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Komatsu 930E-3SE Dump Truck Shop Manual A30366 & UP – PDF DOWNLOAD
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Komatsu 930E-3SE Dump Truck Shop Manual
SERIAL NUMBERS A30366 & UP
Book Code: CEBM015801
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Description
Komatsu 930E-3SE Dump Truck Shop Manual
FILE DETAILS:
Komatsu 930E-3SE Dump Truck Shop Manual
Language : English
Pages :1030
Downloadable : Yes
File Type : PDF
Size: 29.9 MB
Book Code: CEBM015801
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
COVER......................................................................................... 1 FOREWORD...................................................................................... 5 TABLE OF CONTENTS............................................................................. 7 GENERAL INFORMATION........................................................................... 9 TRUCK COMPONENTS AND SPECIFICATIONS....................................................... 11 GENERAL SAFETY AND OPERATING INSTRUCTIONS................................................. 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 WHEN REPAIRS ARE NECESSARY............................................................ 30 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.................................... 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....................................................................... 33 PREPARING FOR OPERATION........................................................... 33 Safety Is Thinking Ahead...................................................... 33 WALK AROUND INSPECTION............................................................ 33 ENGINE START-UP SAFETY PRACTICES.................................................. 36 AFTER STARTING THE ENGINE......................................................... 37 Additional Guidelines......................................................... 37 EMERGENCY STEERING SYSTEM......................................................... 38 Operation..................................................................... 38 Pre-Operation Testing......................................................... 38 MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 39 MACHINE OPERATION ON THE HAUL ROAD................................................ 39 DYNAMIC RETARDING OPERATION....................................................... 40 Dynamic Retarder Control Lever................................................ 41 Dynamic Retarder/Service Brake Pedal.......................................... 41 STARTING ON A GRADE WITH A LOADED TRUCK........................................... 41 PASSING........................................................................... 41 LOADING........................................................................... 42 DUMPING........................................................................... 42 Raising The Dump Body......................................................... 42 Lowering The Dump Body........................................................ 43 TOWING............................................................................ 44 SAFE PARKING PROCEDURES........................................................... 44 NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 45 DELAYED ENGINE SHUTDOWN PROCEDURE................................................. 45 SUDDEN LOSS OF ENGINE POWER....................................................... 46 WARNINGS AND CAUTIONS..................................................................... 47 STANDARD TORQUE CHARTS AND CONVERSION TABLES.............................................. 57 STORAGE AND IDLE MACHINE PREPARATION...................................................... 63 SHORT TERM IDLE PERIODS............................................................... 63 PREPARATION FOR STORAGE............................................................... 64 REMOVAL FROM STORAGE.................................................................. 65 RECONDITIONING AN IDLE VEHICLE........................................................ 67 ENGINE OPERATION...................................................................... 69 After The Engine Has Started...................................................... 70 ENGINE STORAGE........................................................................ 71 Temporary Storage (30 Days Or Less)............................................... 71 Extended Storage (More Than 30 Days).............................................. 71 RESTORING AN ENGINE AFTER EXTENDED STORAGE............................................ 73 ELECTRIC DRIVE TRUCKS................................................................. 74 Storing A Truck That Is Operational............................................... 74 Storing A Truck That Is Not Operational........................................... 75 Storing A Major Component......................................................... 76 Periodic Inspections.............................................................. 76 Placing Equipment Into Service After Storage...................................... 76 STRUCTURES.................................................................................... 79 STRUCTURAL COMPONENTS..................................................................... 81 STRUCTURAL COMPONENTS................................................................. 83 Preparation....................................................................... 83 GRILLE, HOOD AND LADDER........................................................... 84 Removal....................................................................... 84 Installation.................................................................. 84 DECKS............................................................................. 85 RIGHT DECK AND COMPONENTS......................................................... 85 Removal....................................................................... 85 Installation.................................................................. 86 LEFT DECK......................................................................... 86 Removal....................................................................... 86 Installation.................................................................. 86 CENTER DECK....................................................................... 86 DUMP BODY................................................................................. 87 DUMP BODY............................................................................. 89 DUMP BODY......................................................................... 89 Removal....................................................................... 89 Installation.................................................................. 90 BODY PADS......................................................................... 91 Adjustment.................................................................... 91 BODY GUIDE........................................................................ 92 HOIST LIMIT SWITCH................................................................ 92 BODY-UP SWITCH.................................................................... 92 BODY-UP RETENTION CABLE........................................................... 92 ROCK EJECTORS..................................................................... 93 Inspection.................................................................... 93 FUEL TANK................................................................................. 95 FUEL TANK............................................................................. 97 Removal........................................................................... 98 Installation...................................................................... 98 Repair............................................................................ 98 Cleaning.......................................................................... 98 FUEL GAUGE SENDER................................................................. 99 Removal....................................................................... 99 Installation.................................................................. 99 LOW FUEL SWITCH................................................................... 99 WIGGINS QUICK FILL FUEL SYSTEM....................................................100 FUEL RECEIVER.................................................................100 TANK BREATHER VALVE...........................................................100 Removal...................................................................100 Installation..............................................................100 Disassembly...............................................................100 Assembly..................................................................100 LEFT SIDE FILL................................................................101 ENGINE........................................................................................103 POWER MODULE..............................................................................105 POWER MODULE..........................................................................107 Preparation.......................................................................107 Preparation for Removal...........................................................108 Removal - Power Module............................................................111 Installation - Power Module.......................................................113 Hookup - Power Module.............................................................113 COOLING SYSTEM............................................................................115 COOLING SYSTEM........................................................................117 RADIATOR..........................................................................117 Removal.......................................................................117 Installation..................................................................119 RADIATOR FILLING PROCEDURE........................................................120 RADIATOR REPAIR...................................................................120 Internal Inspection...........................................................120 External Cleaning.............................................................120 Disassembly...................................................................121 Cleaning and Inspection.......................................................122 Assembly......................................................................122 Pressure Testing..............................................................123 Additional Service Information................................................123 COOLANT SYSTEM TROUBLESHOOTING....................................................123 POWERTRAIN................................................................................125 POWER TRAIN...........................................................................127 ALTERNATOR........................................................................127 Removal - Alternator..........................................................127 ENGINE/ALTERNATOR MATING..........................................................129 General Instructions..........................................................129 Measuring Procedure...........................................................129 Joining The Alternator and Engine.............................................131 ENGINE............................................................................132 Removal.......................................................................132 Service.......................................................................132 Installation..................................................................132 AIR CLEANERS..............................................................................133 AIR CLEANERS..........................................................................135 OPERATION.........................................................................135 SERVICING THE AIR CLEANERS........................................................135 Replacing The Filter Element..................................................135 Cleaning The Main Filter Element..............................................137 Servicing The Precleaner Section..............................................138 AIR INTAKE TROUBLESHOOTING........................................................139 FAN CLUTCH................................................................................141 FAN CLUTCH............................................................................143 REMOVAL & INSTALLATION TOOLING....................................................143 DISASSEMBLY.......................................................................146 CLEANING AND INSPECTION...........................................................156 ASSEMBLY..........................................................................160 TEST PROCEDURE....................................................................174 ELECTRICAL SYSTEM (24VDC NON-PROPULSION)......................................................175 24VDC ELECTRIC SUPPLY SYSTEM..............................................................177 24VDC ELECTRIC SUPPLY SYSTEM..........................................................179 ELECTRICAL SYSTEM DESCRIPTION.....................................................179 BATTERIES.....................................................................179 Maintenance and Service.......................................................179 Troubleshooting...............................................................179 BATTERY SUPPLY SYSTEM.............................................................181 24VDC Batter Charging Alternator..............................................181 Battery Box...................................................................181 Battery Control Box...........................................................182 Battery Disconnect Switches...................................................182 24VDC Auxiliary Battery Connectors............................................182 24VDC to 12VDC Converter......................................................183 Isolation Diodes..............................................................183 Engine Starter Relay..........................................................183 24VDC ELECTRICAL SYSTEM COMPONENTS........................................................185 24 VDC ELECTRICAL SYSTEM COMPONENTS...................................................187 TRUCK SHUTDOWN PROCEDURE..........................................................187 24 VDC ELECTRICAL SYSTEM COMPONENTS...............................................187 Brake Warning Buzzer (BWB)....................................................187 AUXILIARY CONTROL CABINET COMPONENTS..............................................187 Fuse Block 1 & 2..............................................................188 Power Distribution Terminals..................................................188 PULSE VOLTAGE MODULATOR.......................................................188 5 Minute Idle Timer Components................................................190 5 Minute Idle Timer...........................................................190 5 Minute Idle Circuit Test....................................................190 Tail Light Resistor Diode Assemblies..........................................190 Engine Starter Failure Delay Timer............................................190 Lubrication System Timer......................................................192 Auto Lube Delay Timer.........................................................192 Barometric Pressure Transducer................................................192 Kontrol Power Relay...........................................................192 Alarm Indicating Device (AID) System..........................................194 Temperature and Latch.........................................................195 Hot Switch Inverter...........................................................195 Hot Switch Inverter Card (Slot 4) (Not Used)..................................195 Oil Level.....................................................................195 Temperature...................................................................195 Diode Matrix (Without Sound)..................................................195 Diode Matrix (With Sound).....................................................195 Lamp Test.....................................................................196 Diode Board - DB1.............................................................196 Diode Testing.................................................................196 RELAY BOARDS......................................................................197 Relay Boards RB1, RB3, RB4, RB5...............................................197 Service.......................................................................197 Relay Board Identification....................................................198 RELAY BOARD FUNCTIONS.............................................................199 Relay Board 1 (RB1)...........................................................199 Relay Board 3 (RB3)...........................................................199 Relay Board 6, 7 & 8 (RB6, RB7, RB8)..........................................200 Installing Additional Circuits................................................200 BODY-UP SWITCH....................................................................201 Operation.....................................................................201 Adjustment....................................................................201 Service.......................................................................201 HOIST LIMIT SWITCH................................................................202 Operation.....................................................................202 Adjustment....................................................................202 Service.......................................................................202 FUSE BLOCKS.......................................................................203 CIRCUIT BREAKERS..................................................................203 BATTERY CHARGING ALTERNATOR...............................................................205 BATTERY CHARGING ALTERNATOR...........................................................207 ELECTRICAL SYSTEM DESCRIPTION.....................................................207 BATTERY...........................................................................207 Maintenance and Service.......................................................207 Troubleshooting...............................................................207 BATTERY CHARGING SYSTEM (Niehoff).................................................209 General Description...........................................................209 TROUBLESHOOTING PROCEDURES (On-Truck).............................................209 Equipment Required:...........................................................209 Preliminary Checks............................................................210 Test Setup....................................................................210 Test Procedure................................................................210 Regulator Bypass Test.........................................................211 ON VEHICLE TROUBLESHOOTING GUIDE..................................................213 ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage....213 BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:..............................213 CHARGE VOLT AND AMP VALUES....................................................214 DEFINITIONS...................................................................214 ADVANCED SYSTEM TROUBLESHOOTING...................................................215 Static Test - Engine OFF, Key ON, Battery Switch ON...........................215 Go To Alternator..............................................................215 Go To Regulator (If Required).................................................216 Go To Regulator Connector On The Alternator...................................216 ALTERNATOR OVERHAUL...............................................................217 ALTERNATOR DIMENSIONS.........................................................217 ALTERNATOR SPECIFICATIONS.....................................................218 SERVICE PARTS.................................................................219 ON-VEHICLE TEST...............................................................221 Equipment:................................................................221 Preliminary Checks:.......................................................221 Test Set-up...............................................................221 Test Procedure............................................................221 ON-VEHICLE TEST...............................................................222 Bypass Test:..............................................................222 BENCH TEST....................................................................223 STATIC TESTS..................................................................224 Regulator Tests...........................................................224 Control Box Tests.........................................................225 ALTERNATOR DISASSEMBLY........................................................227 ASSEMBLY- ALTERNATOR..........................................................232 BF4822 STATOR SERVICE TOOL INSTRUCTIONS...........................................241 Stator Removal And Replacement................................................241 Stator Installation...........................................................242 VHMS COMPONENTS...........................................................................245 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...............................................247 VHMS BASIC FEATURES...............................................................247 Gather Data...................................................................247 Convert and Record Data.......................................................248 Communicate Data to Off-Board Systems.........................................248 USING THE VHMS SYSTEM.............................................................249 Turning the VHMS System ON....................................................249 Normal VHMS Operation.........................................................250 Turning the VHMS System OFF...................................................250 Downloading from the VHMS controller..........................................250 VHMS DATA ITEMS...................................................................251 Fault Codes...................................................................251 Machine History...............................................................251 VHMS History..................................................................251 Snapshots.....................................................................251 Manual Snapshots..............................................................253 Trends........................................................................253 Histogram (Load Map) Data.....................................................255 Haul Cycle Data...............................................................255 Alarm and Snapshot Triggers...................................................257 Satellite Features............................................................259 VHMS DIAGNOSTIC FEATURES..........................................................259 Fault History.................................................................259 VHMS LED Digits...............................................................259 VHMS COMPONENTS...................................................................260 VHMS Controller...............................................................260 Removal.......................................................................260 Installation..................................................................261 OrbComm Controller............................................................261 Removal.......................................................................261 Installation..................................................................262 Interface Module..............................................................262 Removal.......................................................................263 Installation..................................................................263 Temperature Sensors...........................................................264 Pressure Sensors..............................................................265 VHMS SOFTWARE.............................................................................267 VHMS SOFTWARE.........................................................................269 Necessary Software................................................................269 Necessary Tools...................................................................270 VHMS TOOL BOX INSTALLATION........................................................270 VHMS SETTING TOOL INSTALLATION....................................................271 VHMS INITIALIZATION PROCEDURE.....................................................271 Preliminary Checks............................................................271 Initialization Steps..........................................................271 Select Operation..............................................................272 VHMS Setting Function.........................................................272 Machine Information Setting(1)................................................272 Machine Information Setting(2)................................................272 Date and Time Setting.........................................................273 GCC Setting...................................................................273 Setting Summary...............................................................273 VHMS SNAPSHOT PROCEDURE...........................................................274 VHMS DOWNLOAD.....................................................................274 VHMS FTP UPLOAD...................................................................275 LOCATION OF DOWNLOAD FILES........................................................276 INSTALLING FLASHBURN PROGRAM......................................................277 INSTALLING APPLICATION CODE INTO INTERFACE MODULE.................................277 INSTALLING REALTIME MONITOR SOFTWARE PROGRAM......................................278 WHEN REPLACING A VHMS CONTROLLER..................................................278 To Set: Date and time, satellite, payload meter...............................280 Review Setting Information....................................................282 VHMS CHECKOUT AND TROUBLESHOOTING.........................................................283 VHMS CHECKOUT AND TROUBLESHOOTING.....................................................285 VHMS CHECKOUT PROCEDURE...........................................................285 General.......................................................................285 Structure and Purpose.........................................................286 Necessary Equipment:..........................................................286 VHMS SYSTEM CHECKOUT..............................................................286 Preliminary...................................................................286 Checking Inputs To The Interface Module.......................................287 For 930E & 960E trucks only:..................................................289 For 830E trucks only:.........................................................289 Checking Outputs From The Interface Module....................................290 For 830E only:................................................................290 For 930E & 960E only:.........................................................290 VHMS CONTROLLER CHECKOUT..........................................................290 TROUBLESHOOTING...................................................................291 Communications Networks.......................................................291 Coaxial Cable.................................................................291 VHMS COMPONENTS...................................................................292 VHMS Controller...............................................................292 OrbComm Controller............................................................293 Interface Module..............................................................293 FAULT CODES.......................................................................294 Fault History.................................................................294 VHMS LED Display Fault Codes..................................................295 Chassis Fault Codes...........................................................296 Engine Fault Codes............................................................300 FAULT TREE ANALYSIS...............................................................306 Unable to connect to VHMS from laptop PC......................................306 Flashing Error Code N4-23 (PLM III Communications Fault)......................307 Flashing Error Code N4-22 (Engine Communications Fault).......................308 No Data Received By WebCARE...................................................309 Coaxial Cable Troubleshooting.................................................310 VHMS FORMS................................................................................311 VHMS FORMS............................................................................313 VHMS INITIALIZATION CHECK LIST....................................................313 VHMS DATA DOWNLOAD................................................................314 VHMS INITIALIZATION FORM..........................................................314 VHMS INITIALIZATION CHECK LIST....................................................316 VHMS INITIALIZATION FORM..........................................................318 ELECTRIC PROPULSION SYSTEM....................................................................319 ELECTRICAL PROPULSION SYSTEM COMPONENTS...................................................321 ELECTRICAL PROPULSION SYSTEM COMPONENTS...............................................323 GENERAL SYSTEM DESCRIPTION........................................................323 SYSTEM COMPONENTS.................................................................325 Propulsion System Controller (PSC)............................................325 Truck Control Interface (TCI).................................................325 Diagnostic Information Display................................................327 DID Panel Event Codes.........................................................327 PSC SOFTWARE FUNCTIONS............................................................351 Input Processing..............................................................351 STATE MANAGEMENT..................................................................351 State Machine.................................................................351 DC Link State.................................................................354 Powering the Link.............................................................354 De-Powering the Link..........................................................354 Control Functions.............................................................354 ALTERNATOR FIELD CONTROL..........................................................355 Desired Three-Phase Voltage...................................................355 Desired DC Link Voltage.......................................................355 Self-load.....................................................................355 Propel Torque Control.........................................................356 Retard Torque Control.........................................................356 Wheel Slide Control...........................................................356 Resistor Grid Control.........................................................357 Chopper Voltage Control.......................................................357 EVENT PROCESSING..................................................................357 Event Detection...............................................................357 Power On Tests................................................................357 Initiated Tests...............................................................358 Periodic Tests................................................................358 EVENT RESTRICTIONS................................................................358 EVENT LOGGING AND STORAGE.........................................................358 Event History Buffer..........................................................359 Data Packs....................................................................359 To Record and Save a Data Pack to a Floppy Disk...............................359 Event Reset...................................................................360 SERIAL DATA COMMUNICATIONS........................................................361 PSC - PTU Communications Processing...........................................361 Inverter Communications Processing............................................361 OUTPUT PROCESSING.................................................................362 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS..........................................362 Fast Start....................................................................362 Engine Shutdown/Engine Not Running............................................362 Limp Home Mode................................................................362 Entering/Exiting Limp Home Mode...............................................362 PROPULSION SYSTEM COMPONENT ABBREVIATIONS.........................................363 ELECTRONIC ACCELERATOR AND RETARD PEDALS..........................................375 Removal.......................................................................375 Installation..................................................................375 Disassembly...................................................................375 Assembly......................................................................375 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.............................................377 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.........................................379 AC DRIVE SYSTEM MAINTENANCE.......................................................379 TRUCK SHUTDOWN PROCEDURES.........................................................379 NORMAL TRUCK SHUTDOWN PROCEDURE...................................................380 SHUTDOWN AFTER SYSTEM FAILURE.....................................................381 SYSTEM CHECKOUT...................................................................382 Battery and Control Checks of System WITH Battery Power OFF...................382 Battery and Control Circuit Checks of System With Battery Power ON............385 Checks with Key Switch OFF....................................................386 CPU Battery Checks............................................................388 MEMORY BACKUP BATTERY REPLACEMENT.................................................388 TCI PROGRAMMING...................................................................389 ICP PROGRAMMING...................................................................389 INVERTER PROGRAMMING..............................................................390 TCI CHECKOUT......................................................................390 Modular Mining Communication Port.............................................391 TCI Input Checks..............................................................392 TCI Digital Output Tests......................................................394 TCI Digital Input Tests.......................................................396 PSC Checkout Procedure........................................................398 PSC Digital Input Checks......................................................402 Miscellaneous Checks..........................................................403 A3PV Panel....................................................................403 LINKV Panel...................................................................403 Thermistor Checks.............................................................403 17FM384 Panel Check...........................................................403 Pedal Percentages and Meter Calibration.......................................404 Meter Calibration Procedure...................................................404 Reprogram With Serial Numbers and Pedal Percentages...........................406 LOAD TESTING......................................................................408 Preload Checks................................................................408 ADDITIONAL TRUCK CHECKS...........................................................410 On-Board Load Testing.........................................................412 Preparation...................................................................412 Initiate Loadbox Test.........................................................415 Manual Offset HP Output Adjustment............................................417 TROUBLESHOOTING...................................................................419 PVM Optimum Load Curve Handshaking Troubleshooting............................419 MISCELLANEOUS COMPONENT REPAIR....................................................420 Troubleshooting Phase Modules and Chopper Modules.............................420 Phase Module Removal and Snubber Resistor Replacement.........................420 Snubber Resistor Installation.................................................421 Phase Module Installation.....................................................421 REAR AXLE, SPINDLES AND WHEELS................................................................423 TIRES AND RIMS............................................................................425 TIRES AND RIMS........................................................................427 WHEEL STUD MAINTENANCE............................................................428 FRONT TIRES AND RIMS..............................................................429 Removal.......................................................................429 Installation..................................................................430 REAR TIRES AND RIMS...............................................................431 Removal.......................................................................431 Installation..................................................................432 RIM...............................................................................433 Tire Removal..................................................................433 Tire Installation.............................................................433 FRONT WHEEL HUB AND SPINDLE...............................................................435 REAR AXLE MOUNTING........................................................................451 REAR AXLE MOUNTING....................................................................453 PIVOT PIN.........................................................................453 Removal.......................................................................453 Installation..................................................................454 PIVOT EYE BEARING.................................................................455 Removal.......................................................................455 Installation..................................................................455 PIVOT EYE REPAIR..................................................................455 Removal.......................................................................455 Disassembly...................................................................455 Assembly......................................................................456 Installation..................................................................456 ANTI-SWAY BAR.....................................................................456 Removal.......................................................................456 Disassembly...................................................................457 Cleaning and Inspection.......................................................457 Assembly......................................................................457 Installation..................................................................457 REAR AXLE HOUSING.........................................................................459 REAR AXLE HOUSING.....................................................................461 REAR AXLE HOUSING.................................................................461 Preparation...................................................................461 Removal.......................................................................461 Cleaning and Inspection - Rear Axle Housing...................................463 Installation - Rear Axle Housing..............................................463 WHEEL MOTOR.......................................................................464 Preparation...................................................................464 Removal.......................................................................464 Cleaning and Inspection - Wheel Motor.........................................465 Installation - Wheel Motor....................................................466 WHEEL MOTOR GEAR OIL..............................................................469 Filtering Requirements........................................................469 Particle Size Analysis........................................................469 Flushing......................................................................469 Oil Sample Analysis...........................................................470 ELEMENT SPECIFICATION CHARTS......................................................471 HYDRAIR® II SUSPENSIONS.......................................................................475 FRONT SUSPENSIONS.........................................................................477 FRONT SUSPENSION......................................................................479 Removal...........................................................................479 Installation......................................................................480 "Turn-Of-The-Nut" Tightening Procedure............................................483 MINOR REPAIRS (LOWER BEARING & SEALS).............................................484 Removal - Bearing Retainer....................................................484 Installation - Bearing Retainer...............................................484 MAJOR SUSPENSION REBUILD..........................................................486 Disassembly...................................................................486 Assembly......................................................................486 REAR SUSPENSIONS..........................................................................489 REAR SUSPENSIONS......................................................................491 SUSPENSION CYLINDER...............................................................492 Removal.......................................................................492 Installation..................................................................494 Disassembly...................................................................494 Cleaning and Inspection.......................................................495 Assembly......................................................................495 SUSPENSION PRESSURE TEST..........................................................497 SUSPENSION OILING AND CHARGING PROCEDURES.................................................499 SUSPENSION OILING AND CHARGING PROCEDURE..............................................501 GENERAL...........................................................................501 Equipment List................................................................501 Installation of Charging Kit..................................................501 Removal of Charging Kit.......................................................502 Support Blocks For Oiling And Charging Dimensions.............................502 FRONT SUSPENSION..................................................................503 Front Suspension Oiling.......................................................503 Front Suspension Nitrogen Charging............................................504 REAR SUSPENSION...................................................................505 Rear Suspension Oiling........................................................505 Rear Suspension Nitrogen Charging.............................................507 OIL AND NITROGEN SPECIFICATIONS CHARTS............................................508 BRAKE CIRCUIT.................................................................................509 BRAKE CIRCUIT.............................................................................511 BRAKE CIRCUIT.........................................................................513 SERVICE BRAKE CIRCUIT.............................................................513 SECONDARY BRAKING AND AUTOMATIC APPLY.............................................515 PARKING BRAKE CIRCUIT.............................................................515 Normal Operation (key switch on, engine running)..............................515 BRAKE LOCK CIRCUIT................................................................516 WARNING CIRCUIT...................................................................516 BRAKE CIRCUIT COMPONENT SERVICE...........................................................519 BRAKE CIRCUIT COMPONENT SERVICE.......................................................521 BRAKE VALVE.......................................................................521 Rebuild Criteria..............................................................521 Removal.......................................................................522 Installation..................................................................522 Disassembly...................................................................523 Cleaning and Inspection.......................................................526 Assembly......................................................................526 Actuator Base Threaded Inserts................................................526 Boot and Cap..................................................................526 Valve Body Seal Installation..................................................526 Regulator Sleeve O-Ring Installation..........................................527 Actuator Plunger O-ring Installation..........................................527 Assembly of Valve.............................................................527 DIFFERENTIAL PRESSURE SWITCH......................................................529 Disassembly...................................................................529 Cleaning and Inspection.......................................................529 Assembly......................................................................529 VALVE BENCH TEST AND ADJUSTMENT...................................................530 Test Set Up Procedure.........................................................531 Brake Valve Output Pressure Adjustment........................................531 Differential Pressure Switch Adjustment.......................................531 Final Test and Adjustment.....................................................532 Installation Of Brake Pedal Actuator Assembly to Brake Valve..................533 Installation of Retard Pedal To Brake Pedal...................................533 DUAL RELAY VALVE..................................................................535 Removal.......................................................................535 Installation..................................................................535 Disassembly...................................................................537 Cleaning and Inspection.......................................................537 Assembly......................................................................537 DIFFERENTIAL PRESSURE SWITCH......................................................538 Disassembly...................................................................538 Cleaning and Inspection.......................................................538 Assembly......................................................................538 VALVE TEST AND ADJUSTMENT.........................................................539 Test Set Up Procedure.........................................................540 Relay Valve Output Pressure Adjustment........................................540 Differential Pressure Switch Adjustment.......................................541 BRAKE MANIFOLD....................................................................542 Removal.......................................................................542 Installation..................................................................543 Disassembly...................................................................543 Cleaning and Inspection.......................................................543 Assembly......................................................................543 BRAKE ACCUMULATORS................................................................544 Brake Accumulator Bleeddown Procedure.........................................544 BRAKE ACCUMULATOR REPAIR..........................................................545 Removal.......................................................................545 Installation..................................................................545 Disassembly...................................................................546 Cleaning and Inspection.......................................................547 Assembly......................................................................547 ACCUMULATOR CHARGING PROCEDURE....................................................549 Temperature During Precharge..................................................551 Precharge Maintenance.........................................................551 Accumulator Storage procedures................................................552 Bladder Storage Procedures....................................................552 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)..................................553 Removal.......................................................................553 Installation..................................................................553 Disassembly and Adjustment....................................................553 Potentiometer Check...........................................................555 Assembly......................................................................555 BRAKE CIRCUIT CHECK-OUT PROCEDURE.........................................................557 BRAKE CIRCUIT CHECK-OUT PROCEDURE.....................................................559 REQUIRED EQUIPMENT................................................................561 INITIAL SYSTEM SET-UP.............................................................562 BRAKE SYSTEM CHECKOUT.............................................................563 Failure Modes Check-Out.......................................................564 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART...................................566 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.................................569 CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.................................570 WET DISC BRAKE ASSEMBLY...................................................................571 WET DISC BRAKE ASSEMBLY...............................................................573 OPERATION.........................................................................573 MAINTENANCE.......................................................................574 Brake Disc Wear Indicator.....................................................574 Removal/Installation - Wet Disc Brake Assembly................................574 BRAKE REBUILD.....................................................................576 Disassembly...................................................................576 Cleaning and Inspection.......................................................579 Assembly......................................................................580 Floating Ring Seal Assembly/Installation......................................583 WET DISC BRAKE BLEEDING PROCEDURE.................................................586 PARKING BRAKE.............................................................................587 PARKING BRAKE.........................................................................589 OPERATION.........................................................................589 MAINTENANCE.......................................................................590 Inspection - Parking Brake....................................................590 Removal - Parking Brake.......................................................590 Installation - Parking Brake..................................................591 Disassembly - Parking Brake...................................................592 Cleaning and Inspection - Parking Brake.......................................592 Assembly - Parking Brake......................................................592 PARKING BRAKE BLEEDING PROCEDURE..................................................594 HYDRAULIC SYSTEM..............................................................................595 HYDRAULIC SYSTEM..........................................................................597 HYDRAULIC SYSTEM......................................................................599 HYDRAULIC PUMP MODULE.............................................................599 HOIST CIRCUIT OPERATION...........................................................600 STEERING CIRCUIT OPERATION........................................................602 DISC BRAKE COOLING SYSTEM.........................................................604 HYDRAULIC SYSTEM COMPONENT REPAIR.........................................................607 HYDRAULIC SYSTEM COMPONENT REPAIR.....................................................609 HOIST PUMP........................................................................609 Removal.......................................................................609 Installation..................................................................611 Disassembly...................................................................612 Inspection....................................................................616 Assembly......................................................................616 TROUBLESHOOTING GUIDE (Hoist Pump)................................................621 HYDRAULIC TANK....................................................................622 Filling Instructions..........................................................622 Removal.......................................................................622 Installation..................................................................623 HYDRAULIC TANK STRAINERS..........................................................623 Removal.......................................................................623 Inspection and Cleaning.......................................................623 Installation..................................................................623 HYDRAULIC TANK BREATHERS..........................................................624 STEERING CIRCUIT..........................................................................625 STEERING CIRCUIT......................................................................627 COMPONENT DESCRIPTION.............................................................628 Steering Control Unit.........................................................628 Bleeddown Manifold Valve......................................................629 Steering Accumulator Bleeddown Solenoid.......................................629 Relief Valves.................................................................631 Hoist Up Limit Solenoid.......................................................631 Steering Accumulators.........................................................631 Low Precharge Warning Switch..................................................631 High Pressure Filter..........................................................631 Quick Disconnect Ports........................................................631 Flow Amplifier................................................................633 FLOW AMPLIFIER SYSTEM OPERATION...................................................634 No Steer......................................................................634 Steering Left.................................................................636 Steering Right................................................................638 No Steer, External Shock Load.................................................640 STEERING PUMP.....................................................................642 Normal Operation..............................................................642 PRINCIPLE OF OPERATION............................................................644 Full Pump Volume..............................................................644 Half Pump Volume..............................................................644 Neutral Position..............................................................644 Steering Pump.................................................................645 STEERING CONTROL UNIT.....................................................................647 STEERING CONTROL UNIT.................................................................649 REMOVAL...........................................................................649 SPLINE INSPECTION.................................................................649 INSTALLATION......................................................................650 DISASSEMBLY.......................................................................650 CLEANING AND INSPECTION...........................................................651 ASSEMBLY..........................................................................653 STEERING CIRCUIT COMPONENT REPAIR.........................................................657 STEERING CIRCUIT COMPONENT REPAIR.....................................................659 BLEEDDOWN MANIFOLD VALVE..........................................................659 Removal.......................................................................659 Installation..................................................................660 FLOW AMPLIFIER....................................................................661 Removal.......................................................................661 Installation..................................................................661 Disassembly...................................................................661 Assembly......................................................................663 STEERING CYLINDERS................................................................664 Disassembly...................................................................665 Piston Seal & Bearing Installation............................................665 Assembly......................................................................665 Testing.......................................................................665 STEERING AND BRAKE PUMP...........................................................666 Removal.......................................................................666 Installation..................................................................667 Disassembly...................................................................668 Inspection....................................................................671 Assembly......................................................................674 Driveshaft Group..............................................................675 Rotating Group................................................................675 Valve Plate Group.............................................................676 STEERING ACCUMULATORS.............................................................677 Removal.......................................................................677 Installation..................................................................677 Disassembly...................................................................678 Cleaning and Inspection.......................................................678 Assembly......................................................................679 Leak Testing..................................................................681 Charging Procedure............................................................682 Precharge Maintenance.........................................................684 Accumulator Storage Procedures................................................685 Bladder Storage Procedures....................................................685 Installing A Bladder Accumulator From Storage.................................685 TROUBLESHOOTING CHART.............................................................686 HOIST CIRCUIT.............................................................................691 HOIST CIRCUIT.........................................................................693 BASIC OPERATION...................................................................693 COMPONENT DESCRIPTION.............................................................694 Hydraulic Tank................................................................694 Hydraulic Pump................................................................694 High Pressure Filters.........................................................694 Hoist Valve...................................................................694 Inlet Sections................................................................694 Work Ports (Rear) Spool Section...............................................695 Tank Ports (Front) Spool Section..............................................695 Hoist Pilot Valve.............................................................695 Bleeddown Manifold............................................................696 Hoist Up Limit Solenoid.......................................................696 Pilot Operated Check Valve....................................................696 Overcenter Manifold...........................................................696 Float Position Of Pilot Valve With Truck Body On Frame........................698 Power Up Operation............................................................700 Hold Operation................................................................702 Power Down Operation..........................................................704 Float Operation...............................................................706 HOIST CIRCUIT OPERATION...........................................................697 Float Position Of Pilot Valve With Truck Body On Frame........................698 Power Up Operation............................................................700 Hold Operation................................................................702 Power Down Operation..........................................................704 Float Operation...............................................................706 HOIST CIRCUIT COMPONENT REPAIR............................................................709 HOIST CIRCUIT COMPONENT REPAIR........................................................711 HOIST VALVE.......................................................................711 Removal.......................................................................711 Installation..................................................................712 O-Ring Replacement............................................................712 INLET SECTION.....................................................................713 Disassembly...................................................................713 Cleaning and Inspection.......................................................714 Assembly......................................................................714 REAR SPOOL SECTION (Work Ports)...................................................715 Disassembly...................................................................715 Cleaning and Inspection.......................................................715 Assembly......................................................................717 FRONT SPOOL SECTION (Tank Ports)..................................................718 Disassembly...................................................................718 Cleaning and Inspection.......................................................718 Assembly......................................................................718 HOIST PILOT VALVE.................................................................720 Removal.......................................................................720 Installation..................................................................720 Disassembly...................................................................721 Cleaning and Inspection.......................................................722 Assembly......................................................................722 HOIST CYLINDERS...................................................................723 Removal.......................................................................723 Installation..................................................................724 Disassembly...................................................................726 Cleaning and Inspection.......................................................727 Assembly - Quill..............................................................728 Assembly - Cylinder...........................................................730 OVERCENTER VALVE MANIFOLD.........................................................731 HYDRAULIC SYSTEM FILTERS..................................................................733 HYDRAULIC SYSTEM FILTERS..............................................................735 HOIST CIRCUIT FILTER..............................................................735 Filter Element Replacement....................................................735 Removal - Hoist Circuit Filter................................................736 Installation - Hoist Circuit Filter...........................................736 Indicator Switch - Hoist Circuit Filter.......................................736 STEERING CIRCUIT FILTER...........................................................737 Filter Element Replacement....................................................737 Removal - Steering Circuit Filter.............................................738 Installation - Steering Circuit Filter........................................738 Indicator Switch - Steering Circuit Filter....................................738 INDICATOR SWITCH..................................................................738 Test Procedure................................................................738 HYDRAULIC CHECK-OUT PROCEDURE.............................................................741 HYDRAULIC CHECK-OUT PROCEDURE.........................................................743 GENERAL INFORMATION...............................................................743 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.................................743 Equipment Requirements........................................................744 Pump Pressure Control Adjustments.............................................744 Steering Control Valve and Flow Amplifier Leakage Test........................745 Bleeddown Manifold Leakage Test...............................................745 STEERING/BRAKE PUMP STROKE ADJUSTMENT.............................................746 SHOCK AND SUCTION VALVES..........................................................747 Equipment Requirements........................................................747 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES.....................748 Equipment Requirements........................................................748 Pressure Gauge Locations......................................................748 Brake Cooling Circuit Test....................................................748 Power Up Relief Pressure Test.................................................749 Adjustment....................................................................749 Power Down Relief Pressure Test...............................................750 Hoist Counterbalance Valve Adjustment Preparation.............................751 Counterbalance Valve Pressure Check...........................................751 Counterbalance Valve Adjustment...............................................752 Preparation...................................................................753 Flushing Procedure............................................................753 Filter Element Replacement....................................................754 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET.............................755 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET................756 OPTIONS AND SPECIAL TOOLS.....................................................................757 FIRE CONTROL SYSTEMS......................................................................759 FIRE CONTROL SYSTEM (MANUAL)..........................................................761 Operation.........................................................................761 Inspection and Maintenance........................................................761 Recharging Procedures.............................................................762 CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1..........................763 Control Module....................................................................763 Actuator..........................................................................764 Linear Detection Wire.............................................................764 Power Wire........................................................................764 Test Kit..........................................................................764 Squib.............................................................................764 Securing the Detection Wire.......................................................765 Preliminary Test Before Final Hook-Up.............................................765 Installation Procedure for Squib..................................................767 Placing the Electric Detection & Actuation System Into Service....................767 INSPECTION AND MAINTENANCE SCHEDULES..............................................768 Daily.........................................................................768 Normal Maintenance Based On Actual Operating Hours............................768 IN CASE OF FIRE...................................................................769 TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM.........................................771 SPECIAL TOOLS.............................................................................773 PAYLOAD METER III ™.......................................................................779 OPERATION SECTION.....................................................................783 Introduction......................................................................783 Data Summary..................................................................783 Data Gathering................................................................783 COMPONENT DESCRIPTION.............................................................784 System Diagram................................................................784 Suspension Pressure Sensors...................................................784 Inclinometer..................................................................784 Operator Display..............................................................784 Operator Switch...............................................................785 Speed Input...................................................................785 Body-Up Switch................................................................785 Brake Lock Switch.............................................................785 Payload Meter.................................................................785 Communications Ports..........................................................785 Key Switch Input..............................................................786 Payload Meter Power...........................................................786 Load Lights...................................................................786 Wiring and Termination........................................................787 TCI Outputs...................................................................787 OPERATOR’S DISPLAY AND SWITCH.....................................................788 Reading the Speedometer.......................................................788 Reading the Load Display......................................................788 Using the Operator ID.........................................................788 Using the Load and Ton Counter................................................788 Total Ton Counter.............................................................788 Total Load Counter............................................................789 Clearing the Counters.........................................................789 Viewing Live Sensor Data......................................................789 Other Display Messages........................................................789 PAYLOAD OPERATION & CALCULATION...................................................790 Description of Haul Cycle States..............................................790 Haul Cycle Description........................................................790 Load Calculation..............................................................791 Carry Back....................................................................791 Measurement Accuracy..........................................................791 SOURCES FOR PAYLOAD ERROR.........................................................791 Payload Error.................................................................791 Loading Conditions............................................................792 Pressure Sensors..............................................................792 Swingloads....................................................................792 Speed and Distance............................................................792 HAUL CYCLE DATA...................................................................792 Haul Cycle Warning Flags......................................................794 Frame Torque Data.............................................................795 Sprung Weight Data............................................................795 Maximum Speed Data............................................................795 Alarm Records.................................................................795 Fault Code Data...............................................................796 PC SOFTWARE OVERVIEW..............................................................797 System Configuration..........................................................797 Installing the PLMIII Software................................................797 DOWNLOADING DATA..................................................................798 PLM III SYSTEM CONFIGURATION......................................................799 Starting Communications.......................................................799 Displayed Payload Units.......................................................799 Time Units....................................................................799 Connection Menu...............................................................799 Connecting to the Payload Meter...............................................800 Configure the Payload Meter...................................................800 Setting the Date and Time.....................................................800 Setting the Truck Type........................................................801 Setting the Gauge Display Units...............................................801 Setting the Frame Serial Number...............................................801 Setting the Truck Number......................................................801 Setting the Komatsu Distributor...............................................801 Setting the Komatsu Customer..................................................801 Clean Truck Tare..............................................................802 Inclinometer Calibration......................................................802 DATA ANALYSIS.....................................................................803 Creating a Query..............................................................803 Sorting on Truck Unit Number..................................................803 Sorting on Truck Type.........................................................803 Sorting on Date Range.........................................................804 Sorting on Time Range.........................................................804 Payload Detail Screen.........................................................805 Creating Reports..............................................................805 Summary - one page report.....................................................806 Detailed - multi-page report..................................................806 Creating Graphs...............................................................807 Exporting Data................................................................807 CSV Export....................................................................807 Compressed....................................................................808 Importing Data................................................................809 Deleting Haul Cycle Records...................................................809 Viewing Alarms................................................................810 Deleting Alarm Records........................................................810 TROUBLESHOOTING SECTION...............................................................811 TROUBLESHOOTING...................................................................811 Viewing Active Alarms.........................................................811 Real-Time Data Display........................................................811 Testing the Payload Lights....................................................811 Creating Log Files of Inputs..................................................812 Daily Inspections.............................................................812 Periodic Maintenance..........................................................812 Abnormal Displays at Power-Up.................................................813 No Payload Display When Key Switch is Turned ON...............................814 No Display on Speedometer.....................................................815 No Display on Operator Display................................................815 No Communications With PC.....................................................816 Load Lights Don’t Light During Loading........................................817 Load Lights Remain ON.........................................................818 Load Lights Remain ON During Dumping..........................................818 Display Doesn't Clear When The Load Is Dumped.................................818 Calibration Problems..........................................................819 Alarm 1 - Left Front Pressure High............................................820 Alarm 2 - Left Front Pressure Low.............................................820 Troubleshoot Wiring to Left Front Suspension..................................820 Alarm 3 - Right Front Pressure High...........................................821 Alarm 4 - Right Front Pressure Low............................................821 Troubleshoot Wiring to Right Front Suspension.................................821 Alarm 5 -Left Rear Pressure High..............................................822 Alarm 6 - Left Rear Pressure Low..............................................822 Troubleshoot Wiring to Left Rear Suspension...................................822 Alarm 7 - Right Rear Pressure High............................................823 Alarm 8 - Right Rear Pressure Low.............................................823 Troubleshoot Wiring to Right Rear Suspension..................................823 Alarm 9 - Inclinometer High...................................................824 Alarm 10 - Inclinometer Low...................................................824 Troubleshoot Inclinometer Wiring..............................................824 Alarm 13 - Body Up Input Failure..............................................825 Alarm 16 - Memory Write Failure...............................................826 Alarm 17 - Memory Read Failure................................................826 Alarm 18......................................................................827 Alarm 19......................................................................827 Alarm 22......................................................................827 Operator Switch Doesn't Work..................................................828 Alarm 26 - User Switch Fault - SELECT.........................................828 Alarm 27 - User Switch Fault - SET............................................828 Connector Map.................................................................829 Connectors....................................................................830 PLMIII CHECK OUT PROCEDURE............................................................831 General Description...............................................................831 Tools Required....................................................................831 Checkout Procedure................................................................831 PLMIII CHECKOUT PROCEDURE CONFIRMATION............................................835 Flashburn Programming.........................................................835 Confirmation Checklist........................................................837 RESERVE ENGINE OIL SYSTEM.................................................................839 RESERVE ENGINE OIL SYSTEM.............................................................841 Operation.........................................................................841 LED Monitor Light.................................................................842 Tank Fill Control (Optional)......................................................842 Filling Procedure (Remote fill feature)...........................................842 SERVICE...........................................................................843 Every 10 Hours, or once each shift:...........................................843 Every 500 Hours:..............................................................843 Changing Oil..................................................................843 TROUBLESHOOTING...................................................................844 Circuit Breaker or Fuse.......................................................844 SYSTEM ELECTRICAL SCHEMATICS......................................................845 OPERATOR CAB..................................................................................847 TRUCK CAB.................................................................................849 TRUCK CAB.............................................................................851 Description.......................................................................851 Preparation.......................................................................852 Removal - Cab.....................................................................852 Installation - Cab................................................................854 CAB DOOR..........................................................................854 Removal.......................................................................854 Installation..................................................................854 Door Adjustment...............................................................855 Door Jamb Bolt Adjustment.....................................................855 Door Handle Plunger Adjustment................................................856 Door Glass Replacement........................................................857 Door Window Regulator Replacement.............................................861 Door Handle or Latch Assembly Replacement.....................................861 Door and Door Hinge Seal Replacement..........................................862 Door Opening Seal Removal.....................................................862 Installation..................................................................862 GLASS REPLACEMENT.................................................................863 Adhesive Bonded Windows.......................................................863 Replacement Procedure.........................................................863 Windshield And Rear Glass.....................................................864 Removal.......................................................................864 Installation..................................................................865 CAB COMPONENTS............................................................................867 CAB COMPONENTS........................................................................869 WINDSHIELD WIPERS.................................................................869 Wiper Motor Replacement.......................................................869 Removal.......................................................................869 Installation..................................................................869 Wiper Arm.....................................................................869 Removal.......................................................................869 Installation..................................................................870 Wiper Linkage Replacement.....................................................870 Removal.......................................................................870 Installation..................................................................870 WINDSHIELD WASHER.................................................................871 Operation.....................................................................871 Service.......................................................................871 OPERATOR SEAT.....................................................................872 Adjustment....................................................................872 Seat Removal..................................................................872 Seat Installation.............................................................872 OPERATOR COMFORT..........................................................................873 OPERATOR COMFORT......................................................................875 HEATER / AIR CONDITIONER..........................................................875 Operation.....................................................................875 Heater/Air Conditioner Vents..................................................875 COMPONENTS........................................................................876 Circuit Breakers..............................................................876 Relays........................................................................876 Heater Core...................................................................876 Fan Motor And Speed Control...................................................877 Actuators.....................................................................877 Cab Air Filter................................................................877 AIR CONDITIONING SYSTEM...........................................................879 Environmental Impact..........................................................879 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.....................................880 PRINCIPLES OF REFRIGERATION...................................................880 Air Conditioning..........................................................880 Refrigeration - The Act Of Cooling........................................881 The Refrigeration Cycle...................................................881 AIR CONDITIONER SYSTEM COMPONENTS.............................................882 Compressor (Refrigerant Pump).............................................882 Service Valves............................................................882 Condenser.................................................................882 Receiver-Drier............................................................882 Expansion Block Valve.....................................................883 Accumulator...............................................................883 Evaporator................................................................883 ELECTRICAL CIRCUIT............................................................884 Thermostat................................................................884 Compressor Clutch.........................................................884 Trinary™ Switch...........................................................885 SYSTEM SERVICING..............................................................886 SERVICE TOOLS AND EQUIPMENT...................................................887 Recovery/Recycle Station..................................................887 Leak Detector.............................................................887 Service Valves............................................................888 Vacuum Pump...............................................................888 Manifold Gauge Set........................................................889 Installing Manifold Gauge Set.............................................890 Purging Air From Service Hoses............................................890 SYSTEM PERFORMANCE TEST.......................................................891 SYSTEM OIL....................................................................892 Handling and Reusing PAG Oil..............................................892 Oil Quantity..............................................................892 Checking System Oil.......................................................892 REFRIGERANT...................................................................893 Recycled Refrigerant......................................................893 Reclaimed Refrigerant.....................................................893 Refrigerant Quantity......................................................893 R-134a Refrigerant Containers.............................................893 SYSTEM LEAK TESTING...........................................................894 Electronic Leak Detector..................................................894 Tracer Dyes...............................................................894 Soap and Water............................................................894 RECOVERING AND RECYCLING THE REFRIGERANT......................................895 Performing the Recovery Cycle.............................................895 Performing the Recycling Procedure........................................895 Evacuating and Charging the A/C System....................................895 SYSTEM REPAIR.................................................................896 System Flushing...........................................................896 COMPONENT REPLACEMENT.........................................................896 Hoses and Fittings........................................................896 Lines.....................................................................896 Expansion Valve...........................................................897 Receiver-Drier............................................................897 Thermostat................................................................897 Compressor................................................................897 Accumulator...............................................................897 Clutch....................................................................898 Servicing the Compressor Clutch...........................................898 Pulley Removal............................................................900 Clutch Coil Check.........................................................901 Pulley Installation.......................................................901 Clutch Assembly Installation..............................................901 EVACUATING THE SYSTEM.........................................................903 CHARGING THE A/C SYSTEM.......................................................905 TROUBLESHOOTING...............................................................906 Preliminary Checks........................................................906 Diagnosis Of Gauge Readings And System Performance........................906 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................907 PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM..............................913 OPERATOR CAB CONTROLS.....................................................................915 OPERATOR CAB CONTROLS.................................................................917 STEERING COLUMN...................................................................917 Removal.......................................................................917 Steering Column Inspection....................................................917 Installation..................................................................917 Steering Wheel Removal........................................................918 Steering Wheel Installation...................................................918 STEERING WHEEL AND CONTROLS.......................................................920 Horn Button...................................................................920 Tilt / Telescope Lever........................................................920 Turn Signal/Headlight Dimmer..................................................920 DYNAMIC RETARDING.................................................................920 Retarder Control Lever........................................................921 Dynamic Retarder/Service Brake Pedal..........................................921 Accelerator (Throttle) Pedal..................................................921 GRADE/SPEED RETARD CHART..........................................................922 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.................................923 Heater/Air Conditioner Vents..................................................923 INSTRUMENT PANEL..................................................................924 OVERHEAD PANEL AND DISPLAYS.......................................................924 CENTER CONSOLE....................................................................925 F-N-R Selector Switch.........................................................925 Hoist Control Lever...........................................................926 Ash Tray......................................................................926 Lighter.......................................................................926 L.H. Window Control Switch....................................................926 R.H. Window Control Switch....................................................926 Engine Shutdown Switch........................................................926 Override/Fault Reset Switch...................................................927 Retard Speed Control (RSC) Switch.............................................927 Retard Speed Control (RSC) Adjust Dial........................................927 Data Store Button.............................................................928 Engine Control System.........................................................928 Service Engine Light (Blue)...................................................928 Engine Diagnostics Download Port..............................................928 Payload Meter Download Port...................................................928 TCI Download Port.............................................................928 PSC Download Port.............................................................928 PAYLOAD METER.................................................................928 INSTRUMENT PANEL AND INDICATOR LIGHTS.............................................929 CONTROL SYMBOLS...............................................................929 INSTRUMENT PANEL..............................................................930 PANEL GAUGES, INDICATORS, AND CONTROLS............................................931 Key Switch....................................................................931 Starting......................................................................931 Cold Weather Starting.........................................................931 Normal Engine Shutdown........................................................931 Engine Shutdown Switch with 5 Minute Idle Timer Delay.........................932 Fog Lights (Optional).........................................................932 Ladder Light Switch...........................................................932 Manual Backup Switch..........................................................932 Panel Illumination Lights.....................................................933 Cab/Air Conditioner Vents.....................................................933 Rotating Beacon Light Switch (Optional).......................................933 Heated Mirror Switch (Optional)...............................................933 Wheel Brake Lock Control......................................................933 Parking Brake Control.........................................................933 Tachometer....................................................................934 Right Turn Signal Indicator...................................................934 High Beam Indicator...........................................................934 Left Turn Signal Indicator....................................................934 Speedometer / Payload Meter...................................................934 Voltmeter.....................................................................934 Engine Oil Pressure Gauge.....................................................934 Water Temperature Gauge.......................................................934 Fuel Gauge....................................................................934 AC Drive System Temperature Gauge.............................................935 Hydraulic Oil Temperature Gauge...............................................935 Hourmeter.....................................................................935 Rest Switch...................................................................935 Light Switch..................................................................936 Windshield Wiper and Washer...................................................936 Panel Light Dimmer............................................................936 Payload Meter Switch..........................................................936 OVERHEAD STATUS / WARNING INDICATORS..........................................937 STATUS / WARNING INDICATOR LIGHT SYMBOLS......................................938 Hazard Warning Lights.....................................................943 Lamp Test Switch..........................................................943 Link-On Warning Light.....................................................943 LUBRICATION AND SERVICE.......................................................................945 LUBRICATION AND SERVICE...................................................................947 LUBRICATION AND SERVICE...............................................................949 930E-3SE SERVICE CAPACITIES.......................................................949 HYDRAULIC TANK SERVICE............................................................949 Adding Oil....................................................................949 WHEEL MOTOR SERVICE...............................................................949 COOLANT LEVEL CHECK...............................................................950 RADIATOR FILLING PROCEDURE........................................................950 RESERVE ENGINE OIL SYSTEM (Optional)..............................................950 Reserve Oil Tank Filling Procedure (Remote fill)..............................950 LUBRICATION CHART.................................................................951 10 HOUR (DAILY) INSPECTION........................................................952 50 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................955 100 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................956 250 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................957 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................................960 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.....................................961 5000 HOUR MAINTENANCE CHECKS......................................................962 AUTOMATIC LUBRICATION SYSTEM..............................................................963 AUTOMATIC LUBRICATION SYSTEM..........................................................965 GENERAL DESCRIPTION...............................................................965 SYSTEM COMPONENTS.................................................................967 Filter........................................................................967 Hydraulic Motor and Pump......................................................967 Grease Reservoir..............................................................967 Pressure Reducing Valve.......................................................967 Flow Control Valve............................................................967 Solenoid Valve................................................................967 Vent Valve....................................................................967 Lubrication Cycle Timer.......................................................967 Time Delay Module.............................................................967 Pump Cutoff Pressure Switch...................................................967 Grease Pressure Failure Switch................................................967 Pressure Gauge................................................................967 Injectors.....................................................................967 SYSTEM OPERATION..................................................................968 Normal Operation..............................................................968 Pressure Failure Detection Circuits...........................................969 GENERAL INSTRUCTIONS..............................................................970 Lubricant Requirements........................................................970 System Priming................................................................970 System Checkout...............................................................970 LUBRICANT PUMP....................................................................970 Pump Housing Oil Level........................................................970 Pump Pressure Control.........................................................970 Lubrication Cycle Timer Check.................................................971 Lubrication Cycle Timer Adjustment............................................971 FILTER ASSEMBLY...................................................................971 INJECTORS (SL-1 Series “H”))......................................................972 Injector Specifications.......................................................972 Injector Adjustment...........................................................972 INJECTOR OPERATION................................................................973 PUMP REBUILD......................................................................974 Disassembly...................................................................974 Cleaning and Inspection.......................................................976 Assembly......................................................................976 SYSTEM TROUBLESHOOTING CHART......................................................977 PREVENTIVE MAINTENANCE PROCEDURES.................................................979 Daily Lubrication System Inspection...........................................979 250 Hour Inspection...........................................................979 1000 Hour Inspection..........................................................979 ALPHABETICAL INDEX............................................................................981 SYSTEM SCHEMATICS.............................................................................985
KOMATSU 930E-3SE DUMP TRUCK SHOP MANUAL A30366 & UP – PDF DOWNLOAD:
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1 review for Komatsu 930E-3SE Dump Truck Shop Manual A30366 & UP – PDF DOWNLOAD
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Damian Leland –
really good