Komatsu 930E-4 Dump Truck Shop Manual CEBM022203 PDF

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Komatsu 930E-4 Dump Truck Shop Manual CEBM022203 – PDF DOWNLOAD

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Komatsu 930E-4 Dump Truck Shop Manual CEBM022203 – PDF DOWNLOAD

Language : English
Pages : 997
Downloadable : Yes
File Type : PDF

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Komatsu 930E-4 Dump Truck Shop Manual CEBM022203 – PDF DOWNLOAD 

SERIAL NUMBERS A30796 – A31001 Tier II

FOREWORD:

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing 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 typical of the component shown and may not be an exact reproduction of what is found on the truck.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
• When assembly instructions are provided without references to specific torque values, standard torque values
  should be used. Standard torque values are shown in torque charts in the General Information section of this
  manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
• A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (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 “E” designates an Electrical wheel motor drive system.
• The Product Identification Number (vehicle serial number) contains information which identifies several
  characteristics of this unit. For a more detailed explanation, see the end of Section A4.
• 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 maximum GVW.
  GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
• To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck
  (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and
  subtract it from the GVW. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu 930E-4 Dump Truck Shop Manual CEBM022203 – PDF DOWNLOAD 

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
MAJOR COMPONENTS & SPECIFICATIONS 11
TRUCK AND ENGINE 11
MAIN ALTERNATOR 11
AC INDUCTION TRACTION MOTORIZED WHEELS 11
SUSPENSION 11
OPERATOR’S CAB 11
POWER STEERING 11
DYNAMIC RETARDING 11
BRAKE SYSTEM 11
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SAFETY 17
GENERAL 17
Safety Rules 17
Safety Features 17
Fire Extinguisher And First Aid Kit 17
Clothing And Personal Items 17
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Unauthorized Modification 19
Precautions When Using ROPS 19
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 20
Safety At The Worksite 20
Fire Prevention 21
Preparing For Operation 21
Ventilation In Enclosed Areas 21
In Operator’s Cab – Before Starting The Engine 21
Seat Belts 21
Mirrors, Windows And Lights 21
OPERATING THE TRUCK 22
When Starting The Engine 22
General Truck Operation 22
Traveling In Reverse 23
Traveling 23
Traveling On Slopes 23
Ensure Good Visibility 23
Operate Carefully On Snow 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 24
When Dumping 24
Working On Loose Ground 24
When Loading 24
Parking The Truck 24
TOWING 24
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Starting With Booster Cables 25
BEFORE PERFORMING MAINTENANCE 26
Warning Tag 26
Stopping The Engine Before Service 26
Proper Tools 26
Securing the Dump Body 26
WHILE PERFORMING MAINTENANCE 27
Keep The Truck Clean 27
Attachments 27
Working Under The Truck 27
Rotating Fan And Belts 27
Adding Fuel Or Oil 27
Radiator Water Level 28
Use Of Lighting 28
Precautions With The Battery 28
Handling High Pressure Hoses 28
Precautions When Performing Maintenance Near High Temperature Or High Pressure 28
Precautions With High Pressure Oil 28
Waste Materials 28
TIRES 29
Handling Tires 29
Storing Tires After Removal 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 31
Preliminary Procedures Before Welding or Performing Maintenance 31
Engine Shutdown Procedure Before Welding or Performing Maintenance 31
Checking for DC Link Capacitor Charge 33
Discharging the DC Link Capacitors 34
OPERATING INSTRUCTIONS 37
PREPARING FOR OPERATION 37
WALK AROUND INSPECTION 37
ENGINE START-UP 41
AFTER ENGINE HAS STARTED 42
Events 42
OPERATION 43
Description 43
Brake Test Exit Criteria 43
PERFORMING THE BRAKE TESTS 44
Setup 44
Service Brake Test 44
Parking Brake Test 45
Retard System Test 46
EMERGENCY STEERING SYSTEM 46
Operation 46
Pre-Operation Testing 46
MACHINE OPERATION SAFETY PRECAUTIONS 47
OPERATING ON THE HAUL ROAD 48
STARTING ON A GRADE WITH A LOADED TRUCK 49
PASSING 49
LOADING 49
DUMPING 49
Raising The Dump Body 49
Lowering The Dump Body (When dumping on flat ground): 50
Lowering The Dump Body (When dumping over a berm or into a crusher): 51
TOWING 51
Special Wiring Harness 52
SAFE PARKING PROCEDURES 54
NORMAL ENGINE SHUTDOWN PROCEDURE 54
SUDDEN LOSS OF ENGINE POWER 55
FUEL DEPLETION 55
DISABLED TRUCK DUMPING PROCEDURE 56
Hookup 56
Raising the Body 56
Lowering the Body 56
WARNINGS AND CAUTIONS 57
GRADE/SPEED CHART 57
KEY SWITCH 57
ROPS/FOPS 57
BATTERIES 58
CRUSHING HAZARD 58
CYLINDER PRESSURE 59
FILLING THE HYDRAULIC TANK 59
HYDRAULIC OIL PRESSURE 60
WHEEL MOTOR OIL LEVEL 60
EMERGENCY TOWING PROCEDURE 60
EMERGENCY DUMP PROCEDURE 60
ACCUMULATOR DRAIN VALVES 60
HOT EXHAUST 60
WELDING 61
EMERGENCY SHUTDOWN 61
CAPACITORS 61
INFORMATION DISPLAY 62
RADIATOR 62
HIGH VOLTAGE 62
LIFTING INSTRUCTIONS 63
PRODUCT IDENTIFICATION PLATE 64
LUBRICATION CHART 64
TORQUE TABLES AND CONVERSION CHARTS 65
STORAGE AND IDLE MACHINE PREPARATION 75
SHORT TERM IDLE PERIODS 75
PREPARATION FOR STORAGE 76
REMOVAL FROM STORAGE 77
RECONDITIONING AN IDLE VEHICLE 79
ENGINE OPERATION 81
After The Engine Has Started 82
ENGINE STORAGE 83
Temporary Storage (30 Days Or Less) 83
Extended Storage (More Than 30 Days) 83
RESTORING AN ENGINE AFTER EXTENDED STORAGE 85
ELECTRIC DRIVE TRUCKS 86
Storing A Truck That Is Operational 86
Storing A Truck That Is Not Operational 87
Storing A Major Component 88
Periodic Inspections 88
Placing Equipment Into Service After Storage 88
SECTION B STRUCTURES INDEX 91
SECTION B2 STRUCTURAL COMPONENTS INDEX 93
STRUCTURAL COMPONENTS 95
PREPARATION 95
DIAGONAL LADDER, GRILLE AND HOOD 96
Removal 96
Installation 96
RIGHT DECK AND COMPONENTS 97
Removal 97
Installation 97
LEFT DECK AND COMPONENTS 98
Removal 98
Installation 98
CENTER DECK 99
Removal 99
Installation 99
SECTION B3 DUMP BODY INDEX 101
DUMP BODY 103
DUMP BODY 103
Removal 103
Installation 104
BODY PADS 105
Adjustment 105
BODY GUIDE 106
HOIST LIMIT SWITCH 106
BODY-UP SWITCH 106
BODY-UP RETENTION CABLE 106
ROCK EJECTORS 107
Inspection 107
SECTION B4 FUEL TANK INDEX 109
FUEL TANK 111
Removal 111
Repair 111
Cleaning 111
Installation 111
FUEL GAUGE SENDER 113
Removal 113
Installation 113
FUEL TANK VENT ASSEMBLY 113
Disassembly 113
Assembly 113
FUEL RECEIVERS (WIGGINS QUICK FILL) 114
SECTION C ENGINE INDEX 115
SECTION C2 POWER MODULE INDEX 117
POWER MODULE 119
SHUTDOWN PROCEDURE 119
PREPARATION FOR REMOVAL 120
REMOVAL 122
INSTALLATION 125
HOOKUP 126
SECTION C3 COOLING SYSTEM INDEX 127
COOLING SYSTEM 129
RADIATOR 129
Removal 129
Installation 131
Filling Procedure 132
REPAIRING THE RADIATOR 132
Internal Inspection 132
External Cleaning 132
Disassembly 133
Cleaning and Inspection 134
Assembly 134
Pressure Testing 135
COOLANT SYSTEM TROUBLESHOOTING 135
SECTION C4 POWER TRAIN INDEX 137
POWER TRAIN 139
ALTERNATOR REMOVAL 139
ALTERNATOR INSTALLATION 141
Measuring Procedure 141
Joining the Alternator and Engine 143
ENGINE 144
Removal 144
Service 144
Installation 144
SECTION C5 AIR CLEANERS INDEX 145
AIR CLEANERS 147
OPERATION 147
SERVICING THE AIR CLEANERS 147
Replacing The Filter Element 147
Cleaning The Main Filter Element 149
Servicing The Precleaner Section 150
AIR INTAKE TROUBLESHOOTING 151
SECTION C5 AIR CLEANERS INDEX 153
AIR CLEANERS 155
OPERATION 155
SERVICING THE AIR CLEANERS 155
Replacing The Elements 156
AIR CLEANER ASSEMBLY CLEANING 157
Primary Element Cleaning 157
Precleaner Section Cleaning 159
AIR INTAKE TROUBLESHOOTING 160
SECTION C7 FAN CLUTCH INDEX 161
FAN CLUTCH 163
REMOVAL & INSTALLATION TOOLING 163
DISASSEMBLY 166
CLEANING AND INSPECTION 176
ASSEMBLY 180
TEST PROCEDURE 194
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 195
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 197
24VDC ELECTRIC SUPPLY SYSTEM 199
ELECTRICAL SYSTEM DESCRIPTION 199
BATTERIES 199
Maintenance and Service 199
Troubleshooting 199
BATTERY SUPPLY SYSTEM 201
24VDC Battery Charging Alternator 201
Battery Box 201
Battery Control Box 201
Engine Start Relay 201
Isolation Diode (if equipped) 201
24VDC Auxiliary Battery Receptacles 201
Battery Disconnect Switches 202
24VDC to 12VDC Converter 202
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 203
24 VDC ELECTRICAL SYSTEM COMPONENTS 205
BRAKE WARNING BUZZER 205
AUXILIARY CONTROL CABINET COMPONENTS 205
Power Distribution Terminals 205
Control Power Relay 205
Auto Lube Timer 205
Diode Board – DB1 207
Fuse Blocks 208
Alarm Indicating Device (AID) System 208
RELAY BOARDS 211
Relay Boards RB1, RB3, RB4, RB5 211
Relay Board RB6, RB7, RB8, RB9 213
Relay Board Functions 214
BODY-UP SWITCH 216
Operation 216
Adjustment 216
Service 216
HOIST LIMIT SWITCH 218
Operation 218
Adjustment 218
Service 218
FUSE BLOCKS AND CIRCUIT BREAKERS 220
SECTION D11 VEHICLE HEALTH MONITORING SYSTEM (VHMS) INDEX 223
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 225
VHMS BASIC FEATURES 225
Gather Data 225
Convert and Record Data 225
Communicate Data to Off-Board Systems 226
USING VHMS 227
Turning VHMS ON 227
Normal VHMS Operation 227
Turning VHMS OFF 228
Downloading from the VHMS Controller 228
VHMS DATA ITEMS 229
Fault Codes 229
Machine History 229
VHMS History 229
Snapshots 230
Manual Snapshots 230
Trends 232
Histogram (Load Map) Data 232
Haul Cycle Data 233
Alarm and Snapshot Triggers 234
Satellite Features 234
VHMS DIAGNOSTIC FEATURES 236
Fault History 236
VHMS LED Digits 236
VHMS CONTROLLER 236
Removal 237
Installation 237
VHMS SOFTWARE 238
VHMS Tool Box Installation 238
VHMS Setting Tool Installation 238
VHMS INITIALIZATION PROCEDURE 239
VHMS CONTROLLER SETUP PROCEDURE 239
VHMS SNAPSHOT PROCEDURE 242
VHMS DOWNLOAD PROCEDURE 243
VHMS FTP UPLOAD PROCEDURE 244
VHMS INITIALIZATION FORMS 245
WHEN REPLACING A VHMS CONTROLLER 246
VHMS CONTROLLER CHECKOUT 251
Necessary Equipment 251
Preliminary 251
VHMS Controller Checkout Procedure 252
ORBCOMM CONTROLLER 254
Removal 254
Installation 254
SECTION D12 INTERFACE MODULE INDEX 255
INTERFACE MODULE 257
Removal 257
Installation 257
SENSORS 258
Temperature Sensors 258
Pressure Sensors 258
INTERFACE MODULE SOFTWARE 259
Flashburn Program Installation 259
Interface Module Application Code Installation 260
Interface Module Realtime Data Monitor Software 260
INTERFACE MODULE CHECKOUT 261
Necessary Equipment 261
Preliminary 262
Check Digital Inputs To The Interface Module 263
Check Analog Inputs To The Interface Module 265
Check Serial Interfaces To The Interface Module 265
Check Outputs From The Interface Module 266
SECTION D13 INTERFACE MODULE AND VHMS TROUBLESHOOTING INDEX 267
INTERFACE MODULE AND VHMS TROUBLESHOOTING 269
GENERAL 269
TROUBLESHOOTING 270
Communications Networks 270
Coaxial Cable 270
FAULT CODES 270
Fault History 270
VHMS LED Display Fault Codes 271
Chassis Fault Codes 272
Engine Fault Codes 276
FAULT TREE ANALYSIS 282
Unable to connect to VHMS from laptop PC 282
Flashing Error Code N4-23 (PLM III Communications Fault) 283
Flashing Error Code N4-22 (Engine Communications Fault) 284
No Data Received By WebCARE 285
Coaxial Cable Troubleshooting 286
SECTION D14 VHMS FORMS INDEX 287
VHMS FORMS 289
VHMS INITIALIZATION CHECK LIST 289
VHMS DATA DOWNLOAD 290
VHMS INITIALIZATION FORM 290
VHMS INITIALIZATION CHECK LIST 292
VHMS INITIALIZATION FORM 294
SECTION E ELECTRIC PROPULSION SYSTEM INDEX 295
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 297
ELECTRICAL PROPULSION SYSTEM COMPONENTS 299
GENERAL SYSTEM DESCRIPTION 299
SYSTEM COMPONENTS 301
Propulsion System Controller (PSC) 301
Truck Control Interface (TCI) 302
Diagnostic Information Display (DID) Panel 303
DID Panel Event Codes 303
PSC SOFTWARE FUNCTIONS 322
Input Processing 322
State Machine 322
DC Link State 325
Engine Control 326
ALTERNATOR FIELD CONTROL 326
Desired Three-Phase Voltage 326
Desired DC Link Voltage 326
Self-Load 327
Propel Torque Control 327
Retard Torque Control 327
Wheel Slide Control 328
Resistor Grid Control 328
Chopper Voltage Control 328
EVENT DETECTION AND PROCESSING 328
Power-On Tests 328
Initiated Tests 329
Periodic Tests 329
EVENT RESTRICTIONS 329
EVENT LOGGING AND STORAGE 329
Event History Buffer 330
Data Packs 330
To Record and Save a Data Pack to a Disk 330
Event Reset 331
SERIAL DATA COMMUNICATIONS 331
PSC – TCI Communications Processing 331
PSC – PTU Communications Processing 331
Inverter Communications Processing 332
OUTPUT PROCESSING 332
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 332
Fast Start 332
Engine Shutdown/Engine Not Running 332
Limp Home Mode 333
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 334
ELECTRONIC ACCELERATOR AND RETARD PEDALS 342
Removal 342
Installation 342
Disassembly 342
Assembly 342
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 343
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 345
AC DRIVE SYSTEM MAINTENANCE 345
NORMAL TRUCK SHUTDOWN PROCEDURE 346
SHUTDOWN AFTER SYSTEM FAILURE 346
SYSTEM CHECKOUT 347
Battery and Control Circuit Checks – Battery Power OFF 347
Battery and Control Circuit Checks – Battery Power ON 350
Checks with Key Switch OFF 351
Checks with Key Switch ON 351
CPU Battery Checks 351
MEMORY BACKUP BATTERY REPLACEMENT 352
TCI PROGRAMMING 352
PSC PROGRAMMING 353
INVERTER PROGRAMMING 353
CPU RESET 353
PSC CHECKOUT 354
PSC Digital Input Checks 354
PSC Digital Output Checks 358
TCI CHECKOUT 359
Modular Mining Communication Port Check 359
TCI Digital Input Checks 359
TCI Digital Output Tests 365
CALIBRATIONS 367
Speedometer 367
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 367
ERASING EVENTS 367
PSC 367
TCI 368
GATE DRIVER POWER CONVERTER TEST 368
LOAD TESTING 369
Preparation 369
Alternator Speed Sensor Checks 369
Battery Boost Check 369
Brake Circuit Switch Checks 370
Hoist & Steering Circuit Switch Checks 370
Link Energized Checks 370
Loadbox Test 372
TROUBLESHOOTING 376
PVM Optimum Load Curve Handshaking Troubleshooting 376
Phase Module and Chopper Module Troubleshooting 376
PHASE MODULE REPLACEMENT 377
Phase Module Removal 377
Phase Module Installation 377
SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX 379
SECTION G2 TIRES AND RIMS INDEX 381
TIRES AND RIMS 383
WHEEL STUD MAINTENANCE 384
FRONT TIRES AND RIMS 385
Removal 385
Installation 386
REAR TIRES AND RIMS 387
Removal 387
Installation 388
RIM 389
Tire Removal 389
Tire Installation 389
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 391
FRONT WHEEL HUB AND SPINDLE 393
WHEEL HUB AND SPINDLE ASSEMBLY 393
Removal 393
Installation 396
Disassembly 397
Cleaning and Inspection 397
Assembly 399
Wheel Bearing Adjustment 399
Brake Installation 400
Seal Assembly Gap Check 401
STEERING CYLINDERS AND TIE ROD 403
Spherical Bearing Wear Limits 403
Removal 404
Installation 405
Bearing Replacement 405
TOE-IN ADJUSTMENT 406
WHEEL SPEED SENSOR TESTING 406
SECTION G4 REAR AXLE MOUNTING INDEX 407
REAR AXLE MOUNTING 409
PIVOT PIN 409
Removal 409
Installation 410
PIVOT EYE BEARING 410
Removal 410
Installation 410
PIVOT EYE REPAIR 411
Removal 411
Installation 411
ANTI-SWAY BAR 412
Removal 412
Disassembly 412
Cleaning and Inspection 412
Assembly 412
Installation 412
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 415
REAR AXLE AND WHEEL MOTOR 417
REAR AXLE HOUSING 417
Preparation 417
Removal 418
Cleaning and Inspection 419
Installation 419
WHEEL MOTOR 419
Preparation 419
Removal 420
Cleaning and Inspection 422
Installation 422
WHEEL MOTOR GEAR OIL 427
Filtering Requirements 427
Particle Size Analysis 427
Flushing 427
Oil Sample Analysis 428
ELEMENT SPECIFICATION CHARTS 429
SECTION H HYDRAIR® II SUSPENSIONS INDEX 433
SECTION H2 FRONT SUSPENSIONS INDEX 435
FRONT SUSPENSION 437
Removal 437
Installation 438
Inspection 443
MINOR REPAIRS (LOWER BEARING & SEALS) 444
Removal – Bearing Retainer 444
Installation – Bearing Retainer 444
MAJOR SUSPENSION REBUILD 446
Disassembly 446
Assembly 447
SUSPENSION PRESSURE TEST 448
SECTION H3 REAR SUSPENSIONS INDEX 449
REAR SUSPENSIONS 451
SUSPENSION CYLINDER 452
Removal 452
Installation 454
Disassembly 454
Cleaning and Inspection 455
Assembly 455
SUSPENSION PRESSURE TEST 457
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 459
SUSPENSION OILING AND CHARGING PROCEDURE 461
GENERAL 461
EQUIPMENT LIST 461
HYDRAIR® CHARGING KIT 462
Installation of Charging Kit 462
Removal of Charging Kit 462
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 463
FRONT SUSPENSION 463
Front Suspension Oiling 463
Front Suspension Nitrogen Charging 465
REAR SUSPENSION 466
Rear Suspension Oiling 467
Rear Suspension Nitrogen Charging 469
OIL AND NITROGEN SPECIFICATIONS CHARTS 470
SECTION J BRAKE CIRCUIT INDEX 471
SECTION J2 BRAKE CIRCUIT INDEX 473
BRAKE CIRCUIT 475
SERVICE BRAKE CIRCUIT 475
PARKING BRAKE CIRCUIT 477
BRAKE LOCK CIRCUIT 477
SECONDARY BRAKING AND AUTOMATIC APPLY 478
WARNING CIRCUIT 478
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 481
BRAKE CIRCUIT COMPONENT SERVICE 483
BRAKE VALVE 483
Rebuild Criteria 483
Removal 484
Installation 484
Disassembly 485
Cleaning and Inspection 488
Assembly 488
Regulator Sleeve O-Ring Installation 489
BRAKE VALVE BENCH TEST AND ADJUSTMENT 491
Test Setup Procedure 492
Brake Valve Output Pressure Adjustment 492
Final Test and Adjustment 493
Installing Brake Pedal Actuator Assembly to Brake Valve 493
Installing Retard Pedal To Brake Pedal 493
DUAL RELAY VALVE 494
Removal 494
Installation 494
Disassembly 494
Cleaning and Inspection 495
Assembly 496
DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT 497
Test Setup Procedure 498
Relay Valve Output Pressure Adjustment 498
BRAKE MANIFOLD 499
Removal 499
Installation 499
Disassembly 499
Cleaning and Inspection 500
Assembly 500
BRAKE ACCUMULATORS 500
Brake Accumulator Bleeddown Procedure 500
Removal 501
Installation 501
Disassembly 502
Cleaning and Inspection 503
Assembly 503
Accumulator Charging Procedure 505
Precharge Maintenance 507
Accumulator Storage Procedures 508
Bladder Storage Procedures 508
Installing A Bladder Accumulator From Storage 508
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 509
Removal 509
Installation 509
Disassembly 509
Lever Adjustments 509
Potentiometer Check 510
Assembly 510
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 513
BRAKE CIRCUIT CHECK-OUT PROCEDURE 515
REQUIRED EQUIPMENT 516
INITIAL SYSTEM SETUP 517
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 518
PARKING BRAKE CHECK-OUT 519
SERVICE BRAKE CHECK-OUT 520
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 521
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 522
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 524
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 527
WET DISC BRAKE ASSEMBLY 529
OPERATION 529
BRAKE DISC WEAR INSPECTION 530
BRAKE REBUILD 531
Disassembly 531
Cleaning and Inspection 535
Assembly 536
Floating Ring Seal Assembly & Installation 541
WET DISC BRAKE BLEEDING PROCEDURE 545
SECTION J7 PARKING BRAKE INDEX 547
PARKING BRAKE 549
OPERATION 549
MAINTENANCE 550
Inspection 550
Removal 550
Installation 551
Disassembly 551
Cleaning and Inspection 551
Assembly 553
PARKING BRAKE BLEEDING PROCEDURE 554
SECTION L HYDRAULIC SYSTEM INDEX 557
SECTION L2 HYDRAULIC SYSTEM INDEX 559
HYDRAULIC SYSTEM 561
HYDRAULIC PUMP MODULE 561
HOIST CIRCUIT OPERATION 562
STEERING CIRCUIT OPERATION 564
DISC BRAKE COOLING SYSTEM 566
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 569
HYDRAULIC SYSTEM COMPONENT REPAIR 571
HOIST PUMP 571
Removal 571
Installation 573
Inspection 578
Assembly 578
HYDRAULIC TANK 584
Filling Instructions 584
Removal 585
Installation 585
HYDRAULIC TANK BREATHERS 585
HYDRAULIC TANK STRAINERS 586
Removal 586
Inspect and Clean 586
Installation 586
SECTION L4 STEERING CIRCUIT INDEX 587
STEERING CIRCUIT 589
COMPONENT DESCRIPTION 590
Steering Control Unit 590
Bleeddown Manifold Valve 591
Steering Accumulator Bleeddown Solenoid 591
Relief Valves 593
Hoist Up Limit Solenoid 593
Steering Accumulators 593
Low Precharge Warning Switch 593
High Pressure Filter 593
Quick Disconnect Ports 593
Flow Amplifier 595
FLOW AMPLIFIER SYSTEM OPERATION 596
No Steer 596
Steering Left 598
Steering Right 600
No Steer, External Shock Load 602
STEERING PUMP 604
Normal Operation 604
PRINCIPLE OF OPERATION 606
Full Pump Volume 606
Half Pump Volume 606
Neutral Position 606
Steering Pump 607
SECTION L5 STEERING CONTROL UNIT INDEX 609
STEERING CONTROL UNIT 611
REMOVAL 611
SPLINE INSPECTION 611
INSTALLATION 612
DISASSEMBLY 612
CLEANING AND INSPECTION 613
ASSEMBLY 615
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 619
STEERING CIRCUIT COMPONENT REPAIR 621
BLEEDDOWN MANIFOLD VALVE 621
Removal 621
Installation 622
FLOW AMPLIFIER 623
Removal 623
Installation 623
Disassembly 623
Assembly 625
STEERING CYLINDERS 626
Disassembly 627
Piston Seal & Bearing Installation 627
Assembly 627
Testing 627
STEERING AND BRAKE PUMP 628
Removal 628
Installation 629
Disassembly 630
Inspection 633
Assembly 636
Driveshaft Group 637
Rotating Group 637
Valve Plate Group 638
STEERING ACCUMULATORS 639
Removal 639
Installation 639
Disassembly 640
Cleaning and Inspection 640
Assembly 641
Leak Testing 643
Charging Procedure 644
Precharge Maintenance 646
Accumulator Storage Procedures 647
Bladder Storage Procedures 647
Installing A Bladder Accumulator From Storage 647
TROUBLESHOOTING CHART 648
SECTION L7 HOIST CIRCUIT INDEX 653
HOIST CIRCUIT 655
BASIC OPERATION 655
COMPONENT DESCRIPTION 656
Hydraulic Tank 656
Hydraulic Pump 656
High Pressure Filters 656
Hoist Valve 656
Inlet Sections 656
Work Ports (Rear) Spool Section 657
Tank Ports (Front) Spool Section 657
Hoist Pilot Valve 657
Bleeddown Manifold 658
Hoist Up Limit Solenoid 658
Pilot Operated Check Valve 658
Overcenter Manifold 658
HOIST CIRCUIT OPERATION 659
Float Position Of Pilot Valve With Truck Body On Frame 660
Power Up Operation 662
Hold Operation 664
Power Down Operation 666
Float Operation 668
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 671
HOIST CIRCUIT COMPONENT REPAIR 673
HOIST VALVE 673
Removal 673
Installation 674
O-Ring Replacement 674
INLET SECTION 675
Disassembly 675
Cleaning and Inspection 676
Assembly 676
REAR SPOOL SECTION (Work Ports) 677
Disassembly 677
Cleaning and Inspection 677
Assembly 679
FRONT SPOOL SECTION (Tank Ports) 680
Disassembly 680
Cleaning and Inspection 680
Assembly 680
HOIST PILOT VALVE 682
Removal 682
Installation 682
Disassembly 683
Cleaning and Inspection 684
Assembly 684
HOIST CYLINDERS 685
Removal 685
Installation 686
Disassembly 688
Cleaning and Inspection 689
Assembly – Quill 690
Assembly – Cylinder 692
Testing 692
OVERCENTER VALVE MANIFOLD 693
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 695
HYDRAULIC SYSTEM FILTERS 697
HOIST CIRCUIT FILTER 697
Filter Element Replacement 697
Removal – Hoist Circuit Filter 698
Installation – Hoist Circuit Filter 698
Indicator Switch – Hoist Circuit Filter 698
STEERING CIRCUIT FILTER 699
Filter Element Replacement 699
Removal – Steering Circuit Filter 700
Installation – Steering Circuit Filter 700
Indicator Switch – Steering Circuit Filter 700
INDICATOR SWITCH 700
Test Procedure 700
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 703
HYDRAULIC CHECKOUT PROCEDURE 705
GENERAL INFORMATION 705
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 712
Equipment Requirements 713
Pump Pressure Control Adjustments 713
Steering Control Valve and Flow Amplifier Leakage Test 714
Bleeddown Manifold Leakage Test 715
STEERING/BRAKE PUMP STROKE ADJUSTMENT 716
SHOCK AND SUCTION VALVES 716
Equipment Requirements 716
Pressure Tests 716
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 717
Equipment Requirements 717
Pressure Gauge Locations 717
Brake Cooling Circuit Test 718
Power Up Relief Pressure Test 719
Power Down Relief Pressure Test 720
Counterbalance Valve Pressure Check 721
Counterbalance Valve Adjustment 722
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 723
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 724
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 725
SECTION M7 HEATER OPTIONS INDEX 727
ENGINE OIL HEATERS 729
GENERAL INFORMATION 729
TROUBLESHOOTING 729
HEATER ELEMENT 729
Removal 729
Installation 730
ENGINE COOLANT HEATER 731
GENERAL 731
Maintenance 731
HEATING ELEMENT 731
Removal 731
Installation 732
THERMOSTAT 732
Removal 732
Installation 732
HYDRAULIC OIL HEATERS 733
GENERAL INFORMATION 733
TROUBLESHOOTING 733
HEATER ELEMENT 733
Removal 733
Installation 734
SECTION M8 SPECIAL TOOLS 735
SECTION M19 RADIATOR SHUTTERS INDEX 741
RADIATOR SHUTTERS 743
OPERATION 743
Hydraulic Circuit 743
Electrical Circuit 744
MAINTENANCE AND REPAIR 744
TROUBLESHOOTING 745
SECTION M20 PAYLOAD METER III ™ INDEX 749
OPERATION SECTION 753
Introduction 753
Data Summary 753
Data Gathering 753
COMPONENT DESCRIPTION 754
System Diagram 754
Suspension Pressure Sensors 754
Inclinometer 754
Operator Display 754
Operator Switch 755
Speed Input 755
Body-Up Switch 755
Brake Lock Switch 755
Payload Meter 755
Communications Ports 755
Key Switch Input 756
Payload Meter Power 756
Load Lights 756
Wiring and Termination 757
TCI Outputs 757
OPERATOR’S DISPLAY AND SWITCH 758
Reading the Speedometer 758
Reading the Load Display 758
Using the Operator ID 758
Using the Load and Ton Counter 758
Total Ton Counter 758
Total Load Counter 759
Clearing the Counters 759
Viewing Live Sensor Data 759
Other Display Messages 759
PAYLOAD OPERATION & CALCULATION 760
Description of Haul Cycle States 760
Haul Cycle Description 760
Load Calculation 761
Carry Back 761
Measurement Accuracy 761
SOURCES FOR PAYLOAD ERROR 761
Payload Error 761
Loading Conditions 762
Pressure Sensors 762
Swingloads 762
Speed and Distance 762
HAUL CYCLE DATA 762
Haul Cycle Warning Flags 764
Frame Torque Data 765
Sprung Weight Data 765
Maximum Speed Data 765
Alarm Records 765
Fault Code Data 766
PC SOFTWARE OVERVIEW 767
System Configuration 767
Installing the PLMIII Software 767
DOWNLOADING DATA 768
PLM III SYSTEM CONFIGURATION 769
Starting Communications 769
Displayed Payload Units 769
Time Units 769
Connection Menu 769
Connecting to the Payload Meter 770
Configure the Payload Meter 770
Setting the Date and Time 770
Setting the Truck Type 771
Setting the Gauge Display Units 771
Setting the Frame Serial Number 771
Setting the Truck Number 771
Setting the Komatsu Distributor 771
Setting the Komatsu Customer 771
Clean Truck Tare 772
Inclinometer Calibration 772
DATA ANALYSIS 773
Creating a Query 773
Sorting on Truck Unit Number 773
Sorting on Truck Type 773
Sorting on Date Range 774
Sorting on Time Range 774
Payload Detail Screen 775
Creating Reports 775
Summary – one page report 776
Detailed – multi-page report 776
Creating Graphs 777
Exporting Data 777
CSV Export 777
Compressed 778
Importing Data 779
Deleting Haul Cycle Records 779
Viewing Alarms 780
Deleting Alarm Records 780
TROUBLESHOOTING SECTION 781
TROUBLESHOOTING 781
Viewing Active Alarms 781
Real-Time Data Display 781
Testing the Payload Lights 781
Creating Log Files of Inputs 782
Daily Inspections 782
Periodic Maintenance 782
Abnormal Displays at Power-Up 783
No Payload Display When Key Switch is Turned ON 784
No Display on Speedometer 785
No Display on Operator Display 785
No Communications With PC 786
Load Lights Don’t Light During Loading 787
Load Lights Remain ON 788
Load Lights Remain ON During Dumping 788
Display Doesn’t Clear When The Load Is Dumped 788
Calibration Problems 789
Alarm 1 – Left Front Pressure High 790
Alarm 2 – Left Front Pressure Low 790
Troubleshoot Wiring to Left Front Suspension 790
Alarm 3 – Right Front Pressure High 791
Alarm 4 – Right Front Pressure Low 791
Troubleshoot Wiring to Right Front Suspension 791
Alarm 5 -Left Rear Pressure High 792
Alarm 6 – Left Rear Pressure Low 792
Troubleshoot Wiring to Left Rear Suspension 792
Alarm 7 – Right Rear Pressure High 793
Alarm 8 – Right Rear Pressure Low 793
Troubleshoot Wiring to Right Rear Suspension 793
Alarm 9 – Inclinometer High 794
Alarm 10 – Inclinometer Low 794
Troubleshoot Inclinometer Wiring 794
Alarm 13 – Body Up Input Failure 795
Alarm 16 – Memory Write Failure 796
Alarm 17 – Memory Read Failure 796
Alarm 18 797
Alarm 19 797
Alarm 22 797
Operator Switch Doesn’t Work 798
Alarm 26 – User Switch Fault – SELECT 798
Alarm 27 – User Switch Fault – SET 798
Connector Map 799
Connectors 800
PLMIII CHECK OUT PROCEDURE 801
General Description 801
Tools Required 801
Checkout Procedure 801
PLMIII CHECKOUT PROCEDURE CONFIRMATION 805
Flashburn Programming 805
Confirmation Checklist 807
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 809
RESERVE ENGINE OIL SYSTEM 811
Operation 812
LED Monitor Light 812
Tank Fill Control (Optional) 813
Filling Procedure (Remote fill feature) 813
SERVICE 814
Every 10 Hours, or once each shift: 814
Every 500 Hours: 814
Changing Oil 814
TROUBLESHOOTING 815
Circuit Fuse 815
SYSTEM ELECTRICAL SCHEMATICS 816
SECTION N OPERATOR CAB INDEX 817
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 819
TRUCK CAB AND COMPONENTS 821
TRUCK CAB 821
Description 821
Removal 822
Installation 823
CAB DOOR 824
Removal 824
Installation 824
Door Jamb Bolt Adjustment 825
Door Handle Plunger Adjustment 826
Replacing the Door Glass 827
Replacing the Door Window Regulator 831
Replacing the Door Handle or Latch Assembly 832
Replacing the Door and Door Hinge Seal 832
Removing the Door Opening Seal 833
Installation 833
GLASS REPLACEMENT (Adhesive-Bonded Windows) 834
Recommended Tools and Supplies 834
Replacement Procedure 834
WINDSHIELD AND REAR GLASS 835
Removal 835
Installation 836
SECTION N3 CAB COMPONENTS INDEX 837
CAB COMPONENTS 839
WINDSHIELD WIPERS 839
WIPER MOTOR 839
Removal 839
Installation 839
WIPER ARM 839
Removal 839
Installation 840
WIPER LINKAGE 840
Removal 840
Installation 840
WINDSHIELD WASHER 841
Operation 841
Service 841
OPERATOR SEAT 842
Adjustment 842
Inspection 843
Removal 843
Installation 843
PASSENGER SEAT 844
Inspection 844
Removal 844
Installation 844
SEAT BELT 845
Removal 845
Installation 845
SECTION N4 HEATER / AIR CONDITIONER INDEX 847
HEATER/AIR CONDITIONER 849
OPERATION 849
Fan Speed Control Knob 849
Temperature Control Knob 849
Air Flow Directional Knob 850
Heater/Air Conditioner Vents 850
COMPONENTS 850
Fuse and Circuit Breaker 850
Relays 850
Heater Core 851
Fan Motor And Speed Control 851
Actuators 851
Cab Air Filter 851
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 854
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 854
PRINCIPLES OF REFRIGERATION 854
Air Conditioning 854
Refrigeration – The Act Of Cooling 855
The Refrigeration Cycle 855
AIR CONDITIONER SYSTEM COMPONENTS 856
Compressor (Refrigerant Pump) 856
Service Valves 856
Condenser 856
Receiver-Drier 856
Expansion Block Valve 857
Accumulator 857
Evaporator 857
ELECTRICAL CIRCUIT 858
Thermostat 858
Compressor Clutch 858
Trinary™ Switch 859
AIR CONDITIONING SYSTEM SERVICING WARNINGS 860
SERVICE TOOLS AND EQUIPMENT 861
Recovery/Recycle Station 861
Leak Detector 861
Manifold Gauge Set 862
Installing Manifold Gauge Set 863
Purging Air From Service Hoses 863
Service Valves 864
Vacuum Pump 864
SYSTEM PERFORMANCE TEST 865
SYSTEM OIL 866
Handling and Reusing PAG Oil 866
Oil Quantity 866
Checking System Oil 866
REFRIGERANT 867
Recycled Refrigerant 867
Reclaimed Refrigerant 867
Refrigerant Quantity 868
R-134a Refrigerant Containers 868
SYSTEM LEAK TESTING 868
Electronic Leak Detector 869
Tracer Dyes 869
Soap and Water 869
RECOVERING AND RECYCLING THE REFRIGERANT 869
Draining Oil from the Previous Recovery Cycle 869
Performing the Recovery Cycle 869
Performing the Recycling Procedure 870
Evacuating and Charging the A/C System 870
SYSTEM REPAIR 870
System Flushing 870
A/C DRIVE BELT CHECKOUT PROCEDURE 871
Pulley Alignment 871
Belt Tension Check 871
COMPONENT REPLACEMENT 873
Hoses and Fittings 873
Lines 873
Expansion Valve 873
Receiver-Drier 873
Thermostat 873
Compressor 874
Accumulator 874
Clutch 874
Servicing the Compressor Clutch 875
Pulley Removal 877
Clutch Coil Check 877
Pulley Installation 877
Clutch Assembly Installation 878
EVACUATING THE SYSTEM 879
CHARGING THE A/C SYSTEM 880
TROUBLESHOOTING 881
Preliminary Checks 881
Diagnosis Of Gauge Readings And System Performance 881
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 882
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 888
SECTION N5 OPERATOR CAB CONTROLS INDEX 889
OPERATOR CAB CONTROLS 891
STEERING COLUMN 892
Removal 892
Inspection 892
Installation 893
STEERING WHEEL 893
Removal 893
Installation 893
STEERING WHEEL AND CONTROLS 894
Horn Button 894
Tilt / Telescope Lever 894
Multi-Function Turn Signal Switch 894
DYNAMIC RETARDING 895
Retarder Lever 895
Brake/Retarder Pedal 895
Throttle/Accelerator Pedal 896
GRADE/SPEED CHART 896
OVERHEAD PANEL AND DISPLAYS 897
CENTER CONSOLE 898
Directional Control Lever 898
Override/Fault Reset Switch 899
Engine Shutdown Switch 899
Window Control Switches 899
Hoist Control Lever 899
Retarder Speed Control (RSC) Adjustment Dial 900
Retarder Speed Control (RSC) Switch 900
Data Store Button 901
VHMS Snapshot In Progress Light 901
Link Energized Light 901
Service Engine Light 901
12V Auxiliary Power Outlets 901
DIAGNOSTIC PORTS 901
VHMS Diagnostic Port 901
Interface Module (IM) Diagnostic Port 901
Payload Meter Diagnostic Port 901
Truck Control Interface (TCI) Diagnostic Port 901
Propulsion System Controller (PSC) Diagnostic Port 901
Engine Diagnostic Port (CENSE) 901
Engine Diagnostic Port (QUANTUM) 901
INSTRUMENT PANEL 902
Control Symbols 902
Key Switch 904
Rotating Beacon Switch (optional) 904
Heated Mirrors Switch (optional) 904
AC Drive System Rest Switch 904
Wheel Brake Lock Switch 905
Hazard Warning Lights 905
Heater/Air Conditioner Vents 905
Engine Oil Pressure Gauge 905
Right Turn Signal Indicator 905
Digital Tachometer 905
High Beam Indicator 905
Speedometer/Payload Meter Display 905
Left Turn Signal Indicator 906
Water Temperature Gauge 906
Lamp Check Switch 906
Headlight/Panel Illumination Light Switch 906
Ladder Light Switch (3-Way) 906
Backup Light Switch 906
Fog Light Switch 907
Payload Meter Switch 907
Panel Illumination Light Dimmer Switch 907
Hydraulic Oil Temperature Gauge 907
Engine Hourmeter 907
Fuel Gauge 907
OVERHEAD STATUS / WARNING INDICATORS 908
A1 High Brake Oil Temperature 909
B1 Low Steering Pressure 909
C1 Low Accumulator Precharge Pressure 910
D1 Not used 910
E1 Low Brake Pressure 910
A2 Low Hydraulic Tank Level 910
B2 Low Automatic Lubrication System Pressure 910
C2 Circuit Breaker Tripped 910
E2 Low Fuel 911
A3 Parking Brake 911
B3 Service Brake 911
C3 Body Up 911
D3 Dynamic Retarding 911
E3 Stop Engine 912
A4 Cranking Motor Failure 912
B4 Backup Lights 912
C4 Engine Shutdown Timer 912
D4 Retard Speed Control (RSC) Indicator 912
E4 Check Engine 912
A5 No Power 913
B5 Propulsion System Warning 913
C5 Propulsion System Temperature 913
D5 System/Component Failure 913
A6 No Propel 913
B6 Propel System At Rest 913
C6 Propel System Not Ready 914
D6 Reduced Propulsion 914
E6 Retard At Continuous Level 914
REAR AXLE LIGHT BAR 915
Backup Lights 915
Retard Lights 915
Brake Light 915
Backup Alarm 915
VEHICLE HEALTH MONITORING SYSTEM (VHMS) 916
Operation 916
Basic Precautions 917
SECTION P LUBRICATION AND SERVICE INDEX 919
SECTION P2 LUBRICATION AND SERVICE INDEX 921
LUBRICATION AND SERVICE 923
GENERAL 923
SERVICE CAPACITIES 923
HYDRAULIC TANK SERVICE 923
Adding Oil 923
COOLING SYSTEM SERVICE 924
Radiator Filling Procedure 924
Coolant Specifications 924
Unacceptable Practices 924
WHEEL MOTOR SERVICE 924
RESERVE OIL TANK SERVICE 925
Filling the Reserve Oil Tank (Remote Fill) 925
Inline Screen 925
LUBRICATION CHART 926
10 HOUR (DAILY) INSPECTIONS 927
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 930
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 930
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 930
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 933
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 934
5000 HOUR MAINTENANCE CHECKS 935
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 937
AUTOMATIC LUBRICATION SYSTEM 939
GENERAL DESCRIPTION 939
SYSTEM COMPONENTS 941
Filter 941
Hydraulic Motor and Pump 941
Grease Reservoir 941
Pressure Reducing Valve 941
Flow Control Valve 941
Solenoid Valve 941
Vent Valve 941
Lubrication Cycle Timer 941
Over Pressure Cutoff Switch 941
Grease Pressure Failure Switch 941
Pressure Gauge 941
Injectors 941
Relief Valve (Unloader Valve) 941
SYSTEM OPERATION 942
GENERAL INSTRUCTIONS 943
Required Lubricant 943
System Priming 943
Filter Assembly 943
LUBRICANT PUMP 944
Pump Housing Oil Level 944
Pump Pressure Control 944
INJECTORS (SL-1 Series “H”) 945
Injector Specifications 945
Injector Adjustment 945
INJECTOR OPERATION 946
PREVENTIVE MAINTENANCE PROCEDURES 947
Daily Lubrication System Inspection 947
250 Hour Inspection 947
1,000 Hour Inspection 947
SYSTEM CHECKOUT 948
Lubrication Controller Check 948
Lubrication Controller Operation 948
Lubrication Controller Components 948
Lubrication Controller Adjustment 948
SYSTEM TROUBLESHOOTING CHART 950
SECTION Q ALPHABETICAL INDEX 953
SECTION R SYSTEM SCHEMATICS INDEX 957
HYDRAULIC SCHEMATIC – EM1371 959
HYDRAULIC BRAKE SCHEMATIC – EM1358 960
ELECTRICAL SCHEMATICS – XS6200 961

S.V 12/12/24