Description
Komatsu 930E-4SE Dump Truck Shop Manual
This is the complete Komatsu 930E-4SE Dump Truck Shop Manual, document number CEBM024100, covering trucks from serial number A31035 and up. It is the full service and repair reference for the 930E-4SE off-highway rear dump truck with AC electric drive, and it goes far beyond a routine maintenance booklet. Every major mechanical and electrical system on the truck is broken down into its own dedicated section, with disassembly, inspection, repair and reassembly procedures written for the technician working on the machine.
If you are searching for the Komatsu 930E-4SE shop manual PDF, this document gives you the same system-by-system coverage that a workshop relies on when a wheel motor comes out, when a hoist cylinder is rebuilt, when the brake circuit needs pressure testing, or when the electric propulsion cabinet has to be opened safely. It is written for the 930E-4SE specifically, not a generic haul truck guide.
File Details
- Manual type: Shop Manual / Service Manual
- Brand: Komatsu
- Model: 930E-4SE Dump Truck
- Document number: CEBM024100
- Serial numbers covered: A31035 & up
- Language: English
- File format: PDF
- Page count: 981 pages
Chapters Covered
The manual is organized into major sections, each with its own index and sub-sections:
- Section A — General Information: Major components & specifications, safety and operating instructions, warnings and cautions, torque tables and conversion charts, storage and idle machine preparation
- Section B — Structures: Structural components, dump body, fuel tank, diagonal ladder, grille and hood, decks
- Section C — Engine: Power module removal and installation, cooling system and radiator repair, power train, alternator removal and installation, air cleaners, fan clutch
- Section D — Electric System (24 VDC, Non-Propulsion): Batteries, 24VDC electrical supply system, 24VDC electrical system components, relay boards, fuse blocks, circuit breakers, KOMTRAX Plus, interface module, troubleshooting
- Section E — Electric Propulsion and Control: Electric propulsion system components, AC drive system electrical checkout procedure, PSC and TCI controllers, DID panel fault codes, event detection and processing, phase module replacement, gate driver power converter testing
- Section G — Drive Axle, Spindles and Wheels: Tires and rims, front wheel hub and spindle, rear axle mounting, rear axle and wheel motor, wheel motor gear oil analysis
- Section H — Hydrair® II Suspensions: Front suspensions, rear suspensions, oiling and charging procedures, oil and nitrogen specifications
- Section J — Brake Circuit: Service brake circuit, parking brake, brake lock, secondary braking and automatic apply, brake valve service and bench testing, dual relay valve, brake manifold, brake accumulators, wet disc brake assembly, parking brake service
- Section L — Hydraulic System: Hydraulic pump module, hoist circuit and component repair, steering circuit and component repair, steering control unit, steering accumulators, hydraulic system filters, hydraulic checkout procedure and flushing
- Section M — Options and Special Tools: Heater options, special tools, radiator shutters, Payload Meter III, reserve engine oil system
- Section N — Operator’s Cab: Truck cab and components, cab components, heater/air conditioner, operator cab controls
- Section P — Lubrication and Service: Lubrication chart, service capacities, 10/50/100/250/500/1000/5000 hour maintenance checks, automatic lubrication system
- Section Q — Alphabetical Index
- Section R — System Schematics: Hydraulic supply, brake cooling, steering and hoist schematics, hydraulic brake system schematic, complete electrical schematics
Complete PDF Bookmark Tree
Complete Bookmarks
The complete bookmarks in the “Komatsu 930E-4SE Dump Truck Shop Manual CEBM024100 – PDF Download” are as follows:
COVERp. 1
FOREWORDp. 5
TABLE OF CONTENTSp. 7
+SECTION A GENERAL INFORMATION INDEXp. 9
+MAJOR COMPONENTS & SPECIFICATIONSp. 11
TRUCK AND ENGINEp. 11
MAIN ALTERNATORp. 11
AC INDUCTION TRACTION MOTORIZED WHEELSp. 11
SUSPENSIONp. 11
OPERATOR CABp. 11
POWER STEERINGp. 11
DYNAMIC RETARDINGp. 11
BRAKE SYSTEMp. 11
+SPECIFICATIONSp. 13
ENGINEp. 13
AC ELECTRIC DRIVE SYSTEMp. 13
DYNAMIC RETARDINGp. 13
BATTERY ELECTRIC SYSTEMp. 13
SERVICE CAPACITIESp. 13
HYDRAULIC SYSTEMSp. 14
SERVICE BRAKESp. 14
STEERINGp. 14
TIRESp. 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONSp. 14
WEIGHT DISTRIBUTIONp. 15
+SAFETYp. 17
+GENERALp. 17
Safety Rulesp. 17
Safety Featuresp. 17
Fire Extinguisher And First Aid Kitp. 17
Clothing And Personal Itemsp. 17
Leaving The Operator’s Seatp. 18
Mounting And Dismountingp. 18
Fire Prevention For Fuel And Oilp. 18
Precautions With High Temperature Fluidsp. 19
Asbestos Dust Hazard Preventionp. 19
Prevention Of Injury By Work Equipmentp. 19
Unauthorized Modificationp. 19
Precautions When Using ROPSp. 19
Precautions For Attachmentsp. 20
Precautions For Starting The Truckp. 20
+PRECAUTIONS BEFORE OPERATIONp. 20
Safety At The Worksitep. 20
Fire Preventionp. 21
Ventilation In Enclosed Areasp. 21
Preparing For Operationp. 21
Mirrors, Windows And Lightsp. 21
In The Operator Cab (Before Starting The Engine)p. 21
Seat Beltsp. 21
+OPERATING THE TRUCKp. 22
When Starting The Enginep. 22
General Truck Operationp. 22
Ensuring Good Visibilityp. 22
Travelingp. 23
Traveling In Reversep. 23
Traveling On Slopesp. 23
Operating On Snow Or Icep. 23
Avoid Damage To Dump Bodyp. 23
Driving Near High Voltage Cablesp. 24
Working On Loose Groundp. 24
When Dumpingp. 24
When Loadingp. 24
Parking The Truckp. 24
Towingp. 24
+WORKING NEAR BATTERIESp. 25
Battery Hazard Preventionp. 25
Starting With Booster Cablesp. 25
+BEFORE PERFORMING MAINTENANCEp. 26
Stopping The Engine Before Servicep. 26
Warning Tagp. 26
Proper Toolsp. 26
Securing The Dump Bodyp. 26
+WHILE PERFORMING MAINTENANCEp. 27
Keep The Truck Cleanp. 27
Attachmentsp. 27
Working Under The Truckp. 27
Rotating Fan And Beltsp. 27
Adding Fuel Or Oilp. 27
Radiator Coolant Levelp. 28
Use Of Lightingp. 28
Precautions With The Batteryp. 28
Handling High Pressure Hosesp. 28
Precautions With High Pressure Oilp. 28
Performing Maintenance Near High Temperature Or High Pressurep. 28
Waste Materialsp. 28
+TIRESp. 29
Handling Tiresp. 29
Storing Tires After Removalp. 29
WHEN REPAIRS ARE NECESSARYp. 30
+SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKSp. 31
Preliminary Procedures Before Welding or Performing Maintenancep. 31
Engine Shutdown Procedure Before Welding or Performing Maintenancep. 31
Checking for DC Link Capacitor Chargep. 33
Discharging the DC Link Capacitorsp. 34
+OPERATING INSTRUCTIONSp. 37
PREPARING FOR OPERATIONp. 37
WALK AROUND INSPECTIONp. 37
ENGINE START-UPp. 41
AFTER ENGINE HAS STARTEDp. 42
+PRE-SHIFT BRAKE CHECK (if equipped)p. 42
Eventsp. 42
+OPERATIONp. 43
Descriptionp. 43
Brake Test Exit Criteriap. 43
+PERFORMING THE BRAKE TESTSp. 44
Setupp. 44
Service Brake Testp. 44
Parking Brake Testp. 45
Retard System Testp. 46
+EMERGENCY STEERING SYSTEMp. 46
Operationp. 46
Pre-Operation Testingp. 46
MACHINE OPERATION SAFETY PRECAUTIONSp. 47
OPERATING ON THE HAUL ROADp. 48
STARTING ON A GRADE WITH A LOADED TRUCKp. 49
PASSINGp. 49
LOADINGp. 49
+DUMPINGp. 49
Raising The Dump Bodyp. 49
Lowering The Dump Body (When dumping on flat ground):p. 50
Lowering The Dump Body (When dumping over a berm or into a crusher):p. 51
+TOWINGp. 51
Special Wiring Harnessp. 52
SAFE PARKING PROCEDURESp. 54
NORMAL ENGINE SHUTDOWN PROCEDUREp. 54
SUDDEN LOSS OF ENGINE POWERp. 55
FUEL DEPLETIONp. 55
+DISABLED TRUCK DUMPING PROCEDUREp. 56
Hookupp. 56
Raising the Bodyp. 56
Lowering the Bodyp. 56
+WARNINGS AND CAUTIONSp. 57
GRADE/SPEED CHARTp. 57
KEY SWITCHp. 57
ROPS/FOPSp. 57
BATTERIESp. 58
CAPACITORSp. 58
CRUSHING HAZARDp. 59
EMERGENCY TOWING PROCEDUREp. 59
CYLINDER PRESSUREp. 59
FILLING THE HYDRAULIC TANKp. 60
HYDRAULIC OIL PRESSUREp. 60
WHEEL MOTOR OIL LEVELp. 60
EMERGENCY DUMP PROCEDUREp. 61
ACCUMULATOR DRAIN VALVESp. 61
HOT EXHAUSTp. 61
WELDINGp. 61
EMERGENCY SHUTDOWNp. 61
INFORMATION DISPLAYp. 62
RADIATORp. 62
EMERGENCY LADDERp. 62
HIGH VOLTAGEp. 62
LIFTING INSTRUCTIONSp. 63
WIRELESS SIGNALSp. 63
PRODUCT IDENTIFICATION PLATEp. 64
LUBRICATION CHARTp. 64
TORQUE TABLES AND CONVERSION CHARTSp. 65
+STORAGE AND IDLE MACHINE PREPARATIONp. 75
SHORT TERM IDLE PERIODSp. 75
PREPARATION FOR STORAGEp. 76
REMOVAL FROM STORAGEp. 77
RECONDITIONING AN IDLE VEHICLEp. 79
+ENGINE OPERATIONp. 81
After The Engine Has Startedp. 82
+ENGINE STORAGEp. 83
Temporary Storage (30 Days Or Less)p. 83
Extended Storage (More Than 30 Days)p. 83
RESTORING AN ENGINE AFTER EXTENDED STORAGEp. 85
+ELECTRIC DRIVE TRUCKSp. 86
Storing A Truck That Is Operationalp. 86
Storing A Truck That Is Not Operationalp. 87
Storing A Major Componentp. 88
Periodic Inspectionsp. 88
Placing Equipment Into Service After Storagep. 88
+SECTION B STRUCTURES INDEXp. 91
+SECTION B2 STRUCTURAL COMPONENTS INDEXp. 93
+STRUCTURAL COMPONENTSp. 95
PREPARATIONp. 95
+DIAGONAL LADDER, GRILLE AND HOODp. 96
Removalp. 96
Installationp. 96
+RIGHT DECK AND COMPONENTSp. 97
Removalp. 97
Installationp. 97
+LEFT DECK AND COMPONENTSp. 98
Removalp. 98
Installationp. 98
+CENTER DECKp. 99
Removalp. 99
Installationp. 99
+SECTION B3 DUMP BODY INDEXp. 101
+DUMP BODYp. 103
+DUMP BODYp. 103
Removalp. 103
Installationp. 104
+BODY PADSp. 105
BODY GUIDEp. 106
HOIST LIMIT SWITCHp. 106
BODY-UP SWITCHp. 106
BODY RETENTION SLINGp. 106
+ROCK EJECTORSp. 107
+SECTION B4 FUEL TANK INDEXp. 109
+FUEL TANKp. 111
+FUEL TANKp. 111
Removalp. 111
Repairp. 111
Cleaningp. 111
Installationp. 111
+FUEL TANK VENT ASSEMBLYp. 113
Disassemblyp. 113
Assemblyp. 113
+FUEL GAUGE SENDERp. 114
Removalp. 114
Installationp. 114
QUICK FILL FUEL RECEIVERSp. 114
+SECTION C ENGINE INDEXp. 115
+SECTION C2 POWER MODULE INDEXp. 117
+POWER MODULEp. 119
PREPARATION FOR REMOVALp. 119
REMOVALp. 124
INSTALLATIONp. 126
HOOKUPp. 127
+SECTION C3 COOLING SYSTEM INDEXp. 129
+COOLING SYSTEMp. 131
+RADIATORp. 131
Removalp. 131
Installationp. 133
Filling Procedurep. 134
+REPAIRING THE RADIATORp. 134
Internal Inspectionp. 134
External Cleaningp. 134
Disassemblyp. 135
Cleaning and Inspectionp. 136
Assemblyp. 136
Pressure Testingp. 137
COOLANT SYSTEM TROUBLESHOOTINGp. 137
+SECTION C4 POWER TRAIN INDEXp. 139
+POWER TRAINp. 141
ALTERNATOR REMOVALp. 141
+ALTERNATOR INSTALLATIONp. 143
Measuring Procedurep. 143
Joining the Alternator and Enginep. 145
+ENGINEp. 146
Removalp. 146
Servicep. 146
Installationp. 146
+SECTION C5 AIR CLEANERS INDEXp. 147
+AIR CLEANERSp. 149
OPERATIONp. 149
+SERVICING THE AIR CLEANERSp. 149
Replacing The Elementsp. 150
+AIR CLEANER ASSEMBLY CLEANINGp. 151
Primary Element Cleaningp. 151
Precleaner Section Cleaningp. 153
AIR INTAKE TROUBLESHOOTINGp. 154
+SECTION C7 FAN CLUTCH INDEXp. 155
+FAN CLUTCHp. 157
REMOVAL & INSTALLATION TOOLINGp. 157
DISASSEMBLYp. 160
CLEANING AND INSPECTIONp. 170
ASSEMBLYp. 174
TEST PROCEDUREp. 188
+SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEXp. 189
+SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM INDEXp. 191
+24VDC ELECTRICAL SUPPLY SYSTEMp. 193
ELECTRICAL SYSTEM DESCRIPTIONp. 193
+BATTERIESp. 193
Maintenance and Servicep. 193
Troubleshootingp. 193
+BATTERY SUPPLY SYSTEMp. 195
24VDC Battery Charging Alternatorp. 195
Batteriesp. 195
Engine Start Relaysp. 195
24VDC Auxiliary Battery Receptaclesp. 195
Battery Disconnect Switchesp. 195
24VDC to 12VDC Converterp. 196
+SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEXp. 197
+24 VDC ELECTRICAL SYSTEM COMPONENTSp. 199
BRAKE WARNING BUZZERp. 199
+AUXILIARY CONTROL CABINET COMPONENTSp. 199
Power Distribution Terminalsp. 199
Control Power Relayp. 199
Auto Lube Timerp. 199
Diode Board – DB1p. 201
Fuse Blocksp. 202
Alarm Indicating Device (AID) Systemp. 202
+RELAY BOARDSp. 205
Relay Boards RB1, RB3, RB4, RB5p. 205
Relay Board RB6, RB7, RB8, RB9p. 207
Relay Board Functionsp. 208
+BODY-UP SWITCHp. 210
Operationp. 210
Adjustmentp. 210
Servicep. 210
+HOIST LIMIT SWITCHp. 211
Operationp. 211
Adjustmentp. 211
Servicep. 211
FUSE BLOCKS AND CIRCUIT BREAKERSp. 212
+SECTION D11 KOMTRAX PLUS INDEXp. 215
+KOMTRAX PLUSp. 217
+KOMTRAX PLUS BASIC FEATURESp. 217
Gather Datap. 217
Convert and Record Datap. 217
Communicate Data to Off-Board Systemsp. 218
+USING KOMTRAX PLUSp. 219
Turning KOMTRAX Plus ONp. 219
Normal KOMTRAX Plus Operationp. 219
Turning KOMTRAX Plus OFFp. 220
Downloading from the KOMTRAX Plus Controllerp. 220
+KOMTRAX PLUS DATA ITEMSp. 221
Fault Codesp. 221
Machine Historyp. 221
KOMTRAX Plus Historyp. 221
Snapshotsp. 222
Manual Snapshotsp. 222
Trendsp. 224
Histogram (Load Map) Datap. 224
Haul Cycle Datap. 225
Alarm and Snapshot Triggersp. 226
Satellite Featuresp. 226
+KOMTRAX PLUS DIAGNOSTIC FEATURESp. 228
Fault Historyp. 228
LED Digitsp. 228
+KOMTRAX PLUS CONTROLLERp. 228
Removalp. 229
Installationp. 229
+KOMTRAX PLUS SOFTWAREp. 230
VHMS Tool Box Installationp. 230
VHMS Setting Tool Installationp. 230
+KOMTRAX PLUS INITIALIZATION PROCEDUREp. 231
CONTROLLER SETUP PROCEDUREp. 231
SNAPSHOT PROCEDUREp. 234
DOWNLOAD PROCEDUREp. 235
FTP UPLOAD PROCEDUREp. 236
INITIALIZATION FORMSp. 237
WHEN REPLACING A KOMTRAX PLUS CONTROLLERp. 238
+KOMTRAX PLUS CONTROLLER CHECKOUTp. 243
Necessary Equipmentp. 243
Preliminaryp. 243
KOMTRAX Plus Controller Checkout Procedurep. 244
+ORBCOMM CONTROLLER (if equipped)p. 246
Removalp. 246
Installationp. 246
+SECTION D12 INTERFACE MODULE INDEXp. 247
+INTERFACE MODULEp. 249
Removalp. 249
Installationp. 249
+SENSORSp. 250
Temperature Sensorsp. 250
Pressure Sensorsp. 250
+INTERFACE MODULE SOFTWAREp. 251
Flashburn Program Installationp. 251
Interface Module Application Code Installationp. 252
Interface Module Realtime Data Monitor Softwarep. 252
+INTERFACE MODULE CHECKOUTp. 253
Necessary Equipmentp. 253
Preliminaryp. 254
Check Digital Inputs To The Interface Modulep. 255
Check Analog Inputs To The Interface Modulep. 258
Check Serial Interfaces To The Interface Modulep. 258
Check Outputs From The Interface Modulep. 259
+SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEXp. 261
+INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTINGp. 263
GENERALp. 263
+TROUBLESHOOTINGp. 264
Communications Networksp. 264
Coaxial Cablep. 264
+FAULT CODESp. 264
Fault Historyp. 264
KOMTRAX Plus LED Display Fault Codesp. 265
Chassis Fault Codesp. 266
Engine Fault Codesp. 270
+FAULT TREE ANALYSISp. 276
Unable to connect to KOMTRAX Plus from laptop PCp. 276
Flashing Error Code N4-23 (PLM III Communications Fault)p. 277
Flashing Error Code N4-22 (Engine Communications Fault)p. 278
No Data Received By WebCAREp. 279
Coaxial Cable Troubleshootingp. 280
+SECTION D14 KOMTRAX PLUS FORMS INDEXp. 281
+KOMTRAX PLUS FORMSp. 283
KOMTRAX PLUS INITIALIZATION CHECK LISTp. 283
KOMTRAX PLUS DATA DOWNLOADp. 284
KOMTRAX PLUS INITIALIZATION FORMp. 287
+SECTION E ELECTRIC PROPULSION SYSTEM INDEXp. 289
+SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEXp. 291
+ELECTRICAL PROPULSION SYSTEM COMPONENTSp. 293
GENERAL SYSTEM DESCRIPTIONp. 293
+SYSTEM COMPONENTSp. 295
Propulsion System Controller (PSC)p. 295
Truck Control Interface (TCI)p. 296
Diagnostic Information Display (DID) Panelp. 297
DID Panel Event Codesp. 297
+PSC SOFTWARE FUNCTIONSp. 316
Input Processingp. 316
State Machinep. 316
DC Link Statep. 319
Engine Controlp. 320
+ALTERNATOR FIELD CONTROLp. 320
Desired Three-Phase Voltagep. 320
Desired DC Link Voltagep. 320
Self-Loadp. 321
Propel Torque Controlp. 321
Retard Torque Controlp. 321
Wheel Slide Controlp. 322
Resistor Grid Controlp. 322
Chopper Voltage Controlp. 322
+EVENT DETECTION AND PROCESSINGp. 322
Power-On Testsp. 322
Initiated Testsp. 323
Periodic Testsp. 323
EVENT RESTRICTIONSp. 323
+EVENT LOGGING AND STORAGEp. 323
Event History Bufferp. 324
Data Packsp. 324
To Record and Save a Data Pack to a Diskp. 324
Event Resetp. 325
+SERIAL DATA COMMUNICATIONSp. 325
PSC – TCI Communications Processingp. 325
PSC – PTU Communications Processingp. 325
Inverter Communications Processingp. 326
OUTPUT PROCESSINGp. 326
+ABNORMAL CONDITIONS/OVERRIDING FUNCTIONSp. 326
Fast Startp. 326
Engine Shutdown/Engine Not Runningp. 326
Limp Home Modep. 327
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONSp. 328
+ELECTRONIC ACCELERATOR AND RETARD PEDALSp. 336
Removalp. 336
Installationp. 336
Disassemblyp. 336
Assemblyp. 336
+SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEXp. 337
+AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDUREp. 339
AC DRIVE SYSTEM MAINTENANCEp. 339
NORMAL TRUCK SHUTDOWN PROCEDUREp. 340
SHUTDOWN AFTER SYSTEM FAILUREp. 340
+SYSTEM CHECKOUTp. 341
Battery and Control Circuit Checks – Battery Power OFFp. 341
Battery and Control Circuit Checks – Battery Power ONp. 344
Checks with Key Switch OFFp. 345
Checks with Key Switch ONp. 345
CPU Battery Checksp. 345
MEMORY BACKUP BATTERY REPLACEMENTp. 346
TCI PROGRAMMINGp. 346
PSC PROGRAMMINGp. 347
INVERTER PROGRAMMINGp. 347
CPU RESETp. 347
+PSC CHECKOUTp. 348
PSC Digital Input Checksp. 348
PSC Digital Output Checksp. 352
+TCI CHECKOUTp. 353
Modular Mining Communication Port Checkp. 353
TCI Digital Input Checksp. 353
TCI Digital Output Testsp. 359
+CALIBRATIONSp. 361
Speedometerp. 361
Accelerator Pedal, Retarder Pedal/Lever and RSC Dialp. 361
+ERASING EVENTSp. 361
GATE DRIVER POWER CONVERTER TESTp. 362
+LOAD TESTINGp. 363
Preparationp. 363
Alternator Speed Sensor Checksp. 363
Battery Boost Checkp. 363
Brake Circuit Switch Checksp. 364
Hoist & Steering Circuit Switch Checksp. 364
Link Energized Checksp. 364
Loadbox Testp. 366
+TROUBLESHOOTINGp. 370
PVM Optimum Load Curve Handshaking Troubleshootingp. 370
Phase Module and Chopper Module Troubleshootingp. 370
+PHASE MODULE REPLACEMENTp. 371
Phase Module Removalp. 371
Phase Module Installationp. 371
+SECTION G REAR AXLE, SPINDLES AND WHEELS INDEXp. 373
+SECTION G2 TIRES AND RIMS INDEXp. 375
+TIRES AND RIMSp. 377
WHEEL STUD MAINTENANCEp. 378
+FRONT TIRES AND RIMSp. 379
Removalp. 379
Installationp. 380
+REAR TIRES AND RIMSp. 381
Removalp. 381
Installationp. 382
+RIMp. 383
Tire Removalp. 383
Tire Installationp. 383
+SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEXp. 385
+FRONT WHEEL HUB AND SPINDLEp. 387
+WHEEL HUB AND SPINDLE ASSEMBLYp. 387
Removalp. 387
Installationp. 390
Disassemblyp. 391
Cleaning and Inspectionp. 391
Assemblyp. 393
Wheel Bearing Adjustmentp. 393
Brake Installationp. 394
Seal Assembly Gap Checkp. 395
+STEERING CYLINDERS AND TIE RODp. 397
Spherical Bearing Wear Limitsp. 397
Removalp. 398
Installationp. 399
Bearing Replacementp. 399
TOE-IN ADJUSTMENTp. 400
WHEEL SPEED SENSOR TESTINGp. 400
+SECTION G4 REAR AXLE MOUNTING INDEXp. 401
+REAR AXLE MOUNTINGp. 403
+PIVOT PINp. 403
Removalp. 403
Installationp. 404
+PIVOT EYE BEARINGp. 404
Removalp. 404
Installationp. 404
+PIVOT EYE REPAIRp. 405
Removalp. 405
Installationp. 405
+ANTI-SWAY BARp. 406
Removalp. 406
Disassemblyp. 406
Cleaning and Inspectionp. 406
Assemblyp. 406
Installationp. 406
+SECTION G5 REAR AXLE AND WHEEL MOTOR INDEXp. 409
+REAR AXLE AND WHEEL MOTORp. 411
+REAR AXLE HOUSINGp. 411
Preparationp. 411
Removalp. 412
Cleaning and Inspectionp. 413
Installationp. 413
+WHEEL MOTORp. 413
Preparationp. 413
Removalp. 414
Cleaning and Inspectionp. 416
Installationp. 416
+WHEEL MOTOR GEAR OILp. 421
Filtering Requirementsp. 421
Particle Size Analysisp. 421
Flushingp. 421
Oil Sample Analysisp. 422
ELEMENT SPECIFICATION CHARTSp. 423
+SECTION H HYDRAIR® II SUSPENSIONS INDEXp. 427
+SECTION H2 FRONT SUSPENSIONS INDEXp. 429
+FRONT SUSPENSIONp. 431
Removalp. 431
Installationp. 432
Inspectionp. 437
+LOWER BEARING & SEALSp. 438
Removalp. 438
Installationp. 438
+MAJOR SUSPENSION REBUILDp. 439
Disassemblyp. 439
Assemblyp. 439
SUSPENSION PRESSURE TESTp. 440
+SECTION H3 REAR SUSPENSIONS INDEXp. 441
+REAR SUSPENSIONSp. 443
+SUSPENSION CYLINDERp. 444
Removalp. 444
Installationp. 446
Disassemblyp. 446
Cleaning and Inspectionp. 447
Assemblyp. 447
SUSPENSION PRESSURE TESTp. 449
+SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEXp. 451
+SUSPENSION OILING AND CHARGING PROCEDUREp. 453
GENERALp. 453
EQUIPMENT LISTp. 453
+HYDRAIR® CHARGING KITp. 454
Installation of Charging Kitp. 454
Removal of Charging Kitp. 454
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONSp. 455
+FRONT SUSPENSIONp. 455
Front Suspension Oilingp. 455
Front Suspension Nitrogen Chargingp. 457
+REAR SUSPENSIONp. 458
Rear Suspension Oilingp. 459
Rear Suspension Nitrogen Chargingp. 461
OIL AND NITROGEN SPECIFICATIONS CHARTSp. 462
+SECTION J BRAKE CIRCUIT INDEXp. 463
+SECTION J2 BRAKE CIRCUIT INDEXp. 465
+BRAKE CIRCUITp. 467
SERVICE BRAKE CIRCUITp. 467
PARKING BRAKE CIRCUITp. 469
BRAKE LOCK CIRCUITp. 469
SECONDARY BRAKING AND AUTOMATIC APPLYp. 470
WARNING CIRCUITp. 470
+SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEXp. 473
+BRAKE CIRCUIT COMPONENT SERVICEp. 475
+BRAKE VALVEp. 475
Rebuild Criteriap. 475
Removalp. 476
Installationp. 476
Disassemblyp. 477
Cleaning and Inspectionp. 480
Assemblyp. 480
Regulator Sleeve O-Ring Installationp. 481
+BRAKE VALVE BENCH TEST AND ADJUSTMENTp. 483
Test Setup Procedurep. 484
Brake Valve Output Pressure Adjustmentp. 484
Final Test and Adjustmentp. 485
Installing Brake Pedal Actuator Assembly to Brake Valvep. 485
Installing Retard Pedal To Brake Pedalp. 485
+DUAL RELAY VALVEp. 486
Removalp. 486
Installationp. 486
Disassemblyp. 486
Cleaning and Inspectionp. 487
Assemblyp. 488
+DUAL RELAY VALVE BENCH TEST AND ADJUSTMENTp. 489
Test Setup Procedurep. 490
Relay Valve Output Pressure Adjustmentp. 490
+BRAKE MANIFOLDp. 491
Removalp. 491
Installationp. 491
Disassemblyp. 491
Cleaning and Inspectionp. 492
Assemblyp. 492
+BRAKE ACCUMULATORSp. 492
Brake Accumulator Bleeddown Procedurep. 492
Removalp. 493
Installationp. 493
Disassemblyp. 494
Cleaning and Inspectionp. 495
Assemblyp. 495
Accumulator Charging Procedurep. 497
Precharge Maintenancep. 499
Accumulator Storage Proceduresp. 500
Bladder Storage Proceduresp. 500
Installing A Bladder Accumulator From Storagep. 500
+RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)p. 501
Removalp. 501
Installationp. 501
Disassemblyp. 501
Lever Adjustmentsp. 501
Potentiometer Checkp. 502
Assemblyp. 502
+SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEXp. 505
+BRAKE CIRCUIT CHECK-OUT PROCEDUREp. 507
REQUIRED EQUIPMENTp. 508
INITIAL SYSTEM SETUPp. 509
BRAKE LOCK / SECONDARY BRAKE CHECK-OUTp. 510
PARKING BRAKE CHECK-OUTp. 511
SERVICE BRAKE CHECK-OUTp. 512
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUTp. 513
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHARTp. 514
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEETp. 516
+SECTION J5 WET DISC BRAKE ASSEMBLY INDEXp. 519
+WET DISC BRAKE ASSEMBLYp. 521
OPERATIONp. 521
BRAKE DISC WEAR INSPECTIONp. 522
+BRAKE REBUILDp. 523
Disassemblyp. 523
Cleaning and Inspectionp. 527
Assemblyp. 528
Floating Ring Seal Assembly & Installationp. 533
WET DISC BRAKE BLEEDING PROCEDUREp. 537
+SECTION J7 PARKING BRAKE INDEXp. 539
+PARKING BRAKEp. 541
OPERATIONp. 541
+MAINTENANCEp. 542
Inspectionp. 542
Removalp. 542
Installationp. 543
Disassemblyp. 543
Cleaning and Inspectionp. 543
Assemblyp. 545
PARKING BRAKE BLEEDING PROCEDUREp. 546
+SECTION L HYDRAULIC SYSTEM INDEXp. 549
+SECTION L2 HYDRAULIC SYSTEM INDEXp. 551
+HYDRAULIC SYSTEMp. 553
HYDRAULIC PUMP MODULEp. 553
HOIST CIRCUIT OPERATIONp. 554
STEERING CIRCUIT OPERATIONp. 556
DISC BRAKE COOLING SYSTEMp. 558
+SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEXp. 561
+HYDRAULIC SYSTEM COMPONENT REPAIRp. 563
+HOIST PUMPp. 563
Removalp. 563
Installationp. 565
Inspectionp. 570
Assemblyp. 570
+HYDRAULIC TANKp. 576
Filling Instructionsp. 576
Removalp. 577
Installationp. 577
HYDRAULIC TANK BREATHERSp. 577
+HYDRAULIC TANK STRAINERSp. 578
Removalp. 578
Inspect and Cleanp. 578
Installationp. 578
+SECTION L4 STEERING CIRCUIT INDEXp. 579
+STEERING CIRCUITp. 581
+COMPONENT DESCRIPTIONp. 582
Steering Control Unitp. 582
Bleeddown Manifold Valvep. 583
Steering Accumulator Bleeddown Solenoidp. 583
Relief Valvesp. 585
Hoist Up Limit Solenoidp. 585
Steering Accumulatorsp. 585
Low Precharge Warning Switchp. 585
High Pressure Filterp. 585
Quick Disconnect Portsp. 585
Flow Amplifierp. 587
+FLOW AMPLIFIER SYSTEM OPERATIONp. 588
No Steerp. 588
Steering Leftp. 590
Steering Rightp. 592
No Steer, External Shock Loadp. 594
+STEERING PUMPp. 596
+PRINCIPLE OF OPERATIONp. 598
Full Pump Volumep. 598
Half Pump Volumep. 598
Neutral Positionp. 598
Steering Pumpp. 599
+SECTION L5 STEERING CONTROL UNIT INDEXp. 601
+STEERING CONTROL UNITp. 603
REMOVALp. 603
SPLINE INSPECTIONp. 603
INSTALLATIONp. 604
DISASSEMBLYp. 604
CLEANING AND INSPECTIONp. 605
ASSEMBLYp. 607
+SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEXp. 611
+STEERING CIRCUIT COMPONENT REPAIRp. 613
+BLEEDDOWN MANIFOLD VALVEp. 613
Removalp. 613
Installationp. 614
+FLOW AMPLIFIERp. 615
Removalp. 615
Installationp. 615
Disassemblyp. 615
Assemblyp. 617
+STEERING CYLINDERSp. 618
Disassemblyp. 619
Piston Seal & Bearing Installationp. 619
Assemblyp. 619
Testingp. 619
+STEERING AND BRAKE PUMPp. 620
Removalp. 620
Installationp. 621
Disassemblyp. 622
Inspectionp. 625
Assemblyp. 628
Driveshaft Groupp. 629
Rotating Groupp. 629
Valve Plate Groupp. 630
+STEERING ACCUMULATORSp. 631
Removalp. 631
Installationp. 631
Disassemblyp. 632
Cleaning and Inspectionp. 632
Assemblyp. 633
Leak Testingp. 635
Charging Procedurep. 636
Precharge Maintenancep. 638
Accumulator Storage Proceduresp. 639
Bladder Storage Proceduresp. 639
Installing A Bladder Accumulator From Storagep. 639
TROUBLESHOOTING CHARTp. 640
+SECTION L7 HOIST CIRCUIT INDEXp. 645
+HOIST CIRCUITp. 647
BASIC OPERATIONp. 647
+COMPONENT DESCRIPTIONp. 648
Hydraulic Tankp. 648
Hydraulic Pumpp. 648
High Pressure Filtersp. 648
Hoist Valvep. 648
Inlet Sectionsp. 648
Work Ports (Rear) Spool Sectionp. 649
Tank Ports (Front) Spool Sectionp. 649
Hoist Pilot Valvep. 649
Bleeddown Manifoldp. 650
Hoist Up Limit Solenoidp. 650
Pilot Operated Check Valvep. 650
Overcenter Manifoldp. 650
+HOIST CIRCUIT OPERATIONp. 651
Float Position Of Pilot Valve With Truck Body On Framep. 652
Power Up Operationp. 654
Hold Operationp. 656
Power Down Operationp. 658
Float Operationp. 660
+SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEXp. 663
+HOIST CIRCUIT COMPONENT REPAIRp. 665
+HOIST VALVEp. 665
Removalp. 665
Installationp. 666
O-Ring Replacementp. 666
+INLET SECTIONp. 667
Disassemblyp. 667
Cleaning and Inspectionp. 668
Assemblyp. 668
+REAR SPOOL SECTION (Work Ports)p. 669
Disassemblyp. 669
Cleaning and Inspectionp. 669
Assemblyp. 671
+FRONT SPOOL SECTION (Tank Ports)p. 672
Disassemblyp. 672
Cleaning and Inspectionp. 672
Assemblyp. 672
+HOIST PILOT VALVEp. 674
Removalp. 674
Installationp. 674
Disassemblyp. 675
Cleaning and Inspectionp. 676
Assemblyp. 676
+HOIST CYLINDERSp. 677
Removalp. 677
Installationp. 678
Disassemblyp. 680
Cleaning and Inspectionp. 681
Assembly – Quillp. 682
Assembly – Cylinderp. 684
Testingp. 684
OVERCENTER VALVE MANIFOLDp. 685
+SECTION L9 HYDRAULIC SYSTEM FILTERS INDEXp. 687
+HYDRAULIC SYSTEM FILTERSp. 689
+HOIST CIRCUIT FILTERp. 689
Filter Element Replacementp. 689
Removal – Hoist Circuit Filterp. 690
Installation – Hoist Circuit Filterp. 690
Indicator Switch – Hoist Circuit Filterp. 690
+STEERING CIRCUIT FILTERp. 691
Filter Element Replacementp. 691
Removal – Steering Circuit Filterp. 692
Installation – Steering Circuit Filterp. 692
Indicator Switch – Steering Circuit Filterp. 692
+INDICATOR SWITCHp. 692
+SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEXp. 695
+HYDRAULIC CHECKOUT PROCEDUREp. 697
GENERAL INFORMATIONp. 697
+STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDUREp. 704
Equipment Requirementsp. 705
Pump Pressure Control Adjustmentsp. 705
Steering Control Valve and Flow Amplifier Leakage Testp. 706
Bleeddown Manifold Leakage Testp. 707
STEERING/BRAKE PUMP STROKE ADJUSTMENTp. 708
+SHOCK AND SUCTION VALVESp. 708
Equipment Requirementsp. 708
Pressure Testsp. 708
+HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURESp. 709
Equipment Requirementsp. 709
Pressure Gauge Locationsp. 709
Brake Cooling Circuit Testp. 710
Power Up Relief Pressure Testp. 711
Power Down Relief Pressure Testp. 712
Counterbalance Valve Pressure Checkp. 713
Counterbalance Valve Adjustmentp. 714
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEETp. 715
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEETp. 716
+SECTION M OPTIONS AND SPECIAL TOOLS INDEXp. 717
+SECTION M7 HEATER OPTIONS INDEXp. 719
+ENGINE OIL HEATERSp. 721
GENERAL INFORMATIONp. 721
TROUBLESHOOTINGp. 721
+HEATER ELEMENTp. 721
Removalp. 721
Installationp. 722
+ENGINE COOLANT HEATERp. 723
+GENERALp. 723
+HEATING ELEMENTp. 723
Removalp. 723
Installationp. 724
+THERMOSTATp. 724
Removalp. 724
Installationp. 724
+HYDRAULIC OIL HEATERSp. 725
GENERAL INFORMATIONp. 725
TROUBLESHOOTINGp. 725
+HEATER ELEMENTp. 725
Removalp. 725
Installationp. 726
SECTION M8 SPECIAL TOOLSp. 727
+SECTION M19 RADIATOR SHUTTERS INDEXp. 733
+RADIATOR SHUTTERSp. 735
+OPERATIONp. 735
Hydraulic Circuitp. 735
Electrical Circuitp. 736
MAINTENANCE AND REPAIRp. 736
TROUBLESHOOTINGp. 737
+SECTION M20 PAYLOAD METER III ™ INDEXp. 741
+OPERATION SECTIONp. 745
+Introductionp. 745
Data Summaryp. 745
Data Gatheringp. 745
+COMPONENT DESCRIPTIONp. 746
System Diagramp. 746
Suspension Pressure Sensorsp. 746
Inclinometerp. 746
Operator Displayp. 746
Operator Switchp. 747
Speed Inputp. 747
Body-Up Switchp. 747
Brake Lock Switchp. 747
Payload Meterp. 747
Communications Portsp. 747
Key Switch Inputp. 748
Payload Meter Powerp. 748
Load Lightsp. 748
Wiring and Terminationp. 749
TCI Outputsp. 749
+OPERATOR’S DISPLAY AND SWITCHp. 750
Reading the Speedometerp. 750
Reading the Load Displayp. 750
Using the Operator IDp. 750
Using the Load and Ton Counterp. 750
Total Ton Counterp. 750
Total Load Counterp. 751
Clearing the Countersp. 751
Viewing Live Sensor Datap. 751
Other Display Messagesp. 751
+PAYLOAD OPERATION & CALCULATIONp. 752
Description of Haul Cycle Statesp. 752
Haul Cycle Descriptionp. 752
Load Calculationp. 753
Carry Backp. 753
Measurement Accuracyp. 753
+SOURCES FOR PAYLOAD ERRORp. 753
Payload Errorp. 753
Loading Conditionsp. 754
Pressure Sensorsp. 754
Swingloadsp. 754
Speed and Distancep. 754
+HAUL CYCLE DATAp. 754
Haul Cycle Warning Flagsp. 756
Frame Torque Datap. 757
Sprung Weight Datap. 757
Maximum Speed Datap. 757
Alarm Recordsp. 757
Fault Code Datap. 758
+PC SOFTWARE OVERVIEWp. 759
System Configurationp. 759
Installing the PLMIII Softwarep. 759
DOWNLOADING DATAp. 760
+PLM III SYSTEM CONFIGURATIONp. 761
Starting Communicationsp. 761
Displayed Payload Unitsp. 761
Time Unitsp. 761
Connection Menup. 761
Connecting to the Payload Meterp. 762
Configure the Payload Meterp. 762
Setting the Date and Timep. 762
Setting the Truck Typep. 763
Setting the Gauge Display Unitsp. 763
Setting the Frame Serial Numberp. 763
Setting the Truck Numberp. 763
Setting the Komatsu Distributorp. 763
Setting the Komatsu Customerp. 763
Clean Truck Tarep. 764
Inclinometer Calibrationp. 764
+DATA ANALYSISp. 765
Creating a Queryp. 765
Sorting on Truck Unit Numberp. 765
Sorting on Truck Typep. 765
Sorting on Date Rangep. 766
Sorting on Time Rangep. 766
Payload Detail Screenp. 767
Creating Reportsp. 767
Summary – one page reportp. 768
Detailed – multi-page reportp. 768
Creating Graphsp. 769
Exporting Datap. 769
CSV Exportp. 769
Compressedp. 770
Importing Datap. 771
Deleting Haul Cycle Recordsp. 771
Viewing Alarmsp. 772
Deleting Alarm Recordsp. 772
+TROUBLESHOOTING SECTIONp. 773
+TROUBLESHOOTINGp. 773
Viewing Active Alarmsp. 773
Real-Time Data Displayp. 773
Testing the Payload Lightsp. 773
Creating Log Files of Inputsp. 774
Daily Inspectionsp. 774
Periodic Maintenancep. 774
Abnormal Displays at Power-Upp. 775
No Payload Display When Key Switch is Turned ONp. 776
No Display on Speedometerp. 777
No Display on Operator Displayp. 777
No Communications With PCp. 778
Load Lights Don’t Light During Loadingp. 779
Load Lights Remain ONp. 780
Load Lights Remain ON During Dumpingp. 780
Display Doesn't Clear When The Load Is Dumpedp. 780
Calibration Problemsp. 781
Alarm 1 – Left Front Pressure Highp. 782
Alarm 2 – Left Front Pressure Lowp. 782
Troubleshoot Wiring to Left Front Suspensionp. 782
Alarm 3 – Right Front Pressure Highp. 783
Alarm 4 – Right Front Pressure Lowp. 783
Troubleshoot Wiring to Right Front Suspensionp. 783
Alarm 5 -Left Rear Pressure Highp. 784
Alarm 6 – Left Rear Pressure Lowp. 784
Troubleshoot Wiring to Left Rear Suspensionp. 784
Alarm 7 – Right Rear Pressure Highp. 785
Alarm 8 – Right Rear Pressure Lowp. 785
Troubleshoot Wiring to Right Rear Suspensionp. 785
Alarm 9 – Inclinometer Highp. 786
Alarm 10 – Inclinometer Lowp. 786
Troubleshoot Inclinometer Wiringp. 786
Alarm 13 – Body Up Input Failurep. 787
Alarm 16 – Memory Write Failurep. 788
Alarm 17 – Memory Read Failurep. 788
Alarm 18p. 789
Alarm 19p. 789
Alarm 22p. 789
Operator Switch Doesn't Workp. 790
Alarm 26 – User Switch Fault – SELECTp. 790
Alarm 27 – User Switch Fault – SETp. 790
Connector Mapp. 791
Connectorsp. 792
+PLMIII CHECK OUT PROCEDUREp. 793
General Descriptionp. 793
Tools Requiredp. 793
Checkout Procedurep. 793
+PLMIII CHECKOUT PROCEDURE CONFIRMATIONp. 797
Flashburn Programmingp. 797
Confirmation Checklistp. 799
+SECTION M31 RESERVE ENGINE OIL SYSTEM INDEXp. 801
+RESERVE ENGINE OIL SYSTEMp. 803
Operationp. 804
LED Monitor Lightp. 804
Tank Fill Control (Optional)p. 805
Filling Procedure (Remote Fill Feature)p. 805
+SERVICEp. 806
Every 10 Hours, or once each shift:p. 806
Every 500 Hoursp. 806
Changing Oilp. 806
+TROUBLESHOOTINGp. 807
SYSTEM ELECTRICAL SCHEMATICSp. 808
+SECTION N OPERATOR CAB INDEXp. 809
+SECTION N2 TRUCK CAB AND COMPONENTS INDEXp. 811
+TRUCK CAB AND COMPONENTSp. 813
+TRUCK CABp. 813
Descriptionp. 813
Removalp. 814
Installationp. 815
+CAB DOORp. 816
Removalp. 816
Installationp. 816
Door Jamb Bolt Adjustmentp. 817
Door Handle Plunger Adjustmentp. 818
Replacing the Door Glassp. 819
Replacing the Door Window Regulatorp. 823
Replacing the Door Handle or Latch Assemblyp. 824
Replacing the Door and Door Hinge Sealp. 824
Removing the Door Opening Sealp. 825
Installationp. 825
+GLASS REPLACEMENT (Adhesive-Bonded Windows)p. 826
Recommended Tools and Suppliesp. 826
Replacement Procedurep. 826
+WINDSHIELD AND REAR GLASSp. 827
Removalp. 827
Installationp. 828
+SECTION N3 CAB COMPONENTS INDEXp. 829
+CAB COMPONENTSp. 831
+WINDSHIELD WIPERSp. 831
+WIPER MOTORp. 831
Removalp. 831
Installationp. 831
+WIPER ARMp. 831
Removalp. 831
Installationp. 832
+WIPER LINKAGEp. 832
Removalp. 832
Installationp. 832
+WINDSHIELD WASHERp. 833
Operationp. 833
Servicep. 833
+OPERATOR SEAT (STANDARD SEAT)p. 834
Adjustmentp. 834
Inspectionp. 835
Removalp. 835
Installationp. 835
+PASSENGER SEAT (STANDARD SEAT)p. 836
Inspectionp. 836
Removalp. 836
Installationp. 836
+SEAT BELTp. 837
Removalp. 837
Installationp. 837
+SECTION N4 HEATER / AIR CONDITIONER INDEXp. 839
+HEATER/AIR CONDITIONERp. 841
+OPERATIONp. 841
Fan Speed Control Knobp. 841
Temperature Control Knobp. 841
Air Flow Directional Knobp. 842
Heater/Air Conditioner Ventsp. 842
+COMPONENTSp. 842
Fuse and Circuit Breakerp. 842
Relaysp. 842
Heater Corep. 843
Fan Motor And Speed Controlp. 843
Actuatorsp. 843
Cab Air Filterp. 843
ENVIRONMENTAL IMPACT OF AIR CONDITIONINGp. 846
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLESp. 846
+PRINCIPLES OF REFRIGERATIONp. 846
Air Conditioningp. 846
Refrigeration – The Act Of Coolingp. 847
The Refrigeration Cyclep. 847
+AIR CONDITIONER SYSTEM COMPONENTSp. 848
Compressor (Refrigerant Pump)p. 848
Service Valvesp. 848
Condenserp. 848
Receiver-Drierp. 848
Expansion Block Valvep. 849
Accumulatorp. 849
Evaporatorp. 849
+ELECTRICAL CIRCUITp. 850
Thermostatp. 850
Compressor Clutchp. 850
Trinary™ Switchp. 851
AIR CONDITIONING SYSTEM SERVICING WARNINGSp. 852
+SERVICE TOOLS AND EQUIPMENTp. 853
Recovery/Recycle Stationp. 853
Leak Detectorp. 853
Manifold Gauge Setp. 854
Installing Manifold Gauge Setp. 855
Purging Air From Service Hosesp. 855
Service Valvesp. 856
Vacuum Pumpp. 856
SYSTEM PERFORMANCE TESTp. 857
+SYSTEM OILp. 858
Handling and Reusing PAG Oilp. 858
Oil Quantityp. 858
Checking System Oilp. 858
+REFRIGERANTp. 859
Recycled Refrigerantp. 859
Reclaimed Refrigerantp. 859
Refrigerant Quantityp. 860
R-134a Refrigerant Containersp. 860
+SYSTEM LEAK TESTINGp. 860
Electronic Leak Detectorp. 861
Tracer Dyesp. 861
Soap and Waterp. 861
+RECOVERING AND RECYCLING THE REFRIGERANTp. 861
Draining Oil from the Previous Recovery Cyclep. 861
Performing the Recovery Cyclep. 861
Performing the Recycling Procedurep. 862
Evacuating and Charging the A/C Systemp. 862
+SYSTEM REPAIRp. 862
+COMPONENT REPLACEMENTp. 863
Hoses and Fittingsp. 863
Linesp. 863
Expansion Valvep. 863
Receiver-Drierp. 863
Thermostatp. 863
Compressorp. 864
Accumulatorp. 864
Clutchp. 864
EVACUATING THE SYSTEMp. 865
CHARGING THE A/C SYSTEMp. 866
+TROUBLESHOOTINGp. 867
Preliminary Checksp. 867
Diagnosis Of Gauge Readings And System Performancep. 867
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGSp. 868
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEMp. 873
+SECTION N5 OPERATOR CAB AND CONTROLS INDEXp. 875
+OPERATOR CAB AND CONTROLSp. 877
+STEERING COLUMNp. 878
Removalp. 878
Inspectionp. 878
Installationp. 879
+STEERING WHEELp. 879
Removalp. 879
Installationp. 879
+STEERING WHEEL AND CONTROLSp. 880
Horn Buttonp. 880
Tilt / Telescope Leverp. 880
Multi-Function Turn Signal Switchp. 880
+DYNAMIC RETARDINGp. 881
Retarder Leverp. 881
Brake/Retarder Pedalp. 881
Throttle/Accelerator Pedalp. 881
GRADE/SPEED CHARTp. 882
OVERHEAD PANEL AND DISPLAYSp. 883
+CENTER CONSOLEp. 884
Directional Control Leverp. 884
Override/Fault Reset Switchp. 885
Engine Shutdown Switchp. 885
Window Control Switchesp. 885
Hoist Control Leverp. 885
Retarder Speed Control (RSC) Adjustment Dialp. 886
Retarder Speed Control (RSC) Switchp. 886
Data Store Buttonp. 887
KOMTRAX Plus Snapshot In Progress Lightp. 887
Link Energized Lightp. 887
Service Engine Lightp. 887
12V Auxiliary Power Outletsp. 887
Fire Suppression Control Outletp. 887
Communication Radio Outletp. 887
+DIAGNOSTIC PORTSp. 887
KOMTRAX Plus Diagnostic Portp. 887
Interface Module (IM) Diagnostic Portp. 887
Payload Meter Diagnostic Portp. 887
Truck Control Interface (TCI) Diagnostic Portp. 887
Propulsion System Controller (PSC) Diagnostic Portp. 887
Engine Diagnostic Port (CENSE)p. 887
Engine Diagnostic Port (QUANTUM)p. 887
+INSTRUMENT PANELp. 888
Control Symbolsp. 888
Key Switchp. 890
Rotating Beacon Switch (optional)p. 890
Heated Mirrors Switch (optional)p. 890
AC Drive System Rest Switchp. 890
Wheel Brake Lock Switchp. 891
Hazard Warning Light Switchp. 891
Heater/Air Conditioner Ventsp. 891
Engine Oil Pressure Gaugep. 891
Right Turn Signal Indicatorp. 891
Digital Tachometerp. 891
High Beam Indicatorp. 891
Speedometer/Payload Meter Displayp. 891
Left Turn Signal Indicatorp. 892
Coolant Temperature Gaugep. 892
Lamp Check Switchp. 892
Headlight/Panel Illumination Light Switchp. 892
Ladder Light Switch (3-Way)p. 892
Backup Light Switchp. 892
Fog Light Switchp. 893
Payload Meter Switchp. 893
Panel Illumination Light Dimmer Switchp. 893
Hydraulic Oil Temperature Gaugep. 893
Engine Hourmeterp. 893
Fuel Gaugep. 893
+OVERHEAD STATUS / WARNING INDICATORSp. 894
A1. High Brake Oil Temperaturep. 895
B1. Low Steering Pressurep. 895
C1. Low Accumulator Precharge Pressurep. 896
D1. Not usedp. 896
E1. Low Brake Pressurep. 896
A2. Low Hydraulic Tank Levelp. 896
B2. Low Automatic Lubrication System Pressurep. 896
C2. Circuit Breaker Trippedp. 896
E2. Low Fuelp. 897
A3. Parking Brakep. 897
B3. Service Brakep. 897
C3. Body Upp. 897
D3. Dynamic Retardingp. 897
E3. Stop Enginep. 898
A4. Cranking Motor Failurep. 898
B4. Backup Lightsp. 898
C4. Engine Shutdown Timerp. 898
D4. Retard Speed Control (RSC) Indicatorp. 898
E4. Check Enginep. 898
A5. No Powerp. 899
B5. Propulsion System Warningp. 899
C5. Propulsion System Temperaturep. 899
D5. System/Component Failurep. 899
A6. No Propelp. 899
B6. Propel System At Restp. 899
C6. Propel System Not Readyp. 900
D6. Reduced Propulsionp. 900
E6. Retard At Continuous Levelp. 900
+REAR AXLE LIGHT BARp. 901
Backup Lightsp. 901
Retard Lightsp. 901
Brake Lightp. 901
Backup Alarmp. 901
+KOMTRAX PLUSp. 902
Operationp. 902
Basic Precautionsp. 903
+SECTION P LUBRICATION AND SERVICE INDEXp. 905
+SECTION P2 LUBRICATION AND SERVICE INDEXp. 907
+LUBRICATION AND SERVICEp. 909
GENERALp. 909
SERVICE CAPACITIESp. 909
+HYDRAULIC TANK SERVICEp. 909
+COOLING SYSTEM SERVICEp. 910
Radiator Filling Procedurep. 910
Coolant Specificationsp. 910
Unacceptable Practicesp. 910
WHEEL MOTOR SERVICEp. 910
+RESERVE OIL TANK SERVICEp. 911
Filling the Reserve Oil Tank (Remote Fill)p. 911
Inline Screenp. 911
LUBRICATION CHARTp. 912
10 HOUR (DAILY) INSPECTIONSp. 913
50 HOUR LUBRICATION AND MAINTENANCE CHECKSp. 915
100 HOUR LUBRICATION AND MAINTENANCE CHECKSp. 915
250 HOUR LUBRICATION AND MAINTENANCE CHECKSp. 915
500 HOUR LUBRICATION AND MAINTENANCE CHECKSp. 918
1000 HOUR LUBRICATION AND MAINTENANCE CHECKSp. 919
5000 HOUR MAINTENANCE CHECKSp. 920
+SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEXp. 921
+AUTOMATIC LUBRICATION SYSTEMp. 923
GENERAL DESCRIPTIONp. 923
+SYSTEM COMPONENTSp. 925
Filterp. 925
Hydraulic Motor and Pumpp. 925
Grease Reservoirp. 925
Pressure Reducing Valvep. 925
Flow Control Valvep. 925
Solenoid Valvep. 925
Vent Valvep. 925
Lubrication Cycle Timerp. 925
Over Pressure Cut Off Switchp. 925
Grease Pressure Failure Switchp. 925
Injectorsp. 925
Relief Valve (unloader valve)p. 925
+SYSTEM OPERATIONp. 926
Normal Operationp. 926
Lubricant Required For Systemp. 927
System Primingp. 927
Filter Assemblyp. 927
+LUBRICANT PUMPp. 928
Pump Housing Oil Levelp. 928
Pump Pressure Controlp. 928
+INJECTORS (SL-1 Series “H”)p. 929
Injector Specificationsp. 929
Injector Adjustmentp. 929
INJECTOR OPERATIONp. 930
+PREVENTIVE MAINTENANCE PROCEDURESp. 931
Daily Lubrication System Inspectionp. 931
250 Hour Inspectionp. 931
1000 Hour Inspectionp. 931
+SYSTEM CHECKOUTp. 932
Lubrication Controller Checkp. 932
Lubrication Controller Componentsp. 932
Lubrication Controller Adjustmentp. 932
SYSTEM TROUBLESHOOTING CHARTp. 934
SECTION Q ALPHABETICAL INDEXp. 937
+SECTION R SYSTEM SCHEMATICS INDEXp. 941
HYDRAULIC SCHEMATIC (EM1371)p. 943
HYDRAULIC BRAKE SCHEMATIC (EM7334)p. 944
ELECTRICAL SCHEMATIC (XS7800)p. 945
What makes this Komatsu 930E-4SE service manual genuinely useful is the depth behind each of those headings. The engine section walks through power module removal using the roll-out subframe, alternator-to-engine alignment and shim measurement, and radiator core tube replacement. The electric propulsion section covers the full AC drive system including the alternator field control, inverters, retarding grids, phase modules, capacitor discharge procedures and the DID panel fault code tables. The brake section covers the hydraulic brake circuit, wet disc brake rebuild, parking brake disassembly and the complete brake circuit check-out procedure with pressure values. The hydraulic section covers the hoist and steering circuits, pump overhaul, flow amplifier operation and system flushing. This is a working-level manual, not a summary.
What This Manual Enables You to Do
With this Komatsu 930E-4SE shop manual on hand, a technician can carry out the full range of service work on the truck: remove and install the power module, repair the cooling system, overhaul the hoist and steering pumps, rebuild the wet disc brakes, service the parking brake, replace wheel motor components, rebuild the Hydrair II suspensions, test the brake and steering circuits, diagnose electric propulsion faults through the DID panel, and follow the correct shutdown and safety procedures before opening any high-voltage cabinet. It also includes the maintenance schedules from 10-hour daily checks through to the 5000-hour service.
Having the correct procedures and specifications matters on a truck of this size. The 930E-4SE carries a gross vehicle weight of 505,611 kg (1,114,670 lb) and an AC drive system that stores dangerous voltage even after shutdown. Working from the wrong torque value, the wrong pressure setting or the wrong shutdown sequence is not an option. This manual gives the actual figures, the actual sequences, and the actual warnings the truck requires.
The PDF is delivered instantly after payment. There is no shipping and no waiting. You can open it on a laptop, tablet or phone, print the pages you need for the workshop floor, and keep the full 981-page manual on file for every job the truck brings in.
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