Komatsu 930E-4 Dump Truck Shop Manual CEBM017909

Description

• Model List:
  • 930E-4 Dump Truck

• 1. COVER
• 2. FOREWORD
• 3. TABLE OF CONTENTS
• 4. SECTION A GENERAL INFORMATION
• 4.1. MAJOR COMPONENTS SPECIFICATIONS
• 4.1.1. TRUCK AND ENGINE
• 4.1.2. MAIN ALTERNATOR
• 4.1.3. AC INDUCTION TRACTION MOTORIZED WHEELS
• 4.1.4. SUSPENSION
• 4.1.5. OPERATORS CAB
• 4.1.6. POWER STEERING
• 4.1.7. DYNAMIC RETARDING
• 4.1.8. BRAKE SYSTEM
• 4.2. SAFETY
• 4.2.1. GENERAL
• 4.2.2. PRECAUTIONS BEFORE OPERATION
• 4.2.3. OPERATING THE TRUCK
• 4.2.4. WORKING NEAR BATTERIES
• 4.2.5. BEFORE PERFORMING MAINTENANCE
• 4.2.6. WHILE PERFORMING MAINTENANCE
• 4.2.7. TIRES
• 4.2.8. WHEN REPAIRS ARE NECESSARY
• 4.2.9. SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS
• 4.2.10. CAPACITOR DISCHARGE SYSTEM
• 4.3. OPERATING INSTRUCTIONS
• 4.3.1. PREPARING FOR OPERATION
• 4.3.2. WALK AROUND INSPECTION
• 4.3.3. ENGINE STARTUP
• 4.3.4. AFTER ENGINE HAS STARTED
• 4.3.5. PRESHIFT BRAKE CHECK (if equipped)
• 4.3.6. OPERATION
• 4.3.7. PERFORMING THE BRAKE TESTS
• 4.3.8. EMERGENCY STEERING SYSTEM
• 4.3.9. MACHINE OPERATION SAFETY PRECAUTIONS
• 4.3.10. OPERATING ON THE HAUL ROAD
• 4.3.11. STARTING ON A GRADE WITH A LOADED TRUCK
• 4.3.12. PASSING
• 4.3.13. LOADING
• 4.3.14. DUMPING
• 4.3.15. TOWING
• 4.3.16. SAFE PARKING PROCEDURES
• 4.3.17. NORMAL ENGINE SHUTDOWN PROCEDURE
• 4.3.18. DELAYED ENGINE SHUTDOWN PROCEDURE
• 4.3.19. SUDDEN LOSS OF ENGINE POWER
• 4.3.20. FUEL DEPLETION
• 4.3.21. DISABLED TRUCK DUMPING PROCEDURE
• 4.4. WARNINGS AND CAUTIONS
• 4.4.1. GRADE/SPEED CHART
• 4.4.2. KEY SWITCH
• 4.4.3. ROPS/FOPS
• 4.4.4. BATTERIES
• 4.4.5. CAPACITORS
• 4.4.6. CRUSHING HAZARD
• 4.4.7. CYLINDER PRESSURE
• 4.4.8. FILLING THE HYDRAULIC TANK
• 4.4.9. HYDRAULIC OIL PRESSURE
• 4.4.10. HOT OIL SPRAY
• 4.4.11. WHEEL MOTOR OIL LEVEL
• 4.4.12. HOT EXHAUST
• 4.4.13. RADIATOR
• 4.4.14. EMERGENCY LADDER
• 4.4.15. ACCUMULATOR DRAIN VALVES
• 4.4.16. EMERGENCY DUMP PROCEDURE
• 4.4.17. EMERGENCY TOWING PROCEDURE
• 4.4.18. WELDING
• 4.4.19. EMERGENCY SHUTDOWN
• 4.4.20. INFORMATION DISPLAY
• 4.4.21. WIRELESS SIGNALS
• 4.4.22. HIGH VOLTAGE
• 4.4.23. LIFTING INSTRUCTIONS
• 4.4.24. PRODUCT IDENTIFICATION PLATE
• 4.4.25. LUBRICATION CHART
• 4.5. TORQUE TABLES AND CONVERSION CHARTS
• 4.6. STORAGE AND IDLE MACHINE PREPARATION
• 4.6.1. SHORT TERM IDLE PERIODS
• 4.6.2. PREPARATION FOR STORAGE
• 4.6.3. REMOVAL FROM STORAGE
• 4.6.4. RECONDITIONING AN IDLE VEHICLE
• 4.6.5. ENGINE OPERATION
• 4.6.6. ENGINE STORAGE
• 4.6.7. RESTORING AN ENGINE AFTER EXTENDED STORAGE
• 4.6.8. ELECTRIC DRIVE TRUCKS
• 5. SECTION B STRUCTURES
• 5.1. SECTION B2 STRUCTURAL COMPONENTS
• 5.1.1. STRUCTURAL COMPONENTS
• 5.2. SECTION B3 DUMP BODY
• 5.3. SECTION B4 FUEL TANK
• 6. SECTION C ENGINE
• 6.1. SECTION C2 POWER MODULE
• 6.1.1. POWER MODULE
• 6.2. SECTION C3 COOLING SYSTEM
• 6.2.1. COOLING SYSTEM
• 6.3. SECTION C4 POWER TRAIN
• 6.3.1. POWER TRAIN
• 6.4. SECTION C5 AIR CLEANERS
• 6.4.1. AIR CLEANERS
• 6.5. SECTION C7 FAN CLUTCH
• 6.5.1. FAN CLUTCH
• 7. SECTION D ELECTRICAL SYSTEM (24VDC NONPROPULSION)
• 7.1. SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM
• 7.1.1. DC ELECTRICAL SUPPLY SYSTEM
• 7.1.2. TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT
• 7.1.3. DC ELECTRIC START SYSTEM
• 7.2. SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS
• 7.2.1. VDC ELECTRICAL SYSTEM COMPONENTS
• 7.3. SECTION D10 BATTERY CHARGING ALTERNATOR
• 7.3.1. BATTERY CHARGING SYSTEM
• 7.4. SECTION D11 KOMTRAX PLUS
• 7.4.1. KOMTRAX PLUS
• 7.5. SECTION D12 INTERFACE MODULE
• 7.5.1. INTERFACE MODULE
• 7.5.2. SENSORS
• 7.5.3. INTERFACE MODULE SOFTWARE
• 7.5.4. INTERFACE MODULE CHECKOUT
• 7.6. SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING
• 7.6.1. INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING
• 7.7. SECTION D14 KOMTRAX PLUS FORMS
• 7.7.1. KOMTRAX PLUS FORMS
• 8. SECTION E ELECTRIC PROPULSION SYSTEM
• 8.1. SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS
• 8.1.1. ELECTRICAL PROPULSION SYSTEM COMPONENTS
• 8.2. SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
• 8.2.1. AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
• 9. SECTION G REAR AXLE, SPINDLES AND WHEELS
• 9.1. SECTION G2 TIRES AND RIMS
• 9.1.1. TIRES AND RIMS
• 9.2. SECTION G3 FRONT WHEEL HUB AND SPINDLE
• 9.2.1. FRONT WHEEL HUB AND SPINDLE
• 9.3. SECTION G4 REAR AXLE MOUNTING
• 9.3.1. REAR AXLE MOUNTING
• 9.4. SECTION G5 REAR AXLE AND WHEEL MOTOR
• 9.4.1. REAR AXLE AND WHEEL MOTOR
• 10. SECTION H HYDRAIR II SUSPENSIONS
• 10.1. SECTION H2 FRONT SUSPENSIONS
• 10.1.1. FRONT SUSPENSION
• 10.2. SECTION H3 REAR SUSPENSIONS
• 10.2.1. REAR SUSPENSIONS
• 10.3. SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES
• 10.3.1. SUSPENSION OILING AND CHARGING PROCEDURE
• 10.3.2. OIL AND NITROGEN SPECIFICATIONS CHARTS
• 11. SECTION J BRAKE CIRCUIT
• 11.1. SECTION J2 BRAKE CIRCUIT
• 11.1.1. BRAKE CIRCUIT
• 11.2. SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE
• 11.2.1. BRAKE CIRCUIT COMPONENT SERVICE
• 11.3. SECTION J4 BRAKE CIRCUIT CHECKOUT PROCEDURE
• 11.3.1. BRAKE CIRCUIT CHECKOUT PROCEDURE
• 11.3.2. BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART
• 11.3.3. HYDRAULIC BRAKE SYSTEM CHECKOUT PROCEDURE DATA SHEET
• 11.4. SECTION J5 WET DISC BRAKE ASSEMBLY
• 11.4.1. WET DISC BRAKE ASSEMBLY
• 11.5. SECTION J7 PARKING BRAKE
• 12. SECTION L HYDRAULIC SYSTEM
• 12.1. SECTION L2 HYDRAULIC SYSTEM
• 12.1.1. HYDRAULIC SYSTEM
• 12.2. SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR
• 12.2.1. HYDRAULIC SYSTEM COMPONENT REPAIR
• 12.3. SECTION L4 STEERING CIRCUIT
• 12.3.1. STEERING CIRCUIT
• 12.4. SECTION L5 STEERING CONTROL UNIT
• 12.4.1. STEERING CONTROL UNIT
• 12.5. SECTION L6 STEERING CIRCUIT COMPONENT REPAIR
• 12.5.1. STEERING CIRCUIT COMPONENT REPAIR
• 12.5.2. TROUBLESHOOTING CHART
• 12.6. SECTION L7 HOIST CIRCUIT
• 12.6.1. HOIST CIRCUIT
• 12.6.2. HOIST CIRCUIT OPERATION
• 12.7. SECTION L8 HOIST CIRCUIT COMPONENT REPAIR
• 12.7.1. HOIST CIRCUIT COMPONENT REPAIR
• 12.8. SECTION L9 HYDRAULIC SYSTEM FILTERS
• 12.8.1. HYDRAULIC SYSTEM FILTERS
• 12.9. SECTION L10 HYDRAULIC CHECKOUT PROCEDURE
• 12.9.1. HYDRAULIC CHECKOUT PROCEDURE
• 12.9.2. CHECKOUT PROCEDURE STEERING SYSTEM DATA SHEET
• 12.9.3. CHECKOUT PROCEDURE BRAKE COOLING HOIST SYSTEM DATA SHEET
• 13. SECTION M OPTIONS AND SPECIAL TOOLS
• 13.1. SECTION M7 HOT START SYSTEM
• 13.1.1. HOT START SYSTEM
• 13.2. SECTION M8 SPECIAL TOOLS
• 13.2.1. HIGH VOLTAGE TOOLS
• 13.2.2. VDC CUSTOM METER KIT (58B0600800)
• 13.3. SECTION M19 RADIATOR SHUTTERS
• 13.3.1. RADIATOR SHUTTERS
• 13.4. SECTION M20 PAYLOAD METER III
• 13.4.1. OPERATION SECTION
• 13.4.2. TROUBLESHOOTING SECTION
• 13.4.3. PLMIII CHECK OUT PROCEDURE
• 13.5. SECTION M31 RESERVE ENGINE OIL SYSTEM
• 13.5.1. RESERVE ENGINE OIL SYSTEM
• 14. SECTION N OPERATOR CAB
• 14.1. SECTION N2 TRUCK CAB AND COMPONENTS
• 14.1.1. TRUCK CAB AND COMPONENTS
• 14.2. SECTION N3 CAB COMPONENTS
• 14.2.1. CAB COMPONENTS
• 14.3. SECTION N4 HEATER / AIR CONDITIONER
• 14.3.1. HEATER/AIR CONDITIONER
• 14.3.2. TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
• 14.3.3. PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
• 14.4. SECTION N5 OPERATOR CAB CONTROLS
• 14.4.1. OPERATOR CAB CONTROLS
• 15. SECTION P LUBRICATION AND SERVICE
• 15.1. SECTION P2 LUBRICATION AND SERVICE
• 15.1.1. LUBRICATION AND SERVICE
• 15.2. SECTION P3 AUTOMATIC LUBRICATION SYSTEM
• 15.2.1. AUTOMATIC LUBRICATION SYSTEM
• 15.2.2. SYSTEM TROUBLESHOOTING CHART
• 16. SECTION Q ALPHABETICAL INDEX
• 17. SECTION R SYSTEM SCHEMATICS
• 17.1. HYDRAULIC SUPPLY, BRAKE COOLING, STEERING HOIST SCHEMATIC
• 17.2. HYDRAULIC BRAKE SYSTEM SCHEMATIC
• 17.3. ELECTRICAL SCHEMATICS