Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD 

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Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD 

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Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD 

Language : English
Pages : 903
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD 

SERIAL NUMBERS A30019, A30026 thru A30119
w/DDC 4000 Engine

MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – MAJOR COMPONENT DESCRIPTION 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions When Handling At High Temperatures 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Fire Extinguisher And First Aid Kit 19
Precautions When Using ROPS 20
Precautions For Attachments 20
PRECAUTIONS DURING OPERATION 21
Safety Is Thinking Ahead 21
Safety At The Worksite 21
Fire Prevention 21
Preparing For Operation 21
Ventilation For Enclosed Areas 21
In Operator’s Cab – Before Starting The Engine 22
Mirrors, Windows, And Lights 22
OPERATING THE MACHINE 22
When Starting The Engine 22
Truck Operation – General 22
Check When Traveling In Reverse 23
Traveling 23
Traveling On Slopes 24
Ensure Good Visibility 24
Operate Carefully On Snow 24
Avoid Damage To Dump Body 24
Driving Near High Voltage Cables 24
When Dumping 25
Working On Loose Ground 25
When Loading 25
Parking The Machine 25
TOWING 25
WORKING NEAR BATTERIES 26
Starting With Booster Cables 26
PRECAUTIONS FOR MAINTENANCE 27
BEFORE PERFORMING MAINTENANCE 27
Warning Tag 27
Proper Tools 27
Stopping The Engine Before Service 27
Securing The Dump Body 27
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keep The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Water Level 29
Use Of Lighting 29
Precautions With The Battery 29
Handling High Pressure Hoses 29
Precautions With High Pressure Oil 29
Precautions When Performing Maintenance At High Temperature Or High Pressure 30
Rotating Fan And Belts 30
Waste Materials 30
TIRES 31
Handling Tires 31
Storing Tires After Removal 31
ADDITIONAL JOB SITE RULES 32
WHEN REPAIRS ARE NECESSARY 33
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 34
Preliminary Procedures before Welding or Performing Maintenance 34
Normal Engine Shutdown Procedure 34
Engine Shutdown Procedure before Welding or Performing Maintenance 35
TRUCK OPERATION 37
PREPARING FOR OPERATION 37
Safety Is Thinking Ahead 37
At The Truck – Ground Level Walk Around Inspection 37
ENGINE START-UP SAFETY PRACTICES 40
Cold Weather Starting 41
AFTER ENGINE HAS STARTED 41
MACHINE OPERATION SAFETY PRECAUTIONS 42
MACHINE OPERATION ON THE HAUL ROAD 42
DYNAMIC RETARDING OPERATION 43
Dynamic Retarder Control Lever 43
Dynamic Retarder/Service Brake Pedal 43
Starting On A Grade With A Loaded Truck 44
PASSING 44
LOADING 44
DUMPING 44
Raising The Dump Body 44
Lowering The Dump Body 45
TOWING 46
SAFE PARKING PROCEDURES 47
NORMAL ENGINE SHUTDOWN PROCEDURE 47
DELAYED ENGINE SHUTDOWN PROCEDURE 47
SUDDEN LOSS OF ENGINE POWER 48
SECTION A4 – WARNINGS AND CAUTIONS 49
SECTION A5 – STANDARD CHARTS AND TABLES 57
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 63
STORAGE AND IDLE MACHINE PREPARATION 65
Short Term Idle Periods 65
PREPARATION FOR STORAGE 66
REMOVAL FROM STORAGE 67
RECONDITIONING AN IDLE VEHICLE 69
ENGINE OPERATION 72
After The Engine Has Started 73
ENGINE STORAGE 74
Preparing Engine For Storage 74
Temporary Storage (30 Days Or Less) 74
Extended Storage (more Than 30 Days) 74
RESTORING AN ENGINE AFTER EXTENDED STORAGE 76
ELECTRIC DRIVE TRUCKS 77
Storage Instructions and Procedures 77
Placing Equipment Into Storage 77
Storing A Truck That Is Operational 77
Storing A Truck That Is Not Operational 78
Storing A Major Component 78
Periodic Inspections 79
Placing Equipment Into Service After Storage 79
When A Truck Is Operational 79
When A Truck Is Not Operational 79
For The First Hour 80
SECTION B – STRUCTURES – INDEX 81
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 83
STRUCTURAL COMPONENTS 85
Preparation 85
GRILLE, HOOD AND LADDER 86
Removal 86
Installation 86
DECKS 87
RIGHT DECK AND COMPONENTS 87
Removal 87
Installation 88
LEFT DECK 88
Removal 88
Installation 88
CENTER DECK 88
SECTION B3 – DUMP BODY – INDEX 89
DUMP BODY 91
Removal 91
Installation 92
BODY PADS 93
Adjustment 93
BODY GUIDE 94
HOIST LIMIT SWITCH 94
BODY UP SWITCH 94
BODY-UP RETENTION CABLE 94
ROCK EJECTORS 95
Rock Ejectors (Type I) 95
Inspection 95
Rock Ejectors (Type II) 96
Inspection 96
SECTION B4 – FUEL TANK – INDEX 97
FUEL TANK 99
Removal 100
Installation 100
Repair 100
Cleaning 100
FUEL GAUGE SENDER 101
Removal 101
Installation 101
LOW FUEL SWITCH 101
WIGGINS QUICK FILL FUEL SYSTEM 102
FUEL RECEIVER 102
TANK BREATHER VALVE 102
Removal 102
Installation 102
Disassembly 102
Assembly 102
LEFT SIDE FILL 103
FUEL – WATER SEPARATOR 104
Installation 104
Filter Service 105
Backflushing Procedure 105
Filter Element Replacement 105
SECTION C – ENGINE – INDEX 107
SECTION C2 – POWER MODULE – INDEX 109
POWER MODULE 111
PREPARATION 111
Preparation for Removal 112
Power Module Removal 115
Power Module Installation 117
Power Module Hookup 117
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul) 119
SECTION C3 – COOLING SYSTEM – INDEX 121
COOLING SYSTEM 123
COOLING SYSTEM DESCRIPTION 123
Coolant Flow 123
RADIATOR 124
Removal 124
RADIATOR REPAIR 126
Internal Inspection 126
External Cleaning 126
Disassembly 127
Cleaning and Inspection 128
Assembly 128
Pressure Testing 129
Additional Service Information 129
Installation 130
RADIATOR FILL PROCEDURE 130
Radiator Pressure Regulator Valve 131
COOLING SYSTEM TROUBLESHOOTING 131
SECTION C4 – POWERTRAIN – INDEX 133
POWER TRAIN 135
ALTERNATOR REMOVAL PROCEDURE 135
Removal (MTU/DDC 4000 Engine) 135
ENGINE/ALTERNATOR MATING 137
General Instructions 137
MEASURING PROCEDURE 137
Joining Alternator and MTU/DDC Engine 139
ENGINE 140
Removal 140
Service 140
Installation 140
SECTION C5 – AIR CLEANERS – INDEX 141
AIR CLEANERS 143
AIR CLEANERS 143
Operation 143
General Service Information 143
FILTER ELEMENT REPLACEMENT 144
Main Filter Element Cleaning 145
Precleaner Section 146
Cleaning Precleaner Tubes 146
AIR INTAKE TROUBLESHOOTING 147
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX 149
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 151
24VDC ELECTRIC SUPPLY SYSTEM 153
ELECTRICAL SYSTEM DESCRIPTION 153
BATTERIES 153
Maintenance and Service 153
Troubleshooting 153
BATTERY SUPPLY SYSTEM 155
24VDC Battery Charging Alternator 155
Battery Box 155
Battery Control Box 155
System Battery Starter Disconnect Relay 155
Battery Disconnect Switches 156
24VDC Auxiliary Battery Connectors 156
Battery Equalizer 157
Troubleshooting 157
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX 159
24 VDC ELECTRICAL SYSTEM COMPONENTS 161
PASSENGER SEAT BASE COMPARTMENT 161
TRUCK SHUTDOWN PROCEDURE 161
COMPONENTS 161
Tail Light Resistor Diode Assemblies 161
5 Minute Idle Timer Components 161
Inclinometer 163
Brake Warning Buzzer (BWB) 163
Alarm Indicating Device (AID) System 163
ELECTRICAL INTERFACE CABINET 166
Lubrication System Timer 166
Barometric Pressure Transducer 166
Special Interface Module 166
Power Distribution Terminals 166
Truck Control Interface Panel 166
Control Power Relay 166
Circuit Breaker Panel 166
Diode Board – DB1 168
Diode Testing 168
RELAY BOARDS 169
Relay Boards – RB1, RB2, RB3, RB4, RB5 169
Service 169
Relay Board Identification 170
Relay Board Functions 171
Relay Board 6 (RB6) 172
BODY-UP SWITCH 173
Operation 173
Adjustment 173
Service 173
HOIST LIMIT SWITCH 174
Operation 174
Adjustment 174
Service 174
SECTION D5 – DDEC ELECTRONIC ENGINE CONTROL – INDEX 177
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE 179
COMPONENT DESCRIPTION 180
Electronic Control Module 180
Electronic Unit Nozzles 182
System Sensors and Operator Inputs 182
ENGINE PROTECTION SYSTEM 183
DIAGNOSTICS 184
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX 185
BATTERY CHARGING ALTERNATOR 187
ELECTRICAL SYSTEM DESCRIPTION 187
BATTERY 187
Maintenance and Service 187
Troubleshooting 187
BATTERY CHARGING SYSTEM (Niehoff) 189
General Description 189
TROUBLESHOOTING PROCEDURES (On-Truck) 189
Equipment Required: 189
Preliminary Checks 190
Test Setup 190
Test Procedure 190
Regulator Bypass Test 191
ON VEHICLE TROUBLESHOOTING GUIDE 193
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 193
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 193
CHARGE VOLT AND AMP VALUES 194
DEFINITIONS 194
ADVANCED SYSTEM TROUBLESHOOTING 195
Static Test – Engine OFF, Key ON, Battery Switch ON 195
Go To Alternator 195
Go To Regulator (If Required) 196
Go To Regulator Connector On The Alternator 196
ALTERNATOR OVERHAUL 197
ALTERNATOR DIMENSIONS 197
ALTERNATOR SPECIFICATIONS 198
SERVICE PARTS 199
ON-VEHICLE TEST 201
Equipment: 201
Preliminary Checks: 201
Test Set-up 201
Test Procedure 201
ON-VEHICLE TEST 202
Bypass Test: 202
BENCH TEST 203
STATIC TESTS 204
Regulator Tests 204
Control Box Tests 205
ALTERNATOR DISASSEMBLY 207
ASSEMBLY- ALTERNATOR 212
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 221
Stator Removal And Replacement 221
Stator Installation 222
SECTION E – ELECTRICAL PROPULSION – INDEX 225
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX 227
ELECTRICAL PROPULSION SYSTEM COMPONENTS 229
GENERAL SYSTEM DESCRIPTION 229
SYSTEM COMPONENTS 231
Auxiliary Blower System 231
Propulsion System Controller (PSC) 231
TRUCK CONTROL INTERFACE PANEL (TCI) 232
Diagnostic Information Display 233
DID PANEL EVENT CODES 233
PSC SOFTWARE FUNCTIONS 258
Input Processing 258
STATE MANAGEMENT 258
State Machine 258
Transitions Between States 259
DC Link State 261
Powering the Link 261
De-Powering the Link 261
Control Functions 261
Engine Control 261
ALTERNATOR FIELD CONTROL 262
Desired Three-Phase Voltage 262
Desired DC Link Voltage 262
Self-load 262
Propel Torque Control 263
Retard Torque Control 263
Wheel Slide Control 263
Resistor Grid Control 264
Chopper Voltage Control 264
AUXILIARY BLOWER CONTROL 264
EVENT PROCESSING 264
Event Detection 264
Power On Tests 264
Initiated Tests 265
Periodic Tests 265
EVENT RESTRICTIONS 265
EVENT LOGGING AND STORAGE 265
Event History Buffer 266
Data Packs 266
To Record and Save a Data Pack to a Floppy Disk 266
Event Reset 267
SERIAL DATA COMMUNICATIONS 268
PSC – TCI Communications processing 268
PSC – PTU Communications Processing 268
Inverter Communications Processing 268
OUTPUT PROCESSING 269
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 269
Fast Start 269
Engine Shutdown/Engine Not Running 269
Limp Home Mode 269
Entering/Exiting Limp Home Mode 269
PROPULSION SYSTEM COMPONENT ABBREVIATIONS 270
ELECTRONIC ACCELERATOR AND RETARD PEDALS 280
Removal 280
Installation 280
Disassembly 280
Assembly 280
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX 281
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 283
AC DRIVE SYSTEM MAINTENANCE 283
TRUCK SHUTDOWN PROCEDURES 283
NORMAL TRUCK SHUTDOWN PROCEDURE 284
SHUTDOWN AFTER SYSTEM FAILURE 285
SYSTEM CHECKOUT 286
Battery and Control Checks of System WITH Battery Power OFF 286
Battery and Control Circuit Checks of System With Battery Power ON 289
Checks with Key Switch OFF 290
CPU Battery Checks 292
MEMORY BACKUP BATTERY REPLACEMENT 292
TCI PROGRAMMING 293
PSC PROGRAMMING 293
INVERTER PROGRAMMING 294
TCI CHECKOUT 294
Modular Mining Communication Port 295
TCI Input Checks 296
TCI Digital Output Tests 298
TCI Digital Input Tests 300
PSC Checkout Procedure 302
PSC Digital Input Checks 306
Miscellaneous Checks 307
A3PV Panel 307
LINKV Panel 307
Thermistor Checks 307
17FM384 Panel Check 307
Pedal Percentages and Meter Calibration 308
Meter Calibration Procedure 308
Reprogram With Serial Numbers and Pedal Percentages 310
LOAD TESTING 312
Preload Checks 312
ADDITIONAL TRUCK CHECKS 314
On-Board Load Testing 316
Preparation 316
Initiate Loadbox Test 319
Manual Offset HP Output Adjustment 321
TROUBLESHOOTING 323
PVM Optimum Load Curve Handshaking Troubleshooting 323
MISCELLANEOUS COMPONENT REPAIR 324
Troubleshooting Phase Modules and Chopper Modules 324
Phase Module Removal and Snubber Resistor Replacement 324
Snubber Resistor Installation 325
Phase Module Installation 325
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING 326
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING 329
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING 330
IGBT TROUBLESHOOTING 331
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX 333
SECTION G2 – TIRES AND RIMS – INDEX 335
TIRES AND RIMS 337
FRONT TIRES AND RIMS 338
Removal 338
Installation 339
REAR TIRES AND RIMS 339
Removal 339
Installation 340
RIM 341
Tire Removal 341
Tire Installation 342
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 343
FRONT WHEEL HUB AND SPINDLE 345
WHEEL HUB AND SPINDLE ASSEMBLY 345
Preparation 345
Removal 345
Installation 348
Disassembly 349
Cleaning and Inspection 349
Assembly 351
Wheel Bearing Adjustment: 351
Brake Installation 352
Seal Assembly Gap Check: 353
STEERING CYLINDERS AND TIE ROD 354
Spherical Bearing Wear Limits 354
Removal 355
Installation 356
Bearing Replacement 356
TOE-IN ADJUSTMENT 357
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX 359
REAR AXLE HOUSING ATTACHMENT 361
PIVOT PIN 361
Removal 361
Installation 361
PIVOT EYE BEARING 362
Disassembly 362
PIVOT EYE REPAIR 363
Removal 363
Disassembly 363
Assembly 363
Installation 363
ANTI-SWAY BAR 364
Removal 364
Installation 364
Disassembly 364
Assembly 364
SECTION G5 – REAR AXLE HOUSING – INDEX 365
REAR AXLE HOUSING 367
REAR AXLE HOUSING 367
PREPARATION 367
Removal 367
Cleaning and Inspection 369
Installation 369
WHEEL MOTOR 370
Preparation 370
Removal 370
Cleaning and Inspection 371
Installation 372
WHEEL MOTOR GEAR OIL 375
Filtering Requirements 375
Particle Size Analysis 375
Flushing 375
Oil Sample Analysis 376
ELEMENT SPECIFICATION CHARTS 377
SECTION H – HYDRAIR II SUSPENSIONS – INDEX 381
SECTION H2 – FRONT SUSPENSION – INDEX 383
FRONT SUSPENSION 385
Removal 385
Installation 386
“TURN-OF-THE-NUT” Tightening Procedure 388
MINOR REPAIR ONLY (LOWER BEARING & SEALS) 389
Lower Bearing Removal 389
Lower Bearing Installation 389
MAJOR SUSPENSION REBUILD 391
Disassembly 391
Assembly 391
SECTION H3 – REAR SUSPENSIONS – INDEX 393
REAR SUSPENSIONS 395
Removal 395
Installation 397
Disassembly 398
Cleaning and Inspection 398
Assembly 398
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX 401
SUSPENSION OILING AND CHARGING PROCEDURE 403
GENERAL 403
EQUIPMENT LIST 403
Hydrair® Charging Kit 403
Installation of Charging Kit 403
Removal of Charging Kit 404
Support Blocks For Oiling And Charging Dimensions 404
FRONT SUSPENSION 405
Front Suspension Oiling 405
Front Suspension Nitrogen Charging 406
REAR SUSPENSION 407
Rear Suspension Oiling 407
Rear Suspension Nitrogen Charging 408
OIL AND NITROGEN SPECIFICATIONS CHART 410
SECTION J – BRAKE CIRCUIT – INDEX 411
SECTION J2 – BRAKE CIRCUIT – INDEX 413
BRAKE CIRCUIT 415
SERVICE BRAKE CIRCUIT 415
SECONDARY BRAKING AND AUTOMATIC APPLY 417
PARKING BRAKE CIRCUIT 417
BRAKE LOCK CIRCUIT 418
WARNING CIRCUIT 418
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 421
BRAKE CIRCUIT COMPONENT SERVICE 423
BRAKE VALVE 423
Rebuild Criteria 423
Removal – Brake Valve 424
Installation – Brake Valve 424
Disassembly – Brake Valve 425
Cleaning and Inspection – Brake Valve 428
Assembly – Actuator Base Threaded Inserts 428
Assembly – Boot and Cap 428
Installation – Valve Body Seal 428
Installation – Regulator Sleeve O-Ring 429
Installation – Actuator Plunger O-ring 429
Assembly – Brake Valve 429
DIFFERENTIAL PRESSURE SWITCH 431
Disassembly 431
Cleaning and Inspection 431
Assembly 431
VALVE BENCH TEST AND ADJUSTMENT 432
Test Set Up Procedure 433
Adjustment – Brake Valve Output Pressure 433
Adjustment – Differential Pressure Switch 433
Final Test and Adjustment 434
Installation – Brake Pedal Actuator Assembly to Brake Valve 435
Installation – Retard Pedal To Brake Pedal 435
DUAL RELAY VALVE 437
Removal 437
Installation 437
Disassembly – Dual Relay Valve 439
Cleaning and Inspection – Dual Relay Valve 439
Assembly – Dual Relay Valve 439
DIFFERENTIAL PRESSURE SWITCH 440
Disassembly 440
Cleaning and Inspection 440
Assembly 440
VALVE TEST AND ADJUSTMENT 441
Test Set Up Procedure 442
Adjustment – Brake Valve Output Pressure 442
Adjustment – Differential Pressure Switch 443
HYDRAULIC BRAKE ACCUMULATORS 444
Brake Accumulator Bleed Down Procedure 444
ACCUMULUTOR – HYDRAULIC COMPONENTS CABINET 444
Removal 444
Installation 444
Disassembly 444
Cleaning and Inspection – Accumulator 445
Assembly – Accumulator 446
Charging Procedure – Accumulator 447
ACCUMULATORS – FRAME MOUNTED 448
Removal 448
Installation 448
Disassembly – Accumulator 449
Cleaning and Inspection – Accumulator 449
Assembly – Accumulator 450
Testing – Accumulator 450
ACCUMULATOR CHARGING PROCEDURE (Frame Mounted Brake Accumulators) 451
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 452
Removal – Retarder Control Lever 452
Installation – Retarder Control Lever 452
Disassembly and Adjustment – Retarder Control Lever 453
Potentiometer Check – Retarder Control Lever 453
Assembly – Retarder Control Lever 453
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX 455
BRAKE CIRCUIT CHECK-OUT PROCEDURE 457
EQUIPMENT REQUIRED 459
INITIAL SYSTEM SET-UP 460
BRAKE SYSTEM CHECKOUT 461
Failure Modes Check-Out 462
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 465
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 469
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX 471
WET DISC BRAKE ASSEMBLY 473
Operation 473
MAINTENANCE 474
Brake Disc Wear Indicator 474
Removal/Installation 474
BRAKE REBUILD 476
Disassembly 476
Cleaning and Inspection 479
Assembly 480
Floating Ring Seal Assembly/Installation 483
WET DISC BRAKE BLEEDING PROCEDURE 486
SECTION J7 – PARKING BRAKE – INDEX 487
PARKING BRAKE 489
OPERATION 489
MAINTENANCE 490
Inspection – Parking Brake 490
Removal – Parking Brake 490
Installation – Parking Brake 491
Disassembly – Parking Brake 492
Cleaning and Inspection – Parking Brake 492
Assembly – Parking Brake 492
PARKING BRAKE BLEEDING PROCEDURE 494
SECTION L – HYDRAULIC SYSTEM – INDEX 495
SECTION L2 – HYDRAULIC SYSTEM – INDEX 497
HYDRAULIC SYSTEM 499
Hoist Circuit Operation 500
Steering Circuit Operation 502
Disc Brake Cooling System 504
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 507
HYDRAULIC SYSTEM COMPONENT REPAIR 509
HOIST PUMP 509
Removal 509
Installation 511
Disassembly 512
Inspection Of Parts 516
Assembly 516
TROUBLESHOOTING GUIDE 521
HYDRAULIC TANK 522
Filling Instructions 522
Removal 522
Installation 523
HYDRAULIC TANK STRAINERS 523
Removal 523
Inspect and Clean 523
Installation 523
Hydraulic Tank Breathers 524
SECTION L4 – STEERING CIRCUIT – INDEX 525
STEERING CIRCUIT 527
STEERING CIRCUIT OPERATION 527
COMPONENT DESCRIPTION 528
Steering Control Valve 528
Bleeddown Manifold Valve 529
Bleeddown Solenoids 529
Accumulators 530
Low Precharge Warning Switch 530
High Pressure Filter 530
Flow Amplifier 530
FLOW AMPLIFIER SYSTEM OPERATION 532
No Steer 532
Steering Left 534
Steering Right 536
No Steer, External Shock Load 538
STEERING PUMP 540
Operation 540
High Altitude Operation 540
PRINCIPLE OF OPERATION 542
Steering Pump 543
SECTION L5 – STEERING CONTROL UNIT – INDEX 545
STEERING CONTROL UNIT 547
Removal 547
Installation 547
STEERING CONTROL UNIT REBUILD 548
Disassembly 548
Cleaning and Inspection – Steering Control Unit 549
Assembly – Steering Control Unit 551
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 555
STEERING CIRCUIT COMPONENT REPAIR 557
BLEEDDOWN MANIFOLD VALVE 557
Removal 557
Installation 557
ACCUMULATORS 558
Removal 558
Installation 558
Disassembly 559
Cleaning and Inspection 559
Assembly 560
Testing 560
STEERING ACCUMULATOR CHARGING PROCEDURE 561
FLOW AMPLIFIER 562
Removal 562
Installation 562
Flow Amplifier Rebuild 562
Disassembly 564
Assembly 565
STEERING CYLINDERS 566
Disassembly 567
Piston Seal & Bearing Installation 567
Cylinder Assembly 567
Test 567
STEERING AND BRAKE PUMP 568
Removal 568
Installation 568
Disassembly 570
Control Piston Group 570
Valve Plate Group 570
Rotating Group 573
Swashblock Group 573
Driveshaft Group 573
Inspection 573
Control Piston Group 573
Valve Plate Group 573
Rotating Group 573
Swashblock Group 575
Driveshaft Group 576
Compensator Block and Unloader Module 576
Stroke Adjuster Assembly 576
Assembly 576
Swashblock Group 576
Driveshaft Group 577
Rotating Group 577
Control Piston Group 577
Valve Plate Group 578
TROUBLESHOOTING 579
SECTION L7 – HOIST CIRCUIT – INDEX 585
HOIST CIRCUIT 587
HOIST CIRCUIT OPERATION 587
COMPONENT DESCRIPTION 588
Hydraulic Tank 588
Hydraulic Pump 588
High Pressure Filters 588
Hoist Valve 588
Inlet Sections 588
Spool Sections 589
Work Ports (Rear) Spool Section 589
Tank Ports (Front) Spool Section 589
Hoist Pilot Valve 589
Hoist Up Limit Solenoid 590
Pilot Operated Check Valve 590
Snubber Valve 590
Counterbalance Valve 590
HOIST CIRCUIT OPERATION 590
POWER UP OPERATION (Figure 7-5) 592
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 601
HOIST CIRCUIT COMPONENT REPAIR 603
HOIST VALVE 603
Removal 603
Installation 604
O-Ring Replacement 604
INLET SECTION 605
Disassembly 605
Cleaning and Inspection 606
Assembly 606
REAR SPOOL SECTION (Work Ports) 606
Disassembly 606
Cleaning and Inspection 608
Assembly 608
FRONT SPOOL SECTION (Tank Ports) 609
Disassembly 609
Cleaning and Inspection 609
Assembly 609
HOIST PILOT VALVE 611
Removal 611
Installation 611
Disassembly 612
Cleaning and Inspection 613
Assembly 613
Hoist Up Limit Solenoid 614
HOIST CYLINDERS 614
Removal 614
Installation 615
Disassembly 617
Cleaning and Inspection 618
Quill and Cylinder – Assembly 619
Quill Installation 619
Installation Of Check Balls And Plugs In Quill 620
Assembly of Cylinder 621
DISABLED TRUCK DUMPING PROCEDURE 622
Hookup 622
Raising the Body: 622
Lowering the Body: 622
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 623
HYDRAULIC SYSTEM FILTERS 625
HOIST CIRCUIT FILTER 625
Filter Element Replacement 625
Removal – Hoist Circuit Filter 626
Installation – Hoist Circuit Filter 626
Indicator Switch – Hoist Circuit Filter 626
STEERING CIRCUIT FILTER 627
Filter Element Replacement 627
Removal – Steering Circuit Filter 628
Installation – Steering Circuit Filter 628
Indicator Switch – Steering Circuit Filter 628
INDICATOR SWITCH 628
Test Procedure 628
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 631
HYDRAULIC CHECK-OUT PROCEDURE 633
GENERAL INFORMATION 633
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 633
Equipment Requirements 634
Pump Pressure Control Adjustments 634
Steering Control Valve and Flow Amplifier Leakage Test 635
Bleeddown Manifold Leakage Test 635
Steering / Brake Pump Stroke Adjustment 636
Shock And Suction Valves 637
Equipment Requirements 637
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 638
Equipment Requirements 638
Pressure Checks 638
Brake Cooling Circuit Test 638
Power Up Relief Pressure Test 639
Adjustment 639
Power Down Relief Pressure Test 640
Adjustment 640
Hoist Counterbalance Valve Adjustment 641
HYDRAULIC SYSTEM FLUSHING PROCEDURE 642
Preparation 642
Flushing Procedure 642
Filter Element Replacement 643
930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET 645
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 647
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX 649
FIRE CONTROL SYSTEM (MANUAL) 651
Operation 651
Inspection and Maintenance 651
Recharging Procedures 652
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1 653
Control Module 653
Actuator 654
Linear Detection Wire 654
Power Wire 654
Test Kit 654
Squib 654
Securing the Detection Wire 655
Preliminary Test Before Final Hook-Up 655
Installation Procedure for Squib 657
Placing the Electric Detection & Actuation System Into Service 657
INSPECTION AND MAINTENANCE SCHEDULES 658
Daily 658
Normal Maintenance Based On Actual Operating Hours 658
IN CASE OF FIRE 659
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM 661
SECTION M8 – SPECIAL TOOLS 663
SECTION M20 – PAYLOAD METER II – INDEX 671
GENERAL INFORMATION 673
Haul Cycles 673
LIGHTS, SWITCHES AND COMPONENTS 674
TIPS FOR OPERATION 675
EXTERNAL DISPLAY LIGHTS 675
THEORY OF OPERATION 676
Basic Description 676
Inclinometer 676
Linkage Factor 676
Gain Factor 677
Brake Lock 677
Sources of Error 677
Typical Data From Service Check Mode 677
Example Calculation of Payload 678
Viewing Payload Calculation Inputs 678
Checking the Gain 679
Adjusting the Gain 679
TYPES OF DATA STORED 680
Cycle Data 680
Engine ON/OFF Data 681
Fault Codes and Warning Data 681
Engine Operation 682
Total Payload and Total Number of Cycles 682
Other Data 682
OPERATOR FUNCTIONS 683
Using the Operator Load Counter 683
Viewing the Operator Load Counter 683
Clearing the Operator Load Counter 683
Dimming the Lights on the Display 683
INITIAL SETUP OF PAYLOAD METER 684
Switch Settings 684
Checking the Operator Check Mode 685
Checking the Service Check Mode 685
Checking the Gt setting: 686
Checking the Inclinometer Settings 686
Calibrating a Truck 686
DISPLAYS AT START-UP 687
Normal Operation 687
SETUP AND MAINTENANCE 688
Setting The Speed Limit 688
Setting the Option Code 688
Setting The Machine I D Code 689
Setting The Operator I D Code 689
Setting The Time and Date 689
DOWNLOAD OF INFORMATION 690
DISPLAY OF FAULT CODES 690
Monitoring Input Signals 694
Service Check Mode 694
UP FACTOR – PAYLOAD CALCULATION GAIN 695
PL MODE -LOAD CALCULATION TIMING 695
FINAL GEAR RATIO SELECTION 696
BATTERY REPLACEMENT PROCEDURE 697
Replacing the Battery 697
After Replacing the Battery 698
SUSPENSION PRESSURE SENSOR 698
Removal 698
Installation 699
INCLINOMETER 699
Removal 699
Installation 699
Adjustment 699
PAYLOAD METER BACK PANEL 700
CONNECTIONS 701
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 702
PAYLOAD CIRCUIT NUMBERS 703
TROUBLESHOOTING 704
COMMON PROBLEMS 704
Suspension Charging 704
Symptom Table 705
Missing Body-Up Signal 705
Missing Speed Signal 706
F-18: Alternator R-Terminal, Oil Pressure Signals 706
Shorted 18v Sensor Power Supply (930E) 706
FAULT TREE DIAGNOSIS 707
Payload Lights Won’t Illuminate 707
Red, Amber or Green Payload Light Does Not Illuminate 708
Cannot Download – PC Communications 709
PC Communications Configuration 710
F CAL: Payload Meter Won’t Calibrate 711
F-20: Sensor Power Fault 712
F-21, F-25: Left Front Pressure Sensor 714
F-22, F-26: Right Front Pressure Sensor 714
F-23, F-27: Left Rear Pressure Sensor 714
F-24, F-28: Right Rear Pressure Sensor 714
F-31, F-32: Inclinometer 716
Body Up Input 718
Brake Lock Input 719
Speed Signal 720
Adjusting the Speed Sensor 720
CONNECTORS AND PRESSURE SENSORS 722
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 725
Menu Functions 728
Using Scope 728
Log File Information 728
Connections to Payload Meter II™ 729
USING SCOPE 730
Monitoring Inputs Using Scope 730
Monitoring Suspension Charging Using Scope 730
Pressure Sensor Dummy Loads 733
GAIN ADJUSTMENT WORKSHEET 734
SECTION N – CAB COMPONENTS – INDEX 735
SECTION N2 – TRUCK CAB – INDEX 737
TRUCK CAB 739
Description 739
Preparation 740
Removal – Cab 740
Installation – Cab 742
CAB DOOR 742
Removal 742
Installation 742
Door Adjustment 743
Door Jamb Bolt Adjustment 743
Door Handle Plunger Adjustment 744
Door Glass Replacement 745
Door Window Regulator Replacement 749
Door Handle or Latch Assembly Replacement 749
Door and Door Hinge Seal Replacement 750
Door Opening Seal Removal 750
Installation 750
GLASS REPLACEMENT 751
Adhesive Bonded Windows 751
Replacement Procedure 751
Windshield And Rear Glass 752
Removal 752
Installation 753
SECTION N3 – CAB COMPONENTS – INDEX 755
CAB COMPONENTS 757
WINDSHIELD WIPERS 757
Wiper Motor Replacement 757
Removal 757
Installation 757
Wiper Arm Replacement 757
Removal 757
Installation 758
Wiper Linkage Replacement 758
Removal 758
Installation 758
WINDSHIELD WASHER 759
Operation 759
Service 759
OPERATOR SEAT 760
Adjustment 760
Removal 760
Installation 760
SECTION N4 – OPERATOR COMFORT – INDEX 761
OPERATOR COMFORT 763
HEATER/AIR CONDITIONER 763
Operation 763
HEATER COMPONENTS 764
Circuit Breakers 764
Heater Control Components 764
Heater Coil 764
Fan Motor And Speed Control 765
Actuators 765
Filter 765
AIR CONDITIONING SYSTEM 767
Environmental Impact 767
OPERATOR CAB AIR CONDITIONING 768
PRINCIPLES OF REFRIGERATION 768
Air Conditioning 768
Refrigeration – The Act Of Cooling 769
The Refrigeration Cycle 769
AIR CONDITIONER SYSTEM COMPONENTS 770
Compressor (Refrigerant Pump) 770
Service Valves 770
Condenser 770
Receiver-Drier 770
Expansion Block Valve 771
Evaporator 771
ELECTRICAL CIRCUIT 772
Thermostat 772
Compressor Clutch 772
Trinary™ Switch 773
SYSTEM SERVICING 774
SYSTEM OIL 775
Handling and Reusing PAG Oil 775
Oil Quantity 775
Replacing Oil After Servicing the System 775
Setting Up a New Compressor 775
REFRIGERANT 776
Recycled Refrigerant 776
Reclaimed Refrigerant 776
Refrigerant Quantity 776
R-134a Refrigerant Containers 776
SERVICE TOOLS AND EQUIPMENT 777
Recovery/Recycle Station 777
Leak Detector 777
Service Valves 778
Vacuum Pump 778
Manifold Gauge Set 779
Installing Manifold Gauge Set 780
Purging Air From Service Hoses 781
Stabilizing the AC System 782
SYSTEM PERFORMANCE TEST 782
SYSTEM LEAK TESTING 783
Electronic Leak Detector 783
Tracer Dyes 783
Soap and Water 783
SYSTEM REPAIR 784
System Cleaning 784
Hoses and Fittings 784
Lines 784
Expansion Valve 784
Receiver-Drier 785
Thermostat 785
Compressor 785
Clutch 785
Servicing the Compressor Clutch 786
Pulley Removal 788
Clutch Coil Check 788
Pulley Installation 788
Clutch Assembly Installation 789
RECOVERING AND RECYCLING THE REFRIGERANT 790
Performing the Recovery Cycle 790
Performing the Recycling Procedure 790
Evacuating and Charging the AC System 790
EVACUATING THE SYSTEM 791
CHARGING THE AC SYSTEM 792
TROUBLESHOOTING 793
Pre-Diagnosis Checks 793
Preparing For Diagnosis 793
Preliminary Steps 793
System Performance Test 793
Diagnosis Of Gauge Readings And System Performance 794
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 795
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 801
SECTION N5 – OPERATOR CAB CONTROLS – INDEX 803
OPERATOR CAB CONTROLS 805
STEERING COLUMN 805
Removal 805
Installation 805
STEERING WHEEL AND CONTROLS 807
DYNAMIC RETARDING 807
RETARDER CONTROL LEVER 808
DYNAMIC RETARDER/SERVICE BRAKE PEDAL 808
ACCELERATOR (THROTTLE) PEDAL 808
Starting on a Grade With a Loaded Truck 808
GRADE/SPEED RETARD CHART 809
HEATER / AIR CONDITIONER VENTS 810
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 810
DEFROSTER VENT CONTROL SWITCH 810
HEAT VENT CONTROL SWITCH 810
FAN CONTROL KNOB 810
AIR CONDITIONER CONTROL KNOB 810
OUTSIDE/INSIDE AIR CONTROL SWITCH 810
SELECTION CONTROL SWITCH 810
HEATER/AIR CONDITIONER VENTS 810
INSTRUMENT PANEL 811
OVERHEAD PANEL AND DISPLAYS 811
F-N-R SELECTOR SWITCH 812
HOIST CONTROL LEVER 813
OVERRIDE /FAULT RESET SWITCH 814
10, FIGURE 5-5 – BLANK 814
RETARD SPEED CONTROL (RSC) “OFF/ON” SWITCH 814
RETARD SPEED CONTROL (RSC) ADJUST DIAL 814
TCI DOWNLOAD PORT 815
PASSENGER SEAT 815
INSTRUMENT PANEL AND INDICATOR LIGHTS 817
CONTROL SYMBOLS 817
INSTRUMENT PANEL (Figure 5-6) 817
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6) 819
KEY SWITCH 819
Starting 819
Cold Weather Starting 819
Normal Engine Shutdown 819
Operation 820
PARKING BRAKE CONTROL 821
AC DRIVE SYSTEM TEMPERATURE GAUGE 823
STATUS / WARNING INDICATOR LIGHT SYMBOLS 826
SECTION P – LUBRICATION AND SERVICE – INDEX 833
SECTION P2 – LUBRICATION AND SERVCIE – INDEX 835
LUBRICATION AND SERVICE 837
930E SERVICE CAPACITIES 837
HYDRAULIC TANK SERVICE 837
Adding Oil 837
WHEEL MOTOR SERVICE 837
COOLANT LEVEL CHECK 838
RADIATOR FILLING PROCEDURE 838
LUBRICATION CHART 839
10 HOUR (DAILY) INSPECTION 840
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 843
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 844
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 845
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 848
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 849
2500 HOUR MAINTENANCE CHECKS 850
5000 HOUR MAINTENANCE CHECKS 850
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX 851
LINCOLN AUTOMATIC LUBRICATION SYSTEM 853
System Components 853
System Operation 855
GENERAL INSTRUCTIONS 856
Lubricant Required for System 856
System Priming 856
SYSTEM CHECKOUT 856
24 VDC SOLID STATE TIMER CHECK 857
24 VDC Solid State Timer Adjustment 857
INJECTORS (SL-1 Series “H”) 858
Injector Specifications 858
Injector Adjustment 858
INJECTOR OPERATION 859
PUMP CYCLE TIMER (FLASHER TIMER) 860
Pump Cycle Timer (Flasher Timer) Installation 860
Pump Cycle Timer (Flasher Timer) Adjustment: 860
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N C ) 860
PRESSURE REDUCER ADJUSTMENT 862
TROUBLESHOOTING CHART 863
Preventative Maintenance Procedures 866
Daily Lubrication System Inspection 866
250 Hour Inspection 866
SECTION Q ALPHABETICAL INDEX 867
SECTION R – SYSTEM SCHEMATICS 871
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH341 873
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH348 874
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC 875
ELECTRICAL SCHEMATIC 876
24 VOLT ELECTRICAL SCHEMATIC 889

DESCRIPTION:

Komatsu 930E Dump Truck Shop Manual CEBM010200 – PDF DOWNLOAD 

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 serviceablearea 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.

S.V 12/12/24