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KOMATSU 930E-3 Shop Manual DUMP TRUCK (930E 3) Sl No: A30310 thru A30328
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KOMATSU 930E-3 Shop Manual DUMP TRUCK Sl No: A30310 thru A30328
Pub Number: CEBMO13301
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Description
KOMATSU 930E-3 Shop Manual DUMP TRUCK – Sl No: A30310 thru A30328
KOMATSU 930E-3 SHOP MANUAL DUMP TRUCK (930E 3) SL NO: A30310 THRU A30328:
IMAGES PREVIEW OF THE MANUAL:
KOMATSU 930E-3 service Manual DUMP TRUCK – KOMATSU 930E-3 DOWNLOAD
DESCRIPTION:
KOMATSU 930E-3 Shop Manual DUMP TRUCK SERVICE MANUAL
- 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.
TABLE OF CONTENTS:
KOMATSU 930E-3 Shop Manual DUMP TRUCK
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
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
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1 review for KOMATSU 930E-3 Shop Manual DUMP TRUCK (930E 3) Sl No: A30310 thru A30328
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Walker Salvatore –
Service was great and the manual I downloaded was great.