Komatsu 930E-2 Dump Truck Shop Manual CEBM011901 – PDF DOWNLOAD
FILE DETAILS:
Komatsu 930E-2 Dump Truck Shop Manual CEBM011901 – PDF DOWNLOAD
Language : English
Pages :935
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu 930E-2 Dump Truck Shop Manual CEBM011901 – PDF DOWNLOAD
SERIAL NUMBERS A30293, A30295,
A30298 & A30299
FOREWORD
- This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.
- For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
- The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration
TABLE OF CONTENTS:
Komatsu 930E-2 Dump Truck Shop Manual CEBM011901 – PDF DOWNLOAD
SERIAL NUMBERS A30293, A30295,
A30298 & A30299
MAIN MENU 0
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – TRUCK COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX 15
GENERAL SAFETY 17
Safety Rules 17
Truck Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 17
Fire Extinguishers And First Aid Kits 18
Precautions For High Temperature Fluids 18
Asbestos Dust Hazard Prevention 18
Fire Prevention For Fuel And Oil 18
ROPS Precautions 19
Preventing Injury From Work Equipment 19
Precautions For Optional Attachments 19
Precautions When Starting The Machine 19
PRECAUTIONS FOR TRUCK OPERATION 20
Safety Is Thinking Ahead 20
Safety At The Worksite 20
Fire Prevention 20
Preparing For Operation 20
Ventilation For Enclosed Areas 20
Mirrors, Windows, And Lights 20
In The Operator’s Cab – Before Starting The Engine 21
OPERATING THE MACHINE 21
Starting The Engine 21
Truck Operation – General 21
Traveling In The Truck 22
Precautions When Traveling In Reverse 22
Traveling On Slopes 22
Ensuring Good Visibility 23
Operating On Snow 23
Avoid Damage To The Dump Body 23
Driving Near High Voltage Cables 23
When Loading The Truck 23
When Dumping 23
Working On Loose Ground 23
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 24
Jump Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Warning Tag 25
Proper Tools 25
Securing The Dump Body 25
DURING MAINTENANCE 26
Personnel 26
Attachments 26
Working Under The Machine 26
Keeping The Machine Clean 26
Rules To Follow When Adding Fuel Or Oil 26
Radiator Coolant Level 26
Use Of Lighting 26
Precautions With The Battery 27
Handling High Pressure Hoses 27
Precautions With High Pressure Oil 27
Maintenance Near High Temperatures And High Pressures 27
Rotating Fan And Belts 27
Waste Materials 27
TIRES 28
Handling Tires 28
Storing Tires After Removal 28
ADDITIONAL JOB SITE RULES 29
WHEN REPAIRS ARE NECESSARY 30
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK 31
Preliminary Procedures before Welding or Performing Maintenance 31
Normal Engine Shutdown Procedure 31
Engine Shutdown Procedure before Welding or Performing Maintenance 31
TRUCK OPERATION 34
PREPARING FOR OPERATION 34
Safety Is Thinking Ahead 34
WALK AROUND INSPECTION 34
ENGINE START-UP SAFETY PRACTICES 38
AFTER STARTING THE ENGINE 39
Additional Guidelines 39
MACHINE OPERATION SAFETY PRECAUTIONS 39
MACHINE OPERATION ON THE HAUL ROAD 40
DYNAMIC RETARDING OPERATION 41
Dynamic Retarder Control Lever 41
Dynamic Retarder/Service Brake Pedal 41
STARTING ON A GRADE WITH A LOADED TRUCK 42
PASSING 42
LOADING 42
DUMPING 42
Raising The Dump Body 42
Lowering The Dump Body 43
TOWING 44
SAFE PARKING PROCEDURES 45
NORMAL ENGINE SHUTDOWN PROCEDURE 45
DELAYED ENGINE SHUTDOWN PROCEDURE 45
SUDDEN LOSS OF ENGINE POWER 46
SECTION A4 – WARNINGS AND CAUTIONS 47
SECTION A5 – STANDARD CHARTS AND TABLES 55
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX 61
STORAGE AND IDLE MACHINE PREPARATION 63
Short Term Idle Periods 63
PREPARATION FOR STORAGE 64
REMOVAL FROM STORAGE 65
RECONDITIONING AN IDLE VEHICLE 67
ENGINE OPERATION 70
After The Engine Has Started 71
ENGINE STORAGE 72
Preparing Engine For Storage 72
Temporary Storage (30 Days Or Less) 72
Extended Storage (more Than 30 Days) 72
RESTORING AN ENGINE AFTER EXTENDED STORAGE 74
ELECTRIC DRIVE TRUCKS 75
Storage Instructions and Procedures 75
Placing Equipment Into Storage 75
Storing A Truck That Is Operational 75
Storing A Truck That Is Not Operational 76
Storing A Major Component 76
Periodic Inspections 77
Placing Equipment Into Service After Storage 77
When A Truck Is Operational 77
When A Truck Is Not Operational 77
For The First Hour 78
SECTION B – STRUCTURES – INDEX 79
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 81
STRUCTURAL COMPONENTS 83
Preparation 83
GRILLE, HOOD AND LADDER 84
Removal 84
Installation 84
DECKS 85
RIGHT DECK AND COMPONENTS 85
Removal 85
Installation 86
LEFT DECK 86
Removal 86
Installation 86
CENTER DECK 86
SECTION B3 – DUMP BODY – INDEX 87
DUMP BODY 89
Removal 89
Installation 90
BODY PADS 91
Adjustment 91
BODY GUIDE 92
HOIST LIMIT SWITCH 92
BODY UP SWITCH 92
BODY-UP RETENTION CABLE 92
ROCK EJECTORS 93
Rock Ejectors (Type I) 93
Inspection 93
Rock Ejectors (Type II) 94
Inspection 94
SECTION B4 – FUEL TANK – INDEX 95
FUEL TANK 97
Removal 98
Installation 98
Repair 98
Cleaning 98
FUEL GAUGE SENDER 99
Removal 99
Installation 99
LOW FUEL SWITCH 99
WIGGINS QUICK FILL FUEL SYSTEM100
FUEL RECEIVER100
TANK BREATHER VALVE100
Removal100
Installation100
Disassembly100
Assembly100
LEFT SIDE FILL101
SECTION C – ENGINE – INDEX103
SECTION C2 – POWER MODULE – INDEX105
POWER MODULE107
Preparation107
Preparation for Removal108
Removal – Power Module111
Installation – Power Module113
Hookup – Power Module113
SECTION C3 – COOLING SYSTEM – INDEX115
COOLING SYSTEM117
RADIATOR117
Removal – Radiator117
RADIATOR REPAIR119
Internal Inspection119
External Cleaning119
Disassembly120
Cleaning and Inspection121
Assembly121
Pressure Testing122
Additional Service Information122
Installation – Radiator123
RADIATOR FILLING PROCEDURE124
COOLANT SYSTEM TROUBLESHOOTING124
SECTION C4 – POWERTRAIN – INDEX125
POWER TRAIN127
ALTERNATOR127
Removal – Alternator127
ENGINE/ALTERNATOR MATING129
General Instructions129
Measuring Procedure129
Joining The Alternator and Engine131
ENGINE132
Removal132
Service132
Installation132
SECTION C5 – AIR CLEANERS – INDEX133
AIR CLEANERS135
AIR CLEANERS135
Operation135
General Service Information135
FILTER ELEMENT REPLACEMENT136
Main Filter Element Cleaning137
Precleaner Section138
Cleaning Precleaner Tubes138
AIR INTAKE TROUBLESHOOTING139
SECTION C7 – FAN CLUTCH – INDEX141
FAN CLUTCH143
REMOVAL & INSTALLATION TOOLING143
FAN CLUTCH – DISASSEMBLY146
CLEANING AND INSPECTION156
ASSEMBLY – FAN CLUTCH160
TEST PROCEDURE174
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX175
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX177
24VDC ELECTRIC SUPPLY SYSTEM179
ELECTRICAL SYSTEM DESCRIPTION179
BATTERIES179
Maintenance and Service179
Troubleshooting179
BATTERY SUPPLY SYSTEM181
24VDC Battery Charging Alternator181
Battery Box181
Battery Control Box181
Isolation Diodes181
Battery Disconnect Switches182
24VDC Auxiliary Battery Connectors182
Battery Equalizer182
Troubleshooting183
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX185
24 VDC ELECTRICAL SYSTEM COMPONENTS187
PASSENGER SEAT BASE COMPARTMENT187
TRUCK SHUTDOWN PROCEDURE187
COMPONENTS187
Tail Light Resistor Diode Assemblies187
5 Minute Idle Timer Components187
5 Minute Idle Timer189
5 Minute Idle Relay189
5 Minute Idle Contactor189
5 Minute Idle Circuit Test189
Inclinometer189
Brake Warning Buzzer (BWB)189
Alarm Indicating Device (AID) System189
Coolant Level/Flasher189
Temperature and Latch Card190
Hot Switch Inverter Card190
Hot Switch Inverter Card (Slot 4) (Not Used)191
Oil Level Card191
Temperature Card191
Diode Matrix (Without Sound) Card191
Diode Matrix (With Sound) Card191
Lamp Test Switch191
Electrical Interface Cabinet192
Lubrication System Timer192
Lincoln Lube Delay Timer192
Barometric Pressure Transducer192
Pulse Voltage Modulator192
Power Distribution Terminals192
Truck Control Interface Panel192
Kontrol Power Relay192
Circuit Breaker Panel192
Diode Board – DB1194
Diode Testing194
Relay Boards195
Relay Boards: RB1, RB2, RB3, RB4, RB5195
Service195
Relay Board Identification196
Relay Board Functions197
Installing Additional Circuits198
Body Up Switch199
Operation199
Adjustment199
Service199
Hoist Limit Switch200
Operation200
Adjustment200
Service200
CIRCUIT BREAKER CHART201
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX203
BATTERY CHARGING ALTERNATOR205
ELECTRICAL SYSTEM DESCRIPTION205
BATTERY205
Maintenance and Service205
Troubleshooting205
BATTERY CHARGING SYSTEM (Niehoff)207
General Description207
TROUBLESHOOTING PROCEDURES (On-Truck)207
Equipment Required:207
Preliminary Checks208
Test Setup208
Test Procedure208
Regulator Bypass Test209
ON VEHICLE TROUBLESHOOTING GUIDE211
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage211
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:211
CHARGE VOLT AND AMP VALUES212
DEFINITIONS212
ADVANCED SYSTEM TROUBLESHOOTING213
Static Test – Engine OFF, Key ON, Battery Switch ON213
Go To Alternator213
Go To Regulator (If Required)214
Go To Regulator Connector On The Alternator214
ALTERNATOR OVERHAUL215
ALTERNATOR DIMENSIONS215
ALTERNATOR SPECIFICATIONS216
SERVICE PARTS217
ON-VEHICLE TEST219
Equipment:219
Preliminary Checks:219
Test Set-up219
Test Procedure219
ON-VEHICLE TEST220
Bypass Test:220
BENCH TEST221
STATIC TESTS222
Regulator Tests222
Control Box Tests223
ALTERNATOR DISASSEMBLY225
ASSEMBLY- ALTERNATOR230
BF4822 STATOR SERVICE TOOL INSTRUCTIONS239
Stator Removal And Replacement239
Stator Installation240
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX243
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX245
ELECTRICAL PROPULSION SYSTEM COMPONENTS247
GENERAL SYSTEM DESCRIPTION247
SYSTEM COMPONENTS249
Auxiliary Blower System249
Propulsion System Controller (PSC)249
TRUCK CONTROL INTERFACE PANEL (TCI)250
Diagnostic Information Display251
DID PANEL EVENT CODES251
PSC SOFTWARE FUNCTIONS276
Input Processing276
STATE MANAGEMENT276
State Machine276
Transitions Between States277
DC Link State279
Powering the Link279
De-Powering the Link279
Control Functions279
Engine Control279
ALTERNATOR FIELD CONTROL280
Desired Three-Phase Voltage280
Desired DC Link Voltage280
Self-load280
Propel Torque Control281
Retard Torque Control281
Wheel Slide Control281
Resistor Grid Control282
Chopper Voltage Control282
AUXILIARY BLOWER CONTROL282
EVENT PROCESSING282
Event Detection282
Power On Tests282
Initiated Tests283
Periodic Tests283
EVENT RESTRICTIONS283
EVENT LOGGING AND STORAGE283
Event History Buffer284
Data Packs284
To Record and Save a Data Pack to a Floppy Disk284
Event Reset285
SERIAL DATA COMMUNICATIONS286
PSC – TCI Communications processing286
PSC – PTU Communications Processing286
Inverter Communications Processing286
OUTPUT PROCESSING287
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS287
Fast Start287
Engine Shutdown/Engine Not Running287
Limp Home Mode287
Entering/Exiting Limp Home Mode287
PROPULSION SYSTEM COMPONENT ABBREVIATIONS288
ELECTRONIC ACCELERATOR AND RETARD PEDALS298
Removal298
Installation298
Disassembly298
Assembly298
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX299
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE301
AC DRIVE SYSTEM MAINTENANCE301
TRUCK SHUTDOWN PROCEDURES301
NORMAL TRUCK SHUTDOWN PROCEDURE302
SHUTDOWN AFTER SYSTEM FAILURE303
SYSTEM CHECKOUT304
Battery and Control Checks of System WITH Battery Power OFF304
Battery and Control Circuit Checks of System With Battery Power ON307
Checks with Key Switch OFF308
CPU Battery Checks310
MEMORY BACKUP BATTERY REPLACEMENT310
TCI PROGRAMMING311
PSC PROGRAMMING311
INVERTER PROGRAMMING312
TCI CHECKOUT312
Modular Mining Communication Port313
TCI Input Checks314
TCI Digital Output Tests316
TCI Digital Input Tests318
PSC Checkout Procedure320
PSC Digital Input Checks324
Miscellaneous Checks325
A3PV Panel325
LINKV Panel325
Thermistor Checks325
17FM384 Panel Check325
Pedal Percentages and Meter Calibration326
Meter Calibration Procedure326
Reprogram With Serial Numbers and Pedal Percentages328
LOAD TESTING330
Preload Checks330
ADDITIONAL TRUCK CHECKS332
On-Board Load Testing334
Preparation334
Initiate Loadbox Test337
Manual Offset HP Output Adjustment339
TROUBLESHOOTING341
PVM Optimum Load Curve Handshaking Troubleshooting341
MISCELLANEOUS COMPONENT REPAIR342
Troubleshooting Phase Modules and Chopper Modules342
Phase Module Removal and Snubber Resistor Replacement342
Snubber Resistor Installation343
Phase Module Installation343
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING344
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING347
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING348
IGBT TROUBLESHOOTING349
SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX351
SECTION G2 – TIRES AND RIMS – INDEX353
TIRES AND RIMS355
WHEEL STUD MAINTENANCE356
FRONT TIRES AND RIMS357
Removal357
Installation358
REAR TIRES AND RIMS359
Removal359
Installation360
RIM361
Tire Removal361
Tire Installation362
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX365
FRONT WHEEL HUB AND SPINDLE367
WHEEL HUB AND SPINDLE ASSEMBLY367
Preparation367
Removal367
Installation – Wheel Hub and Spindle Assembly370
Disassembly – Wheel Hub and Spindle Assembly371
Cleaning and Inspection – Wheel Hub and Spindle Assembly371
Assembly – Wheel Hub and Spindle Assembly373
Wheel Bearing Adjustment:373
Brake Installation374
Seal Assembly Gap Check375
STEERING CYLINDERS AND TIE ROD376
Spherical Bearing Wear Limits376
Removal – Steering Cylinder and Tie Rod377
Installation – Steering Cylinder and Tie Rod378
Bearing Replacement378
TOE-IN ADJUSTMENT379
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX381
REAR AXLE HOUSING ATTACHMENT383
PIVOT PIN383
Removal383
Installation383
PIVOT EYE BEARING384
Disassembly384
Assembly384
PIVOT EYE REPAIR385
Removal385
Disassembly385
Assembly385
Installation385
ANTI-SWAY BAR386
Removal386
Installation386
Disassembly386
Cleaning and Inspection386
Assembly386
SECTION G5 – REAR AXLE HOUSING – INDEX387
REAR AXLE HOUSING389
REAR AXLE HOUSING389
Preparation389
Removal389
Cleaning and Inspection – Rear Axle Housing391
Installation – Rear Axle Housing391
WHEEL MOTOR392
Preparation392
Removal392
Cleaning and Inspection – Wheel Motor393
Installation – Wheel Motor394
WHEEL MOTOR GEAR OIL397
Filtering Requirements397
Particle Size Analysis397
Flushing397
Oil Sample Analysis398
ELEMENT SPECIFICATION CHARTS399
SECTION H – HYDRAIR II SUSPENSIONS – INDEX403
SECTION H2 – FRONT SUSPENSIONS – INDEX405
FRONT SUSPENSION407
Removal407
Installation – Front Suspension408
“Turn-Of-The-Nut” Tightening Procedure411
MINOR REPAIRS (LOWER BEARING & SEALS)412
Removal – Bearing Retainer412
Installation – Bearing Retainer412
MAJOR SUSPENSION REBUILD414
Disassembly414
Assembly414
SECTION H3 – REAR SUSPENSIONS – INDEX417
REAR SUSPENSIONS419
Removal419
Installation – Rear Suspension421
Disassembly – Rear Suspension422
Cleaning and Inspection – Rear Suspension422
Assembly – Rear Suspension422
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX425
SUSPENSION OILING AND CHARGING PROCEDURE427
GENERAL427
EQUIPMENT LIST427
Hydrair® Charging Kit427
Installation of Charging Kit427
Removal of Charging Kit428
Support Blocks For Oiling And Charging Dimensions428
FRONT SUSPENSION429
Front Suspension Oiling429
Front Suspension Nitrogen Charging430
REAR SUSPENSION431
Rear Suspension Oiling431
Rear Suspension Nitrogen Charging432
OIL AND NITROGEN SPECIFICATIONS CHART434
SECTION J – BRAKE CIRCUIT – INDEX435
SECTION J2 – BRAKE CIRCUIT – INDEX437
BRAKE CIRCUIT439
SERVICE BRAKE CIRCUIT439
SECONDARY BRAKING AND AUTOMATIC APPLY441
PARKING BRAKE CIRCUIT441
BRAKE LOCK CIRCUIT442
WARNING CIRCUIT442
Rear Axle Brake Lines444
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX445
BRAKE CIRCUIT COMPONENT SERVICE447
BRAKE VALVE447
Rebuild Criteria447
Removal448
Installation448
DISASSEMBLY449
Cleaning and Inspection452
ASSEMBLY452
Actuator Base Threaded Inserts452
Boot and Cap452
Valve Body Seal Installation452
Regulator Sleeve O-ring Installation453
Actuator Plunger O-ring Installation453
Assembly of Valve453
DIFFERENTIAL PRESSURE SWITCH455
Disassembly455
Cleaning and Inspection455
Assembly455
VALVE BENCH TEST AND ADJUSTMENT456
Test Set Up Procedure457
Brake Valve Output Pressure Adjustment457
Differential Pressure Switch Adjustment457
Final Test and Adjustment458
Installation Of Brake Pedal Actuator Assembly to Brake Valve459
Installation of Retard Pedal To Brake Pedal459
DUAL RELAY VALVE461
Removal461
Installation461
Disassembly463
Cleaning and Inspection463
Assembly463
DIFFERENTIAL PRESSURE SWITCH464
Disassembly464
Cleaning and Inspection464
Assembly464
VALVE TEST AND ADJUSTMENT465
Test Set Up Procedure466
Brake Valve Output Pressure Adjustment466
Differential Pressure Switch Adjustment467
BRAKE MANIFOLD468
Removal468
Installation469
Disassembly469
Cleaning and Inspection469
Assembly469
HYDRAULIC BRAKE ACCUMULATORS470
Brake Accumulator Bleed Down Procedure470
ACCUMULATORS – HYDRAULIC COMPONENT CABINET470
Removal470
Installation470
Disassembly470
Cleaning and Inspection472
Assembly472
BLADDER ACCUMULATOR CHARGING PROCEDURE474
Temperature During Precharge475
Precharge Maintenance475
Accumulator Storage Procedures476
Bladder Storage Procedures477
ACCUMULATORS – FRAME MOUNTED477
Removal477
Installation477
Disassembly479
Cleaning and Inspection479
Assembly – Accumulator480
Accumulator Testing480
ACCUMULATOR CHARGING PROCEDURE481
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)482
Removal482
Installation482
Disassembly and Adjustment482
Potentiometer Check484
Assembly484
SECTION J4 – BRAKE CIRCUIT CHECK-0UT PROCEDURE – INDEX485
BRAKE CIRCUIT CHECK-OUT PROCEDURE487
EQUIPMENT REQUIRED489
INITIAL SYSTEM SET-UP490
BRAKE SYSTEM CHECKOUT491
Failure Modes Check-Out492
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING495
CHECK-OUT PROCEDURE499
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX501
WET DISC BRAKE ASSEMBLY503
OPERATION503
MAINTENANCE504
Brake Disc Wear Indicator504
Removal/Installation – Wet Disc Brake Assembly504
BRAKE REBUILD506
Disassembly506
Cleaning and Inspection509
Assembly510
Floating Ring Seal Assembly/Installation513
WET DISC BRAKE BLEEDING PROCEDURE516
SECTION J7 – PARKING BRAKE – INDEX517
PARKING BRAKE519
OPERATION519
MAINTENANCE520
Inspection – Parking Brake520
Removal – Parking Brake520
Installation – Parking Brake521
Disassembly – Parking Brake522
Cleaning and Inspection – Parking Brake522
Assembly – Parking Brake522
PARKING BRAKE BLEEDING PROCEDURE524
SECTION L – HYDRAULIC SYSTEM – INDEX525
SECTION L2 – HYDRAULIC SYSTEM – INDEX527
HYDRAULIC SYSTEM529
Hoist Circuit Operation530
Steering Circuit Operation532
Disc Brake Cooling System534
SECTION L3 – HYDRAULIC SYSTEM COMPONENTS REPAIR – INDEX537
HYDRAULIC SYSTEM COMPONENT REPAIR539
HOIST PUMP539
Removal539
Installation541
Disassembly542
Inspection of Parts546
Assembly546
TROUBLESHOOTING GUIDE (HOIST PUMP)551
HYDRAULIC TANK552
Filling Instructions552
Removal – Hydraulic Tank552
Installation – Hydraulic Tank553
HYDRAULIC TANK STRAINERS553
Removal553
Inspect and Clean553
Installation553
HYDRAULIC TANK BREATHERS554
SECTION L4 – STEERING CIRCUIT – INDEX555
STEERING CIRCUIT557
STEERING CIRCUIT OPERATION557
COMPONENT DESCRIPTION558
Steering Control Unit558
Bleeddown Manifold Valve559
Bleeddown Solenoid559
Relief Valves561
Hoist Limit Solenoid561
Accumulators561
Low Precharge Warning Switch561
High Pressure Filters561
Quick Disconnect Ports561
Flow Amplifier562
FLOW AMPLIFIER SYSTEM OPERATION564
No Steer564
Steering Left566
Steering Right568
No Steer, External Shock Load570
STEERING PUMP572
Operation572
High Altitude Operation572
PRINCIPLE OF OPERATION574
Full Pump Volume574
Half Pump Volume574
Neutral Position574
ADDITIONAL STEERING PUMP INFORMATION575
SECTION L5 – STEERING CONTROL UNIT – INDEX577
STEERING CONTROL UNIT579
Removal579
Installation579
STEERING CONTROL UNIT REBUILD580
Disassembly580
Cleaning and Inspection – Steering Control Unit581
Assembly – Steering Control Unit583
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX587
STEERING CIRCUIT COMPONENT REPAIR589
BLEEDDOWN MANIFOLD VALVE589
Removal589
Installation589
ACCUMULATORS590
Removal590
Installation590
Disassembly – Accumulators591
Cleaning and Inspection – Accumulators591
Assembly – Accumulators592
Testing – Accumulators592
STEERING ACCUMULATOR CHARGING PROCEDURE593
FLOW AMPLIFIER594
Removal594
Installation594
FLOW AMPLIFIER REBUILD594
Disassembly – Flow Amplifier596
Assembly – Flow Amplifier597
STEERING CYLINDERS598
Disassembly – Steering Cylinder599
Piston Seal & Bearing Installation599
Assembly – Steering Cylinder599
Test – Steering Cylinder599
STEERING AND BRAKE PUMP600
Removal600
Installation600
Disassembly – Steering and Brake Pump602
Control Piston Group602
Valve Plate Group602
Rotating Group605
Swashblock Group605
Driveshaft Group605
Inspection – Steering and Brake Pump605
Control Piston Group605
Valve Plate Group605
Rotating Group605
Swashblock Group607
Driveshaft Group608
Compensator Block and Unloader Module608
Stroke Adjuster Assembly608
Assembly – Steering and Brake Pump608
Swashblock Group608
Driveshaft Group609
Rotating Group609
Control Piston Group609
Valve Plate Group610
TROUBLESHOOTING CHART611
SECTION L7 – HOIST CIRCUIT – INDEX617
HOIST CIRCUIT619
HOIST CIRCUIT OPERATION619
COMPONENT DESCRIPTION620
Hydraulic Tank620
Hydraulic Pump620
High Pressure Filters620
Hoist Valve620
Inlet Sections – Hoist Valve620
Spool Sections – Hoist Valve621
Hoist Pilot Valve621
Bleeddown Manifold622
Hoist-up Limit Solenoid622
Pilot Operated Check Valve622
Overcenter Manifold622
HOIST CIRCUIT OPERATION623
Float Position Of Pilot Valve With Truck Body On Frame624
Power Up Operation626
Hold Operation628
Power Down Operation630
Float Operation632
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX635
HOIST CIRCUIT COMPONENT REPAIR637
HOIST VALVE637
Removal – Hoist Valve637
Installation – Hoist Valve638
O-Ring Replacement638
INLET SECTION639
Disassembly – Inlet Section639
Cleaning and Inspection – Inlet Section640
Assembly – Inlet Section640
REAR SPOOL SECTION (Work Ports)640
Disassembly – Rear Spool Section640
Cleaning and Inspection – Rear Spool Section642
Assembly – Rear Spool Section642
FRONT SPOOL SECTION (Tank Ports)643
Disassembly643
Cleaning and Inspection643
Assembly643
HOIST PILOT VALVE645
Removal – Hoist Pilot Valve645
Installation – Hoist Pilot Valve645
Disassembly – Hoist Pilot Valve646
Cleaning and Inspection – Hoist Pilot Valve647
Assembly – Hoist Pilot Valve647
HOIST CYLINDERS648
Removal – Hoist Cylinder648
Installation – Hoist Cylinder649
Disassembly – Hoist Cylinder651
Cleaning and Inspection – Hoist Cylinder652
Assembly – Quill And Cylinder653
Installation – Quill653
Installation – Check Balls And Plugs In Quill654
Assembly – Hoist Cylinder655
DISABLED TRUCK DUMPING PROCEDURE656
Hookup656
DUMPING PROCEDURE656
Raising the Body656
Lowering the Body656
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX657
HYDRAULIC SYSTEM FILTERS659
HOIST CIRCUIT FILTER659
Filter Element Replacement659
Removal – Hoist Circuit Filter660
Installation – Hoist Circuit Filter660
Indicator Switch – Hoist Circuit Filter660
STEERING CIRCUIT FILTER661
Filter Element Replacement661
Removal – Steering Circuit Filter662
Installation – Steering Circuit Filter662
Indicator Switch – Steering Circuit Filter662
INDICATOR SWITCH662
Test Procedure662
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX665
HYDRAULIC CHECK-OUT PROCEDURE667
GENERAL INFORMATION667
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE667
Equipment Requirements668
Pump Pressure Control Adjustments668
Steering Control Unit and Flow Amplifier Leakage Test669
Bleeddown Manifold Leakage Test669
Steering/Brake Pump Stroke Adjustment670
Shock And Suction Valves671
Equipment Requirements671
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES672
Equipment Requirements672
Pressure Checks672
Brake Cooling Circuit Test672
Power Up Relief Pressure Test673
Adjustment673
Power Down Relief Pressure Test674
Adjustment674
Hoist Counterbalance Valve Adjustment Preparation675
Counterbalance Valve Pressure Check675
Counterbalance Valve Adjustment676
HYDRAULIC SYSTEM FLUSHING PROCEDURE677
Preparation677
Flushing Procedure677
Filter Element Replacement678
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET679
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET680
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX681
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX683
FIRE CONTROL SYSTEM (MANUAL)685
Operation685
Inspection and Maintenance685
Recharging Procedures686
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1687
Control Module687
Actuator688
Linear Detection Wire688
Power Wire688
Test Kit688
Squib688
Securing the Detection Wire689
Preliminary Test Before Final Hook-Up689
Installation Procedure for Squib691
Placing the Electric Detection & Actuation System Into Service691
INSPECTION AND MAINTENANCE SCHEDULES692
Daily692
Normal Maintenance Based On Actual Operating Hours692
IN CASE OF FIRE693
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM695
SECTION M8 – SPECIAL TOOLS697
SECTION M20 – PAYLOAD METER III – INDEX703
OPERATION SECTION707
Introduction707
Data Summary707
Data Gathering707
COMPONENT DESCRIPTION708
System Diagram708
Suspension Pressure Sensors708
Inclinometer708
Operator Display708
Operator Switch709
Speed Input709
Body-Up Switch709
Brake Lock Switch709
Payload Meter709
Communications Ports709
Keyswitch Input710
Payload Meter Power710
Load Lights710
Wiring and Termination711
TCI Outputs711
OPERATOR’S DISPLAY AND SWITCH712
Reading the Speedometer712
Reading the Load Display712
Using the Operator ID712
Using the Load and Ton Counter712
Total Ton Counter712
Total Load Counter713
Clearing the Counters713
Viewing Live Sensor Data713
Other Display Messages713
PAYLOAD OPERATION & CALCULATION714
Description of Haul Cycle States714
Haul Cycle Description714
Load Calculation715
Carry Back715
Measurement Accuracy715
SOURCES FOR PAYLOAD ERROR715
Payload Error715
Loading Conditions716
Pressure Sensors716
Swingloads716
Speed and Distance716
HAUL CYCLE DATA716
Haul Cycle Data717
Haul Cycle Warning Flags718
M: Haul Cycle Too Long719
N: Sensor Input Error719
Frame Torque Data719
Sprung Weight Data719
Maximum Speed Data719
Alarm Records719
Fault Code Data720
PC SOFTWARE OVERVIEW721
PC Overview721
System Configuration721
Installing the PLMIII Software721
DOWNLOADING DATA722
PLM III SYSTEM CONFIGURATION723
Starting Communications723
Displayed Payload Units723
Time Units723
Connection Menu723
Connecting to the Payload Meter724
Configure the Payload Meter724
Setting the Date and Time724
Setting the Truck Type725
Setting the Gauge Display Units725
Setting the Frame Serial Number725
Setting the Truck Number725
Setting the Komatsu Distributor725
Setting the Komatsu Customer725
Clean Truck Tare726
Inclinometer Calibration726
DATA ANALYSIS727
Creating a Query727
Sorting on Truck Unit Number727
Sorting on Truck Type727
Sorting on Date Range728
Sorting on Time Range728
Payload Detail Screen729
Creating Reports729
Summary – one page report730
Detailed – multi-page report730
Creating Graphs731
Exporting Data731
CSV Export731
Compressed732
Importing Data733
Deleting Haul Cycle Records733
Viewing Alarms734
Deleting Alarm Records734
TROUBLESHOOTING SECTION735
TROUBLESHOOTING735
Viewing Active Alarms735
Real-Time Data Display735
Testing the Payload Lights735
Creating Log Files of Inputs736
Daily Inspections736
Periodic Maintenance736
Abnormal Displays at Power-Up737
No Payload Display When Keyswitch is Turned ON738
No Display on Speedometer739
No Display on Operator Display739
No Communications With PC740
Load Lights Don’t Light During Loading741
Load Lights Remain ON742
Load Lights Remain ON During Dumping742
Display Doesn’t Clear When The Load Is Dumped742
Calibration Problems743
Alarm 1 – Left Front Pressure High744
Alarm 2 – Left Front Pressure Low744
Troubleshoot Wiring to Left Front Suspension744
Alarm 3 – Right Front Pressure High745
Alarm 4 – Right Front Pressure Low745
Troubleshoot Wiring to Right Front Suspension745
Alarm 5 -Left Rear Pressure High746
Alarm 6 – Left Rear Pressure Low746
Troubleshoot Wiring to Left Rear Suspension746
Alarm 7 – Right Rear Pressure High747
Alarm 8 – Right Rear Pressure Low747
Troubleshoot Wiring to Right Rear Suspension747
Alarm 9 – Inclinometer High748
Alarm 10 – Inclinometer Low748
Troubleshoot Inclinometer Wiring748
Alarm 13 – Body Up Input Failure749
Alarm 16 – Memory Write Failure750
Alarm 17 – Memory Read Failure750
Alarm 18751
Alarm 19751
Alarm 22751
Operator Switch Doesn’t Work752
Alarm 26 – User Switch Fault – SELECT752
Alarm 27 – User Switch Fault – SET752
Connector Map753
Connectors754
PLMIII CHECK OUT PROCEDURE755
General Description755
Tools Required755
Checkout Procedure755
PLMIII CHECKOUT PROCEDURE CONFIRMATION759
Flashburn Programming759
Confirmation Checklist761
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX763
RESERVE ENGINE OIL SYSTEM765
Operation766
LED Monitor Light766
Tank Fill Control (Optional)767
Filling Procedure (Remote fill feature)767
SERVICE768
Every 10 Hours, or once each shift:768
Every 500 Hours:768
Changing Oil768
TROUBLESHOOTING769
Circuit Breaker or Fuse769
SYSTEM ELECTRICAL SCHEMATICS770
SECTION N – CAB COMPONENTS – INDEX771
SECTION N2 – TRUCK CAB – INDEX773
TRUCK CAB775
Description775
Preparation776
Removal – Cab776
Installation – Cab778
CAB DOOR778
Removal778
Installation778
Door Adjustment779
Door Jamb Bolt Adjustment779
Door Handle Plunger Adjustment780
Door Glass Replacement781
Door Window Regulator Replacement785
Door Handle or Latch Assembly Replacement785
Door and Door Hinge Seal Replacement786
Door Opening Seal Removal786
Installation786
GLASS REPLACEMENT787
Adhesive Bonded Windows787
Replacement Procedure787
Windshield And Rear Glass788
Removal788
Installation789
SECTION N3 – CAB COMPONENTS – INDEX791
CAB COMPONENTS793
WINDSHIELD WIPERS793
Wiper Motor Replacement793
Removal793
Installation793
Wiper Arm Replacement793
Removal793
Installation794
Wiper Linkage Replacement794
Removal794
Installation794
WINDSHIELD WASHER795
Operation795
Service795
OPERATOR SEAT796
Adjustment796
Seat Removal796
Seat Installation796
SECTION N4 – OPERATOR COMFORT – INDEX797
OPERATOR COMFORT799
HEATER / AIR CONDITIONER799
Operation799
Heater/Air Conditioner Vents799
COMPONENTS800
Circuit Breakers800
Relays800
Heater Core800
Fan Motor And Speed Control801
Actuators801
Filter801
Service801
AIR CONDITIONING SYSTEM803
Environmental Impact803
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES804
PRINCIPLES OF REFRIGERATION804
Air Conditioning804
Refrigeration – The Act Of Cooling805
The Refrigeration Cycle805
AIR CONDITIONER SYSTEM COMPONENTS806
Compressor (Refrigerant Pump)806
Service Valves806
Condenser806
Receiver-Drier806
Expansion Block Valve807
Accumulator807
Evaporator807
ELECTRICAL CIRCUIT808
Thermostat808
Compressor Clutch808
Trinary™ Switch809
SYSTEM SERVICING810
SERVICE TOOLS AND EQUIPMENT811
Recovery/Recycle Station811
Leak Detector811
Service Valves812
Vacuum Pump812
Manifold Gauge Set813
Installing Manifold Gauge Set814
Purging Air From Service Hoses814
SYSTEM PERFORMANCE TEST815
SYSTEM OIL816
Handling and Reusing PAG Oil816
Oil Quantity816
Checking System Oil816
REFRIGERANT817
Recycled Refrigerant817
Reclaimed Refrigerant817
Refrigerant Quantity817
R-134a Refrigerant Containers817
SYSTEM LEAK TESTING818
Electronic Leak Detector818
Tracer Dyes818
Soap and Water818
RECOVERING AND RECYCLING THE REFRIGERANT819
Performing the Recovery Cycle819
Performing the Recycling Procedure819
Evacuating and Charging the A/C System819
SYSTEM REPAIR820
System Flushing820
COMPONENT REPLACEMENT820
Hoses and Fittings820
Lines820
Expansion Valve821
Receiver-Drier821
Thermostat821
Compressor821
Accumulator821
Clutch822
Servicing the Compressor Clutch822
Pulley Removal824
Clutch Coil Check825
Pulley Installation825
Clutch Assembly Installation825
EVACUATING THE SYSTEM827
CHARGING THE A/C SYSTEM829
TROUBLESHOOTING830
Preliminary Checks830
Diagnosis Of Gauge Readings And System Performance830
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS831
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM837
SECTION N5 – OPERATOR CAB CONTROLS – INDEX839
OPERATOR CAB CONTROLS841
STEERING COLUMN841
Removal841
Steering Column Inspection841
Installation841
STEERING WHEEL AND CONTROLS843
Horn Button843
Telescope Lock Ring843
Tilt Wheel Lever843
Turn Signal/Headlight Dimmer843
DYNAMIC RETARDING843
Retarder Control Lever844
Dynamic Retarder/Service Brake Pedal844
Accelerator (Throttle) Pedal844
Starting on a Grade With a Loaded Truck844
GRADE/SPEED RETARD CHART845
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS846
Heater/Air Conditioner Vents846
INSTRUMENT PANEL847
OVERHEAD PANEL AND DISPLAYS847
CENTER CONSOLE848
F-N-R Selector Switch848
Hoist Control Lever849
Raising The Dump Body849
Lowering The Dump Body849
Ash Tray849
Lighter849
LH Window Control Switch849
RH Window Control Switch849
Engine Shutdown Switch849
Override/Fault Reset Switch850
Retard Speed Control (RSC) Switch850
Retard Speed Control (RSC) Adjust Dial850
PSC Download Port851
Engine Diagnostics Download Port851
Engine Control System851
TCI Download Port851
Passenger Seat851
PAYLOAD METER851
Payload Meter Download Connector851
INSTRUMENT PANEL AND INDICATOR LIGHTS853
CONTROL SYMBOLS853
INSTRUMENT PANEL853
PANEL GAUGES, INDICATORS, AND CONTROLS855
Key Switch855
Starting855
Cold Weather Starting855
Normal Engine Shutdown855
Engine Shutdown Switch with 5 Minute Idle Timer Delay856
Fog Lights (Optional)856
Ladder Light Switch856
Manual Backup Switch856
Panel Illumination Lights857
Cab/Air Conditioner Vents857
Rotating Beacon Light Switch (Optional)857
Heated Mirror Switch (Optional)857
Wheel Brake Lock Control857
Parking Brake Control857
Tachometer858
Right Turn Signal Indicator858
High Beam Indicator858
Left Turn Signal Indicator858
Speedometer858
Voltmeter858
Engine Oil Pressure Gauge858
Water Temperature Gauge858
Fuel Gauge858
AC Drive System Temperature Gauge859
Hydraulic Oil Temperature Gauge859
Hourmeter859
Rest Switch859
Light Switch860
Windshield Wiper and Washer860
Panel Light Dimmer860
OVERHEAD STATUS / WARNING INDICATORS861
STATUS / WARNING INDICATOR LIGHT SYMBOLS862
Hazard Warning Lights867
Lamp Test Switch867
Link-On Warning Light867
SECTION P – LUBRICATION AND SERVICE – INDEX869
SECTION P2 – LUBRICATION AND SERVICE – INDEX871
LUBRICATION AND SERVICE873
930E SERVICE CAPACITIES873
HYDRAULIC TANK SERVICE873
Adding Oil873
WHEEL MOTOR SERVICE873
COOLANT LEVEL CHECK874
RADIATOR FILLING PROCEDURE874
RESERVE ENGINE OIL SYSTEM (Optional)874
Reserve Oil Tank Filling Procedure (Remote fill)874
LUBRICATION CHART875
10 HOUR (DAILY) INSPECTION876
50 HOUR LUBRICATION AND MAINTENANCE CHECKS879
100 HOUR LUBRICATION AND MAINTENANCE CHECKS880
250 HOUR LUBRICATION AND MAINTENANCE CHECKS881
500 HOUR LUBRICATION AND MAINTENANCE CHECKS884
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS885
5000 HOUR MAINTENANCE CHECKS886
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX887
AUTOMATIC LUBRICATION SYSTEM889
GENERAL DESCRIPTION889
SYSTEM COMPONENTS891
SYSTEM OPERATION892
Normal Operation892
Pressure Failure Detection Circuits893
INJECTOR OPERATION894
GENERAL INSTRUCTIONS895
LUBRICANT REQUIREMENTS895
System Priming895
LUBRICANT PUMP895
Pump Housing Oil Level895
Pump Pressure Control895
Pressure Control Valve Adjustment895
INJECTORS (SL-1 Series “H”))896
Injector Specifications896
Injector Adjustment896
SYSTEM CHECKOUT896
Lubrication Cycle Timer Check897
Lubrication Cycle Timer Adjustment897
FILTER ASSEMBLY897
PUMP REBUILD898
Disassembly898
Cleaning and Inspection898
Assembly900
SYSTEM TROUBLESHOOTING CHART901
PREVENTATIVE MAINTENANCE PROCEDURES904
Daily Lubrication System Inspection904
250 Hour Inspection904
1000 Hour Inspection904
SECTION Q ALPHABETICAL INDEX905
SECTION R – SYSTEM SCHEMATICS – INDEX909
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH347911
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH352912
PLM III ELECTRICAL SYSTEM SCHEMATIC – HE479913
PLM III HOOK-UP WIRING – HE483914
ELECTRICAL SCHEMATIC – XS0500915
IMAGES PREVIEW OF THE MANUAL:
S.M 14/12/24
