Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu 930E-3SE Dump Truck Shop Manual A30171, A30318, A30319, A30322 – PDF DOWNLOAD
Original price was: $52.95.$32.95Current price is: $32.95.
Komatsu 930E-3SE Dump Truck Shop Manual
Book Code: CEBM012100
SERIAL NUMBERS :A30171, A30318, A30319, A30322
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu 930E-3SE Dump Truck Shop Manual
FILE DETAILS:
Komatsu 930E-3SE Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 960E-3SE
Book Code: CEBM012100
Language: English
Pages: 1035
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu 930E-3SE Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu 930E-3SE Dump Truck Shop Manual
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 D11 - VHMS COMPONENTS......................................................... 247 VEHICLE HEALTH MONITORING SYSTEM (VHMS)........................................... 249 VHMS BASIC FEATURES............................................................... 249 Gather Data................................................................... 249 Convert and Record Data....................................................... 250 Communicate Data to Off-Board Systems......................................... 250 USING THE VHMS SYSTEM............................................................. 251 Turning the VHMS System ON.................................................... 251 Normal VHMS Operation......................................................... 252 Turning the VHMS System OFF................................................... 252 Downloading from the VHMS controller.......................................... 252 VHMS DATA ITEMS................................................................... 253 Fault Codes................................................................... 253 Machine History............................................................... 253 VHMS History.................................................................. 253 Snapshots..................................................................... 253 Manual Snapshots.............................................................. 255 Trends........................................................................ 255 Histogram (Load Map) Data..................................................... 257 Haul Cycle Data............................................................... 257 Alarm and Snapshot Triggers................................................... 259 Satellite Features............................................................ 261 VHMS DIAGNOSTIC FEATURES.......................................................... 261 Fault History................................................................. 261 VHMS LED Digits............................................................... 261 VHMS COMPONENTS................................................................... 262 VHMS Controller............................................................... 262 Removal....................................................................... 262 Installation.................................................................. 263 OrbComm Controller............................................................ 263 Removal....................................................................... 263 Installation.................................................................. 264 Interface Module.............................................................. 264 Removal....................................................................... 265 Installation.................................................................. 265 Temperature Sensors........................................................... 266 Pressure Sensors.............................................................. 267 SECTION D12 - VHMS SOFTWARE........................................................... 269 VHMS SOFTWARE..................................................................... 271 NECESSARY SOFTWARE............................................................ 271 NECESSARY TOOLS............................................................... 271 VHMS TOOL BOX INSTALLATION.................................................... 272 VHMS SETTING TOOL INSTALLATION................................................ 272 VHMS INITIALIZATION PROCEDURE................................................. 272 Preliminary Checks........................................................ 272 Initialization Steps...................................................... 273 Select Operation.......................................................... 273 VHMS Setting Function..................................................... 273 Machine Information Setting(1)............................................ 273 Machine Information Setting(2)............................................ 273 Date & Time Setting....................................................... 274 GCC Setting............................................................... 274 Setting Summary........................................................... 274 VHMS SNAPSHOT PROCEDURE....................................................... 275 VHMS DOWNLOAD................................................................. 275 VHMS FTP UPLOAD............................................................... 276 LOCATION OF DOWNLOAD FILES.................................................... 277 INSTALLING FLASHBURN PROGRAM.................................................. 278 INSTALLING APPLICATION CODE INTO INTERFACE MODULE............................. 278 INSTALLING VHMS WATCHER PROGRAM............................................... 279 INSTALLING VHMS WATCHER DATA FILES............................................ 279 WHEN REPLACING A VHMS CONTROLLER.............................................. 279 To Set: Date & Time; Satellite; Payload Meter............................. 282 Review Setting Information................................................ 283 SECTION D13 - VHMS CHECKOUT AND TROUBLESHOOTING....................................... 285 VHMS CHECKOUT & TROUBLESHOOTING................................................... 287 VHMS CHECKOUT PROCEDURE....................................................... 287 General................................................................... 287 Structure and Purpose..................................................... 288 Necessary Equipment:...................................................... 288 VHMS SYSTEM CHECKOUT.......................................................... 288 Preliminary............................................................... 288 Checking Inputs To The Interface Module................................... 289 Checking Outputs From The Interface Module................................ 292 VHMS CONTROLLER CHECKOUT...................................................... 292 TROUBLESHOOTING............................................................... 293 Communications Networks................................................... 293 Coaxial Cable............................................................. 293 VHMS COMPONENTS............................................................... 294 VHMS Controller........................................................... 294 OrbComm Controller........................................................ 295 Interface Module.......................................................... 295 FAULT CODES................................................................... 296 Fault History............................................................. 296 VHMS LED Display Fault Codes.............................................. 297 Chassis Fault Codes....................................................... 298 Engine Fault Codes........................................................ 301 FAULT TREE ANALYSIS........................................................... 307 Unable to connect to VHMS from laptop PC.................................. 307 Flashing Error Code N4-23 (PLM III Communications Fault).................. 308 Flashing Error Code N4-22 (Engine Communications Fault)................... 309 No Data Received By WebCARE............................................... 310 Coaxial Cable Troubleshooting............................................. 311 SECTION D14 - VHMS FORMS.............................................................. 313 VHMS FORMS........................................................................ 315 VHMS INITIALIZATION CHECK LIST................................................ 315 VHMS DATA DOWNLOAD............................................................ 316 VHMS INITIALIZATION FORM...................................................... 316 VHMS INITIALIZATION CHECK LIST................................................ 317 VHMS INITIALIZATION FORM...................................................... 319 SECTION E - ELECTRICAL PROPULSION SYSTEM - INDEX.......................................... 321 SECTION E2 - ELECTRICAL PROPULSION SYSTEM COMPONENTS - INDEX.......................... 323 ELECTRICAL PROPULSION SYSTEM COMPONENTS........................................... 325 GENERAL SYSTEM DESCRIPTION.................................................... 325 SYSTEM COMPONENTS............................................................. 327 Propulsion System Controller(PSC)......................................... 327 Truck Control Interface (TCI)............................................. 327 Diagnostic Information Display............................................ 329 DID Panel Event Codes..................................................... 329 PSC SOFTWARE FUNCTIONS........................................................ 353 Input Processing.......................................................... 353 STATE MANAGEMENT.............................................................. 353 State Machine............................................................. 353 DC Link State............................................................. 356 Powering the Link......................................................... 356 De-Powering the Link...................................................... 356 Control Functions......................................................... 356 ALTERNATOR FIELD CONTROL...................................................... 357 Desired Three-Phase Voltage............................................... 357 Desired DC Link Voltage................................................... 357 Self-load................................................................. 357 Propel Torque Control..................................................... 358 Retard Torque Control..................................................... 358 Wheel Slide Control....................................................... 358 Resistor Grid Control..................................................... 359 Chopper Voltage Control................................................... 359 EVENT PROCESSING.............................................................. 359 Event Detection........................................................... 359 Power On Tests............................................................ 359 Initiated Tests........................................................... 360 Periodic Tests............................................................ 360 EVENT RESTRICTIONS............................................................ 360 EVENT LOGGING AND STORAGE..................................................... 360 Event History Buffer...................................................... 361 Data Packs................................................................ 361 To Record and Save a Data Pack to a Floppy Disk........................... 361 Event Reset............................................................... 362 SERIAL DATA COMMUNICATIONS.................................................... 363 PSC - PTU Communications Processing....................................... 363 Inverter Communications Processing........................................ 363 OUTPUT PROCESSING............................................................. 364 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS...................................... 364 Fast Start................................................................ 364 Engine Shutdown/Engine Not Running........................................ 364 Limp Home Mode............................................................ 364 Entering/Exiting Limp Home Mode........................................... 364 PROPULSION SYSTEM COMPONENT ABBREVIATIONS..................................... 365 ELECTRONIC ACCELERATOR AND RETARD PEDALS...................................... 377 Removal................................................................... 377 Installation.............................................................. 377 Disassembly............................................................... 377 Assembly.................................................................. 377 SECTION E3 - AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................ 379 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE..................................... 381 AC DRIVE SYSTEM MAINTENANCE................................................... 381 TRUCK SHUTDOWN PROCEDURES..................................................... 381 NORMAL TRUCK SHUTDOWN PROCEDURE............................................... 382 SHUTDOWN AFTER SYSTEM FAILURE................................................. 383 SYSTEM CHECKOUT............................................................... 384 Battery and Control Checks of System WITH Battery Power OFF............... 384 Battery and Control Circuit Checks of System With Battery Power ON........ 387 Checks with Key Switch OFF................................................ 388 CPU Battery Checks........................................................ 390 MEMORY BACKUP BATTERY REPLACEMENT............................................. 390 TCI PROGRAMMING............................................................... 391 ICP PROGRAMMING............................................................... 391 INVERTER PROGRAMMING.......................................................... 392 TCI CHECKOUT.................................................................. 392 Modular Mining Communication Port......................................... 393 TCI Input Checks.......................................................... 394 TCI Digital Output Tests.................................................. 396 TCI Digital Input Tests................................................... 398 PSC Checkout Procedure.................................................... 400 PSC Digital Input Checks.................................................. 404 Miscellaneous Checks...................................................... 405 A3PV Panel................................................................ 405 LINKV Panel............................................................... 405 Thermistor Checks......................................................... 405 17FM384 Panel Check....................................................... 405 Pedal Percentages and Meter Calibration................................... 406 Meter Calibration Procedure............................................... 406 Reprogram With Serial Numbers and Pedal Percentages....................... 408 LOAD TESTING.................................................................. 410 Preload Checks............................................................ 410 ADDITIONAL TRUCK CHECKS....................................................... 412 On-Board Load Testing..................................................... 414 Preparation............................................................... 414 Initiate Loadbox Test..................................................... 417 Manual Offset HP Output Adjustment........................................ 419 TROUBLESHOOTING................................................................... 421 PVM Optimum Load Curve Handshaking Troubleshooting............................ 421 MISCELLANEOUS COMPONENT REPAIR................................................ 422 Troubleshooting Phase Modules and Chopper Modules......................... 422 Phase Module Removal and Snubber Resistor Replacement..................... 422 Snubber Resistor Installation............................................. 423 Phase Module Installation................................................. 423 SECTION G - REAR AXLE, SPINDLES AND WHEELS - INDEX....................................... 425 SECTION G2 - TIRES AND RIMS - INDEX................................................... 427 TIRES AND RIMS.................................................................... 429 WHEEL STUD MAINTENANCE........................................................ 430 FRONT TIRES AND RIMS.......................................................... 431 Removal................................................................... 431 Installation.............................................................. 432 REAR TIRES AND RIMS........................................................... 433 Removal................................................................... 433 Installation.............................................................. 434 RIM........................................................................... 435 Tire Removal.............................................................. 435 Tire Installation......................................................... 436 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX...................................... 439 FRONT WHEEL HUB AND SPINDLE....................................................... 441 WHEEL HUB AND SPINDLE ASSEMBLY................................................ 441 Preparation............................................................... 441 Removal................................................................... 441 Installation - Wheel Hub and Spindle Assembly............................. 444 Disassembly - Wheel Hub and Spindle Assembly.............................. 445 Cleaning and Inspection - Wheel Hub and Spindle Assembly.................. 445 Assembly - Wheel Hub and Spindle Assembly................................. 447 Wheel Bearing Adjustment:................................................. 447 Brake Installation........................................................ 448 Seal Assembly Gap Check................................................... 449 STEERING CYLINDERS AND TIE ROD................................................ 450 Spherical Bearing Wear Limits............................................. 450 Removal - Steering Cylinder and Tie Rod................................... 451 Installation - Steering Cylinder and Tie Rod.............................. 452 Bearing Replacement....................................................... 452 TOE-IN ADJUSTMENT............................................................. 453 SECTION G4 - REAR AXLE HOUSING ATTACHMENT - INDEX..................................... 455 REAR AXLE HOUSING ATTACHMENT...................................................... 457 PIVOT PIN..................................................................... 457 Removal................................................................... 457 Installation.............................................................. 458 PIVOT EYE BEARING............................................................. 459 Removal................................................................... 459 Installation.............................................................. 459 PIVOT EYE REPAIR.............................................................. 459 Removal................................................................... 459 Disassembly............................................................... 459 Assembly.................................................................. 460 Installation.............................................................. 460 ANTI-SWAY BAR................................................................. 460 Removal................................................................... 460 Installation.............................................................. 461 Disassembly............................................................... 461 Cleaning and Inspection................................................... 461 Assembly.................................................................. 461 SECTION G5 - REAR AXLE HOUSING - INDEX................................................ 463 REAR AXLE HOUSING................................................................. 465 REAR AXLE HOUSING............................................................. 465 Preparation............................................................... 465 Removal................................................................... 465 Cleaning and Inspection - Rear Axle Housing............................... 467 Installation - Rear Axle Housing.......................................... 467 WHEEL MOTOR................................................................... 468 Preparation............................................................... 468 Removal................................................................... 468 Cleaning and Inspection - Wheel Motor..................................... 469 Installation - Wheel Motor................................................ 470 WHEEL MOTOR GEAR OIL.......................................................... 473 Filtering Requirements.................................................... 473 Particle Size Analysis.................................................... 473 Flushing.................................................................. 473 Oil Sample Analysis....................................................... 474 ELEMENT SPECIFICATION CHARTS.................................................. 475 SECTION H - HYDRAIR II SUSPENSIONS - INDEX................................................ 479 SECTION H2 - FRONT SUSPENSIONS - INDEX................................................ 481 FRONT SUSPENSION.................................................................. 483 Removal....................................................................... 483 Installation - Front Suspension............................................... 484 "Turn-Of-The-Nut" Tightening Procedure........................................ 487 MINOR REPAIRS (LOWER BEARING & SEALS)......................................... 488 Removal - Bearing Retainer................................................ 488 Installation - Bearing Retainer........................................... 488 MAJOR SUSPENSION REBUILD...................................................... 490 Disassembly............................................................... 490 Assembly.................................................................. 490 SECTION H3 - REAR SUSPENSIONS - INDEX................................................. 493 REAR SUSPENSIONS.................................................................. 495 Removal....................................................................... 495 Installation - Rear Suspension................................................ 497 Disassembly - Rear Suspension................................................. 498 Cleaning and Inspection - Rear Suspension..................................... 498 Assembly - Rear Suspension.................................................... 498 SECTION H4 - SUSPENSION OILING AND CHARGING PROCEDURE - INDEX......................... 501 SUSPENSION OILING AND CHARGING PROCEDURE.......................................... 503 GENERAL....................................................................... 503 EQUIPMENT LIST................................................................ 503 Hydrair® Charging Kit..................................................... 503 Installation of Charging Kit.............................................. 503 Removal of Charging Kit................................................... 504 Support Blocks For Oiling And Charging Dimensions......................... 504 FRONT SUSPENSION.............................................................. 505 Front Suspension Oiling................................................... 505 Front Suspension Nitrogen Charging........................................ 506 REAR SUSPENSION............................................................... 507 Rear Suspension Oiling.................................................... 507 Rear Suspension Nitrogen Charging......................................... 508 OIL AND NITROGEN SPECIFICATIONS CHART............................................. 510 SECTION J - BRAKE CIRCUIT - INDEX......................................................... 511 SECTION J2 - BRAKE CIRCUIT - INDEX.................................................... 513 BRAKE CIRCUIT..................................................................... 515 SERVICE BRAKE CIRCUIT......................................................... 515 SECONDARY BRAKING AND AUTOMATIC APPLY......................................... 517 PARKING BRAKE CIRCUIT......................................................... 517 Normal Operation (key switch on, engine running).......................... 517 BRAKE LOCK CIRCUIT............................................................ 518 WARNING CIRCUIT............................................................... 518 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.................................. 521 BRAKE CIRCUIT COMPONENT SERVICE................................................... 523 BRAKE VALVE................................................................... 523 Rebuild Criteria.......................................................... 523 Removal................................................................... 524 Installation.............................................................. 524 Disassembly............................................................... 525 Cleaning and Inspection................................................... 528 Assembly.................................................................. 528 Actuator Base Threaded Inserts............................................ 528 Boot and Cap.............................................................. 528 Valve Body Seal Installation.............................................. 528 Regulator Sleeve O-Ring Installation...................................... 529 Actuator Plunger O-ring Installation...................................... 529 Assembly of Valve......................................................... 529 DIFFERENTIAL PRESSURE SWITCH.................................................. 531 Disassembly............................................................... 531 Cleaning and Inspection................................................... 531 Assembly.................................................................. 531 VALVE BENCH TEST AND ADJUSTMENT............................................... 532 Test Set Up Procedure..................................................... 533 Brake Valve Output Pressure Adjustment.................................... 533 Differential Pressure Switch Adjustment................................... 533 Final Test and Adjustment................................................. 534 Installation Of Brake Pedal Actuator Assembly to Brake Valve.............. 535 Installation of Retard Pedal To Brake Pedal............................... 535 DUAL RELAY VALVE.............................................................. 537 Removal................................................................... 537 Installation.............................................................. 537 Disassembly............................................................... 539 Cleaning and Inspection................................................... 539 Assembly.................................................................. 539 DIFFERENTIAL PRESSURE SWITCH.................................................. 540 Disassembly............................................................... 540 Cleaning and Inspection................................................... 540 Assembly.................................................................. 540 VALVE TEST AND ADJUSTMENT..................................................... 541 Test Set Up Procedure..................................................... 542 Relay Valve Output Pressure Adjustment.................................... 542 Differential Pressure Switch Adjustment................................... 543 BRAKE MANIFOLD................................................................ 544 Removal................................................................... 544 Installation.............................................................. 545 Disassembly............................................................... 545 Cleaning and Inspection................................................... 545 Assembly.................................................................. 545 BRAKE ACCUMULATORS............................................................ 546 Brake Accumulator Bleeddown Procedure..................................... 546 BRAKE ACCUMULATOR REPAIR...................................................... 547 Removal................................................................... 547 Installation.............................................................. 547 Disassembly............................................................... 548 Cleaning and Inspection................................................... 549 Assembly.................................................................. 549 ACCUMULATOR CHARGING PROCEDURE................................................ 551 Temperature During Precharge.............................................. 552 Precharge Maintenance..................................................... 553 Recharging Accumulators................................................... 553 Accumulator Storage procedures............................................ 554 Bladder Storage Procedures................................................ 554 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).................................. 555 Removal....................................................................... 555 Installation.................................................................. 555 Disassembly and Adjustment.................................................... 555 Potentiometer Check........................................................... 557 Assembly...................................................................... 557 SECTION J4 - BRAKE CIRCUIT CHECK-OUT PROCEDURE - INDEX................................ 559 BRAKE CIRCUIT CHECK-OUT PROCEDURE................................................. 561 REQUIRED EQUIPMENT............................................................ 563 INITIAL SYSTEM SET-UP......................................................... 564 BRAKE SYSTEM CHECKOUT......................................................... 565 Failure Modes Check-Out................................................... 566 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART............................... 568 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................. 571 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................. 572 SECTION J5 - WET DISC BRAKE ASSEMBLY - INDEX.......................................... 573 WET DISC BRAKE ASSEMBLY........................................................... 575 OPERATION..................................................................... 575 MAINTENANCE................................................................... 576 Brake Disc Wear Indicator................................................. 576 Removal/Installation - Wet Disc Brake Assembly............................ 576 BRAKE REBUILD................................................................. 578 Disassembly............................................................... 578 Cleaning and Inspection................................................... 581 Assembly.................................................................. 582 Floating Ring Seal Assembly/Installation.................................. 585 WET DISC BRAKE BLEEDING PROCEDURE............................................. 588 SECTION J7 - PARKING BRAKE - INDEX.................................................... 589 PARKING BRAKE..................................................................... 591 OPERATION..................................................................... 591 MAINTENANCE................................................................... 592 Inspection - Parking Brake................................................ 592 Removal - Parking Brake................................................... 592 Installation - Parking Brake.............................................. 593 Disassembly - Parking Brake............................................... 594 Cleaning and Inspection - Parking Brake................................... 594 Assembly - Parking Brake.................................................. 594 PARKING BRAKE BLEEDING PROCEDURE.............................................. 596 SECTION L - HYDRAULIC SYSTEM - INDEX...................................................... 597 SECTION L2 - HYDRAULIC SYSTEM - INDEX................................................. 599 HYDRAULIC SYSTEM.................................................................. 601 HYDRAULIC PUMP MODULE......................................................... 601 HOIST CIRCUIT OPERATION....................................................... 602 STEERING CIRCUIT OPERATION.................................................... 604 DISC BRAKE COOLING SYSTEM..................................................... 606 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX................................ 609 HYDRAULIC SYSTEM COMPONENT REPAIR................................................. 611 HOIST PUMP.................................................................... 611 Removal................................................................... 611 Installation.............................................................. 613 INSPECTION OF PARTS........................................................... 618 Assembly.................................................................. 618 HYDRAULIC TANK................................................................ 624 Filling Instructions...................................................... 624 Removal................................................................... 624 Installation.............................................................. 625 HYDRAULIC TANK STRAINERS...................................................... 625 Removal................................................................... 625 Inspect and Clean......................................................... 625 Installation.............................................................. 625 HYDRAULIC TANK BREATHERS...................................................... 626 SECTION L4 - STEERING CIRCUIT - INDEX................................................. 627 STEERING CIRCUIT.................................................................. 629 COMPONENT DESCRIPTION......................................................... 630 Steering Control Unit..................................................... 630 Bleeddown Manifold Valve.................................................. 631 Bleeddown Solenoid........................................................ 631 Relief Valves............................................................. 633 Hoist Limit Solenoid...................................................... 633 Accumulators.............................................................. 633 Low Precharge Warning Switch.............................................. 633 High Pressure Filter...................................................... 633 Quick Disconnect Ports.................................................... 633 Flow Amplifier............................................................ 634 FLOW AMPLIFIER SYSTEM OPERATION............................................... 636 No Steer.................................................................. 636 Steering Left............................................................. 638 Steering Right............................................................ 640 No Steer, External Shock Load............................................. 642 STEERING PUMP................................................................. 644 Operation................................................................. 644 PRINCIPLE OF OPERATION........................................................ 646 Full Pump Volume:......................................................... 646 Half Pump Volume:......................................................... 646 Neutral Position:......................................................... 646 Steering Pump............................................................. 647 SECTION L5 - STEERING CONTROL UNIT - INDEX............................................ 649 STEERING CONTROL UNIT............................................................. 651 Removal....................................................................... 651 Spline Inspection............................................................. 651 Installation.................................................................. 652 STEERING CONTROL UNIT REBUILD................................................. 652 Disassembly............................................................... 652 Cleaning and Inspection - Steering Control Unit........................... 653 Assembly - Steering Control Unit.......................................... 655 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX................................ 659 STEERING CIRCUIT COMPONENT REPAIR................................................. 661 BLEEDDOWN MANIFOLD VALVE...................................................... 661 Removal................................................................... 661 Installation.............................................................. 661 FLOW AMPLIFIER................................................................ 663 Removal................................................................... 663 Installation.............................................................. 663 FLOW AMPLIFIER REBUILD........................................................ 663 Disassembly............................................................... 666 Assembly.................................................................. 667 STEERING CYLINDERS............................................................ 668 Disassembly............................................................... 669 Piston Seal & Bearing Installation........................................ 669 Cylinder Assembly......................................................... 669 Test...................................................................... 669 STEERING AND BRAKE PUMP....................................................... 670 Removal................................................................... 670 Installation.............................................................. 670 Disassembly............................................................... 672 Control Piston Group...................................................... 672 Valve Plate Group......................................................... 672 Rotating Group............................................................ 675 Swashblock Group.......................................................... 675 Driveshaft Group.......................................................... 675 Inspection................................................................ 675 Control Piston Group...................................................... 675 Valve Plate Group......................................................... 675 Rotating Group............................................................ 675 Swashblock Group.......................................................... 677 Driveshaft Group.......................................................... 678 Compensator Block and Unloader Module..................................... 678 Stroke Adjuster Assembly.................................................. 678 Assembly.................................................................. 678 Swashblock Group.......................................................... 678 Driveshaft Group.......................................................... 679 Rotating Group............................................................ 679 Valve Plate Group......................................................... 680 STEERING ACCUMULATORS......................................................... 681 Removal................................................................... 681 Installation.............................................................. 681 Disassembly............................................................... 682 Cleaning and Inspection................................................... 682 Assembly.................................................................. 683 Leak Testing.............................................................. 685 Charging Procedure........................................................ 686 Temperature During Precharge.............................................. 687 Precharge Maintenance..................................................... 688 Accumulator Storage procedures............................................ 689 Bladder Storage Procedures................................................ 689 TROUBLESHOOTING CHART............................................................. 690 SECTION L7 - HOIST CIRCUIT - INDEX.................................................... 695 HOIST CIRCUIT..................................................................... 697 HOIST CIRCUIT OPERATION....................................................... 697 COMPONENT DESCRIPTION......................................................... 698 Hydraulic Tank............................................................ 698 Hydraulic Pump............................................................ 698 High Pressure Filters..................................................... 698 Hoist Valve............................................................... 698 Inlet Sections - Hoist Valve.............................................. 698 Spool Sections - Hoist Valve.............................................. 699 Hoist Pilot Valve......................................................... 699 Bleeddown Manifold........................................................ 700 Hoist-up Limit Solenoid................................................... 700 Pilot Operated Check Valve................................................ 700 Overcenter Manifold....................................................... 700 HOIST CIRCUIT OPERATION........................................................... 701 Float Position Of Pilot Valve With Truck Body On Frame........................ 702 Power Up Operation............................................................ 704 Hold Operation................................................................ 706 Power Down Operation.......................................................... 708 Float Operation............................................................... 710 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX................................... 713 HOIST CIRCUIT COMPONENT REPAIR.................................................... 715 HOIST VALVE................................................................... 715 Removal................................................................... 715 Installation.............................................................. 716 O-Ring Replacement........................................................ 716 INLET SECTION................................................................. 717 Disassembly............................................................... 717 Cleaning and Inspection................................................... 718 Assembly.................................................................. 718 REAR SPOOL SECTION (Work Ports)............................................... 718 Disassembly............................................................... 718 Cleaning and Inspection................................................... 720 Assembly.................................................................. 720 FRONT SPOOL SECTION (Tank Ports).............................................. 721 Disassembly............................................................... 721 Cleaning and Inspection................................................... 721 Assembly.................................................................. 721 HOIST PILOT VALVE............................................................. 723 Removal................................................................... 723 Installation.............................................................. 723 Disassembly............................................................... 724 Cleaning and Inspection................................................... 725 Assembly.................................................................. 725 HOIST CYLINDERS............................................................... 726 Removal................................................................... 726 Installation.............................................................. 727 Disassembly............................................................... 729 Cleaning and Inspection................................................... 730 Assembly - Quill and Cylinder............................................. 731 Quill Installation........................................................ 731 Installation Of Check Balls And Plugs In Quill............................ 732 Assembly of Cylinder...................................................... 733 OVERCENTER VALVE MANIFOLD..................................................... 734 DISABLED TRUCK DUMPING PROCEDURE.............................................. 735 Hookup.................................................................... 735 Raising the Body.......................................................... 735 Lowering the Body......................................................... 735 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX......................................... 737 HYDRAULIC SYSTEM FILTERS.......................................................... 739 HOIST CIRCUIT FILTER.......................................................... 739 Filter Element Replacement................................................ 739 Removal - Hoist Circuit Filter............................................ 740 Installation - Hoist Circuit Filter....................................... 740 Indicator Switch - Hoist Circuit Filter................................... 740 STEERING CIRCUIT FILTER....................................................... 741 Filter Element Replacement................................................ 741 Removal - Steering Circuit Filter......................................... 742 Installation - Steering Circuit Filter.................................... 742 Indicator Switch - Steering Circuit Filter................................ 742 INDICATOR SWITCH.............................................................. 742 Test Procedure............................................................ 742 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX................................... 745 HYDRAULIC CHECK-OUT PROCEDURE..................................................... 747 GENERAL INFORMATION........................................................... 747 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE............................. 747 Equipment Requirements.................................................... 748 Pump Pressure Control Adjustments......................................... 748 Steering Control Valve and Flow Amplifier Leakage Test.................... 749 Bleeddown Manifold Leakage Test........................................... 749 STEERING/BRAKE PUMP STROKE ADJUSTMENT......................................... 750 SHOCK AND SUCTION VALVES...................................................... 751 Equipment Requirements.................................................... 751 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES................. 752 Equipment Requirements.................................................... 752 Pressure Gauge Locations.................................................. 752 Brake Cooling Circuit Test................................................ 752 Power Up Relief Pressure Test............................................. 753 Adjustment................................................................ 753 Power Down Relief Pressure Test........................................... 754 Hoist Counterbalance Valve Adjustment Preparation......................... 755 Counterbalance Valve Pressure Check....................................... 755 Counterbalance Valve Adjustment........................................... 756 HYDRAULIC SYSTEM FLUSHING PROCEDURE............................................... 757 Preparation................................................................... 757 Flushing Procedure............................................................ 757 Filter Element Replacement.................................................... 758 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET............................. 759 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................ 760 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX............................................. 761 SECTION M2 - FIRE CONTROL SYSTEMS - INDEX............................................. 763 FIRE CONTROL SYSTEM (MANUAL)...................................................... 765 Operation..................................................................... 765 Inspection and Maintenance.................................................... 765 Recharging Procedures......................................................... 766 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1...................... 767 Control Module................................................................ 767 Actuator...................................................................... 768 Linear Detection Wire......................................................... 768 Power Wire.................................................................... 768 Test Kit...................................................................... 768 Squib......................................................................... 768 Securing the Detection Wire................................................... 769 Preliminary Test Before Final Hook-Up......................................... 769 Installation Procedure for Squib.............................................. 771 Placing the Electric Detection & Actuation System Into Service................ 771 INSPECTION AND MAINTENANCE SCHEDULES.......................................... 772 Daily..................................................................... 772 Normal Maintenance Based On Actual Operating Hours........................ 772 IN CASE OF FIRE............................................................... 773 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM..................................... 775 SECTION M8 - SPECIAL TOOLS............................................................ 777 SECTION M20 - PAYLOAD METER III - INDEX............................................... 783 OPERATION SECTION................................................................. 787 Introduction.................................................................. 787 Data Summary.............................................................. 787 Data Gathering............................................................ 787 COMPONENT DESCRIPTION......................................................... 788 System Diagram............................................................ 788 Suspension Pressure Sensors............................................... 788 Inclinometer.............................................................. 788 Operator Display.......................................................... 788 Operator Switch........................................................... 789 Speed Input............................................................... 789 Body-Up Switch............................................................ 789 Brake Lock Switch......................................................... 789 Payload Meter............................................................. 789 Communications Ports...................................................... 789 Keyswitch Input........................................................... 790 Payload Meter Power....................................................... 790 Load Lights............................................................... 790 Wiring and Termination.................................................... 791 TCI Outputs............................................................... 791 OPERATOR’S DISPLAY AND SWITCH................................................. 792 Reading the Speedometer................................................... 792 Reading the Load Display.................................................. 792 Using the Operator ID..................................................... 792 Using the Load and Ton Counter............................................ 792 Total Ton Counter......................................................... 792 Total Load Counter........................................................ 793 Clearing the Counters..................................................... 793 Viewing Live Sensor Data.................................................. 793 Other Display Messages.................................................... 793 PAYLOAD OPERATION & CALCULATION............................................... 794 Description of Haul Cycle States.......................................... 794 Haul Cycle Description.................................................... 794 Load Calculation.......................................................... 795 Carry Back................................................................ 795 Measurement Accuracy...................................................... 795 SOURCES FOR PAYLOAD ERROR..................................................... 795 Payload Error............................................................. 795 Loading Conditions........................................................ 796 Pressure Sensors.......................................................... 796 Swingloads................................................................ 796 Speed and Distance........................................................ 796 HAUL CYCLE DATA............................................................... 796 Haul Cycle Data........................................................... 797 Haul Cycle Warning Flags.................................................. 798 M: Haul Cycle Too Long.................................................... 799 N: Sensor Input Error..................................................... 799 Frame Torque Data......................................................... 799 Sprung Weight Data........................................................ 799 Maximum Speed Data........................................................ 799 Alarm Records............................................................. 799 Fault Code Data........................................................... 800 PC SOFTWARE OVERVIEW.......................................................... 801 PC Overview............................................................... 801 System Configuration...................................................... 801 Installing the PLMIII Software............................................ 801 DOWNLOADING DATA.............................................................. 802 PLM III SYSTEM CONFIGURATION.................................................. 803 Starting Communications................................................... 803 Displayed Payload Units................................................... 803 Time Units................................................................ 803 Connection Menu........................................................... 803 Connecting to the Payload Meter........................................... 804 Configure the Payload Meter............................................... 804 Setting the Date and Time................................................. 804 Setting the Truck Type.................................................... 805 Setting the Gauge Display Units........................................... 805 Setting the Frame Serial Number........................................... 805 Setting the Truck Number.................................................. 805 Setting the Komatsu Distributor........................................... 805 Setting the Komatsu Customer.............................................. 805 Clean Truck Tare.......................................................... 806 Inclinometer Calibration.................................................. 806 DATA ANALYSIS................................................................. 807 Creating a Query.......................................................... 807 Sorting on Truck Unit Number.............................................. 807 Sorting on Truck Type..................................................... 807 Sorting on Date Range..................................................... 808 Sorting on Time Range..................................................... 808 Payload Detail Screen..................................................... 809 Creating Reports.......................................................... 809 Summary - one page report................................................. 810 Detailed - multi-page report.............................................. 810 Creating Graphs........................................................... 811 Exporting Data............................................................ 811 CSV Export................................................................ 811 Compressed................................................................ 812 Importing Data............................................................ 813 Deleting Haul Cycle Records............................................... 813 Viewing Alarms............................................................ 814 Deleting Alarm Records.................................................... 814 TROUBLESHOOTING SECTION........................................................... 815 TROUBLESHOOTING............................................................... 815 Viewing Active Alarms..................................................... 815 Real-Time Data Display.................................................... 815 Testing the Payload Lights................................................ 815 Creating Log Files of Inputs.............................................. 816 Daily Inspections......................................................... 816 Periodic Maintenance...................................................... 816 Abnormal Displays at Power-Up............................................. 817 No Payload Display When Keyswitch is Turned ON............................ 818 No Display on Speedometer................................................. 819 No Display on Operator Display............................................ 819 No Communications With PC................................................. 820 Load Lights Don’t Light During Loading.................................... 821 Load Lights Remain ON..................................................... 822 Load Lights Remain ON During Dumping...................................... 822 Display Doesn't Clear When The Load Is Dumped............................. 822 Calibration Problems...................................................... 823 Alarm 1 - Left Front Pressure High........................................ 824 Alarm 2 - Left Front Pressure Low......................................... 824 Troubleshoot Wiring to Left Front Suspension.............................. 824 Alarm 3 - Right Front Pressure High....................................... 825 Alarm 4 - Right Front Pressure Low........................................ 825 Troubleshoot Wiring to Right Front Suspension............................. 825 Alarm 5 -Left Rear Pressure High.......................................... 826 Alarm 6 - Left Rear Pressure Low.......................................... 826 Troubleshoot Wiring to Left Rear Suspension............................... 826 Alarm 7 - Right Rear Pressure High........................................ 827 Alarm 8 - Right Rear Pressure Low......................................... 827 Troubleshoot Wiring to Right Rear Suspension.............................. 827 Alarm 9 - Inclinometer High............................................... 828 Alarm 10 - Inclinometer Low............................................... 828 Troubleshoot Inclinometer Wiring.......................................... 828 Alarm 13 - Body Up Input Failure.......................................... 829 Alarm 16 - Memory Write Failure........................................... 830 Alarm 17 - Memory Read Failure............................................ 830 Alarm 18.................................................................. 831 Alarm 19.................................................................. 831 Alarm 22.................................................................. 831 Operator Switch Doesn't Work.............................................. 832 Alarm 26 - User Switch Fault - SELECT..................................... 832 Alarm 27 - User Switch Fault - SET........................................ 832 Connector Map............................................................. 833 Connectors................................................................ 834 PLMIII CHECK OUT PROCEDURE........................................................ 835 General Description........................................................... 835 Tools Required................................................................ 835 Checkout Procedure............................................................ 835 PLMIII CHECKOUT PROCEDURE CONFIRMATION........................................ 839 Flashburn Programming..................................................... 839 Confirmation Checklist.................................................... 841 SECTION M31 - RESERVE ENGINE OIL SYSTEM - INDEX....................................... 843 RESERVE ENGINE OIL SYSTEM......................................................... 845 Operation..................................................................... 845 LED Monitor Light............................................................. 846 Tank Fill Control (Optional).................................................. 846 Filling Procedure (Remote fill feature)....................................... 846 SERVICE....................................................................... 847 Every 10 Hours, or once each shift:....................................... 847 Every 500 Hours:.......................................................... 847 Changing Oil.............................................................. 847 TROUBLESHOOTING............................................................... 848 Circuit Breaker or Fuse................................................... 848 SYSTEM ELECTRICAL SCHEMATICS.................................................. 849 SECTION N - CAB COMPONENTS - INDEX........................................................ 851 SECTION N2 - TRUCK CAB - INDEX........................................................ 853 TRUCK CAB......................................................................... 855 Description................................................................... 855 Preparation................................................................... 856 Removal - Cab................................................................. 856 Installation - Cab............................................................ 858 CAB DOOR...................................................................... 858 Removal................................................................... 858 Installation.............................................................. 858 Door Adjustment........................................................... 859 Door Jamb Bolt Adjustment................................................. 859 Door Handle Plunger Adjustment............................................ 860 Door Glass Replacement.................................................... 861 Door Window Regulator Replacement......................................... 865 Door Handle or Latch Assembly Replacement................................. 865 Door and Door Hinge Seal Replacement...................................... 866 Door Opening Seal Removal................................................. 866 Installation.............................................................. 866 GLASS REPLACEMENT............................................................. 867 Adhesive Bonded Windows................................................... 867 Replacement Procedure..................................................... 867 Windshield And Rear Glass................................................. 868 Removal................................................................... 868 Installation.............................................................. 869 SECTION N3 - CAB COMPONENTS - INDEX................................................... 871 CAB COMPONENTS.................................................................... 873 WINDSHIELD WIPERS............................................................. 873 Wiper Motor Replacement................................................... 873 Removal................................................................... 873 Installation.............................................................. 873 Wiper Arm................................................................. 873 Removal................................................................... 873 Installation.............................................................. 874 Wiper Linkage Replacement................................................. 874 Removal................................................................... 874 Installation.............................................................. 874 WINDSHIELD WASHER............................................................. 875 Operation................................................................. 875 Service................................................................... 875 OPERATOR SEAT................................................................. 876 Adjustment................................................................ 876 Seat Removal.............................................................. 876 Seat Installation......................................................... 876 SECTION N4 - OPERATOR COMFORT - INDEX................................................. 877 OPERATOR COMFORT.................................................................. 879 HEATER / AIR CONDITIONER...................................................... 879 Operation................................................................. 879 Heater/Air Conditioner Vents.............................................. 879 COMPONENTS.................................................................... 880 Circuit Breakers.......................................................... 880 Relays.................................................................... 880 Heater Core............................................................... 880 Fan Motor And Speed Control............................................... 881 Actuators................................................................. 881 Cab Air Filter............................................................ 881 AIR CONDITIONING SYSTEM........................................................... 883 Environmental Impact.......................................................... 883 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES..................................... 884 PRINCIPLES OF REFRIGERATION................................................... 884 Air Conditioning.......................................................... 884 Refrigeration - The Act Of Cooling........................................ 885 The Refrigeration Cycle................................................... 885 AIR CONDITIONER SYSTEM COMPONENTS............................................. 886 Compressor (Refrigerant Pump)............................................. 886 Service Valves............................................................ 886 Condenser................................................................. 886 Receiver-Drier............................................................ 886 Expansion Block Valve..................................................... 887 Accumulator............................................................... 887 Evaporator................................................................ 887 ELECTRICAL CIRCUIT............................................................ 888 Thermostat................................................................ 888 Compressor Clutch......................................................... 888 Trinary™ Switch........................................................... 889 SYSTEM SERVICING.............................................................. 890 SERVICE TOOLS AND EQUIPMENT................................................... 891 Recovery/Recycle Station.................................................. 891 Leak Detector............................................................. 891 Service Valves............................................................ 892 Vacuum Pump............................................................... 892 Manifold Gauge Set........................................................ 893 Installing Manifold Gauge Set............................................. 894 Purging Air From Service Hoses............................................ 894 SYSTEM PERFORMANCE TEST....................................................... 895 SYSTEM OIL.................................................................... 896 Handling and Reusing PAG Oil.............................................. 896 Oil Quantity.............................................................. 896 Checking System Oil....................................................... 896 REFRIGERANT................................................................... 897 Recycled Refrigerant...................................................... 897 Reclaimed Refrigerant..................................................... 897 Refrigerant Quantity...................................................... 897 R-134a Refrigerant Containers............................................. 897 SYSTEM LEAK TESTING........................................................... 898 Electronic Leak Detector.................................................. 898 Tracer Dyes............................................................... 898 Soap and Water............................................................ 898 RECOVERING AND RECYCLING THE REFRIGERANT...................................... 899 Performing the Recovery Cycle............................................. 899 Performing the Recycling Procedure........................................ 899 Evacuating and Charging the A/C System.................................... 899 SYSTEM REPAIR................................................................. 900 System Flushing........................................................... 900 COMPONENT REPLACEMENT......................................................... 900 Hoses and Fittings........................................................ 900 Lines..................................................................... 900 Expansion Valve........................................................... 901 Receiver-Drier............................................................ 901 Thermostat................................................................ 901 Compressor................................................................ 901 Accumulator............................................................... 901 Clutch.................................................................... 902 Servicing the Compressor Clutch........................................... 902 Pulley Removal............................................................ 904 Clutch Coil Check......................................................... 905 Pulley Installation....................................................... 905 Clutch Assembly Installation.............................................. 905 EVACUATING THE SYSTEM......................................................... 907 CHARGING THE A/C SYSTEM....................................................... 909 TROUBLESHOOTING................................................................... 910 Preliminary Checks............................................................ 910 Diagnosis Of Gauge Readings And System Performance............................ 910 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.................................... 911 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.................................. 917 SECTION N5 - OPERATOR CAB CONTROLS - INDEX............................................ 919 OPERATOR CAB CONTROLS............................................................. 919 OPERATOR CAB CONTROLS............................................................. 921 STEERING COLUMN............................................................... 921 Removal................................................................... 921 Steering Column Inspection................................................ 921 Installation.............................................................. 921 STEERING WHEEL AND CONTROLS................................................... 923 Horn Button............................................................... 923 Telescope Lock Ring....................................................... 923 Tilt Wheel Lever.......................................................... 923 Turn Signal/Headlight Dimmer.............................................. 923 DYNAMIC RETARDING............................................................. 923 Retarder Control Lever.................................................... 924 Dynamic Retarder/Service Brake Pedal...................................... 924 Accelerator (Throttle) Pedal.............................................. 924 Starting on a Grade With a Loaded Truck................................... 924 GRADE/SPEED RETARD CHART...................................................... 925 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS............................. 926 Heater/Air Conditioner Vents.............................................. 926 INSTRUMENT PANEL.............................................................. 927 OVERHEAD PANEL AND DISPLAYS................................................... 927 CENTER CONSOLE................................................................ 928 F-N-R Selector Switch..................................................... 928 Hoist Control Lever....................................................... 929 Raising The Dump Body..................................................... 929 Lowering The Dump Body:................................................... 929 Ash Tray.................................................................. 929 Lighter................................................................... 929 L.H. Window Control Switch................................................ 929 R.H. Window Control Switch................................................ 929 Engine Shutdown Switch.................................................... 929 Override/Fault Reset Switch............................................... 930 Retard Speed Control (RSC) Switch......................................... 930 Retard Speed Control (RSC) Adjust Dial.................................... 930 Data Store Button......................................................... 931 Engine Control System..................................................... 931 Service Engine Light (Blue)............................................... 931 Engine Diagnostics Download Port.......................................... 931 Payload Meter............................................................. 931 TCI Download Port......................................................... 931 PSC Download Port......................................................... 931 PAYLOAD METER............................................................. 931 INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 933 CONTROL SYMBOLS............................................................... 933 INSTRUMENT PANEL.............................................................. 933 PANEL GAUGES, INDICATORS, AND CONTROLS............................................ 935 Key Switch.................................................................... 935 Starting...................................................................... 935 Cold Weather Starting......................................................... 935 Normal Engine Shutdown........................................................ 935 Engine Shutdown Switch with 5 Minute Idle Timer Delay......................... 936 Fog Lights (Optional)......................................................... 936 Ladder Light Switch........................................................... 936 Manual Backup Switch.......................................................... 936 Panel Illumination Lights..................................................... 937 Cab/Air Conditioner Vents..................................................... 937 Rotating Beacon Light Switch (Optional)....................................... 937 Heated Mirror Switch (Optional)............................................... 937 Wheel Brake Lock Control...................................................... 937 Parking Brake Control......................................................... 937 Tachometer.................................................................... 938 Right Turn Signal Indicator................................................... 938 High Beam Indicator........................................................... 938 Left Turn Signal Indicator.................................................... 938 Speedometer / Payload Meter................................................... 938 Voltmeter..................................................................... 938 Engine Oil Pressure Gauge..................................................... 938 Water Temperature Gauge....................................................... 938 Fuel Gauge.................................................................... 938 AC Drive System Temperature Gauge............................................. 939 Hydraulic Oil Temperature Gauge............................................... 939 Hourmeter..................................................................... 939 Rest Switch................................................................... 939 Light Switch.................................................................. 940 Windshield Wiper and Washer................................................... 940 Panel Light Dimmer............................................................ 940 Payload Meter Switch.......................................................... 940 OVERHEAD STATUS / WARNING INDICATORS.......................................... 941 STATUS / WARNING INDICATOR LIGHT SYMBOLS...................................... 942 Hazard Warning Lights..................................................... 947 Lamp Test Switch.......................................................... 947 Link-On Warning Light..................................................... 947 SECTION P - LUBRICATION AND SERVICE - INDEX............................................... 949 SECTION P2 - LUBRICATION AND SERVICE - INDEX.......................................... 951 LUBRICATION AND SERVICE........................................................... 953 930E SERVICE CAPACITIES....................................................... 953 HYDRAULIC TANK SERVICE........................................................ 953 Adding Oil................................................................ 953 WHEEL MOTOR SERVICE........................................................... 953 COOLANT LEVEL CHECK........................................................... 954 RADIATOR FILLING PROCEDURE.................................................... 954 RESERVE ENGINE OIL SYSTEM (Optional).......................................... 954 Reserve Oil Tank Filling Procedure (Remote fill).......................... 954 LUBRICATION CHART............................................................. 955 10 HOUR (DAILY) INSPECTION.................................................... 956 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 959 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 960 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 961 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 964 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS................................. 965 5000 HOUR MAINTENANCE CHECKS.................................................. 966 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX..................................... 967 AUTOMATIC LUBRICATION SYSTEM...................................................... 969 GENERAL DESCRIPTION........................................................... 969 SYSTEM COMPONENTS............................................................. 971 Filter.................................................................... 971 Hydraulic Motor and Pump.................................................. 971 Grease Reservoir.......................................................... 971 Pressure Reducing Valve................................................... 971 Flow Control Valve........................................................ 971 Solenoid Valve............................................................ 971 Vent Valve................................................................ 971 Lubrication Cycle Timer................................................... 971 Time Delay Module......................................................... 971 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]).................. 971 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])............... 971 Pressure Gauge............................................................ 971 Injectors................................................................. 971 SYSTEM OPERATION.............................................................. 972 Normal Operation.......................................................... 972 Pressure Failure Detection Circuits....................................... 973 GENERAL INSTRUCTIONS.......................................................... 974 Lubricant Requirements.................................................... 974 System Priming............................................................ 974 LUBRICANT PUMP................................................................ 974 Pump Housing Oil Level.................................................... 974 Pump Pressure Control..................................................... 974 Lubrication Cycle Timer Check............................................. 975 Lubrication Cycle Timer Adjustment........................................ 975 FILTER ASSEMBLY............................................................... 975 SYSTEM CHECKOUT............................................................... 976 INJECTORS (SL-1 Series “H”)).................................................. 976 Injector Specifications................................................... 976 Injector Adjustment....................................................... 976 INJECTOR OPERATION............................................................ 977 PUMP REBUILD.................................................................. 978 Disassembly............................................................... 978 Cleaning and Inspection................................................... 980 Assembly.................................................................. 980 SYSTEM TROUBLESHOOTING CHART...................................................... 982 PREVENTATIVE MAINTENANCE PROCEDURES............................................... 985 Daily Lubrication System Inspection........................................... 985 250 Hour Inspection........................................................... 985 1000 Hour Inspection.......................................................... 985 SECTION Q ALPHABETICAL INDEX.............................................................. 987 SECTION R - SYSTEM SCHEMATICS - INDEX..................................................... 991 HYDRAULIC BRAKE SYSTEM SCHEMATIC - HH358.............................................. 993 HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC - HH359.................................. 994 ELECTRICAL SCHEMATIC - XS1300......................................................... 995 EL1130 - VHMS ELECTRICAL SCHEMATIC....................................................1029
KOMATSU 930E-3SE DUMP TRUCK SHOP MANUAL A30171, A30318, A30319, A30322 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
