Komatsu 930E-3 Dump Truck Service Repair Shop Manual (A30304 - A30309) - CEBM008400

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Dump Truck 930E-3 (SN: A30304 - A30309) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu 930E-3 Dump Truck
Serial Numbers : A30304 - A30309


TABLE OF CONTENTS :

- GENERAL INFORMATION
- STRUCTURES
- ENGINE SYSTEMS
- ELECTRIC SYSTEM (24 VDC. NON-PROPULSION)
- ELECTRIC PROPULSION AND CONTROL
- DRIVE AXLE, SPINDLES AND WHEELS
- HYDRAIR II SUSPENSIONS
- BRAKE CIRCUIT
- HYDRAULIC SYSTEM
- OPTIONS AND SPECIAL TOOLS
- OPERATOR‘S CAB
- LUBRICATION AND SERVICE
- ALPHABETICAL INDEX
- SYSTEM SCHEMATICS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM008400
Total Pages : 904


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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COVER
FOREWORD
TABLE OF CONTENTS

GENERAL INFORMATION
TRUCK COMPONENTS AND SPECIFICATIONS
GENERAL SAFETY AND OPERATING INSTRUCTIONS
GENERAL SAFETY
Safety Rules
Safety Features
Clothing And Personal Items
Unauthorized Modification
Leaving The Operator’s Seat
Mounting And Dismounting
Fire Prevention For Fuel And Oil
Precautions When Handling At High Temperatures
Asbestos Dust Hazard Prevention
Prevention Of Injury By Work Equipment
Fire Extinguisher And First Aid Kit
Precautions When Using ROPS
Precautions For Attachments
Precautions For Starting Machine
PRECAUTIONS DURING OPERATION
Safety Is Thinking Ahead
Safety At The Worksite
Fire Prevention
Preparing For Operation
Ventilation For Enclosed Areas
In Operator’s Cab - Before Starting The Engine
Mirrors, Windows, And Lights
OPERATING THE MACHINE
When Starting The Engine
Truck Operation - General
Check When Traveling In Reverse
Traveling
Traveling On Slopes
Ensure Good Visibility
Operate Carefully On Snow
Avoid Damage To Dump Body
Driving Near High Voltage Cables
When Dumping
Working On Loose Ground
When Loading
Parking The Machine
TOWING
WORKING NEAR BATTERIES
Starting With Booster Cables
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
Warning Tag
Proper Tools
Stopping The Engine Before Service
Securing The Dump Body
DURING MAINTENANCE
Personnel
Attachments
Working Under The Machine
Keep The Machine Clean
Rules To Follow When Adding Fuel Or Oil
Radiator Water Level
Use Of Lighting
Precautions With The Battery
Handling High Pressure Hoses
Precautions With High Pressure Oil
Precautions When Performing Maintenance At High Temperature Or High Pressure
Rotating Fan And Belts
Waste Materials
TIRES
Handling Tires
Storing Tires After Removal
ADDITIONAL JOB SITE RULES
WHEN REPAIRS ARE NECESSARY
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK
Preliminary Procedures before Welding or Performing Maintenance
Normal Engine Shutdown Procedure
Engine Shutdown Procedure before Welding or Performing Maintenance
TRUCK OPERATION
PREPARING FOR OPERATION
Safety Is Thinking Ahead
At The Truck - Ground Level Walk Around Inspection
ENGINE START-UP SAFETY PRACTICES
Cold Weather Starting
AFTER ENGINE HAS STARTED
MACHINE OPERATION SAFETY PRECAUTIONS
MACHINE OPERATION ON THE HAUL ROAD
DYNAMIC RETARDING OPERATION
Dynamic Retarder Control Lever
Dynamic Retarder/Service Brake Pedal
Starting On A Grade With A Loaded Truck
PASSING
LOADING
DUMPING
Raising The Dump Body
Lowering The Dump Body
TOWING
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DELAYED ENGINE SHUTDOWN PROCEDURE
SUDDEN LOSS OF ENGINE POWER
WARNINGS AND CAUTIONS
CHARTS AND TABLES
STORAGE AND IDLE MACHINE PREPARATION
STORAGE AND IDLE MACHINE PREPARATION
Short Term Idle Periods
PREPARATION FOR STORAGE
REMOVAL FROM STORAGE
RECONDITIONING AN IDLE VEHICLE
ENGINE OPERATION
After The Engine Has Started
ENGINE STORAGE
Preparing Engine For Storage
Temporary Storage (30 Days Or Less)
Extended Storage (more Than 30 Days)
RESTORING AN ENGINE AFTER EXTENDED STORAGE
ELECTRIC DRIVE TRUCKS
Storage Instructions and Procedures
Placing Equipment Into Storage
Storing A Truck That Is Operational
Storing A Truck That Is Not Operational
Storing A Major Component
Periodic Inspections
Placing Equipment Into Service After Storage
When A Truck Is Operational
When A Truck Is Not Operational
For The First Hour

STRUCTURES
STRUCTURAL COMPONENTS
STRUCTURAL COMPONENTS
Preparation
GRILLE, HOOD AND LADDER
Removal
Installation
DECKS
RIGHT DECK AND COMPONENTS
Removal
Installation
LEFT DECK
Removal
Installation
CENTER DECK
DUMP BODY
DUMP BODY
Removal
Installation
BODY PADS
Adjustment
BODY GUIDE
HOIST LIMIT SWITCH
BODY UP SWITCH
BODY-UP RETENTION CABLE
ROCK EJECTORS
Rock Ejectors (Type II)
Inspection
FUEL TANK
FUEL TANK
Removal
Installation
Repair
Cleaning
FUEL GAUGE SENDER
Removal
Installation
LOW FUEL SWITCH
WIGGINS QUICK FILL FUEL SYSTEM
FUEL RECEIVER
TANK BREATHER VALVE
Removal
Installation
Disassembly
Assembly
LEFT SIDE FILL

ENGINE
POWER MODULE
POWER MODULE
Preparation
Preparation for Removal
Removal - Power Module
Installation - Power Module
Hookup - Power Module
COOLING SYSTEM
COOLING SYSTEM
RADIATOR
Removal - Radiator
Installation - Radiator
RADIATOR FILLING PROCEDURE
RADIATOR REPAIR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
Additional Service Information
COOLANT SYSTEM TROUBLESHOOTING
POWERTRAIN
POWER TRAIN
ALTERNATOR
Removal - Alternator
ENGINE/ALTERNATOR MATING
General Instructions
Measuring Procedure
Joining The Alternator and Engine
ENGINE
Removal
Service
Installation
AIR CLEANERS
AIR CLEANERS
AIR CLEANERS
Operation
General Service Information
FILTER ELEMENT REPLACEMENT
Main Filter Element Cleaning
Precleaner Section
Cleaning Precleaner Tubes
AIR INTAKE TROUBLESHOOTING

ELECTRICAL SYSTEM (24VDC NON-PROPULSION)
24VDC ELECTRIC SUPPLY SYSTEM
24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERIES
Maintenance and Service
Troubleshooting
BATTERY SUPPLY SYSTEM
24VDC BATTERY CHARGING ALTERNATOR
BATTERY BOX
BATTERY CONTROL BOX
Battery Disconnect Switches
24VDC Auxiliary Battery Connectors
24VDC to 12VDC Converter
Isolation Diodes
Engine Starter Relay
24VDC ELECTRICAL SYSTEM COMPONENTS
24 VDC ELECTRICAL SYSTEM COMPONENTS
TRUCK SHUTDOWN PROCEDURE
24 VDC ELECTRICAL SYSTEM COMPONENTS
BRAKE WARNING BUZZER (BWB)
AUXILIARY CONTROL CABINET COMPONENTS
FUSE BLOCK 1 & 2
POWER DISTRIBUTION TERMINALS
PULSE VOLTAGE MODULATOR
5 MINUTE IDLE TIMER COMPONENTS
5 Minute Idle Timer
5 Minute Idle Circuit Test
TAIL LIGHT RESISTOR DIODE ASSEMBLIES
ENGINE STARTER FAILURE DELAY TIMER
LUBRICATION SYSTEM TIMER
AUTO LUBE DELAY TIMER
BAROMETRIC PRESSURE TRANSDUCER
KONTROL POWER RELAY
ALARM INDICATING DEVICE (AID) SYSTEM
Temperature and Latch
Hot Switch Inverter
Hot Switch Inverter Card (Slot 4) (Not Used)
Oil Level
Temperature
Diode Matrix (Without Sound)
Diode Matrix (With Sound)
Lamp Test
DIODE BOARD - DB1
Diode Testing
RELAY BOARDS
RELAY BOARDS RB1, RB3, RB4, RB5
Service
RELAY BOARD IDENTIFICATION
RELAY BOARD FUNCTIONS
Relay Board 1 (RB1)
Relay Board 3 (RB3)
Relay Board 6, 7 & 8 (RB6, RB7, RB8)
Installing Additional Circuits
BODY-UP SWITCH
Operation
Adjustment
Service
HOIST LIMIT SWITCH
Operation
Adjustment
Service
BATTERY CHARGING ALTERNATOR
BATTERY CHARGING ALTERNATOR
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
Maintenance and Service
Troubleshooting
BATTERY CHARGING SYSTEM (Niehoff)
General Description
TROUBLESHOOTING PROCEDURES (On-Truck)
Equipment Required:
Preliminary Checks
Test Setup
Test Procedure
Regulator Bypass Test
ON VEHICLE TROUBLESHOOTING GUIDE
ALTERNATOR ELECTRICAL CONDITIONS - Low Voltage - High Voltage - No Voltage
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:
CHARGE VOLT AND AMP VALUES
DEFINITIONS
ADVANCED SYSTEM TROUBLESHOOTING
Static Test - Engine OFF, Key ON, Battery Switch ON.
Go To Alternator
Go To Regulator (If Required)
Go To Regulator Connector On The Alternator
ALTERNATOR OVERHAUL
ALTERNATOR DIMENSIONS
ALTERNATOR SPECIFICATIONS
SERVICE PARTS
ON-VEHICLE TEST
Equipment:
Preliminary Checks:
Test Set-up
Test Procedure
ON-VEHICLE TEST
Bypass Test:
BENCH TEST
STATIC TESTS
Regulator Tests
Control Box Tests
ALTERNATOR DISASSEMBLY
ASSEMBLY- ALTERNATOR
BF4822 STATOR SERVICE TOOL INSTRUCTIONS
Stator Removal And Replacement
Stator Installation

ELECTRICAL PROPULSION SYSTEM
ELECTRICAL PROPULSION SYSTEM COMPONENTS
ELECTRICAL PROPULSION SYSTEM COMPONENTS
GENERAL SYSTEM DESCRIPTION
SYSTEM COMPONENTS
Auxiliary Blower System
Propulsion System Controller (PSC)
TRUCK CONTROL INTERFACE PANEL (TCI)
Diagnostic Information Display
DID PANEL EVENT CODES
PSC SOFTWARE FUNCTIONS
Input Processing
STATE MANAGEMENT
State Machine
Transitions Between States
DC Link State
Powering the Link
De-Powering the Link
Control Functions
Engine Control
ALTERNATOR FIELD CONTROL
Desired Three-Phase Voltage
Desired DC Link Voltage
Self-load
Propel Torque Control
Retard Torque Control
Wheel Slide Control
Resistor Grid Control
Chopper Voltage Control
AUXILIARY BLOWER CONTROL
EVENT PROCESSING
Event Detection
Power On Tests
Initiated Tests
Periodic Tests
EVENT RESTRICTIONS
EVENT LOGGING AND STORAGE
Event History Buffer
Data Packs
To Record and Save a Data Pack to a Floppy Disk
Event Reset
SERIAL DATA COMMUNICATIONS
PSC - TCI Communications processing
PSC - PTU Communications Processing
Inverter Communications Processing
OUTPUT PROCESSING
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS
Fast Start
Engine Shutdown/Engine Not Running
Limp Home Mode
Entering/Exiting Limp Home Mode
PROPULSION SYSTEM COMPONENT ABBREVIATIONS
ELECTRONIC ACCELERATOR AND RETARD PEDALS
Removal
Installation
Disassembly
Assembly
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
AC DRIVE SYSTEM MAINTENANCE
TRUCK SHUTDOWN PROCEDURES
NORMAL TRUCK SHUTDOWN PROCEDURE
SHUTDOWN AFTER SYSTEM FAILURE
SYSTEM CHECKOUT
Battery and Control Checks of System WITH Battery Power OFF
Battery and Control Circuit Checks of System With Battery Power ON
Checks with Key Switch OFF
CPU Battery Checks
MEMORY BACKUP BATTERY REPLACEMENT
TCI PROGRAMMING
PSC PROGRAMMING
INVERTER PROGRAMMING
TCI CHECKOUT
Modular Mining Communication Port
TCI Input Checks
TCI Digital Output Tests
TCI Digital Input Tests
PSC Checkout Procedure
PSC Digital Input Checks
Miscellaneous Checks
A3PV Panel
LINKV Panel
Thermistor Checks
17FM384 Panel Check
Pedal Percentages and Meter Calibration
Meter Calibration Procedure
Reprogram With Serial Numbers and Pedal Percentages
LOAD TESTING
Preload Checks
ADDITIONAL TRUCK CHECKS
On-Board Load Testing
Preparation
Initiate Loadbox Test
Manual Offset HP Output Adjustment
TROUBLESHOOTING
PVM Optimum Load Curve Handshaking Troubleshooting
MISCELLANEOUS COMPONENT REPAIR
Troubleshooting Phase Modules and Chopper Modules
Phase Module Removal and Snubber Resistor Replacement
Snubber Resistor Installation
Phase Module Installation
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING
IGBT TROUBLESHOOTING

REAR AXLE, SPINDLES AND WHEELS
TIRES AND RIMS
TIRES AND RIMS
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRES AND RIMS
Removal
Installation
RIM
Tire Removal
Tire Installation
FRONT WHEEL HUB AND SPINDLE
FRONT WHEEL HUB AND SPINDLE
WHEEL HUB AND SPINDLE ASSEMBLY
Preparation
Removal
Installation - Wheel Hub and Spindle Assembly
Disassembly - Wheel Hub and Spindle Assembly
Cleaning and Inspection - Wheel Hub and Spindle Assembly
Assembly - Wheel Hub and Spindle Assembly
Wheel Bearing Adjustment:
Brake Installation
Seal Assembly Gap Check
STEERING CYLINDERS AND TIE ROD
Spherical Bearing Wear Limits
Removal - Steering Cylinder and Tie Rod
Installation - Steering Cylinder and Tie Rod
Bearing Replacement
TOE-IN ADJUSTMENT
REAR AXLE HOUSING ATTACHMENT
REAR AXLE HOUSING ATTACHMENT
PIVOT PIN
Removal
Installation
PIVOT EYE BEARING
Disassembly
Assembly
PIVOT EYE REPAIR
Removal
Disassembly
Assembly
Installation
ANTI-SWAY BAR
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
REAR AXLE HOUSING
REAR AXLE HOUSING
REAR AXLE HOUSING
Preparation
Removal
Cleaning and Inspection - Rear Axle Housing
Installation - Rear Axle Housing
WHEEL MOTOR
Preparation
Removal
Cleaning and Inspection - Wheel Motor
Installation - Wheel Motor
WHEEL MOTOR GEAR OIL
Filtering Requirements
Particle Size Analysis
Flushing
Oil Sample Analysis
ELEMENT SPECIFICATION CHARTS

HYDRAIR II SUSPENSIONS
FRONT SUSPENSIONS
FRONT SUSPENSION
Removal
Installation - Front Suspension
"Turn-Of-The-Nut" Tightening Procedure
MINOR REPAIRS (LOWER BEARING & SEALS)
Removal - Bearing Retainer
Installation - Bearing Retainer
MAJOR SUSPENSION REBUILD
Disassembly
Assembly
REAR SUSPENSIONS
REAR SUSPENSIONS
Removal
Installation - Rear Suspension
Disassembly - Rear Suspension
Cleaning and Inspection - Rear Suspension
Assembly - Rear Suspension
SUSPENSION OILING AND CHARGING PROCEDURE
SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL
EQUIPMENT LIST
Hydrair® Charging Kit
Installation of Charging Kit
Removal of Charging Kit
Support Blocks For Oiling And Charging Dimensions
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
Rear Suspension Oiling
Rear Suspension Nitrogen Charging
OIL AND NITROGEN SPECIFICATIONS CHART

BRAKE CIRCUIT
BRAKE CIRCUIT
BRAKE CIRCUIT
SERVICE BRAKE CIRCUIT
SECONDARY BRAKING AND AUTOMATIC APPLY
PARKING BRAKE CIRCUIT
Normal Operation (key switch on, engine running)
BRAKE LOCK CIRCUIT
WARNING CIRCUIT
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE VALVE
Rebuild Criteria
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Actuator Base Threaded Inserts
Boot and Cap
Valve Body Seal Installation
Regulator Sleeve O-Ring Installation
Actuator Plunger O-ring Installation
Assembly of Valve
DIFFERENTIAL PRESSURE SWITCH
Disassembly
Cleaning and Inspection
Assembly
VALVE BENCH TEST AND ADJUSTMENT
Test Set Up Procedure
Brake Valve Output Pressure Adjustment
Differential Pressure Switch Adjustment
Final Test and Adjustment
Installation Of Brake Pedal Actuator Assembly to Brake Valve
Installation of Retard Pedal To Brake Pedal
DUAL RELAY VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
DIFFERENTIAL PRESSURE SWITCH
Disassembly
Cleaning and Inspection
Assembly
VALVE TEST AND ADJUSTMENT
Test Set Up Procedure
Relay Valve Output Pressure Adjustment
Differential Pressure Switch Adjustment
BRAKE ACCUMULATORS
Brake Accumulator Bleeddown Procedure
BRAKE ACCUMULATOR REPAIR
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
ACCUMULATOR CHARGING PROCEDURE
RECHARGING ACCUMULATORS
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)
Removal
Installation
Disassembly and Adjustment
Potentiometer Check
Assembly
BRAKE CIRCUIT CHECK-OUT PROCEDURE
BRAKE CIRCUIT CHECK-OUT PROCEDURE
INITIAL SYSTEM SET-UP
BRAKE SYSTEM CHECKOUT
Failure Modes Check-Out
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET
WET DISC BRAKE ASSEMBLY
WET DISC BRAKE ASSEMBLY
OPERATION
MAINTENANCE
Brake Disc Wear Indicator
Removal/Installation - Wet Disc Brake Assembly
BRAKE REBUILD
Disassembly
Cleaning and Inspection
Assembly
Floating Ring Seal Assembly/Installation
WET DISC BRAKE BLEEDING PROCEDURE
PARKING BRAKE
PARKING BRAKE
OPERATION
MAINTENANCE
Inspection - Parking Brake
Removal - Parking Brake
Installation - Parking Brake
Disassembly - Parking Brake
Cleaning and Inspection - Parking Brake
Assembly - Parking Brake
PARKING BRAKE BLEEDING PROCEDURE

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC PUMP MODULE
HOIST CIRCUIT OPERATION
STEERING CIRCUIT OPERATION
DISC BRAKE COOLING SYSTEM
HYDRAULIC SYSTEM COMPONENT REPAIR
HYDRAULIC SYSTEM COMPONENT REPAIR
HOIST PUMP
Removal
Installation
INSPECTION OF PARTS
Assembly
HYDRAULIC TANK
Filling Instructions
Removal
Installation
HYDRAULIC TANK STRAINERS
Removal
Inspect and Clean
Installation
HYDRAULIC TANK BREATHERS
STEERING CIRCUIT
STEERING CIRCUIT
COMPONENT DESCRIPTION
Steering Control Unit
Bleeddown Manifold Valve
Bleeddown Solenoid
Relief Valves
Hoist Limit Solenoid
Accumulators
Low Precharge Warning Switch
High Pressure Filter
Quick Disconnect Ports
Flow Amplifier
FLOW AMPLIFIER SYSTEM OPERATION
No Steer
Steering Left
Steering Right
No Steer, External Shock Load
STEERING PUMP
Operation
PRINCIPLE OF OPERATION
Full Pump Volume:
Half Pump Volume:
Neutral Position:
Steering Pump
STEERING CONTROL UNIT
STEERING CONTROL UNIT
Removal.
Spline Inspection
Installation
STEERING CONTROL UNIT REBUILD
Disassembly
Cleaning and Inspection - Steering Control Unit
Assembly - Steering Control Unit
STEERING CIRCUIT COMPONENT REPAIR
STEERING CIRCUIT COMPONENT REPAIR
BLEEDDOWN MANIFOLD VALVE
Removal
Installation
FLOW AMPLIFIER
Removal
Installation
FLOW AMPLIFIER REBUILD
Disassembly
Assembly
STEERING CYLINDERS
Disassembly
Piston Seal & Bearing Installation
Cylinder Assembly
Test
STEERING AND BRAKE PUMP
Removal
Installation
Disassembly
Control Piston Group
Valve Plate Group
Rotating Group
Swashblock Group
Driveshaft Group
Inspection
Control Piston Group
Valve Plate Group
Rotating Group
Swashblock Group
Driveshaft Group
Compensator Block and Unloader Module
Stroke Adjuster Assembly
Assembly
Swashblock Group
Driveshaft Group
Rotating Group
Valve Plate Group
STEERING ACCUMULATORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
TESTING
STEERING ACCUMULATOR CHARGING PROCEDURE
TROUBLESHOOTING CHART
HOIST CIRCUIT
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
COMPONENT DESCRIPTION
Hydraulic Tank
Hydraulic Pump
High Pressure Filters
Hoist Valve
Inlet Sections - Hoist Valve
Spool Sections - Hoist Valve
Hoist Pilot Valve
Bleeddown Manifold
Hoist-up Limit Solenoid
Pilot Operated Check Valve
Overcenter Manifold
HOIST CIRCUIT OPERATION
Float Position Of Pilot Valve With Truck Body On Frame
Power Up Operation
Hold Operation
Power Down Operation
Float Operation
HOIST CIRCUIT COMPONENT REPAIR
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Installation
O-Ring Replacement
INLET SECTION
Disassembly
Cleaning and Inspection
Assembly
REAR SPOOL SECTION (Work Ports)
Disassembly
Cleaning and Inspection
Assembly
FRONT SPOOL SECTION (Tank Ports)
Disassembly
Cleaning and Inspection
Assembly
HOIST PILOT VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
HOIST CYLINDERS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly - Quill and Cylinder
Quill Installation
Installation Of Check Balls And Plugs In Quill
Assembly of Cylinder
OVERCENTER VALVE MANIFOLD
DISABLED TRUCK DUMPING PROCEDURE
Hookup
DUMPING PROCEDURE
Raising the Body
Lowering the Body
HYDRAULIC SYSTEM FILTERS
HYDRAULIC SYSTEM FILTERS
HOIST CIRCUIT FILTER
Filter Element Replacement
Removal - Hoist Circuit Filter
Installation - Hoist Circuit Filter
Indicator Switch - Hoist Circuit Filter
STEERING CIRCUIT FILTER
Filter Element Replacement
Removal - Steering Circuit Filter
Installation - Steering Circuit Filter
Indicator Switch - Steering Circuit Filter
INDICATOR SWITCH
Test Procedure
HYDRAULIC CHECK-OUT PROCEDURE
HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE
Equipment Requirements
Pump Pressure Control Adjustments
Steering Control Unit and Flow Amplifier Leakage Test
Bleeddown Manifold Leakage Test
STEERING/BRAKE PUMP STROKE ADJUSTMENT
SHOCK AND SUCTION VALVES
Equipment Requirements
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES
Equipment Requirements
Pressure Gauge Locations
Brake Cooling Circuit Test
Power Up Relief Pressure Test
Adjustment
Power Down Relief Pressure Test
Hoist Counterbalance Valve Adjustment
Preparation:
Counterbalance Valve Pressure Check Only:
Counterbalance Valve Adjustment
Preparation
Flushing Procedure
Filter Element Replacement
930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET
930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET

OPTIONS AND SPECIAL TOOLS
FIRE CONTROL SYSTEMS
FIRE CONTROL SYSTEM (MANUAL)
Operation
Inspection and Maintenance
Recharging Procedures
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM - SERIES 1
Control Module
Actuator
Linear Detection Wire
Power Wire
Test Kit
Squib
Securing the Detection Wire
Preliminary Test Before Final Hook-Up
Installation Procedure for Squib
Placing the Electric Detection & Actuation System Into Service
INSPECTION AND MAINTENANCE SCHEDULES
Daily
Normal Maintenance Based On Actual Operating Hours
IN CASE OF FIRE
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM
POSSIBLE CAUSES
SUGGESTED CORRECTIVE ACTION
TROUBLE: Test Module Light Will Not Illuminate.
POSSIBLE CAUSES
SUGGESTED CORRECTIVE ACTION
TROUBLE: Test Module Light Will Not Go Out
POSSIBLE CAUSES
SUGGESTED CORRECTIVE ACTION
TROUBLE: Detonated Squib
POSSIBLE CAUSES
SUGGESTED CORRECTIVE ACTION
SPECIAL TOOLS
PAYLOAD METER III ™
OPERATION SECTION
Introduction
Data Summary
Data Gathering
COMPONENT DESCRIPTION
System Diagram
Suspension Pressure Sensors
Inclinometer
Operator Display
Operator Switch
Speed Input
Body-Up Switch
Brake Lock Switch
Payload Meter
Communications Ports
Keyswitch Input
Payload Meter Power
Load Lights
Wiring and Termination
TCI Outputs
OPERATOR’S DISPLAY AND SWITCH
Reading the Speedometer
Reading the Load Display
Using the Operator ID
Using the Load and Ton Counter
Total Ton Counter
Total Load Counter
Clearing the Counters
Viewing Live Sensor Data
Other Display Messages
PAYLOAD OPERATION & CALCULATION
Description of Haul Cycle States
Haul Cycle Description
Load Calculation
Carry Back
Measurement Accuracy
SOURCES FOR PAYLOAD ERROR
Payload Error
Loading Conditions
Pressure Sensors
Swingloads
Speed and Distance
HAUL CYCLE DATA
Haul Cycle Data
Haul Cycle Warning Flags
M: Haul Cycle Too Long
N: Sensor Input Error
Alarm Records
Frame Torque Data
Sprung Weight Data
Maximum Speed Data
PC SOFTWARE OVERVIEW
PC Overview
System Configuration
Installing the PLMIII Software
DOWNLOADING DATA
PLM III SYSTEM CONFIGURATION
Starting Communications
Displayed Payload Units
Time Units
Connection Menu
Connecting to the Payload Meter
Configure the Payload Meter
Setting the Date and Time
Setting the Truck Type
Setting the Gauge Display Units
Setting the Frame Serial Number
Setting the Truck Number
Setting the Komatsu Distributor
Setting the Komatsu Customer
Clean Truck Tare
Inclinometer Calibration
DATA ANALYSIS
Creating a Query
Sorting on Truck Unit Number
Sorting on Truck Type
Sorting on Date Range
Sorting on Time Range
Payload Detail Screen
Creating Reports
Summary - one page report
Detailed - multi-page report
Creating Graphs
Exporting Data
CSV Export
Compressed
Importing Data
Deleting Haul Cycle Records
Viewing Alarms
Deleting Alarm Records
TROUBLESHOOTING SECTION
TROUBLESHOOTING
Viewing Active Alarms
Real-Time Data Display
Testing the Payload Lights
Creating Log Files of Inputs
Daily Inspections
Periodic Maintenance
Abnormal Displays at Power-Up
No Payload Display When Keyswitch is Turned ON
No Display on Speedometer
No Display on Operator Display
No Communications With PC
Load Lights Don’t Light During Loading
Load Lights Remain ON
Load Lights Remain ON During Dumping
Display Doesn't Clear When The Load Is Dumped
Calibration Problems
Alarm 1 - Left Front Pressure High
Alarm 2 - Left Front Pressure Low
Troubleshoot Wiring to Left Front Suspension
Alarm 3 - Right Front Pressure High
Alarm 4 - Right Front Pressure Low
Troubleshoot Wiring to Right Front Suspension
Alarm 5 -Left Rear Pressure High
Alarm 6 - Left Rear Pressure Low
Troubleshoot Wiring to Left Rear Suspension
Alarm 7 - Right Rear Pressure High
Alarm 8 - Right Rear Pressure Low
Troubleshoot Wiring to Right Rear Suspension
Alarm 9 - Inclinometer High
Alarm 10 - Inclinometer Low
Troubleshoot Inclinometer Wiring
Alarm 13 - Body Up Input Failure
Alarm 15 - Memory Write Failure
Alarm 16 - Memory Read Failure
Alarm 24 - System Key-On Status
Operator Switch Doesn't Work
Alarm 26 - User Switch Fault - SELECT
Alarm 27 - User Switch Fault - SET
Connector Map
Connectors
PLMIII CHECK OUT PROCEDURE
General Description
Tools Required
Checkout Procedure
PLMIII CHECKOUT PROCEDURE CONFIRMATION
Flashburn Programming
Confirmation Checklist
PAYLOAD METER III COMPONENTS
RESERVE ENGINE OIL SYSTEM
RESERVE ENGINE OIL SYSTEM
Operation
LED Monitor Light
Tank Fill Control (Optional)
Filling Procedure (Remote fill feature)
SERVICE
Every 10 Hours, or once each shift:
Every 500 Hours:
Changing Oil
TROUBLESHOOTING
Circuit Breaker or Fuse
SYSTEM ELECTRICAL SCHEMATICS

CAB COMPONENTS
TRUCK CAB
TRUCK CAB
Description
Preparation
Removal - Cab
Installation - Cab
CAB DOOR
Removal
Installation
Door Adjustment
Door Jamb Bolt Adjustment
Door Handle Plunger Adjustment
Door Glass Replacement
Door Window Regulator Replacement
Door Handle or Latch Assembly Replacement
Door and Door Hinge Seal Replacement
Door Opening Seal Removal
Installation
GLASS REPLACEMENT
Adhesive Bonded Windows
Replacement Procedure
Windshield And Rear Glass
Removal
Installation
CAB COMPONENTS
CAB COMPONENTS
WINDSHIELD WIPERS
Wiper Motor Replacement
Removal
Installation
Wiper Arm
Removal
Installation
Wiper Linkage Replacement
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR SEAT
Adjustment
Seat Removal
Seat Installation
OPERATOR COMFORT
OPERATOR COMFORT
HEATER / AIR CONDITIONER
Operation
Heater/Air Conditioner Vents
COMPONENTS
Circuit Breakers
Relays
Heater Core
Fan Motor And Speed Control
Actuators
Filter
Service
AIR CONDITIONING SYSTEM
Environmental Impact
OPERATOR CAB AIR CONDITIONING
PRINCIPLES OF REFRIGERATION
Air Conditioning
Refrigeration - The Act Of Cooling
The Refrigeration Cycle
AIR CONDITIONER SYSTEM COMPONENTS
Compressor (Refrigerant Pump)
Service Valves
Condenser
Receiver-Drier
Expansion Block Valve
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
SYSTEM SERVICING
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Replacing Oil After Servicing the System
Setting Up a New Compressor
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Leak Detector
Service Valves
Vacuum Pump
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air From Service Hoses
Stabilizing the AC System
SYSTEM PERFORMANCE TEST
SYSTEM LEAK TESTING
Electronic Leak Detector
Tracer Dyes
Soap and Water
SYSTEM REPAIR
System Cleaning
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
RECOVERING AND RECYCLING THE REFRIGERANT
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the AC System
EVACUATING THE SYSTEM
CHARGING THE AC SYSTEM
TROUBLESHOOTING
Pre-Diagnosis Checks
Preparing For Diagnosis
Preliminary Steps
System Performance Test
Diagnosis Of Gauge Readings And System Performance
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM
OPERATOR CAB CONTROLS
OPERATOR CAB CONTROLS
STEERING COLUMN
Removal
Steering Column Inspection
Installation
STEERING WHEEL AND CONTROLS
Horn Button
Telescope Lock Ring
Tilt Wheel Lever
Turn Signal/Headlight Dimmer
DYNAMIC RETARDING
Retarder Control Lever
Dynamic Retarder/Service Brake Pedal
Accelerator (Throttle) Pedal
Starting on a Grade With a Loaded Truck
GRADE/SPEED RETARD CHART
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS
Heater/Air Conditioner Vents
INSTRUMENT PANEL
OVERHEAD PANEL AND DISPLAYS
CENTER CONSOLE
F-N-R Selector Switch
Hoist Control Lever
Raising The Dump Body
Lowering The Dump Body:
Ash Tray
Lighter
L.H. Window Control Switch
R.H. Window Control Switch
Engine Shutdown Switch
Override/Fault Reset Switch
Retard Speed Control (RSC) Switch
Retard Speed Control (RSC) Adjust Dial
Data Store Button
Engine Control System
Service Engine Light (Blue)
Engine Diagnostics Download Port
Payload Meter
TCI Download Port
PSC Download Port
PAYLOAD METER
INSTRUMENT PANEL AND INDICATOR LIGHTS
CONTROL SYMBOLS
INSTRUMENT PANEL
PANEL GAUGES, INDICATORS, AND CONTROLS
Key Switch
Starting
Cold Weather Starting
Normal Engine Shutdown
Engine Shutdown Switch with 5 Minute Idle Timer Delay
Fog Lights (Optional)
Ladder Light Switch
Manual Backup Switch
Panel Illumination Lights
Cab/Air Conditioner Vents
Rotating Beacon Light Switch (Optional)
Heated Mirror Switch (Optional)
Wheel Brake Lock Control
Parking Brake Control
Tachometer
Right Turn Signal Indicator
High Beam Indicator
Left Turn Signal Indicator
Speedometer / Payload Meter
Voltmeter
Engine Oil Pressure Gauge
Water Temperature Gauge
Fuel Gauge
AC Drive System Temperature Gauge
Hydraulic Oil Temperature Gauge
Hourmeter
Rest Switch
Light Switch
Windshield Wiper and Washer
Panel Light Dimmer
Payload Meter Switch
OVERHEAD STATUS / WARNING INDICATORS
STATUS / WARNING INDICATOR LIGHT SYMBOLS
Hazard Warning Lights
Lamp Test Switch
Link-On Warning Light

LUBRICATION AND SERVICE
LUBRICATION AND SERVICE
LUBRICATION AND SERVICE
930E SERVICE CAPACITIES
HYDRAULIC TANK SERVICE
Adding Oil
WHEEL MOTOR SERVICE
COOLANT LEVEL CHECK
RADIATOR FILLING PROCEDURE
RESERVE ENGINE OIL SYSTEM (Optional)
Reserve Oil Tank Filling Procedure (Remote fill)
LUBRICATION CHART
10 HOUR (DAILY) INSPECTION
50 HOUR LUBRICATION AND MAINTENANCE CHECKS
100 HOUR LUBRICATION AND MAINTENANCE CHECKS
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
2500 HOUR MAINTENANCE CHECKS
5000 HOUR MAINTENANCE CHECKS
AUTOMATIC LUBRICATION SYSTEM
AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
SYSTEM COMPONENTS
SYSTEM OPERATION
Normal Operation
Pressure Failure Detection Circuits
GENERAL INSTRUCTIONS
LUBRICANT REQUIREMENTS
System Priming
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
Pressure Control Valve Adjustment
Lubrication Cycle Timer Check
Lubrication Cycle Timer Adjustment
FILTER ASSEMBLY
SYSTEM CHECKOUT
INJECTORS (SL-1 Series “H”))
Injector Specifications
Injector Adjustment
INJECTOR OPERATION
PUMP REBUILD
Disassembly
Cleaning and Inspection
Assembly
SYSTEM TROUBLESHOOTING CHART
PREVENTATIVE MAINTENANCE PROCEDURES
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection

ALPHABETICAL INDEX

SYSTEM SCHEMATICS
HH359 HYDRAULIC SCHEMATIC
HH358 BRAKE SCHEMATIC
XS1300 ELECTRICAL SCHEMATIC
XS1301 INDEX & SYMBOLS
XS1302 G.E. SYSTEM BLOCK DIAGRAM
XS1303 MAIN PROPULSION SCHEMATIC
XS1304 24V/15V POWER DISTRIBUTION
XS1305 G.E. INVERTER FIRING
XS1306 G.E. INVERTER FIRING
XS1307 ENGINE I.O.
XS1308 G.E. 24V - DIGITAL I.O.
XS1309 G.E. / TRUCK ANALOG I.O.
XS1310 POWER DISTRIBUTION / CIRCUIT PROTECTION
XS1311 OPERATOR CAB / OVERHEAD WARNING LIGHTS
XS1312 OPERATOR CAB / OVERHEAD WARNING LIGHTS
XS1313 OPERATOR CAB / OVERHEAD WARNING LIGHTS
XS1314 OPERATOR CAB / OVERHEAD WARNING LIGHTS
XS1315 LINCOLN LUBE
XS1316 OPERATOR CAB GAUGES & OPTIONS SWITCHES
XS1317 HEATER, AIR CONDITIONER CONTROLS
XS1318 WORK LIGHTS & HORN
XS1319 RETARD LIGHTS, BACKUP LIGHTS & HORNS
XS1320 OPERATOR DRIVE SYSTEM CONTROLS
XS1321 RADIO, WINDOWS & WIPER CONTROLS
XS1322 TURN SIGNAL & CLEARANCE LIGHTS
XS1323 FOG LIGHTS & HEAD LIGHTS
XS1324 OPERATOR CAB INSTRUMENT LIGHTS
XS1325 KEY SWITCH & 5 MINUTE IDLE SHUTDOWN
XS1326 QSK-60 START CIRCUIT
XS1327 ENGINE CIRCUITS - CUMMINS QSK-60
XS1328 PAYLOAD METER III
XS1329 DIAGNOSTIC CONNECTORS / MM DISPATCH SYSTEM
XS1330 CIRCUIT LOCATOR SHEET
XS1331 COMPONENT LOCATOR SHEET

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