Komatsu 930E-3SE Dump Truck Shop Manual CEBM015801 PDF

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Komatsu 930E-3SE Dump Truck Shop Manual CEBM015801 – PDF DOWNLOAD

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Komatsu 930E-3SE Dump Truck Shop Manual CEBM015801 – PDF DOWNLOAD 

Language : English
Pages : 1030
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 930E-3SE Dump Truck Shop Manual CEBM015801 – PDF DOWNLOAD 

SERIAL NUMBERS A30366 & UP

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.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 930E-3SE Dump Truck Shop Manual CEBM015801 – PDF DOWNLOAD 

SERIAL NUMBERS A30366 & UP

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

S.V 15/12/24