................................................................425 Removal.......................................................................425 Installation - Rear Suspension................................................427 Disassembly - Rear Suspension.................................................428 Cleaning and Inspection - Rear Suspension.....................................428 Assembly - Rear Suspension....................................................428 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX.........................431 SUSPENSION OILING AND CHARGING PROCEDURE..........................................433 GENERAL.......................................................................433 EQUIPMENT LIST................................................................433 Hydrair® Charging Kit.....................................................433 Installation of Charging Kit..............................................433 Removal of Charging Kit...................................................434 Support Blocks For Oiling And Charging Dimensions.........................434 FRONT SUSPENSION..............................................................435 Front Suspension Oiling...................................................435 Front Suspension Nitrogen Charging........................................436 REAR SUSPENSION...............................................................437 Rear Suspension Oiling....................................................437 Rear Suspension Nitrogen Charging.........................................438 OIL AND NITROGEN SPECIFICATIONS CHART.............................................440 SECTION J - BRAKE CIRCUIT - INDEX.........................................................441 SECTION J2 - BRAKE CIRCUIT - INDEX....................................................443 BRAKE CIRCUIT.....................................................................445 SERVICE BRAKE CIRCUIT.........................................................445 SECONDARY BRAKING AND AUTOMATIC APPLY.........................................447 PARKING BRAKE CIRCUIT.........................................................447 Normal Operation (key switch on, engine running)..........................447 BRAKE LOCK CIRCUIT............................................................448 WARNING CIRCUIT...............................................................448 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX..................................451 BRAKE CIRCUIT COMPONENT SERVICE...................................................453 BRAKE VALVE...................................................................453 Rebuild Criteria..........................................................453 Removal...................................................................454 Installation..............................................................454 Disassembly...............................................................455 Cleaning and Inspection...................................................458 Assembly..................................................................458 Actuator Base Threaded Inserts............................................458 Boot and Cap..............................................................458 Valve Body Seal Installation..............................................458 Regulator Sleeve O-Ring Installation......................................459 Actuator Plunger O-ring Installation......................................459 Assembly of Valve.........................................................459 DIFFERENTIAL PRESSURE SWITCH..................................................461 Disassembly...............................................................461 Cleaning and Inspection...................................................461 Assembly..................................................................461 VALVE BENCH TEST AND ADJUSTMENT...............................................462 Test Set Up Procedure.....................................................463 Brake Valve Output Pressure Adjustment....................................463 Differential Pressure Switch Adjustment...................................463 Final Test and Adjustment.................................................464 Installation Of Brake Pedal Actuator Assembly to Brake Valve..............465 Installation of Retard Pedal To Brake Pedal...............................465 DUAL RELAY VALVE..............................................................467 Removal...................................................................467 Installation..............................................................467 Disassembly...............................................................469 Cleaning and Inspection...................................................469 Assembly..................................................................469 DIFFERENTIAL PRESSURE SWITCH..................................................470 Disassembly...............................................................470 Cleaning and Inspection...................................................470 Assembly..................................................................470 VALVE TEST AND ADJUSTMENT.....................................................471 Test Set Up Procedure.....................................................472 Relay Valve Output Pressure Adjustment....................................472 Differential Pressure Switch Adjustment...................................473 BRAKE MANIFOLD................................................................474 Removal...................................................................474 Installation..............................................................475 Disassembly...............................................................475 Cleaning and Inspection...................................................475 Assembly..................................................................475 BRAKE ACCUMULATORS............................................................476 Brake Accumulator Bleeddown Procedure.....................................476 BRAKE ACCUMULATOR REPAIR......................................................477 Removal...................................................................477 Installation..............................................................477 Disassembly...............................................................478 Cleaning and Inspection...................................................479 Assembly..................................................................479 ACCUMULATOR CHARGING PROCEDURE................................................481 Temperature During Precharge..............................................482 Precharge Maintenance.....................................................483 Recharging Accumulators...................................................483 Accumulator Storage procedures............................................484 Bladder Storage Procedures................................................484 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)..................................485 Removal.......................................................................485 Installation..................................................................485 Disassembly and Adjustment....................................................485 Potentiometer Check...........................................................487 Assembly......................................................................487 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................489 BRAKE CIRCUIT CHECK-OUT PROCEDURE.................................................491 REQUIRED EQUIPMENT............................................................493 INITIAL SYSTEM SET-UP.........................................................494 BRAKE SYSTEM CHECKOUT.........................................................495 Failure Modes Check-Out...................................................496 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART...............................498 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................501 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................502 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX..........................................503 WET DISC BRAKE ASSEMBLY...........................................................505 OPERATION.....................................................................505 MAINTENANCE...................................................................506 Brake Disc Wear Indicator.................................................506 Removal/Installation - Wet Disc Brake Assembly............................506 BRAKE REBUILD.................................................................508 Disassembly...............................................................508 Cleaning and Inspection...................................................511 Assembly..................................................................512 Floating Ring Seal Assembly/Installation..................................515 WET DISC BRAKE BLEEDING PROCEDURE.............................................518 SECTION J7 - PARKING BRAKE - INDEX....................................................519 PARKING BRAKE.....................................................................521 OPERATION.....................................................................521 MAINTENANCE...................................................................522 Inspection - Parking Brake................................................522 Removal - Parking Brake...................................................522 Installation - Parking Brake..............................................523 Disassembly - Parking Brake...............................................524 Cleaning and Inspection - Parking Brake...................................524 Assembly - Parking Brake..................................................524 PARKING BRAKE BLEEDING PROCEDURE..............................................526 SECTION L - HYDRAULIC SYSTEM - INDEX......................................................527 SECTION L2 - HYDRAULIC SYSTEM - INDEX.................................................529 HYDRAULIC SYSTEM..................................................................531 HYDRAULIC PUMP MODULE.........................................................531 HOIST CIRCUIT OPERATION.......................................................532 STEERING CIRCUIT OPERATION....................................................534 DISC BRAKE COOLING SYSTEM.....................................................536 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................539 HYDRAULIC SYSTEM COMPONENT REPAIR.................................................541 HOIST PUMP....................................................................541 Removal...................................................................541 Installation..............................................................543 INSPECTION OF PARTS...........................................................548 Assembly..................................................................548 HYDRAULIC TANK................................................................554 Filling Instructions......................................................554 Removal...................................................................554 Installation..............................................................555 HYDRAULIC TANK STRAINERS......................................................555 Removal...................................................................555 Inspect and Clean.........................................................555 Installation..............................................................555 HYDRAULIC TANK BREATHERS......................................................556 SECTION L4 - STEERING CIRCUIT - INDEX.................................................557 STEERING CIRCUIT..................................................................559 COMPONENT DESCRIPTION.........................................................560 Steering Control Unit.....................................................560 Bleeddown Manifold Valve..................................................561 Bleeddown Solenoid........................................................561 Relief Valves.............................................................563 Hoist Limit Solenoid......................................................563 Accumulators..............................................................563 Low Precharge Warning Switch..............................................563 High Pressure Filter......................................................563 Quick Disconnect Ports....................................................563 Flow Amplifier............................................................564 FLOW AMPLIFIER SYSTEM OPERATION...............................................566 No Steer..................................................................566 Steering Left.............................................................568 Steering Right............................................................570 No Steer, External Shock Load.............................................572 STEERING PUMP.................................................................574 Operation.................................................................574 PRINCIPLE OF OPERATION........................................................576 Full Pump Volume:.........................................................576 Half Pump Volume:.........................................................576 Neutral Position:.........................................................576 Steering Pump.............................................................577 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................579 STEERING CONTROL UNIT.............................................................581 Removal.......................................................................581 Spline Inspection.............................................................581 Installation..................................................................582 STEERING CONTROL UNIT REBUILD.................................................582 Disassembly...............................................................582 Cleaning and Inspection - Steering Control Unit...........................583 Assembly - Steering Control Unit..........................................585 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................589 STEERING CIRCUIT COMPONENT REPAIR.................................................591 BLEEDDOWN MANIFOLD VALVE......................................................591 Removal...................................................................591 Installation..............................................................591 FLOW AMPLIFIER................................................................593 Removal...................................................................593 Installation..............................................................593 FLOW AMPLIFIER REBUILD........................................................593 Disassembly...............................................................596 Assembly..................................................................597 STEERING CYLINDERS............................................................598 Disassembly...............................................................599 Piston Seal & Bearing Installation........................................599 Cylinder Assembly.........................................................599 Test......................................................................599 STEERING AND BRAKE PUMP.......................................................600 Removal...................................................................600 Installation..............................................................600 Disassembly...............................................................602 Control Piston Group......................................................602 Valve Plate Group.........................................................602 Rotating Group............................................................605 Swashblock Group..........................................................605 Driveshaft Group..........................................................605 Inspection................................................................605 Control Piston Group......................................................605 Valve Plate Group.........................................................605 Rotating Group............................................................605 Swashblock Group..........................................................607 Driveshaft Group..........................................................608 Compensator Block and Unloader Module.....................................608 Stroke Adjuster Assembly..................................................608 Assembly..................................................................608 Swashblock Group..........................................................608 Driveshaft Group..........................................................609 Rotating Group............................................................609 Valve Plate Group.........................................................610 STEERING ACCUMULATORS.........................................................611 Removal...................................................................611 Installation..............................................................611 Disassembly...............................................................612 Cleaning and Inspection...................................................612 Assembly..................................................................613 Leak Testing..............................................................615 Charging Procedure........................................................616 Temperature During Precharge..............................................617 Precharge Maintenance.....................................................618 Accumulator Storage procedures............................................619 Bladder Storage Procedures................................................619 TROUBLESHOOTING CHART.............................................................620 SECTION L7 - HOIST CIRCUIT - INDEX....................................................625 HOIST CIRCUIT.....................................................................627 HOIST CIRCUIT OPERATION.......................................................627 COMPONENT DESCRIPTION.........................................................628 Hydraulic Tank............................................................628 Hydraulic Pump............................................................628 High Pressure Filters.....................................................628 Hoist Valve...............................................................628 Inlet Sections - Hoist Valve..............................................628 Spool Sections - Hoist Valve..............................................629 Hoist Pilot Valve.........................................................629 Bleeddown Manifold........................................................630 Hoist-up Limit Solenoid...................................................630 Pilot Operated Check Valve................................................630 Overcenter Manifold.......................................................630 HOIST CIRCUIT OPERATION...........................................................631 Float Position Of Pilot Valve With Truck Body On Frame........................632 Power Up Operation............................................................634 Hold Operation................................................................636 Power Down Operation..........................................................638 Float Operation...............................................................640 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...................................643 HOIST CIRCUIT COMPONENT REPAIR....................................................645 HOIST VALVE...................................................................645 Removal...................................................................645 Installation..............................................................646 O-Ring Replacement........................................................646 INLET SECTION.................................................................647 Disassembly...............................................................647 Cleaning and Inspection...................................................648 Assembly..................................................................648 REAR SPOOL SECTION (Work Ports)...............................................648 Disassembly...............................................................648 Cleaning and Inspection...................................................650 Assembly..................................................................650 FRONT SPOOL SECTION (Tank Ports)..............................................651 Disassembly...............................................................651 Cleaning and Inspection...................................................651 Assembly..................................................................651 HOIST PILOT VALVE.............................................................653 Removal...................................................................653 Installation..............................................................653 Disassembly...............................................................654 Cleaning and Inspection...................................................655 Assembly..................................................................655 HOIST CYLINDERS...............................................................656 Removal...................................................................656 Installation..............................................................657 Disassembly...............................................................659 Cleaning and Inspection...................................................660 Assembly - Quill and Cylinder.............................................661 Quill Installation........................................................661 Installation Of Check Balls And Plugs In Quill............................662 Assembly of Cylinder......................................................663 OVERCENTER VALVE MANIFOLD.....................................................664 DISABLED TRUCK DUMPING PROCEDURE..............................................665 Hookup....................................................................665 Raising the Body..........................................................665 Lowering the Body.........................................................665 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.........................................667 HYDRAULIC SYSTEM FILTERS..........................................................669 HOIST CIRCUIT FILTER..........................................................669 Filter Element Replacement................................................669 Removal - Hoist Circuit Filter............................................670 Installation - Hoist Circuit Filter.......................................670 Indicator Switch - Hoist Circuit Filter...................................670 STEERING CIRCUIT FILTER.......................................................671 Filter Element Replacement................................................671 Removal - Steering Circuit Filter.........................................672 Installation - Steering Circuit Filter....................................672 Indicator Switch - Steering Circuit Filter................................672 INDICATOR SWITCH..............................................................672 Test Procedure............................................................672 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...................................675 HYDRAULIC CHECK-OUT PROCEDURE.....................................................677 GENERAL INFORMATION...........................................................677 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.............................677 Equipment Requirements....................................................678 Pump Pressure Control Adjustments.........................................678 Steering Control Valve and Flow Amplifier Leakage Test....................679 Bleeddown Manifold Leakage Test...........................................679 STEERING/BRAKE PUMP STROKE ADJUSTMENT.........................................680 SHOCK AND SUCTION VALVES......................................................681 Equipment Requirements....................................................681 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.................682 Equipment Requirements....................................................682 Pressure Gauge Locations..................................................682 Brake Cooling Circuit Test................................................682 Power Up Relief Pressure Test.............................................683 Adjustment................................................................683 Power Down Relief Pressure Test...........................................684 Hoist Counterbalance Valve Adjustment Preparation.........................685 Counterbalance Valve Pressure Check.......................................685 Counterbalance Valve Adjustment...........................................686 Preparation...............................................................687 Flushing Procedure........................................................687 Filter Element Replacement................................................688 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.............................688 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................690 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.............................................691 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX.............................................693 FIRE CONTROL SYSTEM (MANUAL)......................................................695 Operation.....................................................................695 Inspection and Maintenance....................................................695 Recharging Procedures.........................................................696 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1......................697 Control Module................................................................697 Actuator......................................................................698 Linear Detection Wire.........................................................698 Power Wire....................................................................698 Test Kit......................................................................698 Squib.........................................................................698 Securing the Detection Wire...................................................699 Preliminary Test Before Final Hook-Up.........................................699 Installation Procedure for Squib..............................................701 Placing the Electric Detection & Actuation System Into Service................701 INSPECTION AND MAINTENANCE SCHEDULES..........................................702 Daily.....................................................................702 Normal Maintenance Based On Actual Operating Hours........................702 IN CASE OF FIRE...............................................................703 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.....................................705 SECTION M8 - SPECIAL TOOLS............................................................707 SECTION M20 - PAYLOAD METER III - INDEX...............................................713 OPERATION SECTION.................................................................717 Introduction..................................................................717 Data Summary..............................................................717 Data Gathering............................................................717 COMPONENT DESCRIPTION.........................................................718 System Diagram............................................................718 Suspension Pressure Sensors...............................................718 Inclinometer..............................................................718 Operator Display..........................................................718 Operator Switch...........................................................719 Speed Input...............................................................719 Body-Up Switch............................................................719 Brake Lock Switch.........................................................719 Payload Meter.............................................................719 Communications Ports......................................................719 Keyswitch Input...........................................................720 Payload Meter Power.......................................................720 Load Lights...............................................................720 Wiring and Termination....................................................721 TCI Outputs...............................................................721 OPERATOR’S DISPLAY AND SWITCH.................................................722 Reading the Speedometer...................................................722 Reading the Load Display..................................................722 Using the Operator ID.....................................................722 Using the Load and Ton Counter............................................722 Total Ton Counter.........................................................722 Total Load Counter........................................................723 Clearing the Counters.....................................................723 Viewing Live Sensor Data..................................................723 Other Display Messages....................................................723 PAYLOAD OPERATION & CALCULATION...............................................724 Description of Haul Cycle States..........................................724 Haul Cycle Description....................................................724 Load Calculation..........................................................725 Carry Back................................................................725 Measurement Accuracy......................................................725 SOURCES FOR PAYLOAD ERROR.....................................................725 Payload Error.............................................................725 Loading Conditions........................................................726 Pressure Sensors..........................................................726 Swingloads................................................................726 Speed and Distance........................................................726 HAUL CYCLE DATA...............................................................726 Haul Cycle Data...........................................................727 Haul Cycle Warning Flags..................................................728 M: Haul Cycle Too Long....................................................729 N: Sensor Input Error.....................................................729 Frame Torque Data.........................................................729 Sprung Weight Data........................................................729 Maximum Speed Data........................................................729 Alarm Records.............................................................729 Fault Code Data...........................................................730 PC SOFTWARE OVERVIEW..........................................................731 PC Overview...............................................................731 System Configuration......................................................731 Installing the PLMIII Software............................................731 DOWNLOADING DATA..............................................................732 PLM III SYSTEM CONFIGURATION..................................................733 Starting Communications...................................................733 Displayed Payload Units...................................................733 Time Units................................................................733 Connection Menu...........................................................733 Connecting to the Payload Meter...........................................734 Configure the Payload Meter...............................................734 Setting the Date and Time.................................................734 Setting the Truck Type....................................................735 Setting the Gauge Display Units...........................................735 Setting the Frame Serial Number...........................................735 Setting the Truck Number..................................................735 Setting the Komatsu Distributor...........................................735 Setting the Komatsu Customer..............................................735 Clean Truck Tare..........................................................736 Inclinometer Calibration..................................................736 DATA ANALYSIS.................................................................737 Creating a Query..........................................................737 Sorting on Truck Unit Number..............................................737 Sorting on Truck Type.....................................................737 Sorting on Date Range.....................................................738 Sorting on Time Range.....................................................738 Payload Detail Screen.....................................................739 Creating Reports..........................................................739 Summary - one page report.................................................740 Detailed - multi-page report..............................................740 Creating Graphs...........................................................741 Exporting Data............................................................741 CSV Export................................................................741 Compressed................................................................742 Importing Data............................................................743 Deleting Haul Cycle Records...............................................743 Viewing Alarms............................................................744 Deleting Alarm Records....................................................744 TROUBLESHOOTING SECTION...........................................................745 TROUBLESHOOTING...............................................................745 Viewing Active Alarms.....................................................745 Real-Time Data Display....................................................745 Testing the Payload Lights................................................745 Creating Log Files of Inputs..............................................746 Daily Inspections.........................................................746 Periodic Maintenance......................................................746 Abnormal Displays at Power-Up.............................................747 No Payload Display When Keyswitch is Turned ON............................748 No Display on Speedometer.................................................749 No Display on Operator Display............................................749 No Communications With PC.................................................750 Load Lights Don’t Light During Loading....................................751 Load Lights Remain ON.....................................................752 Load Lights Remain ON During Dumping......................................752 Display Doesn't Clear When The Load Is Dumped.............................752 Calibration Problems......................................................753 Alarm 1 - Left Front Pressure High........................................754 Alarm 2 - Left Front Pressure Low.........................................754 Troubleshoot Wiring to Left Front Suspension..............................754 Alarm 3 - Right Front Pressure High.......................................755 Alarm 4 - Right Front Pressure Low........................................755 Troubleshoot Wiring to Right Front Suspension.............................755 Alarm 5 -Left Rear Pressure High..........................................756 Alarm 6 - Left Rear Pressure Low..........................................756 Troubleshoot Wiring to Left Rear Suspension...............................756 Alarm 7 - Right Rear Pressure High........................................757 Alarm 8 - Right Rear Pressure Low.........................................757 Troubleshoot Wiring to Right Rear Suspension..............................757 Alarm 9 - Inclinometer High...............................................758 Alarm 10 - Inclinometer Low...............................................758 Troubleshoot Inclinometer Wiring..........................................758 Alarm 13 - Body Up Input Failure..........................................759 Alarm 16 - Memory Write Failure...........................................760 Alarm 17 - Memory Read Failure............................................760 Alarm 18..................................................................761 Alarm 19..................................................................761 Alarm 22..................................................................761 Operator Switch Doesn't Work..............................................762 Alarm 26 - User Switch Fault - SELECT.....................................762 Alarm 27 - User Switch Fault - SET........................................762 Connector Map.............................................................763 Connectors................................................................764 PLMIII CHECK OUT PROCEDURE........................................................765 General Description...........................................................765 Tools Required................................................................765 Checkout Procedure............................................................765 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................769 Flashburn Programming.....................................................769 Confirmation Checklist....................................................771 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX.......................................773 RESERVE ENGINE OIL SYSTEM.........................................................775 Operation.....................................................................776 LED Monitor Light.............................................................776 Tank Fill Control (Optional)..................................................777 Filling Procedure (Remote fill feature).......................................777 SERVICE.......................................................................778 Every 10 Hours, or once each shift:.......................................778 Every 500 Hours:..........................................................778 Changing Oil..............................................................778 TROUBLESHOOTING...............................................................779 Circuit Breaker or Fuse...................................................779 SYSTEM ELECTRICAL SCHEMATICS..................................................780 SECTION N - CAB COMPONENTS - INDEX........................................................781 SECTION N2 - TRUCK CAB - INDEX........................................................783 TRUCK CAB.........................................................................785 Description...................................................................785 Preparation...................................................................786 Removal - Cab.................................................................786 Installation - Cab............................................................788 CAB DOOR......................................................................788 Removal...................................................................788 Installation..............................................................788 Door Adjustment...........................................................789 Door Jamb Bolt Adjustment.................................................789 Door Handle Plunger Adjustment............................................790 Door Glass Replacement....................................................791 Door Window Regulator Replacement.........................................795 Door Handle or Latch Assembly Replacement.................................795 Door and Door Hinge Seal Replacement......................................796 Door Opening Seal Removal.................................................796 Installation..............................................................796 GLASS REPLACEMENT.............................................................797 Adhesive Bonded Windows...................................................797 Replacement Procedure.....................................................797 Windshield And Rear Glass.................................................798 Removal...................................................................798 Installation..............................................................799 SECTION N3 - CAB COMPONENTS - INDEX...................................................801 CAB COMPONENTS....................................................................803 WINDSHIELD WIPERS.............................................................803 Wiper Motor Replacement...................................................803 Removal...................................................................803 Installation..............................................................803 Wiper Arm.................................................................803 Removal...................................................................803 Installation..............................................................804 Wiper Linkage Replacement.................................................804 Removal...................................................................804 Installation..............................................................804 WINDSHIELD WASHER.............................................................805 Operation.................................................................805 Service...................................................................805 OPERATOR SEAT.................................................................806 Adjustment................................................................806 Seat Removal..............................................................806 Seat Installation.........................................................806 SECTION N4 - OPERATOR COMFORT - INDEX.................................................807 OPERATOR COMFORT..................................................................809 HEATER / AIR CONDITIONER......................................................809 Operation.................................................................809 Heater/Air Conditioner Vents..............................................809 COMPONENTS....................................................................810 Circuit Breakers..........................................................810 Relays....................................................................810 Heater Core...............................................................810 Fan Motor And Speed Control...............................................811 Actuators.................................................................811 Filter....................................................................811 Service...................................................................811 AIR CONDITIONING SYSTEM...........................................................813 Environmental Impact..........................................................813 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................814 PRINCIPLES OF REFRIGERATION...................................................814 Air Conditioning..........................................................814 Refrigeration - The Act Of Cooling........................................815 The Refrigeration Cycle...................................................815 AIR CONDITIONER SYSTEM COMPONENTS.............................................816 Compressor (Refrigerant Pump).............................................816 Service Valves............................................................816 Condenser.................................................................816 Receiver-Drier............................................................816 Expansion Block Valve.....................................................817 Accumulator...............................................................817 Evaporator................................................................817 ELECTRICAL CIRCUIT............................................................818 Thermostat................................................................818 Compressor Clutch.........................................................818 Trinary™ Switch...........................................................819 SYSTEM SERVICING..............................................................820 SERVICE TOOLS AND EQUIPMENT...................................................821 Recovery/Recycle Station..................................................821 Leak Detector.............................................................821 Service Valves............................................................822 Vacuum Pump...............................................................822 Manifold Gauge Set........................................................823 Installing Manifold Gauge Set.............................................824 Purging Air From Service Hoses............................................824 SYSTEM PERFORMANCE TEST.......................................................825 SYSTEM OIL....................................................................826 Handling and Reusing PAG Oil..............................................826 Oil Quantity..............................................................826 Checking System Oil.......................................................826 REFRIGERANT...................................................................827 Recycled Refrigerant......................................................827 Reclaimed Refrigerant.....................................................827 Refrigerant Quantity......................................................827 R-134a Refrigerant Containers.............................................827 SYSTEM LEAK TESTING...........................................................828 Electronic Leak Detector..................................................828 Tracer Dyes...............................................................828 Soap and Water............................................................828 RECOVERING AND RECYCLING THE REFRIGERANT......................................829 Performing the Recovery Cycle.............................................829 Performing the Recycling Procedure........................................829 Evacuating and Charging the A/C System....................................829 SYSTEM REPAIR.................................................................830 System Flushing...........................................................830 COMPONENT REPLACEMENT.........................................................830 Hoses and Fittings........................................................830 Lines.....................................................................830 Expansion Valve...........................................................831 Receiver-Drier............................................................831 Thermostat................................................................831 Compressor................................................................831 Accumulator...............................................................831 Clutch....................................................................832 Servicing the Compressor Clutch...........................................832 Pulley Removal............................................................834 Clutch Coil Check.........................................................835 Pulley Installation.......................................................835 Clutch Assembly Installation..............................................835 EVACUATING THE SYSTEM.........................................................837 CHARGING THE A/C SYSTEM.......................................................839 TROUBLESHOOTING...................................................................840 Preliminary Checks............................................................840 Diagnosis Of Gauge Readings And System Performance............................840 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS....................................841 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..................................847 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................849 OPERATOR CAB CONTROLS.............................................................851 STEERING COLUMN...............................................................851 Removal...................................................................851 Steering Column Inspection................................................851 Installation..............................................................851 STEERING WHEEL AND CONTROLS...................................................853 Horn Button...............................................................853 Telescope Lock Ring.......................................................853 Tilt Wheel Lever..........................................................853 Turn Signal/Headlight Dimmer..............................................853 DYNAMIC RETARDING.............................................................853 Retarder Control Lever....................................................854 Dynamic Retarder/Service Brake Pedal......................................854 Accelerator (Throttle) Pedal..............................................854 Starting on a Grade With a Loaded Truck...................................854 GRADE/SPEED RETARD CHART......................................................855 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.............................856 Heater/Air Conditioner Vents..............................................856 INSTRUMENT PANEL..............................................................857 OVERHEAD PANEL AND DISPLAYS...................................................857 CENTER CONSOLE................................................................858 F-N-R Selector Switch.....................................................858 Hoist Control Lever.......................................................859 Raising The Dump Body.....................................................859 Lowering The Dump Body:...................................................859 Ash Tray..................................................................859 Lighter...................................................................859 L.H. Window Control Switch................................................859 R.H. Window Control Switch................................................859 Engine Shutdown Switch....................................................859 Override/Fault Reset Switch...............................................860 Retard Speed Control (RSC) Switch.........................................860 Retard Speed Control (RSC) Adjust Dial....................................860 Data Store Button.........................................................861 Engine Control System.....................................................861 Service Engine Light (Blue)...............................................861 Engine Diagnostics Download Port..........................................861 Payload Meter.............................................................861 TCI Download Port.........................................................861 PSC Download Port.........................................................861 PAYLOAD METER.............................................................861 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................863 CONTROL SYMBOLS...............................................................863 INSTRUMENT PANEL..............................................................863 PANEL GAUGES, INDICATORS, AND CONTROLS............................................865 Key Switch....................................................................865 Starting......................................................................865 Cold Weather Starting.........................................................865 Normal Engine Shutdown........................................................865 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................866 Fog Lights (Optional).........................................................866 Ladder Light Switch...........................................................866 Manual Backup Switch..........................................................866 Panel Illumination Lights.....................................................867 Cab/Air Conditioner Vents.....................................................867 Rotating Beacon Light Switch (Optional).......................................867 Heated Mirror Switch (Optional)...............................................867 Wheel Brake Lock Control......................................................867 Parking Brake Control.........................................................867 Tachometer....................................................................868 Right Turn Signal Indicator...................................................868 High Beam Indicator...........................................................868 Left Turn Signal Indicator....................................................868 Speedometer / Payload Meter...................................................868 Voltmeter.....................................................................868 Engine Oil Pressure Gauge.....................................................868 Water Temperature Gauge.......................................................868 Fuel Gauge....................................................................868 AC Drive System Temperature Gauge.............................................869 Hydraulic Oil Temperature Gauge...............................................869 Hourmeter.....................................................................869 Rest Switch...................................................................869 Light Switch..................................................................870 Windshield Wiper and Washer...................................................870 Panel Light Dimmer............................................................870 Payload Meter Switch..........................................................870 OVERHEAD STATUS / WARNING INDICATORS..........................................871 STATUS / WARNING INDICATOR LIGHT SYMBOLS......................................872 Hazard Warning Lights.....................................................877 Lamp Test Switch..........................................................877 Link-On Warning Light.....................................................877 SECTION P - LUBRICATION AND SERVICE - INDEX...............................................879 SECTION P2 - LUBRICATION AND SERVICE - INDEX..........................................881 LUBRICATION AND SERVICE...........................................................883 930E SERVICE CAPACITIES.......................................................883 HYDRAULIC TANK SERVICE........................................................883 Adding Oil................................................................883 WHEEL MOTOR SERVICE...........................................................883 COOLANT LEVEL CHECK...........................................................884 RADIATOR FILLING PROCEDURE....................................................884 RESERVE ENGINE OIL SYSTEM (Optional)..........................................884 Reserve Oil Tank Filling Procedure (Remote fill)..........................884 LUBRICATION CHART.............................................................885 10 HOUR (DAILY) INSPECTION....................................................886 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................889 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................890 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................891 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................894 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................895 5000 HOUR MAINTENANCE CHECKS..................................................896 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.....................................897 AUTOMATIC LUBRICATION SYSTEM......................................................899 GENERAL DESCRIPTION...........................................................899 SYSTEM COMPONENTS.............................................................901 Filter....................................................................901 Hydraulic Motor and Pump..................................................901 Grease Reservoir..........................................................901 Pressure Reducing Valve...................................................901 Flow Control Valve........................................................901 Solenoid Valve............................................................901 Vent Valve................................................................901 Lubrication Cycle Timer...................................................901 Time Delay Module.........................................................901 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])..................901 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])...............901 Pressure Gauge............................................................901 Injectors.................................................................901 SYSTEM OPERATION..............................................................902 Normal Operation..........................................................902 Pressure Failure Detection Circuits.......................................903 GENERAL INSTRUCTIONS..........................................................904 Lubricant Requirements....................................................904 System Priming............................................................904 LUBRICANT PUMP................................................................904 Pump Housing Oil Level....................................................904 Pump Pressure Control.....................................................904 Lubrication Cycle Timer Check.............................................905 Lubrication Cycle Timer Adjustment........................................905 FILTER ASSEMBLY...............................................................905 SYSTEM CHECKOUT...............................................................906 INJECTORS (SL-1 Series “H”))..................................................906 Injector Specifications...................................................906 Injector Adjustment.......................................................906 INJECTOR OPERATION............................................................907 PUMP REBUILD..................................................................908 Disassembly...............................................................908 Cleaning and Inspection...................................................910 Assembly..................................................................910 SYSTEM TROUBLESHOOTING CHART......................................................912 PREVENTATIVE MAINTENANCE PROCEDURES...............................................915 Daily Lubrication System Inspection...........................................915 250 Hour Inspection...........................................................915 1000 Hour Inspection..........................................................915 SECTION Q ALPHABETICAL INDEX..............................................................917 SECTION R - SYSTEM SCHEMATICS - INDEX.....................................................921 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH358..............................................923 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH359..................................924 ELECTRICAL SCHEMATIC - XS1300.........................................................925
DESCRIPTION:
KOMATSU 930E-3 DUMP TRUCK Shop Manual SERIAL NUMBERS A30304 – A30309
- 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.
PLEASE NOTE:
- This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
- The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
- Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer
