Komatsu 930E-2 Dump Truck Shop Manual – CEBM012200

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Komatsu 930E-2 Dump Truck Shop Manual – CEBM012200

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This complete service repair workshop manual PDF download for the Komatsu 930E-2 Dump Truck 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 :

Machine Model :
Komatsu 930E-2

Serial Numbers :
A30296, A30297, A30300

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 : CEBM012200
Total Pages : 924

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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SECTION A – GENERAL INFORMATION – INDEX
SECTION A2 – MAJOR COMPONENT DESCRIPTION
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX
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 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
SECTION A4 – WARNINGS AND CAUTIONS
SECTION A5 – STANDARD CHARTS AND TABLES
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX
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

SECTION B – STRUCTURES – INDEX
SECTION B2 – STRUCTURAL COMPONENTS – INDEX
STRUCTURAL COMPONENTS
Preparation
GRILLE, HOOD AND LADDER
Removal
Installation
DECKS
RIGHT DECK AND COMPONENTS
Removal
Installation
LEFT DECK
Removal
Installation
CENTER DECK
SECTION B3 – DUMP BODY – INDEX
DUMP BODY
Removal
Installation
BODY PADS
Adjustment
BODY GUIDE
HOIST LIMIT SWITCH
BODY UP SWITCH
BODY-UP RETENTION CABLE
ROCK EJECTORS
Rock Ejectors (Type I)
Inspection
Rock Ejectors (Type II)
Inspection
SECTION B4 – FUEL TANK – INDEX
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

SECTION C – ENGINE – INDEX
SECTION C2 – POWER MODULE – INDEX
POWER MODULE
Preparation
Preparation for Removal
Removal – Power Module
Installation – Power Module
Hookup – Power Module
SECTION C3 – COOLING SYSTEM – INDEX
COOLING SYSTEM
RADIATOR
Removal – Radiator
RADIATOR REPAIR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
Additional Service Information
Installation – Radiator
RADIATOR FILLING PROCEDURE
COOLANT SYSTEM TROUBLESHOOTING
SECTION C4 – POWERTRAIN – INDEX
POWER TRAIN
ALTERNATOR
Removal – Alternator
ENGINE/ALTERNATOR MATING
General Instructions
Measuring Procedure
Joining The Alternator and Engine
ENGINE
Removal
Service
Installation
SECTION C5 – AIR CLEANERS – INDEX
AIR CLEANERS
AIR CLEANERS
Operation
General Service Information
FILTER ELEMENT REPLACEMENT
Main Filter Element Cleaning
Precleaner Section
Cleaning Precleaner Tubes
AIR INTAKE TROUBLESHOOTING
SECTION C7 – FAN CLUTCH – INDEX
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
FAN CLUTCH – DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY – FAN CLUTCH
TEST PROCEDURE

SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX
24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERIES
Maintenance and Service
Troubleshooting
BATTERY SUPPLY SYSTEM
24VDC Battery Charging Alternator
Battery Box
Battery Control Box
Isolation Diodes
Battery Disconnect Switches
24VDC Auxiliary Battery Connectors
Battery Equalizer
Troubleshooting
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX
24 VDC ELECTRICAL SYSTEM COMPONENTS
PASSENGER SEAT BASE COMPARTMENT
TRUCK SHUTDOWN PROCEDURE
COMPONENTS
Tail Light Resistor Diode Assemblies
5 Minute Idle Timer Components
5 Minute Idle Timer
5 Minute Idle Relay
5 Minute Idle Contactor
5 Minute Idle Circuit Test
Inclinometer
Brake Warning Buzzer (BWB)
Alarm Indicating Device (AID) System
Coolant Level/Flasher
Temperature and Latch Card
Hot Switch Inverter Card
Hot Switch Inverter Card (Slot 4) (Not Used)
Oil Level Card
Temperature Card
Diode Matrix (Without Sound) Card
Diode Matrix (With Sound) Card
Lamp Test Switch
Electrical Interface Cabinet
Lubrication System Timer
Lincoln Lube Delay Timer
Barometric Pressure Transducer
Pulse Voltage Modulator
Power Distribution Terminals
Truck Control Interface Panel
Kontrol Power Relay
Circuit Breaker Panel
Diode Board – DB1
Diode Testing
Relay Boards
Relay Boards: RB1, RB2, RB3, RB4, RB5
Service
Relay Board Identification
Relay Board Functions
Installing Additional Circuits
Body Up Switch
Operation
Adjustment
Service
Hoist Limit Switch
Operation
Adjustment
Service
CIRCUIT BREAKER CHART
BATTERY CHARGING ALTERNATOR
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
Maintenance and Service
Troubleshooting
TROUBLESHOOTING
Preliminary Checks
Preliminary Troubleshooting
Disassembly
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX
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

SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX
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
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX
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

SECTION G – REAR AXLE, SPINDLES AND WHEELS – INDEX
SECTION G2 – TIRES AND RIMS – INDEX
TIRES AND RIMS
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRES AND RIMS
Removal
Installation
RIM
Tire Removal
Tire Installation
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX
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
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX
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
SECTION G5 – REAR AXLE HOUSING – INDEX
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

SECTION H – HYDRAIR® II SUSPENSIONS – INDEX
SECTION H2 – FRONT SUSPENSIONS – INDEX
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
SECTION H3 – REAR SUSPENSIONS – INDEX
REAR SUSPENSIONS
Removal
Installation – Rear Suspension
Disassembly – Rear Suspension
Cleaning and Inspection – Rear Suspension
Assembly – Rear Suspension
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX
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

SECTION J – BRAKE CIRCUIT – INDEX
SECTION J2 – BRAKE CIRCUIT – INDEX
BRAKE CIRCUIT
SERVICE BRAKE CIRCUIT
SECONDARY BRAKING AND AUTOMATIC APPLY
PARKING BRAKE CIRCUIT
BRAKE LOCK CIRCUIT
WARNING CIRCUIT
Rear Axle Brake Lines
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX
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
Brake Valve Output Pressure Adjustment
Differential Pressure Switch Adjustment
HYDRAULIC BRAKE ACCUMULATORS
Brake Accumulator Bleed Down Procedure
ACCUMULATORS – HYDRAULICS COMPONENTS CABINET
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Charging Procedure
ACCUMULATORS – FRAME MOUNTED
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Testing
ACCUMULATOR CHARGING PROCEDURE
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)
Removal
Installation
Disassembly and Adjustment
Potentiometer Check
Assembly
SECTION J4 – BRAKE CIRCUIT CHECK-OUT PROCEDURE – INDEX
BRAKE CIRCUIT CHECK-OUT PROCEDURE
EQUIPMENT REQUIRED
INITIAL SYSTEM SET-UP
BRAKE SYSTEM CHECKOUT
Failure Modes Check-Out
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING
CHECK-OUT PROCEDURE
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX
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
SECTION J7 – PARKING BRAKE – INDEX
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

SECTION L – HYDRAULIC SYSTEM – INDEX
SECTION L2 – HYDRAULIC SYSTEM – INDEX
HYDRAULIC SYSTEM
HYDRAULIC PUMP MODULE
HOIST CIRCUIT OPERATION
STEERING CIRCUIT OPERATION
DISC BRAKE COOLING SYSTEM
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX
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
SECTION L4 – STEERING CIRCUIT – INDEX
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
SECTION L5 – STEERING CONTROL UNIT – INDEX
STEERING CONTROL UNIT
Removal
Installation
STEERING CONTROL UNIT REBUILD
Disassembly
Cleaning and Inspection – Steering Control Unit
Assembly – Steering Control Unit
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX
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
ACCUMULATORS
Removal
Installation
Disassembly – Accumulators
Cleaning and Inspection – Accumulators
Assembly – Accumulators
Testing – Accumulators
Charging Procedure
TROUBLESHOOTING CHART
SECTION L7 – HOIST CIRCUIT – INDEX
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
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX
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
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX
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
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX
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

SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX
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
SECTION M8 – SPECIAL TOOLS
SECTION M20 – PAYLOAD METER III – INDEX
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
SECTION M31 – RESERVE ENGINE OIL SYSTEM – INDEX
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

SECTION N – CAB COMPONENTS – INDEX
SECTION N2 – TRUCK CAB – INDEX
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
SECTION N3 – CAB COMPONENTS – INDEX
CAB COMPONENTS
WINDSHIELD WIPERS
Wiper Motor Replacement
Removal
Installation
Wiper Arm Replacement
Removal
Installation
Wiper Linkage Replacement
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR COMFORT
OPERATOR SEAT
Adjustment
SECTION N4 – OPERTATOR COMFORT – INDEX
OPERATOR COMFORT
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
HEATER / AIR CONDITIONER
Operation
Heater/Air Conditioner Vents
COMPONENTS
Circuit Breakers
Relays
Heater Core
Fan Motor And Speed Control
Actuators
Filter
Service
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
SECTION N5 – OPERATOR CAB CONTROLS – INDEX
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
PSC Download Port
Engine Diagnostics Download Port
Engine Control System
TCI Download Port
Passenger Seat
PAYLOAD METER
Payload Meter Download Connector
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
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
OVERHEAD STATUS / WARNING INDICATORS
STATUS / WARNING INDICATOR LIGHT SYMBOLS
Hazard Warning Lights
Lamp Test Switch
Link-On Warning Light

SECTION P – LUBRICATION AND SERVICE – INDEX
SECTION P2 – LUBRICATION AND SERVICE – INDEX
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
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX
AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
SYSTEM COMPONENTS
SYSTEM OPERATION
Normal Operation
Pressure Failure Detection Circuits
INJECTOR OPERATION
GENERAL INSTRUCTIONS
LUBRICANT REQUIREMENTS
System Priming
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
Pressure Control Valve Adjustment
INJECTORS (SL-1 Series “H”))
Injector Specifications
Injector Adjustment
SYSTEM CHECKOUT
Lubrication Cycle Timer Check
Lubrication Cycle Timer Adjustment
FILTER ASSEMBLY
PUMP REBUILD
Disassembly
Cleaning and Inspection
Assembly
SYSTEM TROUBLESHOOTING CHART
PREVENTATIVE MAINTENANCE PROCEDURES
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection

SECTION Q ALPHABETICAL INDEX

SECTION R SYSTEM SCHEMATICS
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC
HYDRAULIC BRAKE SYSTEM SCHEMATIC
PLM III ELECTRICAL SYSTEM SCHEMATIC
PLM III HOOK-UP WIRING
ELECTRICAL SCHEMATIC

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