Komatsu 930E-4 Dump Truck (A30462-A30600) Shop Manual – CEBM017904

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Komatsu 930E-4 Dump Truck (A30462-A30600) Shop Manual – CEBM017904

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This complete service repair workshop manual PDF download for the Komatsu 930E-4 Dump Truck (SN: A30462-A30600) 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 : 930E-4
Serial Numbers : A30462 – A30600

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 : CEBM017904
Total Pages : 1027

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
MAJOR COMPONENTS & SPECIFICATIONS
TRUCK AND ENGINE
MAIN ALTERNATOR
AC INDUCTION TRACTION MOTORIZED WHEELS
SUSPENSION
OPERATOR’S CAB
POWER STEERING
DYNAMIC RETARDING
BRAKE SYSTEM
ENGINE
AC ELECTRIC DRIVE SYSTEM
DYNAMIC RETARDING
BATTERY ELECTRIC SYSTEM
SERVICE CAPACITIES
HYDRAULIC SYSTEMS
SERVICE BRAKES
STEERING
TIRES
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS
WEIGHT DISTRIBUTION
SAFETY
GENERAL
Safety Rules
Safety Features
Fire Extinguisher And First Aid Kit
Clothing And Personal Items
Leaving The Operator’s Seat
Mounting And Dismounting
Fire Prevention For Fuel And Oil
Precautions With High Temperature Fluids
Asbestos Dust Hazard Prevention
Prevention Of Injury By Work Equipment
Unauthorized Modification
Precautions When Using ROPS
Precautions For Attachments
Precautions For Starting The Truck
PRECAUTIONS BEFORE OPERATION
Safety At The Worksite
Fire Prevention
Preparing For Operation
Ventilation In Enclosed Areas
In Operator’s Cab – Before Starting The Engine
Mirrors, Windows And Lights
OPERATING THE TRUCK
When Starting The Engine
General Truck Operation
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 Truck
TOWING
WORKING NEAR BATTERIES
Battery Hazard Prevention
Starting With Booster Cables
BEFORE PERFORMING MAINTENANCE
Warning Tag
Stopping The Engine Before Service
Proper Tools
Securing The Dump Body
WHILE PERFORMING MAINTENANCE
Keep The Truck Clean
Attachments
Working Under The Truck
Rotating Fan And Belts
Adding Fuel Or Oil
Radiator Water Level
Use Of Lighting
Precautions With The Battery
Handling High Pressure Hoses
Precautions When Performing Maintenance Near High Temperature Or High Pressure
Precautions With High Pressure Oil
Waste Materials
TIRES
Handling Tires
Storing Tires After Removal
WHEN REPAIRS ARE NECESSARY
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS
Preliminary Procedures Before Welding or Performing Maintenance
Normal Engine Shutdown Procedure
Engine Shutdown Procedure Before Welding or Performing Maintenance
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION
WALK-AROUND INSPECTION
ENGINE START-UP
AFTER ENGINE HAS STARTED
EMERGENCY STEERING SYSTEM
Operation
Pre-Operation Testing
MACHINE OPERATION SAFETY PRECAUTIONS
OPERATING ON THE HAUL ROAD
STARTING ON A GRADE WITH A LOADED TRUCK
PASSING
LOADING
DUMPING
Raising The Dump Body
Lowering The Dump Body (When dumping on flat ground):
Lowering The Dump Body (When dumping over a berm or into a crusher):
TOWING
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DELAYED ENGINE SHUTDOWN PROCEDURE
SUDDEN LOSS OF ENGINE POWER
FUEL DEPLETION
DISABLED TRUCK DUMPING PROCEDURE
Hookup
Raising the Body
Lowering the Body
WARNINGS AND CAUTIONS
GRADE/SPEED CHART
KEY SWITCH
ROPS/FOPS
BATTERIES
CRUSHING HAZARD
CYLINDER PRESSURE
FILLING THE HYDRAULIC TANK
HYDRAULIC OIL PRESSURE
WHEEL MOTOR OIL LEVEL
EMERGENCY TOWING PROCEDURE
EMERGENCY DUMP PROCEDURE
ACCUMULATOR DRAIN VALVES
HOT EXHAUST
WELDING
EMERGENCY SHUTDOWN
CAPACITORS
INFORMATION DISPLAY
RADIATOR
HIGH VOLTAGE
LIFTING INSTRUCTIONS
PRODUCT IDENTIFICATION PLATE
LUBRICATION CHART
STANDARD TORQUE SHARTS AND CONVERSION TABLES
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
Temporary Storage (30 Days Or Less)
Extended Storage (More Than 30 Days)
RESTORING AN ENGINE AFTER EXTENDED STORAGE
ELECTRIC DRIVE TRUCKS
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

SECTION B STRUCTURES INDEX
SECTION B2 STRUCTURAL COMPONENTS INDEX
STRUCTURAL COMPONENTS
PREPARATION
GRILLE, HOOD AND LADDER
Removal
Installation
RIGHT DECK AND COMPONENTS
Removal
Installation
LEFT DECK AND COMPONENTS
Removal
Installation
CENTER DECK
Removal
Installation
SECTION B3 DUMP BODY INDEX
DUMP BODY
DUMP BODY
Removal
Installation
BODY PADS
Adjustment
BODY GUIDE
HOIST LIMIT SWITCH
BODY-UP SWITCH
BODY-UP RETENTION CABLE
ROCK EJECTORS
Inspection
SECTION B4 FUEL TANK INDEX
FUEL TANK
Removal
Repair
Cleaning
Installation
FUEL GAUGE SENDER
Removal
Installation
FUEL TANK BREATHER VALVE
Disassembly
Assembly
FUEL RECEIVERS (WIGGINS QUICK FILL)

SECTION C ENGINE INDEX
SECTION C2 POWER MODULE INDEX
POWER MODULE
SHUTDOWN PRODEURE
PREPARATION FOR REMOVAL
REMOVAL
INSTALLATION
HOOKUP
SECTION C3 COOLING SYSTEM INDEX
COOLING SYSTEM
RADIATOR
Removal
Installation
Filling Procedure
REPAIRING THE RADIATOR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
COOLANT SYSTEM TROUBLESHOOTING
SECTION C4 POWER TRAIN INDEX
POWER TRAIN
ALTERNATOR REMOVAL
ALTERNATOR INSTALLATION
Measuring Procedure
Joining the Alternator and Engine
ENGINE
Removal
Service
Installation
SECTION C5 AIR CLEANERS INDEX
AIR CLEANERS
OPERATION
SERVICING THE AIR CLEANERS
Replacing The Filter Element
Cleaning The Main Filter Element
Servicing The Precleaner Section
AIR INTAKE TROUBLESHOOTING
SECTION C7 FAN CLUTCH INDEX
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
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
Battery Disconnect Switches
24VDC Auxiliary Battery Receptacles
Isolator Diode
Engine Start Relay
24VDC to 12VDC Converter
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX
24 VDC ELECTRICAL SYSTEM COMPONENTS
TRUCK SHUTDOWN PROCEDURE
BRAKE WARNING BUZZER
AUXILIARY CONTROL CABINET COMPONENTS
Power Distribution Terminals
Engine Starter Failure Delay Timer
5 Minute Idle Timer
Pulse Voltage Modulator (PMV)
Control Power Relay
Auto Lube Timer
Diode Board – DB1
Fuse Blocks
Alarm Indicating Device (AID) System
RELAY BOARDS
Relay Boards RB1, RB3, RB4, RB5
Relay Board RB6, RB7, RB8, RB9
Relay Board Functions
BODY-UP SWITCH
Operation
Adjustment
Service
HOIST LIMIT SWITCH
Operation
Adjustment
Service
FUSE BLOCKS & CIRCUIT BREAKER
SECTION D10 BATTERY CHARGING ALTERNATOR INDEX
BATTERY CHARGING SYSTEM
BATTERY CHARGING SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
CHARGE VOLT AND AMP VALUES
BATTERY
Maintenance and Service
Troubleshooting
Undercharging
Overcharging
Corrosion
Acid Levels
Non-Use or Storage
Freezing
BATTERY CHARGING ALTERNATOR
GENERAL INFORMATION
General Description
Terminal Identification and Location
Battery Positive (B+)
Battery Negative (B-)
DC Output (D+)
AC Output (R)
Regulator Harness Plug Identification
Alternator Specifications
Performance Curve
Battery/Alternator Terminology
WIRING DIAGRAM
DIMENSIONS AND TORQUE VALUES
PERIODIC MAINTENANCE
TESTING
GENERAL INFORMATION
Troubleshooting Alternator (On-Truck)
Equipment Required
Preliminary Checks
Test Set-up
Test Procedure
REGULATOR TESTING
Regulator Bypass Test (No Output)
Regulator Bypass Test (Amp Rating)
BENCH TESTING
Equipment
Identification Record
Advanced Troubleshooting
Bench Test 1: No-Load Test
Bench Test 2: Full Load Test
Bench Test 3: Regulator Bypass Test
STATIC TESTING
Equipment
Identification Record
Regulator Tester
Check For Shorted Power Transistor
Circuit Tests
FIELD COIL TESTS
Field Coil Test 1: Check for Open or Shorted Field Coil
Field Coil Test 2: Check For Grounded Field Coil
STATOR TESTS
Stator Test 1: Check For Stator-To-Stator Continuity
Stator Test 2: Check For Grounded Stators
THERMAL SWITCH TEST
Initial Test
Verifying a Faulty Thermal Switch
TROUBLESHOOTING TIPS
ALTERNATOR
ALTERNATOR REPAIR
Removal
Installation
Special Tools and Lubricants
Epoxy Adhesive
Liquid Threadlockers
Elastoplastic Silicone Resin
ALTERNATOR EXPLODED VIEW
ALTERNATOR DISASSEMBLY
Regulator Removal
Fan Removal
Pulley Removal
Anti-Drive End Housing Removal
Anti-Drive End Rotor Removal
Drive End Housing Removal
Drive End Rotor Removal
Field Coil Removal
Drive End and/or Anti-Drive End Stator Removal
CLEANING AND INSPECTION
ALTERNATOR ASSEMBLY
Anti-Drive End Stator Installation
Drive End Stator Installation
Field Coil Installation
Drive End Bearing Installation
Drive End Rotor Installation
Rotor and Rotor Shaft Installation
Drive End Housing Installation
Anti-Drive End Rotor Installation
Anti-Drive End Housing Installation
Regulator Installation
THERMAL SWITCH
Removal
Installation
SUPPORT STAND
SECTION D11 VEHICLE HEALTH MONITORING SYSTEM (VHMS) INDEX
VEHICLE HEALTH MONITORING SYSTEM (VHMS)
VHMS BASIC FEATURES
Gather Data
Convert and Record Data
Communicate Data to Off-Board Systems
USING VHMS
Turning VHMS ON
Normal VHMS Operation
Turning VHMS OFF
Downloading from the VHMS Controller
VHMS DATA ITEMS
Fault Codes
Machine History
VHMS History
Snapshots
Manual Snapshots
Trends
Histogram (Load Map) Data
Haul Cycle Data
Alarm and Snapshot Triggers
Satellite Features
VHMS DIAGNOSTIC FEATURES
Fault History
VHMS LED Digits
VHMS CONTROLLER
Removal
Installation
VHMS SOFTWARE
VHMS Tool Box Installation
VHMS Setting Tool Installation
VHMS INITIALIZATION PROCEDURE
VHMS CONTROLLER SETUP PROCEDURE
VHMS SNAPSHOT PROCEDURE
VHMS DOWNLOAD PROCEDURE
VHMS FTP UPLOAD PROCEDURE
VHMS INITIALIZATION FORMS
WHEN REPLACING A VHMS CONTROLLER
VHMS CONTROLLER CHECKOUT
Necessary Equipment
Preliminary
VHMS Controller Checkout Procedure
ORBCOMM CONTROLLER
Removal
Installation
SECTION D12 INTERFACE MODULE INDEX
INTERFACE MODULE
Removal
Installation
SENSORS
Temperature Sensors
Pressure Sensors
INTERFACE MODULE SOFTWARE
Flashburn Program Installation
Interface Module Application Code Installation
Interface Module Realtime Data Monitor Software
INTERFACE MODULE CHECKOUT
Necessary Equipment
Preliminary
Check Digital Inputs To The Interface Module
Check Analog Inputs To The Interface Module
Check Serial Interfaces To The Interface Module
Check Outputs From The Interface Module
SECTION D13 INTERFACE MODULE AND VHMS TROUBLESHOOTING INDEX
INTERFACE MODULE AND VHMS TROUBLESHOOTING
GENERAL
TROUBLESHOOTING
Communications Networks
Coaxial Cable
FAULT CODES
Fault History
VHMS LED Display Fault Codes
Chassis Fault Codes
Engine Fault Codes
FAULT TREE ANALYSIS
Unable to connect to VHMS from laptop PC
Flashing Error Code N4-23 (PLM III Communications Fault)
Flashing Error Code N4-22 (Engine Communications Fault)
No Data Received By WebCARE
Coaxial Cable Troubleshooting
SECTION D14 VHMS FORMS INDEX
VHMS FORMS
VHMS INITIALIZATION CHECK LIST
VHMS DATA DOWNLOAD
VHMS INITIALIZATION FORM
VHMS INITIALIZATION CHECK LIST
VHMS INITIALIZATION FORM

SECTION E ELECTRICAL PROPULSION SYSTEM INDEX
SECTION E2 ELECTRICAL PROPULSION SYSTEM COMPONENTS INDEX
ELECTRICAL PROPULSION SYSTEM COMPONENTS
GENERAL SYSTEM DESCRIPTION
SYSTEM COMPONENTS
Propulsion System Controller (PSC)
Truck Control Interface (TCI)
Diagnostic Information Display (DID) Panel
DID Panel Event Codes
PSC SOFTWARE FUNCTIONS
Input Processing
State Machine
DC Link State
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
EVENT DETECTION AND PROCESSING
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 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
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS
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
NORMAL TRUCK SHUTDOWN PROCEDURE
SHUTDOWN AFTER SYSTEM FAILURE
SYSTEM CHECKOUT
Battery and Control Circuit Checks – Battery Power OFF
Battery and Control Circuit Checks – Battery Power ON
Checks with Key Switch OFF
Checks with Key Switch ON
CPU Battery Checks
MEMORY BACKUP BATTERY REPLACEMENT
TCI PROGRAMMING
PSC PROGRAMMING
INVERTER PROGRAMMING
CPU RESET
PSC CHECKOUT
PSC Digital Input Checks
PSC Digital Output Checks
TCI CHECKOUT
Modular Mining Communication Port Check
TCI Digital Input Checks
TCI Digital Output Tests
CALIBRATIONS
Speedometer
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial
ERASING EVENTS
PSC
TCI
GATE DRIVER POWER CONVERTER TEST
LOAD TESTING
Preparation
Alternator Speed Sensor Checks
Battery Boost Check
Brake Circuit Switch Checks
Hoist & Steering Circuit Switch Checks
Link Energized Checks
Loadbox Test
TROUBLESHOOTING
PVM Optimum Load Curve Handshaking Troubleshooting
Phase Module and Chopper Module Troubleshooting
PHASE MODULE REPLACEMENT
Phase Module Removal
Phase Module Installation

SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX
SECTION G2 TIRES AND RIMS INDEX
TIRES AND RIMS
WHEEL STUD MAINTENANCE
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
Disassembly
Cleaning and Inspection
Assembly
Wheel Bearing Adjustment
Brake Installation
Seal Assembly Gap Check
STEERING CYLINDERS AND TIE ROD
Spherical Bearing Wear Limits
Removal
Installation
Bearing Replacement
TOE-IN ADJUSTMENT
SECTION G4 REAR AXLE MOUNTING INDEX
REAR AXLE MOUNTING
PIVOT PIN
Removal
Installation
PIVOT EYE BEARING
Removal
Installation
PIVOT EYE REPAIR
Removal
Disassembly
Assembly
Installation
ANTI-SWAY BAR
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
SECTION G5 REAR AXLE HOUSING INDEX
REAR AXLE HOUSING
REAR AXLE HOUSING
Preparation
Removal
Cleaning and Inspection
Installation
WHEEL MOTOR
Preparation
Removal
Cleaning and Inspection
Installation
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
“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
SUSPENSION CYLINDER
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
SUSPENSION PRESSURE TEST
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX
SUSPENSION OILING AND CHARGING PROCEDURE
GENERAL
Equipment List
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 CHARTS

SECTION J BRAKE CIRCUIT INDEX
SECTION J2 BRAKE CIRCUIT INDEX
BRAKE CIRCUIT
SERVICE BRAKE CIRCUIT
PARKING BRAKE CIRCUIT
BRAKE LOCK CIRCUIT
SECONDARY BRAKING AND AUTOMATIC APPLY
WARNING CIRCUIT
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE VALVE
Rebuild Criteria
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Regulator Sleeve O-Ring Installation
BRAKE VALVE BENCH TEST AND ADJUSTMENT
Test Setup Procedure
Brake Valve Output Pressure Adjustment
Final Test and Adjustment
Installing Brake Pedal Actuator Assembly to Brake Valve
Installing Retard Pedal To Brake Pedal
DUAL RELAY VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT
Test Setup Procedure
Relay Valve Output Pressure Adjustment
BRAKE MANIFOLD
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
BRAKE ACCUMULATORS
Brake Accumulator Bleeddown Procedure
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Accumulator Charging Procedure
Precharge Maintenance
Accumulator Storage Procedures
Bladder Storage Procedures
Installing A Bladder Accumulator From Storage
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)
Removal
Installation
Disassembly
Lever Adjustments
Potentiometer Check
Assembly
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX
BRAKE CIRCUIT CHECK-OUT PROCEDURE
REQUIRED EQUIPMENT
INITIAL SYSTEM SETUP
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT
PARKING BRAKE CHECK-OUT
SERVICE BRAKE CHECK-OUT
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET – PAGE 1
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET – PAGE 2
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX
WET DISC BRAKE ASSEMBLY
OPERATION
BRAKE DISC WEAR INSPECTION
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
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
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
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
Steering Accumulator Bleeddown Solenoid
Relief Valves
Hoist Up Limit Solenoid
Steering 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
Normal Operation
PRINCIPLE OF OPERATION
Full Pump Volume
Half Pump Volume
Neutral Position
Steering Pump
SECTION L5 STEERING CONTROL UNIT INDEX
STEERING CONTROL UNIT
REMOVAL
SPLINE INSPECTION
INSTALLATION
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX
STEERING CIRCUIT COMPONENT REPAIR
BLEEDDOWN MANIFOLD VALVE
Removal
Installation
FLOW AMPLIFIER
Removal
Installation
Disassembly
Assembly
STEERING CYLINDERS
Disassembly
Piston Seal & Bearing Installation
Assembly
Testing
STEERING AND BRAKE PUMP
Removal
Installation
Disassembly
Inspection
Assembly
Driveshaft Group
Rotating Group
Valve Plate Group
STEERING ACCUMULATORS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Leak Testing
Charging Procedure
Precharge Maintenance
Accumulator Storage Procedures
Bladder Storage Procedures
Installing A Bladder Accumulator From Storage
TROUBLESHOOTING CHART
BASIC OPERATION
FIGURE 7-1. HOIST CIRCUIT SCHEMATIC
COMPONENT DESCRIPTION
Hydraulic Tank
Hydraulic Pump
High Pressure Filters
Hoist Valve
FIGURE 7-2. HOIST VALVE
Inlet Sections
Work Ports (Rear) Spool Section
Tank Ports (Front) Spool Section
Hoist Pilot Valve
FIGURE 7-3. HOIST PILOT VALVE
Bleeddown Manifold
Hoist Up Limit Solenoid
Pilot Operated Check Valve
Overcenter Manifold
FIGURE 7-4. PUMP MODULE
Float Position Of Pilot Valve With Truck Body On Frame
FIGURE 7-5. FLOAT POSITION
Power Up Operation
(Figure 7-6)
FIGURE 7-6. POWER UP POSITION
Hold Operation
(Figure 7-7)
FIGURE 7-7. HOLD POSITION
Power Down Operation
(Figure 7-8)
FIGURE 7-8. POWER DOWN POSITION
Float Operation
(Figure 7-9)
FIGURE 7-9. FLOAT POSITION
SECTION L7 HOIST CIRCUIT INDEX
HOIST CIRCUIT
BASIC OPERATION
COMPONENT DESCRIPTION
Hydraulic Tank
Hydraulic Pump
High Pressure Filters
Hoist Valve
Inlet Sections
Work Ports (Rear) Spool Section
Tank Ports (Front) Spool Section
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
Assembly – Cylinder
OVERCENTER VALVE MANIFOLD
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 Valve and Flow Amplifier Leakage Test
Bleeddown Manifold Leakage Test
STEERING/BRAKE PUMP STROKE ADJUSTMENT
SHOCK AND SUCTION VALVES
Equipment Requirements
Pressure Tests
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES
Equipment Requirements
Pressure Gauge Locations
Brake Cooling Circuit Test
Power Up Relief Pressure Test
Power Down Relief Pressure Test
Counterbalance Valve Pressure Check
Counterbalance Valve Adjustment
HYDRAULIC SYSTEM FLUSHING PROCEDURE
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)
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
TROUBLE: Detonated Squib
Operation
Inspection and Maintenance
Recharging Procedures
SECTION M7 ENGINE OIL HEATER INDEX
ENGINE OIL HEATERS
GENERAL INFORMATION
TROUBLESHOOTING
HEATER ELEMENT
Removal
Installation
SECTION M7 ENGINE COOLANT HEATER INDEX
ENGINE COOLANT HEATER
GENERAL
Maintenance
HEATING ELEMENT
Removal
Installation
THERMOSTAT
Removal
Installation
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
Key Switch 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 Warning Flags
Frame Torque Data
Sprung Weight Data
Maximum Speed Data
Alarm Records
Fault Code Data
PC SOFTWARE 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 Key Switch 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 16 – Memory Write Failure
Alarm 17 – Memory Read Failure
Alarm 18
Alarm 19
Alarm 22
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
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 Fuse
SYSTEM ELECTRICAL SCHEMATICS

SECTION N OPERATOR CAB INDEX
SECTION N2 TRUCK CAB AND COMPONENTS INDEX
TRUCK CAB AND COMPONENTS
TRUCK CAB
Description
Removal
Installation
CAB DOOR
Removal
Installation
Door Adjustment
Door Jamb Bolt Adjustment
Door Handle Plunger Adjustment
Replacing the Door Glass
Replacing the Door Window Regulator
Replacing the Door Handle or Latch Assembly
Replacing the Door and Door Hinge Seal
Removing the Door Opening Seal
Installation
GLASS REPLACEMENT (Adhesive-Bonded Windows)
Recommended Tools and Supplies
Replacement Procedure
WINDSHIELD AND REAR GLASS
Removal
Installation
SECTION N3 CAB COMPONENTS INDEX
CAB COMPONENTS
WINDSHIELD WIPERS
WIPER MOTOR
Removal
Installation
WIPER ARM
Removal
Installation
WIPER LINKAGE
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR SEAT
Adjustment
Seat Removal
Seat Installation
SECTION N4 HEATER / AIR CONDITIONER INDEX
HEATER/AIR CONDITIONER
OPERATION
Fan Control Knob
Temperature Control Knob
Directional Control Knob
Heater Vents
COMPONENTS
Fuse and Circuit Breaker
Relays
Heater Core
Fan Motor And Speed Control
Actuators
Cab Air Filter
ENVIRONMENTAL IMPACT OF AIR CONDITIONING
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES
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
Accumulator
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
AIR CONDITIONING SYSTEM SERVICING WARNINGS
SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Leak Detector
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air From Service Hoses
Service Valves
Vacuum Pump
SYSTEM PERFORMANCE TEST
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Checking System Oil
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SYSTEM LEAK TESTING
Electronic Leak Detector
Tracer Dyes
Soap and Water
RECOVERING AND RECYCLING THE REFRIGERANT
Draining Oil from the Previous Recovery Cycle
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the A/C System
SYSTEM REPAIR
System Flushing
A/C DRIVE BELT CHECKOUT PROCEDURE
Pulley Alignment
Belt Tension Check
COMPONENT REPLACEMENT
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Accumulator
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
EVACUATING THE SYSTEM
CHARGING THE A/C SYSTEM
TROUBLESHOOTING
Preliminary Checks
Diagnosis Of Gauge Readings And System Performance
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
SECTION N5 OPERATOR CAB CONTROLS INDEX
OPERATOR CAB CONTROLS
STEERING COLUMN
Removal
Inspection
Installation
STEERING WHEEL
Removal
Installation
STEERING WHEEL AND CONTROLS
Horn Button
Tilt / Telescope Lever
Multi-Function Turn Signal Switch
DYNAMIC RETARDING
Retarder Lever
Brake/Retarder Pedal
Throttle/Accelerator Pedal
GRADE/SPEED CHART
OVERHEAD PANEL AND DISPLAYS
Speakers
Warning Alarm Buzzer
Radio/CD Player
Warning Indicator Light Dimmer Control
Status/Warning Indicator Light Panel
Air Cleaner Restriction Gauges
CENTER CONSOLE
Directional Control Lever
Override/Fault Reset Switch
Engine Shutdown Switch
L.H. Window Control Switch R.H. Window Control Switch
Hoist Control Lever
Retarder Speed Control (RSC) Adjustment Dial
Retarder Speed Control (RSC) Switch
Data Store Button
VHMS Snapshot In Progress Light
Link Energized Light
Service Engine Light
12V Auxiliary Power Outlets
DIAGNOSTIC PORTS
VHMS Diagnostic Port
Interface Module (IM) Diagnostic Port
Payload Meter Diagnostic Port
Truck Control Interface (TCI) Diagnostic Port
Propulsion System Controller (PSC) Diagnostic Port
Engine Diagnostic Port (CENSE)
Engine Diagnostic Port (QUANTUM)
INSTRUMENT PANEL
Control Symbols
Key Switch
Engine Shutdown Timer Switch with 5 Minute Idle Delay
Air Conditioner Compressor Switch
Rotating Beacon Switch (optional)
Heated Mirrors Switch (optional)
AC Drive System Rest Switch
Wheel Brake Lock Switch
Hazard Warning Lights
Heater/Air Conditioner Vents
Engine Oil Pressure Gauge
Right Turn Signal Indicator
Digital Tachometer
High Beam Indicator
Speedometer/Payload Meter Display
Left Turn Signal Indicator
Water Temperature Gauge
Lamp Check Switch
Headlight/Panel Illumination Light Switch
Ladder Light Switch (3-Way)
Backup Light Switch
Fog Lights
Payload Meter Switch
Panel Illumination Light Dimmer Switch
Hydraulic Oil Temperature Gauge
Engine Hourmeter
Fuel Gauge
OVERHEAD STATUS / WARNING INDICATORS
A1. High Hydraulic Oil Temperature
B1. Low Steering Pressure
C1. Low Accumulator Precharge Pressure
D1. Not used
E1. Low Brake Pressure
A2. Low Hydraulic Tank Level
B2. Low Automatic Lubrication System Pressure
C2. Circuit Breaker Tripped
E2. Low Fuel
A3. Parking Brake
B3. Service Brake
C3. Body Up
D3. Dynamic Retarding
E3. Stop Engine
A4. Cranking Motor Failure
B4. Backup Lights
C4. Engine Shutdown Timer – 5 Minute Idle
D4. Retard Speed Control (RSC) Indicator
E4. Check Engine
A5. No Power
B5. Propulsion System Warning
C5. Propulsion System Temperature
D5. System/Component Failure
E5. Battery Charging System Failure
A6. No Propel
B6. Propel System @ Rest
C6. Propel System Not Ready
D6. Reduced Propulsion
E6. Retard At Continuous Level
VEHICLE HEALTH MONITORING SYSTEM (VHMS)
Operation
Basic Precautions

SECTION P LUBRICATION AND SERVICE INDEX
SECTION P2 LUBRICATION AND SERVICE INDEX
LUBRICATION AND SERVICE
GENERAL
930E SERVICE CAPACITIES
HYDRAULIC TANK SERVICE
Adding Hydraulic Oil
WHEEL MOTOR SERVICE
COOLING SYSTEM SERVICE
Radiator Filling Procedure
RESERVE ENGINE OIL SYSTEM
Reserve Oil Tank Filling Procedure (Remote Fill)
LUBRICATION CHART
10 HOUR (DAILY) INSPECTIONS
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
5000 HOUR MAINTENANCE CHECKS
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX
AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
SYSTEM COMPONENTS
Filter
Hydraulic Motor and Pump
Grease Reservoir
Pressure Reducing Valve
Flow Control Valve
Solenoid Valve
Vent Valve
Lubrication Cycle Timer
Pump Cutoff Pressure Switch
Grease Pressure Failure Switch
Pressure Gauge
Injectors
SYSTEM OPERATION
Normal Operation
LUBRICANT REQUIRED FOR SYSTEM
System Priming
Filter Assembly
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
Pressure Control Valve Adjustment
INJECTORS (SL-1 Series “H”)
Injector Specifications
Injector Adjustment
Injector Operation
PREVENTIVE MAINTENANCE PROCEDURES
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection
SYSTEM CHECKOUT
Lubrication Controller Check
Lubrication Controller Operation
Lubrication Controller Components
Lubrication Controller Adjustment
SYSTEM TROUBLESHOOTING CHART

SECTION Q ALPHABETICAL INDEX

SECTION R SYSTEM SCHEMATICS INDEX
HYDRAULIC SCHEMATIC (EM1364)
HYDRAULIC BRAKE SCHEMATIC (EM1358)
ELECTRICAL SCHEMATICS (XS4300)

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