Komatsu 930E-3 Dump Truck Shop Manual SN A30310 thru A30328 PDF

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Komatsu 930E-3 Dump Truck Shop Manual SN A30310 thru A30328 – PDF DOWNLOAD

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Komatsu 930E-3 Dump Truck Shop Manual SN A30310 thru A30328 – PDF DOWNLOAD 

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

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DESCRIPTION:

Komatsu 930E-3 Dump Truck Shop Manual SN A30310 thru A30328 – PDF DOWNLOAD 

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per- sonnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accom- plishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other gen- eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical 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 æ 10% tolerance unless otherwise specified.
  A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig- nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
  The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
  The Product Identification Number (vehicle serial number) contains information which will identify the original man- ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
  The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo- nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
  To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 930E-3 Dump Truck Shop Manual SN A30310 thru A30328 – PDF DOWNLOAD 

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 57
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 63
STORAGE AND IDLE MACHINE PREPARATION 65
Short Term Idle Periods 65
PREPARATION FOR STORAGE 66
REMOVAL FROM STORAGE 67
RECONDITIONING AN IDLE VEHICLE 69
ENGINE OPERATION 72
After The Engine Has Started 73
ENGINE STORAGE 74
Preparing Engine For Storage 74
Temporary Storage (30 Days Or Less) 74
Extended Storage (more Than 30 Days) 74
RESTORING AN ENGINE AFTER EXTENDED STORAGE 76
ELECTRIC DRIVE TRUCKS 77
Storage Instructions and Procedures 77
Placing Equipment Into Storage 77
Storing A Truck That Is Operational 77
Storing A Truck That Is Not Operational 78
Storing A Major Component 78
Periodic Inspections 79
Placing Equipment Into Service After Storage 79
When A Truck Is Operational 79
When A Truck Is Not Operational 79
For The First Hour 80
SECTION B – STRUCTURES – INDEX 81
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 83
STRUCTURAL COMPONENTS 85
Preparation 85
GRILLE, HOOD AND LADDER 86
Removal 86
Installation 86
DECKS 87
RIGHT DECK AND COMPONENTS 87
Removal 87
Installation 88
LEFT DECK 88
Removal 88
Installation 88
CENTER DECK 88
SECTION B3 – DUMP BODY – INDEX 89
DUMP BODY 91
Removal 91
Installation 92
BODY PADS 93
Adjustment 93
BODY GUIDE 94
HOIST LIMIT SWITCH 94
BODY UP SWITCH 94
BODY-UP RETENTION CABLE 94
ROCK EJECTORS 95
Rock Ejectors 95
Inspection 95
SECTION B4 – FUEL TANK – INDEX 97
FUEL TANK 99
Removal 100
Installation 100
Repair 100
Cleaning 100
FUEL GAUGE SENDER 101
Removal 101
Installation 101
LOW FUEL SWITCH 101
WIGGINS QUICK FILL FUEL SYSTEM 102
FUEL RECEIVER 102
TANK BREATHER VALVE 102
Removal 102
Installation 102
Disassembly 102
Assembly 102
LEFT SIDE FILL 103
SECTION C – ENGINE – INDEX 105
SECTION C2 – POWER MODULE – INDEX 107
POWER MODULE 109
Preparation 109
Preparation for Removal 110
Removal – Power Module 113
Installation – Power Module 115
Hookup – Power Module 115
SECTION C3 – COOLING SYSTEM – INDEX 117
COOLING SYSTEM 119
RADIATOR 119
Removal – Radiator 119
Installation – Radiator 121
RADIATOR FILLING PROCEDURE 122
RADIATOR REPAIR 122
Internal Inspection 122
External Cleaning 122
Disassembly 123
Cleaning and Inspection 124
Assembly 124
Pressure Testing 125
Additional Service Information 125
COOLANT SYSTEM TROUBLESHOOTING 126
SECTION C4 – POWERTRAIN – INDEX 127
POWER TRAIN 129
ALTERNATOR 129
Removal – Alternator 129
ENGINE/ALTERNATOR MATING 131
General Instructions 131
Measuring Procedure 131
Joining The Alternator and Engine 133
ENGINE 134
Removal 134
Service 134
Installation 134
SECTION C5 – AIR CLEANERS – INDEX 135
AIR CLEANERS 137
AIR CLEANERS 137
Operation 137
General Service Information 137
FILTER ELEMENT REPLACEMENT 138
Main Filter Element Cleaning 139
Precleaner Section 140
Cleaning Precleaner Tubes 140
AIR INTAKE TROUBLESHOOTING 141
SECTION C7 – FAN CLUTCH – INDEX 143
FAN CLUTCH 145
REMOVAL & INSTALLATION TOOLING 145
FAN CLUTCH – DISASSEMBLY 148
CLEANING AND INSPECTION 158
ASSEMBLY – FAN CLUTCH 162
TEST PROCEDURE 176
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX 177
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 179
24VDC ELECTRIC SUPPLY SYSTEM 181
ELECTRICAL SYSTEM DESCRIPTION 181
BATTERIES 181
Maintenance and Service 181
Troubleshooting 181
BATTERY SUPPLY SYSTEM 183
24VDC Batter Charging Alternator 183
Battery Box 183
Batter Control Box 184
Battery Disconnect Switches 184
24VDC Auxiliary Battery Connectors 184
24VDC to 12VDC Converter 185
Isolation Diodes 185
Engine Starter Relay 185
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX 187
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
TRUCK SHUTDOWN PROCEDURE 189
24 VDC ELECTRICAL SYSTEM COMPONENTS 189
Brake Warning Buzzer (BWB) 189
AUXILIARY CONTROL CABINET COMPONENTS 189
Fuse Block 1 & 2 190
Power Distribution Terminals 190
PULSE VOLTAGE MODULATOR 190
5 Minute Idle Timer Components 192
5 Minute Idle Timer 192
5 Minute Idle Circuit Test 192
Tail Light Resistor Diode Assemblies 192
Engine Starter Failure Delay Timer 192
Lubrication System Timer 194
Auto Lube Delay Timer 194
Barometric Pressure Transducer 194
Kontrol Power Relay 194
Alarm Indicating Device (AID) System 196
Temperature and Latch 197
Hot Switch Inverter 197
Hot Switch Inverter Card (Slot 4) (Not Used) 197
Oil Level 197
Temperature 197
Diode Matrix (Without Sound) 197
Diode Matrix (With Sound) 197
Lamp Test 198
Diode Board – DB1 198
Diode Testing 198
RELAY BOARDS 199
Relay Boards RB1, RB3, RB4, RB5 199
Service 199
Relay Board Identification 200
RELAY BOARD FUNCTIONS 201
Relay Board 1 (RB1) 201
Relay Board 3 (RB3) 201
Relay Board 6, 7 & 8 (RB6, RB7, RB8) 202
Installing Additional Circuits 202
BODY-UP SWITCH 203
Operation 203
Adjustment 203
Service 203
HOIST LIMIT SWITCH 204
Operation 204
Adjustment 204
Service 204
FUSE BLOCKS 205
CIRCUIT BREAKERS 205
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX 207
BATTERY CHARGING ALTERNATOR 209
ELECTRICAL SYSTEM DESCRIPTION 209
BATTERY 209
Maintenance and Service 209
Troubleshooting 209
BATTERY CHARGING SYSTEM (Niehoff) 211
General Description 211
TROUBLESHOOTING PROCEDURES (On-Truck) 211
Equipment Required: 211
Preliminary Checks 212
Test Setup 212
Test Procedure 212
Regulator Bypass Test 213
ON VEHICLE TROUBLESHOOTING GUIDE 215
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 215
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 215
CHARGE VOLT AND AMP VALUES 216
DEFINITIONS 216
ADVANCED SYSTEM TROUBLESHOOTING 217
Static Test – Engine OFF, Key ON, Battery Switch ON 217
Go To Alternator 217
Go To Regulator (If Required) 218
Go To Regulator Connector On The Alternator 218
ALTERNATOR OVERHAUL 219
ALTERNATOR DIMENSIONS 219
ALTERNATOR SPECIFICATIONS 220
SERVICE PARTS 221
ON-VEHICLE TEST 223
Equipment: 223
Preliminary Checks: 223
Test Set-up 223
Test Procedure 223
ON-VEHICLE TEST 224
Bypass Test: 224
BENCH TEST 225
STATIC TESTS 226
Regulator Tests 226
Control Box Tests 227
ALTERNATOR DISASSEMBLY 229
ASSEMBLY- ALTERNATOR 234
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 243
Stator Removal And Replacement 243
Stator Installation 244
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX 247
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 249
ELECTRICAL PROPULSION SYSTEM COMPONENTS 251
GENERAL SYSTEM DESCRIPTION 251
SYSTEM COMPONENTS 253
Propulsion System Controller(PSC) 253
Truck Control Interface (TCI) 253
Diagnostic Information Display 255
DID Panel Event Codes 255
PSC SOFTWARE FUNCTIONS 279
Input Processing 279
STATE MANAGEMENT 279
State Machine 279
DC Link State 282
Powering the Link 282
De-Powering the Link 282
Control Functions 282
ALTERNATOR FIELD CONTROL 283
Desired Three-Phase Voltage 283
Desired DC Link Voltage 283
Self-load 283
Propel Torque Control 284
Retard Torque Control 284
Wheel Slide Control 284
Resistor Grid Control 285
Chopper Voltage Control 285
EVENT PROCESSING 285
Event Detection 285
Power On Tests 285
Initiated Tests 286
Periodic Tests 286
EVENT RESTRICTIONS 286
EVENT LOGGING AND STORAGE 286
Event History Buffer 287
Data Packs 287
To Record and Save a Data Pack to a Floppy Disk 287
Event Reset 288
SERIAL DATA COMMUNICATIONS 289
PSC – PTU Communications Processing 289
Inverter Communications Processing 289
OUTPUT PROCESSING 290
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 290
Fast Start 290
Engine Shutdown/Engine Not Running 290
Limp Home Mode 290
Entering/Exiting Limp Home Mode 290
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 291
ELECTRONIC ACCELERATOR AND RETARD PEDALS 303
Removal 303
Installation 303
Disassembly 303
Assembly 303
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 305
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 307
AC DRIVE SYSTEM MAINTENANCE 307
TRUCK SHUTDOWN PROCEDURES 307
NORMAL TRUCK SHUTDOWN PROCEDURE 308
SHUTDOWN AFTER SYSTEM FAILURE 309
SYSTEM CHECKOUT 310
Battery and Control Checks of System WITH Battery Power OFF 310
Battery and Control Circuit Checks of System With Battery Power ON 313
Checks with Key Switch OFF 314
CPU Battery Checks 316
MEMORY BACKUP BATTERY REPLACEMENT 316
TCI PROGRAMMING 317
PSC PROGRAMMING 317
INVERTER PROGRAMMING 318
TCI CHECKOUT 318
Modular Mining Communication Port 319
TCI Input Checks 320
TCI Digital Output Tests 322
TCI Digital Input Tests 324
PSC Checkout Procedure 326
PSC Digital Input Checks 330
Miscellaneous Checks 331
A3PV Panel 331
LINKV Panel 331
Thermistor Checks 331
17FM384 Panel Check 331
Pedal Percentages and Meter Calibration 332
Meter Calibration Procedure 332
Reprogram With Serial Numbers and Pedal Percentages 334
LOAD TESTING 336
Preload Checks 336
ADDITIONAL TRUCK CHECKS 338
On-Board Load Testing 340
Preparation 340
Initiate Loadbox Test 343
Manual Offset HP Output Adjustment 345
TROUBLESHOOTING 347
PVM Optimum Load Curve Handshaking Troubleshooting 347
MISCELLANEOUS COMPONENT REPAIR 348
Troubleshooting Phase Modules and Chopper Modules 348
Phase Module Removal and Snubber Resistor Replacement 348
Snubber Resistor Installation 349
Phase Module Installation 349
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 350
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 353
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 354
IGBT TROUBLESHOOTING 355
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 357
SECTION G2 – TIRES AND RIMS – INDEX 359
TIRES AND RIMS 361
WHEEL STUD MAINTENANCE 362
FRONT TIRES AND RIMS 363
Removal 363
Installation 364
REAR TIRES AND RIMS 365
Removal 365
Installation 366
RIM 367
Tire Removal 367
Tire Installation 368
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 371
FRONT WHEEL HUB AND SPINDLE 373
WHEEL HUB AND SPINDLE ASSEMBLY 373
Preparation 373
Removal 373
Installation – Wheel Hub and Spindle Assembly 376
Disassembly – Wheel Hub and Spindle Assembly 377
Cleaning and Inspection – Wheel Hub and Spindle Assembly 377
Assembly – Wheel Hub and Spindle Assembly 379
Wheel Bearing Adjustment: 379
Brake Installation 380
Seal Assembly Gap Check 381
STEERING CYLINDERS AND TIE ROD 382
Spherical Bearing Wear Limits 382
Removal – Steering Cylinder and Tie Rod 383
Installation – Steering Cylinder and Tie Rod 384
Bearing Replacement 384
TOE-IN ADJUSTMENT 385
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 387
REAR AXLE HOUSING ATTACHMENT 389
PIVOT PIN 389
Removal 389
Installation 390
PIVOT EYE BEARING 391
Removal 391
Installation 391
PIVOT EYE REPAIR 391
Removal 391
Disassembly 391
Assembly 392
Installation 392
ANTI-SWAY BAR 392
Removal 392
Installation 393
Disassembly 393
Cleaning and Inspection 393
Assembly 393
SECTION G5 – REAR AXLE HOUSING – INDEX 395
REAR AXLE HOUSING 397
REAR AXLE HOUSING 397
Preparation 397
Removal 397
Cleaning and Inspection – Rear Axle Housing 399
Installation – Rear Axle Housing 399
WHEEL MOTOR 400
Preparation 400
Removal 400
Cleaning and Inspection – Wheel Motor 401
Installation – Wheel Motor 402
WHEEL MOTOR GEAR OIL 405
Filtering Requirements 405
Particle Size Analysis 405
Flushing 405
Oil Sample Analysis 406
ELEMENT SPECIFICATION CHARTS 407
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 411
SECTION H2 – FRONT SUSPENSIONS – INDEX 413
FRONT SUSPENSION 415
Removal 415
Installation – Front Suspension 416
“Turn-Of-The-Nut” Tightening Procedure 419
MINOR REPAIRS (LOWER BEARING & SEALS) 420
Removal – Bearing Retainer 420
Installation – Bearing Retainer 420
MAJOR SUSPENSION REBUILD 422
Disassembly 422
Assembly 422
SECTION H3 – REAR SUSPENSIONS – INDEX 425
REAR SUSPENSIONS 427
Removal 427
Installation – Rear Suspension 429
Disassembly – Rear Suspension 430
Cleaning and Inspection – Rear Suspension 430
Assembly – Rear Suspension 430
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 433
SUSPENSION OILING AND CHARGING PROCEDURE 435
GENERAL 435
EQUIPMENT LIST 435
Hydrair® Charging Kit 435
Installation of Charging Kit 435
Removal of Charging Kit 436
Support Blocks For Oiling And Charging Dimensions 436
FRONT SUSPENSION 437
Front Suspension Oiling 437
Front Suspension Nitrogen Charging 438
REAR SUSPENSION 439
Rear Suspension Oiling 439
Rear Suspension Nitrogen Charging 440
OIL AND NITROGEN SPECIFICATIONS CHART 442
SECTION J – BRAKE CIRCUIT – INDEX 443
SECTION J2 – BRAKE CIRCUIT – INDEX 445
BRAKE CIRCUIT 447
SERVICE BRAKE CIRCUIT 447
SECONDARY BRAKING AND AUTOMATIC APPLY 449
PARKING BRAKE CIRCUIT 449
Normal Operation (key switch on, engine running) 449
BRAKE LOCK CIRCUIT 450
WARNING CIRCUIT 450
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 453
BRAKE CIRCUIT COMPONENT SERVICE 455
BRAKE VALVE 455
Rebuild Criteria 455
Removal 456
Installation 456
Disassembly 457
Cleaning and Inspection 460
Assembly 460
Actuator Base Threaded Inserts 460
Boot and Cap 460
Valve Body Seal Installation 460
Regulator Sleeve O-Ring Installation 461
Actuator Plunger O-ring Installation 461
Assembly of Valve 461
DIFFERENTIAL PRESSURE SWITCH 463
Disassembly 463
Cleaning and Inspection 463
Assembly 463
VALVE BENCH TEST AND ADJUSTMENT 464
Test Set Up Procedure 465
Brake Valve Output Pressure Adjustment 465
Differential Pressure Switch Adjustment 465
Final Test and Adjustment 466
Installation Of Brake Pedal Actuator Assembly to Brake Valve 467
Installation of Retard Pedal To Brake Pedal 467
DUAL RELAY VALVE 469
Removal 469
Installation 469
Disassembly 471
Cleaning and Inspection 471
Assembly 471
DIFFERENTIAL PRESSURE SWITCH 472
Disassembly 472
Cleaning and Inspection 472
Assembly 472
VALVE TEST AND ADJUSTMENT 473
Test Set Up Procedure 474
Relay Valve Output Pressure Adjustment 474
Differential Pressure Switch Adjustment 475
BRAKE MANIFOLD 476
Removal 476
Installation 477
Disassembly 477
Cleaning and Inspection 477
Assembly 477
BRAKE ACCUMULATORS 478
Brake Accumulator Bleeddown Procedure 478
BRAKE ACCUMULATOR REPAIR 479
Removal 479
Installation 479
Disassembly 480
Cleaning and Inspection 481
Assembly 481
ACCUMULATOR CHARGING PROCEDURE 483
Temperature During Precharge 484
Precharge Maintenance 485
Recharging Accumulators 485
Accumulator Storage procedures 486
Bladder Storage Procedures 486
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 487
Removal 487
Installation 487
Disassembly and Adjustment 487
Potentiometer Check 489
Assembly 489
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 491
BRAKE CIRCUIT CHECK-OUT PROCEDURE 493
REQUIRED EQUIPMENT 495
INITIAL SYSTEM SET-UP 496
BRAKE SYSTEM CHECKOUT 497
Failure Modes Check-Out 498
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 500
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 503
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 504
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 505
WET DISC BRAKE ASSEMBLY 507
OPERATION 507
MAINTENANCE 508
Brake Disc Wear Indicator 508
Removal/Installation – Wet Disc Brake Assembly 508
BRAKE REBUILD 510
Disassembly 510
Cleaning and Inspection 513
Assembly 514
Floating Ring Seal Assembly/Installation 517
WET DISC BRAKE BLEEDING PROCEDURE 520
SECTION J7 – PARKING BRAKE – INDEX 521
PARKING BRAKE 523
OPERATION 523
MAINTENANCE 524
Inspection – Parking Brake 524
Removal – Parking Brake 524
Installation – Parking Brake 525
Disassembly – Parking Brake 526
Cleaning and Inspection – Parking Brake 526
Assembly – Parking Brake 526
PARKING BRAKE BLEEDING PROCEDURE 528
SECTION L – HYDRAULIC SYSTEM – INDEX 529
SECTION L2 – HYDRAULIC SYSTEM – INDEX 531
HYDRAULIC SYSTEM 533
HYDRAULIC PUMP MODULE 533
HOIST CIRCUIT OPERATION 534
STEERING CIRCUIT OPERATION 536
DISC BRAKE COOLING SYSTEM 538
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 541
HYDRAULIC SYSTEM COMPONENT REPAIR 543
HOIST PUMP 543
Removal 543
Installation 545
INSPECTION OF PARTS 550
Assembly 550
HYDRAULIC TANK 556
Filling Instructions 556
Removal 556
Installation 557
HYDRAULIC TANK STRAINERS 557
Removal 557
Inspect and Clean 557
Installation 557
HYDRAULIC TANK BREATHERS 558
SECTION L4 – STEERING CIRCUIT – INDEX 559
STEERING CIRCUIT 561
COMPONENT DESCRIPTION 562
Steering Control Unit 562
Bleeddown Manifold Valve 563
Bleeddown Solenoid 563
Relief Valves 565
Hoist Limit Solenoid 565
Accumulators 565
Low Precharge Warning Switch 565
High Pressure Filter 565
Quick Disconnect Ports 565
Flow Amplifier 566
FLOW AMPLIFIER SYSTEM OPERATION 568
No Steer 568
Steering Left 570
Steering Right 572
No Steer, External Shock Load 574
STEERING PUMP 576
Operation 576
PRINCIPLE OF OPERATION 578
Full Pump Volume: 578
Half Pump Volume: 578
Neutral Position: 578
Steering Pump 579
SECTION L5 – STEERING CONTROL UNIT – INDEX 581
STEERING CONTROL UNIT 583
Removal 583
Spline Inspection 583
Installation 584
STEERING CONTROL UNIT REBUILD 584
Disassembly 584
Cleaning and Inspection – Steering Control Unit 585
Assembly – Steering Control Unit 587
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 591
STEERING CIRCUIT COMPONENT REPAIR 593
BLEEDDOWN MANIFOLD VALVE 593
Removal 593
Installation 593
FLOW AMPLIFIER 595
Removal 595
Installation 595
FLOW AMPLIFIER REBUILD 595
Disassembly 598
Assembly 599
STEERING CYLINDERS 600
Disassembly 601
Piston Seal & Bearing Installation 601
Cylinder Assembly 601
Test 601
STEERING AND BRAKE PUMP 602
Removal 602
Installation 602
Disassembly 604
Control Piston Group 604
Valve Plate Group 604
Rotating Group 607
Swashblock Group 607
Driveshaft Group 607
Inspection 607
Control Piston Group 607
Valve Plate Group 607
Rotating Group 607
Swashblock Group 609
Driveshaft Group 610
Compensator Block and Unloader Module 610
Stroke Adjuster Assembly 610
Assembly 610
Swashblock Group 610
Driveshaft Group 611
Rotating Group 611
Valve Plate Group 612
STEERING ACCUMULATORS 613
Removal 613
Installation 613
Disassembly 614
Cleaning and Inspection 614
Assembly 615
Leak Testing 617
Charging Procedure 618
Temperature During Precharge 619
Precharge Maintenance 620
Accumulator Storage procedures 621
Bladder Storage Procedures 621
TROUBLESHOOTING CHART 622
SECTION L7 – HOIST CIRCUIT – INDEX 627
HOIST CIRCUIT 629
HOIST CIRCUIT OPERATION 629
COMPONENT DESCRIPTION 630
Hydraulic Tank 630
Hydraulic Pump 630
High Pressure Filters 630
Hoist Valve 630
Inlet Sections – Hoist Valve 630
Spool Sections – Hoist Valve 631
Hoist Pilot Valve 631
Bleeddown Manifold 632
Hoist-up Limit Solenoid 632
Pilot Operated Check Valve 632
Overcenter Manifold 632
HOIST CIRCUIT OPERATION 633
Float Position Of Pilot Valve With Truck Body On Frame 634
Power Up Operation 636
Hold Operation 638
Power Down Operation 640
Float Operation 642
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 645
HOIST CIRCUIT COMPONENT REPAIR 647
HOIST VALVE 647
Removal 647
Installation 648
O-Ring Replacement 648
INLET SECTION 649
Disassembly 649
Cleaning and Inspection 650
Assembly 650
REAR SPOOL SECTION (Work Ports) 650
Disassembly 650
Cleaning and Inspection 652
Assembly 652
FRONT SPOOL SECTION (Tank Ports) 653
Disassembly 653
Cleaning and Inspection 653
Assembly 653
HOIST PILOT VALVE 655
Removal 655
Installation 655
Disassembly 656
Cleaning and Inspection 657
Assembly 657
HOIST CYLINDERS 658
Removal 658
Installation 659
Disassembly 661
Cleaning and Inspection 662
Assembly – Quill and Cylinder 663
Quill Installation 663
Installation Of Check Balls And Plugs In Quill 664
Assembly of Cylinder 665
OVERCENTER VALVE MANIFOLD 666
DISABLED TRUCK DUMPING PROCEDURE 667
Hookup 667
Raising the Body 667
Lowering the Body 667
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 669
HYDRAULIC SYSTEM FILTERS 671
HOIST CIRCUIT FILTER 671
Filter Element Replacement 671
Removal – Hoist Circuit Filter 672
Installation – Hoist Circuit Filter 672
Indicator Switch – Hoist Circuit Filter 672
STEERING CIRCUIT FILTER 673
Filter Element Replacement 673
Removal – Steering Circuit Filter 674
Installation – Steering Circuit Filter 674
Indicator Switch – Steering Circuit Filter 674
INDICATOR SWITCH 674
Test Procedure 674
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 677
HYDRAULIC CHECK-OUT PROCEDURE 679
GENERAL INFORMATION 679
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 679
Equipment Requirements 680
Pump Pressure Control Adjustments 680
Steering Control Valve and Flow Amplifier Leakage Test 681
Bleeddown Manifold Leakage Test 681
STEERING/BRAKE PUMP STROKE ADJUSTMENT 682
SHOCK AND SUCTION VALVES 683
Equipment Requirements 683
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 684
Equipment Requirements 684
Pressure Gauge Locations 684
Brake Cooling Circuit Test 684
Power Up Relief Pressure Test 685
Adjustment 685
Power Down Relief Pressure Test 686
Hoist Counterbalance Valve Adjustment Preparation 687
Counterbalance Valve Pressure Check 687
Counterbalance Valve Adjustment 688
Preparation 689
Flushing Procedure 689
Filter Element Replacement 690
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 691
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 692
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 693
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX 695
FIRE CONTROL SYSTEM (MANUAL) 697
Operation 697
Inspection and Maintenance 697
Recharging Procedures 698
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 699
Control Module 699
Actuator 700
Linear Detection Wire 700
Power Wire 700
Test Kit 700
Squib 700
Securing the Detection Wire 701
Preliminary Test Before Final Hook-Up 701
Installation Procedure for Squib 703
Placing the Electric Detection & Actuation System Into Service 703
INSPECTION AND MAINTENANCE SCHEDULES 704
Daily 704
Normal Maintenance Based On Actual Operating Hours 704
IN CASE OF FIRE 705
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 707
TROUBLE: Detonated Squib 707
SECTION M8 – SPECIAL TOOLS 709
SECTION M20 – PAYLOAD METER III – INDEX 715
OPERATION SECTION 719
Introduction 719
Data Summary 719
Data Gathering 719
COMPONENT DESCRIPTION 720
System Diagram 720
Suspension Pressure Sensors 720
Inclinometer 720
Operator Display 720
Operator Switch 721
Speed Input 721
Body-Up Switch 721
Brake Lock Switch 721
Payload Meter 721
Communications Ports 721
Keyswitch Input 722
Payload Meter Power 722
Load Lights 722
Wiring and Termination 723
TCI Outputs 723
OPERATOR’S DISPLAY AND SWITCH 724
Reading the Speedometer 724
Reading the Load Display 724
Using the Operator ID 724
Using the Load and Ton Counter 724
Total Ton Counter 724
Total Load Counter 725
Clearing the Counters 725
Viewing Live Sensor Data 725
Other Display Messages 725
PAYLOAD OPERATION & CALCULATION 726
Description of Haul Cycle States 726
Haul Cycle Description 726
Load Calculation 727
Carry Back 727
Measurement Accuracy 727
SOURCES FOR PAYLOAD ERROR 727
Payload Error 727
Loading Conditions 728
Pressure Sensors 728
Swingloads 728
Speed and Distance 728
HAUL CYCLE DATA 728
Haul Cycle Data 729
Haul Cycle Warning Flags 730
M: Haul Cycle Too Long 731
N: Sensor Input Error 731
Frame Torque Data 731
Sprung Weight Data 731
Maximum Speed Data 731
Alarm Records 731
Fault Code Data 732
PC SOFTWARE OVERVIEW 733
PC Overview 733
System Configuration 733
Installing the PLMIII Software 733
DOWNLOADING DATA 734
PLM III SYSTEM CONFIGURATION 735
Starting Communications 735
Displayed Payload Units 735
Time Units 735
Connection Menu 735
Connecting to the Payload Meter 736
Configure the Payload Meter 736
Setting the Date and Time 736
Setting the Truck Type 737
Setting the Gauge Display Units 737
Setting the Frame Serial Number 737
Setting the Truck Number 737
Setting the Komatsu Distributor 737
Setting the Komatsu Customer 737
Clean Truck Tare 738
Inclinometer Calibration 738
DATA ANALYSIS 739
Creating a Query 739
Sorting on Truck Unit Number 739
Sorting on Truck Type 739
Sorting on Date Range 740
Sorting on Time Range 740
Payload Detail Screen 741
Creating Reports 741
Summary – one page report 742
Detailed – multi-page report 742
Creating Graphs 743
Exporting Data 743
CSV Export 743
Compressed 744
Importing Data 745
Deleting Haul Cycle Records 745
Viewing Alarms 746
Deleting Alarm Records 746
TROUBLESHOOTING SECTION 747
TROUBLESHOOTING 747
Viewing Active Alarms 747
Real-Time Data Display 747
Testing the Payload Lights 747
Creating Log Files of Inputs 748
Daily Inspections 748
Periodic Maintenance 748
Abnormal Displays at Power-Up 749
No Payload Display When Keyswitch is Turned ON 750
No Display on Speedometer 751
No Display on Operator Display 751
No Communications With PC 752
Load Lights Don’t Light During Loading 753
Load Lights Remain ON 754
Load Lights Remain ON During Dumping 754
Display Doesn’t Clear When The Load Is Dumped 754
Calibration Problems 755
Alarm 1 – Left Front Pressure High 756
Alarm 2 – Left Front Pressure Low 756
Troubleshoot Wiring to Left Front Suspension 756
Alarm 3 – Right Front Pressure High 757
Alarm 4 – Right Front Pressure Low 757
Troubleshoot Wiring to Right Front Suspension 757
Alarm 5 -Left Rear Pressure High 758
Alarm 6 – Left Rear Pressure Low 758
Troubleshoot Wiring to Left Rear Suspension 758
Alarm 7 – Right Rear Pressure High 759
Alarm 8 – Right Rear Pressure Low 759
Troubleshoot Wiring to Right Rear Suspension 759
Alarm 9 – Inclinometer High 760
Alarm 10 – Inclinometer Low 760
Troubleshoot Inclinometer Wiring 760
Alarm 13 – Body Up Input Failure 761
Alarm 16 – Memory Write Failure 762
Alarm 17 – Memory Read Failure 762
Alarm 18 763
Alarm 19 763
Alarm 22 763
Operator Switch Doesn’t Work 764
Alarm 26 – User Switch Fault – SELECT 764
Alarm 27 – User Switch Fault – SET 764
Connector Map 765
Connectors 766
PLMIII CHECK OUT PROCEDURE 767
General Description 767
Tools Required 767
Checkout Procedure 767
PLMIII CHECKOUT PROCEDURE CONFIRMATION 771
Flashburn Programming 771
Confirmation Checklist 773
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX 775
RESERVE ENGINE OIL SYSTEM 777
Operation 778
LED Monitor Light 778
Tank Fill Control (Optional) 779
Filling Procedure (Remote fill feature) 779
SERVICE 780
Every 10 Hours, or once each shift: 780
Every 500 Hours: 780
Changing Oil 780
TROUBLESHOOTING 781
Circuit Breaker or Fuse 781
SYSTEM ELECTRICAL SCHEMATICS 782
SECTION N – CAB COMPONENTS – INDEX 783
SECTION N2 – TRUCK CAB – INDEX 785
TRUCK CAB 787
Description 787
Preparation 788
Removal – Cab 788
Installation – Cab 790
CAB DOOR 790
Removal 790
Installation 790
Door Adjustment 791
Door Jamb Bolt Adjustment 791
Door Handle Plunger Adjustment 792
Door Glass Replacement 793
Door Window Regulator Replacement 797
Door Handle or Latch Assembly Replacement 797
Door and Door Hinge Seal Replacement 798
Door Opening Seal Removal 798
Installation 798
GLASS REPLACEMENT 799
Adhesive Bonded Windows 799
Replacement Procedure 799
Windshield And Rear Glass 800
Removal 800
Installation 801
SECTION N3 – CAB COMPONENTS – INDEX 803
CAB COMPONENTS 805
WINDSHIELD WIPERS 805
Wiper Motor Replacement 805
Removal 805
Installation 805
Wiper Arm 805
Removal 805
Installation 806
Wiper Linkage Replacement 806
Removal 806
Installation 806
WINDSHIELD WASHER 807
Operation 807
Service 807
OPERATOR SEAT 808
Adjustment 808
Seat Removal 808
Seat Installation 808
SECTION N4 – OPERATOR COMFORT – INDEX 809
OPERATOR COMFORT 811
HEATER / AIR CONDITIONER 811
Operation 811
Heater/Air Conditioner Vents 811
COMPONENTS 812
Circuit Breakers 812
Relays 812
Heater Core 812
Fan Motor And Speed Control 813
Actuators 813
Filter 813
Service 813
AIR CONDITIONING SYSTEM 815
Environmental Impact 815
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 816
PRINCIPLES OF REFRIGERATION 816
Air Conditioning 816
Refrigeration – The Act Of Cooling 817
The Refrigeration Cycle 817
AIR CONDITIONER SYSTEM COMPONENTS 818
Compressor (Refrigerant Pump) 818
Service Valves 818
Condenser 818
Receiver-Drier 818
Expansion Block Valve 819
Accumulator 819
Evaporator 819
ELECTRICAL CIRCUIT 820
Thermostat 820
Compressor Clutch 820
Trinary™ Switch 821
SYSTEM SERVICING 822
SERVICE TOOLS AND EQUIPMENT 823
Recovery/Recycle Station 823
Leak Detector 823
Service Valves 824
Vacuum Pump 824
Manifold Gauge Set 825
Installing Manifold Gauge Set 826
Purging Air From Service Hoses 826
SYSTEM PERFORMANCE TEST 827
SYSTEM OIL 828
Handling and Reusing PAG Oil 828
Oil Quantity 828
Checking System Oil 828
REFRIGERANT 829
Recycled Refrigerant 829
Reclaimed Refrigerant 829
Refrigerant Quantity 829
R-134a Refrigerant Containers 829
SYSTEM LEAK TESTING 830
Electronic Leak Detector 830
Tracer Dyes 830
Soap and Water 830
RECOVERING AND RECYCLING THE REFRIGERANT 831
Performing the Recovery Cycle 831
Performing the Recycling Procedure 831
Evacuating and Charging the A/C System 831
SYSTEM REPAIR 832
System Flushing 832
COMPONENT REPLACEMENT 832
Hoses and Fittings 832
Lines 832
Expansion Valve 833
Receiver-Drier 833
Thermostat 833
Compressor 833
Accumulator 833
Clutch 834
Servicing the Compressor Clutch 834
Pulley Removal 836
Clutch Coil Check 837
Pulley Installation 837
Clutch Assembly Installation 837
EVACUATING THE SYSTEM 839
CHARGING THE A/C SYSTEM 841
TROUBLESHOOTING 842
Preliminary Checks 842
Diagnosis Of Gauge Readings And System Performance 842
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 843
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 849
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 851
OPERATOR CAB CONTROLS 853
STEERING COLUMN 853
Removal 853
Steering Column Inspection 853
Installation 853
STEERING WHEEL AND CONTROLS 855
Horn Button 855
Telescope Lock Ring 855
Tilt Wheel Lever 855
Turn Signal/Headlight Dimmer 855
DYNAMIC RETARDING 855
Retarder Control Lever 856
Dynamic Retarder/Service Brake Pedal 856
Accelerator (Throttle) Pedal 856
Starting on a Grade With a Loaded Truck 856
GRADE/SPEED RETARD CHART 857
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 858
Heater/Air Conditioner Vents 858
INSTRUMENT PANEL 859
OVERHEAD PANEL AND DISPLAYS 859
CENTER CONSOLE 860
F-N-R Selector Switch 860
Hoist Control Lever 861
Raising The Dump Body 861
Lowering The Dump Body: 861
Ash Tray 861
Lighter 861
L H Window Control Switch 861
R H Window Control Switch 861
Engine Shutdown Switch 861
Override/Fault Reset Switch 862
Retard Speed Control (RSC) Switch 862
Retard Speed Control (RSC) Adjust Dial 862
Data Store Button 863
Engine Control System 863
Service Engine Light (Blue) 863
Engine Diagnostics Download Port 863
Payload Meter 863
TCI Download Port 863
PSC Download Port 863
PAYLOAD METER 863
INSTRUMENT PANEL AND INDICATOR LIGHTS 865
CONTROL SYMBOLS 865
INSTRUMENT PANEL 865
PANEL GAUGES, INDICATORS, AND CONTROLS 867
Key Switch 867
Starting 867
Cold Weather Starting 867
Normal Engine Shutdown 867
Engine Shutdown Switch with 5 Minute Idle Timer Delay 868
Fog Lights (Optional) 868
Ladder Light Switch 868
Manual Backup Switch 868
Panel Illumination Lights 869
Cab/Air Conditioner Vents 869
Rotating Beacon Light Switch (Optional) 869
Heated Mirror Switch (Optional) 869
Wheel Brake Lock Control 869
Parking Brake Control 869
Tachometer 870
Right Turn Signal Indicator 870
High Beam Indicator 870
Left Turn Signal Indicator 870
Speedometer / Payload Meter 870
Voltmeter 870
Engine Oil Pressure Gauge 870
Water Temperature Gauge 870
Fuel Gauge 870
AC Drive System Temperature Gauge 871
Hydraulic Oil Temperature Gauge 871
Hourmeter 871
Rest Switch 871
Light Switch 872
Windshield Wiper and Washer 872
Panel Light Dimmer 872
Payload Meter Switch 872
OVERHEAD STATUS / WARNING INDICATORS 873
STATUS / WARNING INDICATOR LIGHT SYMBOLS 874
Hazard Warning Lights 879
Lamp Test Switch 879
Link-On Warning Light 879
SECTION P – LUBRICATION AND SERVICE – INDEX 881
SECTION P2 – LUBRICATION AND SERVICE – INDEX 883
LUBRICATION AND SERVICE 885
930E SERVICE CAPACITIES 885
HYDRAULIC TANK SERVICE 885
Adding Oil 885
WHEEL MOTOR SERVICE 885
COOLANT LEVEL CHECK 886
RADIATOR FILLING PROCEDURE 886
RESERVE ENGINE OIL SYSTEM (Optional) 886
Reserve Oil Tank Filling Procedure (Remote fill) 886
LUBRICATION CHART 887
10 HOUR (DAILY) INSPECTION 888
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 891
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 892
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 893
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 896
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 897
5000 HOUR MAINTENANCE CHECKS 898
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 899
AUTOMATIC LUBRICATION SYSTEM 901
GENERAL DESCRIPTION 901
SYSTEM COMPONENTS 903
Filter 903
Hydraulic Motor and Pump 903
Grease Reservoir 903
Pressure Reducing Valve 903
Flow Control Valve 903
Solenoid Valve 903
Vent Valve 903
Lubrication Cycle Timer 903
Time Delay Module 903
Pump Cutoff Pressure Switch (N O 2500 psi [17 237 kPa]) 903
Grease Pressure Failure Switch (N O 2000 psi [13 789 kPa]) 903
Pressure Gauge 903
Injectors 903
SYSTEM OPERATION 904
Normal Operation 904
Pressure Failure Detection Circuits 905
GENERAL INSTRUCTIONS 906
Lubricant Requirements 906
System Priming 906
LUBRICANT PUMP 906
Pump Housing Oil Level 906
Pump Pressure Control 906
Lubrication Cycle Timer Check 907
Lubrication Cycle Timer Adjustment 907
FILTER ASSEMBLY 907
SYSTEM CHECKOUT 908
INJECTORS (SL-1 Series “H”)) 908
Injector Specifications 908
Injector Adjustment 908
INJECTOR OPERATION 909
PUMP REBUILD 910
Disassembly 910
Cleaning and Inspection 912
Assembly 912
SYSTEM TROUBLESHOOTING CHART 914
PREVENTATIVE MAINTENANCE PROCEDURES 917
Daily Lubrication System Inspection 917
250 Hour Inspection 917
1000 Hour Inspection 917
SECTION Q ALPHABETICAL INDEX 919
SECTION R – SYSTEM SCHEMATICS – INDEX 923
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH358 925
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH359 926
ELECTRICAL SCHEMATIC – XS1300 927

S.V 11/12/24