Komatsu 930E-4 Dump Truck Parts Manual CEBM030303 PDF DOWNLOAD

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Komatsu 930E-4 Dump Truck Parts Manual CEBM030303 –  PDF DOWNLOAD

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Komatsu 930E-4 Dump Truck Parts Manual CEBM030303 – PDF DOWNLOAD

Language : English
Pages : 1400
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4 Dump Truck Parts Manual CEBM030303 – PDF DOWNLOAD

• A31879 and up
• A31880 and up
• A31882 and up
• A31990 and up
• A31992 and up

COVER 1
SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENTS & SPECIFICATIONS INDEX 11
MAJOR COMPONENT DESCRIPTIONS 11
Truck And Engine 11
Main Alternator 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SECTION A3 GENERAL SAFETY AND OPERATING INSTRUCTIONS INDEX 17
SAFETY 17
GENERAL 17
Safety Rules 17
Safety Features 17
Fire Extinguisher And First Aid Kit 17
Clothing And Personal Items 17
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Unauthorized Modification 19
Precautions When Using ROPS 19
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 20
Safety At The Worksite 20
Fire Prevention 21
Ventilation In Enclosed Areas 21
Preparing For Operation 21
Mirrors, Windows And Lights 21
In The Operator Cab (Before Starting The Engine) 21
Seat Belts 21
OPERATING THE TRUCK 22
When Starting The Engine 22
General Truck Operation 22
Ensuring Good Visibility 22
Traveling 23
Traveling In Reverse 23
Traveling On Slopes 23
Operating On Snow Or Ice 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 24
When Dumping 24
When Loading 24
Parking The Truck 24
Towing 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump Starting With Jumper Cables 26
Jump Starting With Receptacles 27
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Electrical Systems Isolation 28
Warning Tag 30
Proper Tools 30
Use of Tie-Off Anchor During Maintenance and Repair 30
Securing The Dump Body 30
Jack Point Locations 31
WHILE PERFORMING MAINTENANCE 32
Keep The Truck Clean 32
Attachments 32
Working Under The Truck 32
Rotating Fan And Belts 32
Waste Materials 32
Adding Fuel Or Oil 33
Radiator Coolant Level 33
Use Of Lighting 33
Precautions With The Battery 33
Handling High Pressure Hoses 33
Precautions With High Pressure Oil 33
Performing Maintenance Near High Temperature Or High Pressure 33
TIRES 34
Inspection 34
Maintenance 34
Storage 35
Handling 36
WHEN REPAIRS ARE NECESSARY 37
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 38
Preliminary Procedures Before Welding or Performing Maintenance 38
Engine Shutdown Procedure Before Welding or Performing Maintenance 38
CAPACITOR DISCHARGE SYSTEM 40
Necessary Tools 40
Warnings and Cautions 41
Manual DC Link Capacitor Discharge Procedure 42
Failure of the Discharge System 44
Manual Discharge of Capacitors 45
Short Isolated Capacitor Terminals 47
OPERATING INSTRUCTIONS 48
PREPARING FOR OPERATION 48
WALK AROUND INSPECTION 48
RETRACTABLE LADDER SYSTEM (Optional) 53
Description 53
Normal Operation 53
General Safety 53
IN-CAB CONTROL PANEL 54
Digital Display Screen 54
Command Buttons 54
USING THE IN-CAB CONTROL PANEL 55
Raising the Ladder 56
Lowering the Ladder 56
USING THE GROUND LEVEL CONTROL BOX 57
Raising the Ladder 57
Lowering the Ladder 57
EMERGENCY OPERATION 58
ENGINE START-UP 59
AFTER ENGINE HAS STARTED 60
PRE-SHIFT BRAKE CHECK 61
Events 61
OPERATION 61
Description 61
Brake Test Exit Criteria 62
PERFORMING THE BRAKE TESTS 63
Setup 63
Service Brake Test 63
Parking Brake Test 64
Retard System Test 65
EMERGENCY STEERING SYSTEM 65
Operation 65
Pre-Operation Testing 65
Additional Guidelines 66
MACHINE OPERATION SAFETY PRECAUTIONS 66
OPERATING ON THE HAUL ROAD 68
STARTING ON A GRADE WITH A LOADED TRUCK 69
PASSING 69
LOADING 69
Overload Speed Limit Function 69
DUMPING 70
Raising The Dump Body 70
Lowering The Dump Body (When dumping on flat ground) 71
Lowering The Dump Body (When dumping over a berm or into a crusher) 71
Sudden loss of engine power or loss of drive system function 72
FUEL DEPLETION 72
SAFE PARKING PROCEDURES 73
NORMAL ENGINE SHUTDOWN PROCEDURE 74
DISABLED TRUCK DUMPING PROCEDURE 75
Hookup 75
Raising the Body 75
Lowering the Body 75
HOIST SYSTEM 76
Hookup 76
Dumping Procedure 77
TOWING 77
Special Wiring Harness 78
Towing Procedure 78
SECTION A4 WARNINGS AND CAUTIONS INDEX 81
GRADE/SPEED CHART 81
KEY SWITCH 81
ROPS/FOPS 81
BATTERIES 82
ISOLATION BOX 83
PROPEL LOCKOUT LEVER 83
CAPACITORS 84
CRUSHING HAZARD 84
CYLINDER PRESSURE 85
FILLING THE HYDRAULIC TANK 85
HYDRAULIC OIL PRESSURE 86
HOT OIL SPRAY 86
WHEEL MOTOR OIL LEVEL 86
HOT EXHAUST 86
RADIATOR 87
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 87
EMERGENCY LADDER 87
ACCUMULATOR DRAIN VALVES 87
EMERGENCY DUMP PROCEDURE 87
EMERGENCY TOWING PROCEDURE 88
WELDING 88
EMERGENCY SHUTDOWN 88
INFORMATION DISPLAY 88
WIRELESS SIGNALS 89
HIGH VOLTAGE 89
LIFTING INSTRUCTIONS 90
TOW SOCKET 91
PRODUCT IDENTIFICATION PLATE 91
LUBRICATION CHART 92
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS INDEX 93
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 94
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 94
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 95
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 96
SECTION A7 STORAGE PROCEDURES AND IDLE MACHINE PREPARATION INDEX 103
SHORT TERM IDLE PERIODS 103
PREPARATION FOR STORAGE 104
REMOVAL FROM STORAGE 105
RECONDITIONING AN IDLE VEHICLE 106
ENGINE OPERATION 108
After The Engine Has Started 109
ENGINE STORAGE 110
Temporary Storage (30 Days Or Less) 110
Extended Storage (More Than 30 Days) 110
RESTORING AN ENGINE AFTER EXTENDED STORAGE 111
ELECTRIC DRIVE TRUCKS 112
Storing A Truck That Is Operational 112
Storing A Truck That Is Not Operational 113
Storing A Major Component 113
Periodic Inspections 113
Placing Equipment Into Service After Storage 114
SECTION B STRUCTURES 115
SECTION B2 STRUCTURAL COMPONENTS INDEX 117
STRUCTURAL COMPONENTS 119
PREPARATION 119
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 120
Removal 120
Installation 120
RH DECK AND RETARDING GRID 121
Removal 121
Installation 121
LH DECK 122
Removal 122
Installation 122
CENTER DECK 123
Removal 123
Installation 123
SECTION B3 DUMP BODY INDEX 125
DUMP BODY 127
DUMP BODY 127
Removal 127
Installation 128
BODY PADS 129
Body Pad Shimming Procedure 130
BODY GUIDE 131
HOIST LIMIT SWITCH 131
BODY-UP SWITCH 131
BODY RETENTION SLING 131
ROCK EJECTORS 132
Inspection 132
SECTION B4 FUEL TANK INDEX 133
FUEL TANK 134
Removal 134
Installation 134
Repair 136
Cleaning 136
FUEL TANK VENT ASSEMBLY 136
Disassembly 136
Assembly 136
FUEL GAUGE SENDER (TOP) 137
Removal 137
Installation 137
Operation 138
Specifications: 138
QUICK FILL FUEL RECEIVERS 139
SECTION C ENGINE 141
SECTION C2 POWER MODULE INDEX 143
POWER MODULE 145
PREPARATION FOR REMOVAL 145
REMOVAL 150
INSTALLATION 152
HOOKUP 153
EXHAUST TUBE INSTALLATION 154
EXHAUST BLANKET INSTALLATION 154
SECTION C3 COOLING SYSTEM INDEX 155
COOLING SYSTEM 157
RADIATOR 157
Removal 157
Installation 159
Filling Procedure 160
REPAIRING THE RADIATOR 160
Internal Inspection 160
External Cleaning 160
Disassembly 161
Cleaning and Inspection 162
Assembly 162
Pressure Testing 163
COOLANT SYSTEM TROUBLESHOOTING 163
SECTION C4 POWER TRAIN INDEX 165
POWER TRAIN 167
ALTERNATOR REMOVAL 167
ALTERNATOR INSTALLATION 169
Engine Flywheel Adapter Face Runout 169
Engine Crankshaft Endplay 170
Engine Flywheel to Flywheel Housing Adapter – Measurement “C” 170
Alternator Housing to Rotor – Measurement “A” 171
Measurements After Joining the Alternator and Engine 173
Flywheel Housing Face Runout 173
Flywheel Housing Radial Runout 174
Flywheel/Flexplate Face Runout 174
Flywheel/Flexplate Radial Runout 175
Rotor Shaft Radial Runout (assembled) 175
ENGINE 176
Removal 176
Service 176
Installation 176
SECTION C5 AIR CLEANERS INDEX 177
AIR CLEANERS 179
OPERATION 179
SERVICING THE AIR CLEANERS 179
Replacing The Elements 180
AIR CLEANER ASSEMBLY CLEANING 181
Primary Element Cleaning 181
Precleaner Section Cleaning 183
AIR INTAKE TROUBLESHOOTING 184
SECTION C7 FAN CLUTCH INDEX 185
FAN CLUTCH 187
REMOVAL & INSTALLATION TOOLING 187
DISASSEMBLY 190
CLEANING AND INSPECTION 200
ASSEMBLY 204
TEST PROCEDURE 219
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 221
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM INDEX 223
24VDC ELECTRIC SUPPLY SYSTEM 227
ELECTRICAL SYSTEM DESCRIPTION 227
BATTERIES 227
Maintenance and Service 227
Troubleshooting 227
BATTERY SUPPLY SYSTEM 229
24VDC Battery Charging Alternator 229
Battery Box 229
Removal 229
Installation 230
Battery Control Box 230
24VDC Auxiliary Battery Receptacles 230
Engine Start Relay 230
ISOLATION BOX ASSEMBLY 230
Engine Shutdown Switch 230
Access Ladder Light Switch 230
Battery Disconnect Switches 230
Propel Lockout Lever 231
LED Lights 231
AUXILIARY CONTROL CABINET 232
24VDC to 12VDC Converter 232
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 233
Operation 233
Pressure Switch 233
Check Valve 233
Timer Solenoid 233
MAINTENANCE 234
Prelube System Operation Checks 234
Check Valve 234
Timer Solenoid 234
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 235
24VDC ELECTRIC START SYSTEM 237
CRANKING MOTORS 237
Operation 237
Removal 237
Installation 237
CRANKING MOTOR TROUBLESHOOTING 238
Preliminary Inspection 238
No-Load Test 238
Interpreting Results of Tests 239
Disassembly 239
Cleaning and Inspection 240
Armature Servicing 242
Field Coil Checks 242
Field Coil Removal 242
SOLENOID CHECKS 243
Test 243
Assembly 244
Bearing Replacement: 244
Motor Assembly: 244
Pinion Clearance 245
MAGNETIC SWITCH 246
Removal 246
Installation 246
Coil Test 246
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 247
24 VDC ELECTRICAL SYSTEM COMPONENTS 249
TRUCK SHUTDOWN PROCEDURE 249
BRAKE WARNING BUZZER 249
AUXILIARY CONTROL CABINET COMPONENTS 249
Interface Module 250
Payload Meter 250
24VDC to 12VDC Converter 250
Circuit Breaker (CB60) 250
Inclinometer 250
Pump Module Service Light Timer 251
Power Distribution Terminals 251
Ground Terminal 251
Relays 252
Engine Service Light Timer 252
RTMR1 – VEC Block 253
Vehicle Electrical Centers (VEC) 253
VEC-89 254
VEC-90 256
VEC-91 258
MAGNETIC SWITCHES 260
Body position switches (With proximity switch and magnet) 260
Proximity switch operation 260
Service 260
BODY-UP SWITCH 261
Adjusting the Body-Up Switch 261
HOIST LIMIT SWITCH 262
Operation 262
Adjusting the Hoist Limit Switch 263
SECTION D11 KOMTRAX PLUS INDEX 265
KOMTRAX PLUS 267
KOMTRAX PLUS BASIC FEATURES 267
Gather Data 267
Convert and Record Data 267
Communicate Data to Off-Board Systems 268
USING KOMTRAX PLUS 269
Turning KOMTRAX Plus ON 269
Normal KOMTRAX Plus Operation 269
Turning KOMTRAX Plus OFF 270
Downloading from the KOMTRAX Plus Controller 270
KOMTRAX PLUS DATA ITEMS 271
Fault Codes 271
Machine History 271
KOMTRAX Plus History 271
Snapshots 272
Manual Snapshots 272
Trends 274
Histogram (Load Map) Data 274
Haul Cycle Data 275
Alarm and Snapshot Triggers 276
Satellite Features 276
KOMTRAX PLUS DIAGNOSTIC FEATURES 278
Fault History 278
LED Digits 278
KOMTRAX PLUS CONTROLLER 278
Removal 279
Installation 279
KOMTRAX PLUS SOFTWARE 280
VHMS Tool Box Installation 280
VHMS Setting Tool Installation 280
PDM Software Installation 280
KOMTRAX PLUS INITIALIZATION PROCEDURE 281
CONTROLLER SETUP PROCEDURE 281
SNAPSHOT PROCEDURE 284
DOWNLOAD PROCEDURE 285
FTP UPLOAD PROCEDURE 286
INITIALIZATION FORMS 287
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 288
KOMTRAX PLUS CONTROLLER CHECKOUT 293
Necessary Equipment 293
Preliminary 293
KOMTRAX Plus Controller Checkout Procedure 294
ORBCOMM CONTROLLER (if equipped) 296
Removal 296
Installation 296
Troubleshooting 297
SECTION D12 INTERFACE MODULE INDEX 303
INTERFACE MODULE 305
Removal 305
Installation 305
SENSORS 306
Temperature Sensors 306
Pressure Sensors 306
INTERFACE MODULE SOFTWARE 307
Flashburn Program Installation 307
Interface Module Application Code Installation 308
Interface Module Realtime Data Monitor Software 308
INTERFACE MODULE CHECKOUT 309
Necessary Equipment 309
Preliminary 310
Check Digital Inputs To The Interface Module 311
Check Analog Inputs To The Interface Module 315
Check Serial Interfaces To The Interface Module 315
Check Outputs From The Interface Module 316
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 321
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES 323
GENERAL 323
Structure and Purpose 323
TROUBLESHOOTING 324
Communications Networks 324
Coaxial Cable 324
FAULT CODES 324
Fault History 324
KOMTRAX Plus LED Display Fault Codes 325
Chassis Fault Codes 326
Engine Fault Codes 331
FAULT TREE ANALYSIS 336
Unable to connect to KOMTRAX Plus from laptop PC 336
Flashing Error Code N4-23 (PLM Communications Fault) 337
Flashing Error Code N4-22 (Engine Communications Fault) 338
No Data Received By WebCARE 339
Coaxial Cable Troubleshooting 340
SECTION D14 KOMTRAX PLUS FORMS INDEX 341
KOMTRAX PLUS FORMS 343
KOMTRAX PLUS INITIALIZATION CHECK LIST 343
KOMTRAX PLUS DATA DOWNLOAD 344
KOMTRAX PLUS INITIALIZATION CHECK LIST 345
KOMTRAX PLUS INITIALIZATION FORM 347
SECTION E ELECTRIC PROPULSION SYSTEM 349
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 351
ELECTRICAL PROPULSION SYSTEM COMPONENTS 353
GENERAL SYSTEM DESCRIPTION 353
SYSTEM COMPONENTS 355
Drive System Controller (DSC) 355
Diagnostic Information Display (DID) Panel 356
DID Panel Event Codes 356
DSC SOFTWARE FUNCTIONS 384
Input Processing 384
State Machine 384
DC Link State 387
Engine Control 388
ALTERNATOR FIELD CONTROL 388
Desired DC Link Voltage 388
Self-Load 388
Propel Torque Control 389
Retard Torque Control 389
Wheel Slide Control 389
Resistor Grid Control 390
Chopper Voltage Control 390
EVENT DETECTION AND PROCESSING 391
Power-On Tests 391
Initiated Tests 392
Periodic Tests 392
EVENT RESTRICTIONS 392
EVENT LOGGING AND STORAGE 392
Event History Buffer 393
Data Packs 393
Event Reset 393
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 394
Fast Start 394
Engine Shutdown/Engine Not Running 394
Limp Home Mode 394
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 395
ELECTRONIC ACCELERATOR AND RETARD PEDALS 402
Removal 402
Installation 402
Disassembly 402
Assembly 402
PHASE MODULE REPLACEMENT 403
Removal 403
Installation 403
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 405
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 407
AC DRIVE SYSTEM MAINTENANCE 407
NORMAL TRUCK SHUTDOWN PROCEDURE 408
TEST EQUIPMENT 409
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 409
REST MODE ACTIVATION 409
INITIAL CHECKOUT PROCEDURES 410
Circuit Continuity and Resistance Checks 410
Megger Test for Grounds 410
Preparation for Megger Test 411
Megger Test Procedure 412
Troubleshooting for Grounds 414
Low Voltage Power Supply Checks 415
Preparation for Power Supply Checks 415
Power Supply Check Procedure 415
Drive System Controller (DSC) Card Checks 416
Propulsion System Software Installation 416
DSC Manual Test Procedures 419
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 421
Set Truck ID Number 425
Control Cabinet Pressure Switch Check 426
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 427
Verifying DSC Software Version 427
Resetting and Erasing DSC Event Data 428
ENGINE RUNNING TESTS 429
Battery Boost Circuit Verification 429
Selector Switch Check 431
Ground Detection Network Tests 433
Self Load Engine Test (Loadbox) Procedure 437
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 439
DID Panel Display Selection 439
DID Modes Display 441
Function Key F1 – DID Events or Faults Display 442
Function Key F4 – DID Menu Display 445
DID Self Load Engine Test (Loadbox) 446
DID Link Capacitance Test 448
DID Speedometer Test 449
DID View Software Version 450
DID View Overspeed Setting 451
DID View Data Menu 452
DID Inverter Cutout Menu 457
DID Truck Configuration Menu 458
Language Selection 463
VIEWING EVENT AND STATISTICAL DATA 464
Viewing the DSC Event Summary, Trigger Data, and Data Packs 464
Viewing the Statistical Data 466
LOGIC SCREENS 467
DATALOGGER FUNCTION 469
Setting Up the Datalogger 469
Starting the Datalogger 471
UPLOADING DATA 473
Consolidated Truck Data Save 473
USB Drive 474
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 475
Fault Code A001: Left front suspension pressure sensor signal is high 477
Related circuit diagram 477
Fault Code A002: Left front suspension pressure sensor signal is low 478
Related circuit diagram 478
Fault Code A003: Right front suspension pressure sensor signal is high 479
Related circuit diagram 479
Fault Code A004: Right front suspension pressure sensor signal is low 480
Related circuit diagram 480
Fault Code A005: Left rear suspension pressure sensor signal is high 481
Related circuit diagram 481
Fault Code A006: Left rear suspension pressure sensor signal is low 482
Related circuit diagram 482
Fault Code A007: Right rear suspension pressure sensor signal is high 483
Related circuit diagram 483
Fault Code A008: Right rear suspension pressure sensor signal is low 484
Related circuit diagram 484
Fault Code A009: Incline sensor signal is high 485
Related circuit diagram 485
Fault Code A010: Incline sensor signal is low 486
Related circuit diagram 486
Fault Code A011: Payload meter speed sensor signal has failed 487
Related circuit diagram 487
Fault Code A013: Body up switch has failed 488
Related circuit diagram 488
Fault Code A014: Payload meter checksum computation has failed 489
Related circuit diagram 489
Fault Code A016: Payload meter write to flash memory has failed 490
Related circuit diagram 490
Fault Code A017: Payload meter flash memory read has failed 490
Related circuit diagram 490
Fault Code A018: Right rear flat suspension cylinder warning 491
Related circuit diagram 492
Fault Code A019: Left rear flat suspension cylinder warning 493
Related circuit diagram 494
Fault Code A022: Carryback load is excessive 495
Related circuit diagram 496
Fault Code A101: High pressure detected across a hydraulic pump filter 497
Related circuit diagram 499
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 501
Related circuit diagram 502
Fault Code A109: GE has generated a propel system reduced level signal 503
Related circuit diagram 503
Fault Code A111 & A247: Low steering pressure warning 504
Related circuit diagram 505
Fault Code A115: Low steering precharge pressure is detected 506
Related circuit diagram 507
Fault Code A117 & A261: Low brake accumulator pressure warning 508
Related circuit diagram 509
Fault Code A118: Brake pressure is low while brake lock is activated 510
Related circuit diagram 511
Fault Code A123: GE has generated a reduced retarding caution 512
Related circuit diagram 512
Fault Code A124: GE has generated a no propel / no retard warning 514
Related circuit diagram 515
Fault Code A125: GE has generated a no propel warning 516
Related circuit diagram 516
Fault Code A126: Oil level in the hydraulic tank is low 517
Related circuit diagram 517
Fault Code A127: IM furnished +5 volt output for sensors is low 518
Related circuit diagram 519
Fault Code A128: IM furnished +5 volt output for sensors is high 520
Related circuit diagram 521
Fault Code A139 & A310: Low fuel level warning 522
Related circuit diagram 523
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 524
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 525
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A247) INDEX 527
Fault Code A152: Starter failure 529
Fault Code A153: Battery voltage is low with truck in operation 530
Fault Code A154: Battery charging voltage is excessive 531
Fault Code A155: Battery charging voltage is low 532
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 533
Fault Code A166: Left rear hydraulic oil temp sensor is low 534
Fault Code A167: Right rear hydraulic oil temp sensor is low 535
Fault Code A168: Left front hydraulic oil temp sensor is low 536
Fault Code A169: Right front hydraulic oil temp sensor is low 537
Fault Code A170: Left rear hydraulic oil temp sensor is high 538
Fault Code A171: Right rear hydraulic oil temp sensor is high 539
Fault Code A172: Left front hydraulic oil temp sensor is high 540
Fault Code A173: Right front hydraulic oil temp sensor is high 541
Fault Code A184: J1939 data link is not connected 542
Fault Code A190: Auto lube control has detected an incomplete lube cycle 543
Fault Code A194: Left front hydraulic oil temperature is high 544
Fault Code A195: Right front hydraulic oil temperature is high 545
Fault Code A196: Left rear hydraulic oil temperature is high 546
Fault Code A197: Right rear hydraulic oil temperature is high 547
Fault Code A198: Hoist pressure 1 sensor is high 548
Fault Code A199: Hoist pressure 2 sensor is high 548
Fault Code A200: Steering pressure sensor is high 549
Fault Code A201: Brake pressure sensor is high 550
Fault Code A202: Hoist pressure 1 sensor is low 551
Fault Code A203: Hoist pressure 2 sensor is low 552
Fault Code A204: Steering pressure sensor is low 553
Fault Code A205: Brake pressure sensor is low 554
Fault Code A206: Ambient temperature sensor is high 555
Fault Code A207: Ambient temperature sensor is low 556
Fault Code A212: Bad truck speed signal 557
Fault Code A213: Parking brake should have applied but is detected as not having applied 558
Fault Code A214: Parking brake should have released but is detected as not having released 560
Fault Code A215: The brake auto apply relay circuit is defective 562
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 563
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 564
Fault Code A230: Parking brake has been requested while truck still moving 565
Fault Code A231: Dump body is up while traveling or intending to travel 566
Fault Code A233: Drive system CAN/RPC Control Link not connected 568
Fault Code A235: Steering accumulator is in the process of being bled down 569
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 570
Fault Code A237: The CAN/RPC connection to the display is open 571
Fault Code A240: The keyswitch input to the interface module is open 572
Fault Code A242: The fuel gauge within the display panel is defective 573
Fault Code A243: The engine coolant temp gauge within the display panel is defective 574
Fault Code A244: The drive system temp gauge within the display panel is defective 575
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 576
Fault Code A246: Payload meter reports truck overload 577
Fault Code A247 & A111: Low steering pressure warning 578
Related circuit diagram 579
SECTION E5 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX 581
Fault Code A248: The status indicator module within the display panel is defective 583
Fault Code A249: The red warning lamp within the display panel is shorted 584
Fault Code A250: Battery voltage is low with the truck parked 585
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 587
Fault Code A252: Start enable output circuit is either open or shorted to ground 588
Fault Code A253: Steering bleed circuit is not open while running 589
Fault Code A255: IM has detected a fault on IM output 1N 590
Fault Code A256: The red warning lamp in the ACTIA display but driven by IM, is open 591
Fault Code A257: Payload CAN/RPC is not connected 592
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 593
Fault Code A260: Parking brake failure 594
Fault Code A261 & A117: Low brake accumulator pressure warning 595
Fault Code A262: Steering bleed valve circuit open during shutdown 596
Fault Code A264: Parking brake relay circuit is defective 597
Fault Code A265: Service brake failure 598
Fault Code A266: Selector lever was not in park while attempting to crank engine 599
Fault Code A267: Parking brake was not set while attempting to crank engine 600
Fault Code A268: Secondary engine shutdown while cranking 601
Fault Code A270: Brake lock switch power supply is not on when required 602
Fault Code A271: Shifter not in gear 604
Fault Code A272: Brake lock switch power supply is not off when required 605
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 607
Fault Code A274: A brake setting fault has been detected 608
Fault Code A275: A starter has been detected as engaged without a cranking attempt 609
Fault Code A277: Parking brake applied while loading 610
Fault Code A278: Service brake applied while loading 611
Fault Code A279: Low steering pressure switch is defective 612
Fault Code A280: Steering accumulator bleed down switch is defective 613
Fault Code A281: Brake lock degradation switch is defective 614
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 615
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 616
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 617
Fault Code A285: The parking brake was not set when the key switch was turned off 618
Fault Code A286: A fault was detected in the shutdown delay relay circuit 619
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 620
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 621
Fault Code A303: Shifter is defective 623
Fault Code A304: Auto lube grease level is low 624
Fault Code A307: Both GE inverters are disabled 625
Fault Code A309: No brakes applied when expected 626
Fault Code A310 & A139: Low fuel level warning 627
Fault Code A311: Brake lock switch is on when it should not be 628
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 629
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 630
Fault Code A315: DC-DC converter 12 volt circuit is low 631
Fault Code A316: Starter engagement has been attempted with engine running 632
Fault Code A317: Operation of brake auto apply circuit without a detected response 633
Fault Code A318: Unexpected power loss to interface module 634
Fault Code A328: Drive system not powered up 635
Fault Code A332: Seat belt not buckled 636
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 637
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 638
Fault Code A335: Manual/Auto Apply Pressure Fault 639
Fault Code A350: Overload on output 1B 640
Fault Code A351: Overload on output 1E 641
Fault Code A352: Overload on output 1H 642
Fault Code A353: Overload on output 1J 643
Fault Code A354: Overload on output 1K 644
Fault Code A355: Overload on output 1L 645
Fault Code A356: Overload on output 1M 646
Fault Code A357: Overload on output 1N 647
Fault Code A358: Overload on output 1P 648
Fault Code A359: Overload on output 1R 649
Fault Code A360: Overload on output 1S 650
Fault Code A361: Overload on output 1T 651
Fault Code A362: Overload on output 1U 652
Fault Code A363: Overload on output 1X 653
Fault Code A364: Overload on output 1Y 654
Fault Code A365: Overload on output 1Z 655
SECTION G REAR AXLE, SPINDLES AND WHEELS 657
SECTION G2 TIRES AND RIMS INDEX 659
TIRES AND RIMS 661
GENERAL PRECAUTIONS 661
WHEEL STUD MAINTENANCE 662
WHEEL STUD INSTALLATION HEIGHT 663
FRONT TIRES AND RIMS 664
Removal 664
Installation 665
REAR TIRES AND RIMS 665
Removal 665
Installation 666
RIM COMPONENTS 668
Smart Rim Component Layout 668
RIM AND TIRE SERVICE 669
Lubricants 669
Tire Inflation 669
Lock Ring Retainer Installation 669
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 670
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 671
Removal (5-Piece Standard Rim) 672
Removal (7-Piece Smart Rim) 675
Removal (5-Piece Smart Rim) 677
Preparation Before Assembly 678
Installation (5-Piece Standard Rim) 679
Installation – Horizontal Mount (Smart Rim) 681
Installation – Vertical Mount (5-Piece Smart Rim) 683
Installation – Vertical Mount (7-Piece Smart Rim) 684
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 685
FRONT WHEEL HUB AND SPINDLE 687
WHEEL HUB AND SPINDLE ASSEMBLY 687
Removal 687
Spindle Removal Procedure (off of the truck) 690
Installation 692
Disassembly 693
Cleaning and Inspection 695
Assembly 695
Wheel Bearing Adjustment 696
Brake Installation 697
Seal Assembly Gap Check 698
WHEEL SPEED SENSOR TESTING 699
STEERING CYLINDERS 700
Spherical Bearing Wear Limits 700
Removal 701
Installation 701
Bearing Replacement (Steering Cylinder and Tie Rod) 701
TIE ROD 703
Removal 703
Installation 703
Disassembly 704
Assembly 704
Toe-In Adjustment 705
TIE ROD INSPECTION AND TORQUE PROCEDURE 706
SECTION G4 REAR AXLE MOUNTING INDEX 707
REAR AXLE MOUNTING 709
PIVOT PIN 709
Removal 709
Installation 710
PIVOT EYE BEARING 710
Removal 710
Installation 710
PIVOT EYE REPAIR 711
Removal 711
Installation 711
ANTI-SWAY BAR 712
Removal 712
Disassembly 712
Cleaning and Inspection 712
Assembly 712
Installation 712
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 715
REAR AXLE AND WHEEL MOTOR 717
REAR AXLE HOUSING 717
Preparation 717
Removal 718
Cleaning and Inspection 719
Installation 719
BLOWER PRESSURE SWITCH ADJUSTMENT 719
WHEEL MOTOR 720
Preparation 720
Removal 721
Cleaning and Inspection 723
Installation 723
WHEEL MOTOR GEAR OIL 728
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 728
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 728
Filtering Requirements 728
Particle Size Analysis 729
Flushing 729
Spectrographic Oil Sample Analysis 730
ELEMENT SPECIFICATION CHARTS 731
SECTION H HYDRAIR® II SUSPENSIONS 735
SECTION H2 FRONT SUSPENSIONS INDEX 737
FRONT SUSPENSION 739
Removal 739
Installation 740
Inspection 745
LOWER BEARING & SEALS 746
Removal 746
Installation 746
MAJOR SUSPENSION REBUILD 747
Disassembly 747
Assembly 748
SUSPENSION PRESSURE TEST 749
SECTION H3 REAR SUSPENSIONS INDEX 751
REAR SUSPENSIONS 753
SUSPENSION CYLINDER 754
Removal 754
Installation 755
Disassembly 756
Cleaning and Inspection 756
Assembly 756
SUSPENSION PRESSURE TEST 758
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 759
SUSPENSION OILING AND CHARGING PROCEDURES 761
CHECKING FOR IMPROPER SUSPENSION CHARGE 761
GENERAL 762
REQUIRED EQUIPMENT 762
HYDRAIR® CHARGING KIT 763
Installation of Charging Kit 763
Removal of Charging Kit 763
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 764
FRONT SUSPENSION 767
REAR SUSPENSION 770
OIL AND NITROGEN SPECIFICATIONS CHARTS 773
SECTION J BRAKE CIRCUIT 775
SECTION J2 BRAKE CIRCUIT INDEX 777
BRAKE CIRCUIT 779
SERVICE BRAKE CIRCUIT 779
PARKING BRAKE CIRCUIT 781
BRAKE LOCK CIRCUIT 781
SECONDARY BRAKING AND AUTOMATIC APPLY 782
WARNING CIRCUIT 782
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 785
BRAKE CIRCUIT COMPONENT SERVICE 787
BRAKE VALVE 787
Rebuild Criteria 787
Removal 788
Installation 788
BRAKE VALVE/PEDAL ASSEMBLY 789
Disassembly 789
Assembly 790
Installation 792
DUAL RELAY VALVE 792
Removal 792
Installation 793
BRAKE MANIFOLD 793
Removal 793
Installation 794
Disassembly 794
Cleaning and Inspection 794
Assembly 794
BRAKE ACCUMULATORS 795
Accumulator charging and storage 795
Temperature during precharge 795
BLADDER BRAKE ACCUMULATORS 796
Brake Accumulator Bleed Down Procedure 796
Removal 796
Installation 797
Disassembly 797
Cleaning and Inspection 799
Assembly 799
Precharge Maintenance 800
Accumulator Storage Procedures 800
Installing A Bladder Accumulator From Storage 801
PISTON BRAKE ACCUMULATORS 801
Brake Accumulator bleed down Procedure 801
Removal 801
Installation 803
Disassembly 804
Cleaning and Inspection 804
Assembly 805
Piston accumulator charging procedure 805
Testing 808
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 808
Removal 808
Installation 808
Disassembly 809
Lever Adjustments 809
Potentiometer Check 809
Assembly 810
FRONT BRAKE COOLING HOSE INSTALLATION 812
Installation 812
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 815
BRAKE CIRCUIT CHECK-OUT PROCEDURE 817
REQUIRED EQUIPMENT 818
INITIAL SYSTEM SETUP 819
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 820
AUTO APPLY (LOW BRAKE PRESSURE) CHECK-OUT 821
SERVICE BRAKES 822
PARKING BRAKES 822
PARKING BRAKE CONTROL LOGIC 823
BRAKE LOCK CONTROL LOGIC 824
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 827
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 829
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 835
WET DISC BRAKE ASSEMBLY 837
OPERATION 837
BRAKE DISC WEAR INSPECTION 838
BRAKE REBUILD 839
Disassembly 839
Cleaning and Inspection 843
Assembly 844
Brake floating ring seal assembly and installation 849
Brake Floating Seal Assembly and Installation 858
WET DISC BRAKE BLEEDING PROCEDURE 866
SECTION J7 PARKING BRAKE INDEX 867
PARKING BRAKE 869
OPERATION 869
MAINTENANCE 870
Inspection 870
Removal 870
Installation 871
Disassembly 871
Cleaning and Inspection 871
Assembly 873
Cleaning and Inspecting New Discs 874
PARKING BRAKE BLEEDING PROCEDURE 875
SECTION L HYDRAULIC SYSTEM INDEX 877
SECTION L2 HYDRAULIC SYSTEM INDEX 879
SECTION L HYDRAULIC SYSTEM 877
SECTION L2 HYDRAULIC SYSTEM INDEX 879
HYDRAULIC SYSTEM 881
HYDRAULIC PUMP MODULE 881
HOIST CIRCUIT OPERATION 882
STEERING CIRCUIT OPERATION 884
DISC BRAKE COOLING SYSTEM 886
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 889
HYDRAULIC SYSTEM COMPONENT REPAIR 891
HOIST PUMP 891
Removal 891
Installation 893
Inspection 898
Assembly 898
HOIST PUMP TROUBLESHOOTING GUIDE 903
HYDRAULIC TANK 904
Removal 904
Installation 905
HYDRAULIC TANK STRAINERS 905
Removal 905
Inspect and Clean 907
Installation 907
SECTION L4 STEERING CIRCUIT INDEX 909
STEERING CIRCUIT 911
STEERING CIRCUIT OPERATION 911
COMPONENT DESCRIPTION 912
Steering Control Unit 912
Bleeddown Manifold 913
Steering Accumulator Bleeddown Solenoid 913
Relief Valves 915
Hoist Up Limit Solenoid 915
Steering Accumulators 915
Low Precharge Warning Switch 915
High Pressure Filter 915
Quick Disconnect Ports 915
Flow Amplifier 917
FLOW AMPLIFIER SYSTEM OPERATION 918
No Steer 918
Steering Left 920
Steering Right 922
No Steer, External Shock Load 924
STEERING PUMP 926
Normal Operation 926
High Altitude Operation 926
PRINCIPLE OF OPERATION 928
Full Pump Volume 928
Half Pump Volume 928
Neutral Position 928
Steering Pump 929
SECTION L5 STEERING CONTROL UNIT INDEX 931
STEERING CONTROL UNIT 933
REMOVAL 933
SPLINE INSPECTION 934
INSTALLATION 934
DISASSEMBLY 935
CLEANING AND INSPECTION 936
ASSEMBLY 938
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 941
STEERING CIRCUIT COMPONENT REPAIR 943
BLEEDDOWN MANIFOLD VALVE 943
Removal 943
Installation 944
FLOW AMPLIFIER 945
Removal 945
Installation 945
STEERING CYLINDERS 946
Disassembly 947
Piston Seal & Bearing Installation 947
Assembly 947
Testing 947
STEERING AND BRAKE PUMP 948
Removal 948
Installation 949
Disassembly 950
Inspection 953
Assembly 956
Driveshaft Group 957
Rotating Group 957
Valve Plate Group 958
PISTON STEERING ACCUMULATORS 960
Removal 960
Installation 961
Disassembly 962
Cleaning and Inspection 962
Assembly 963
Testing 963
TROUBLESHOOTING 964
STEERING CIRCUIT 964
STEERING PUMP 966
Basic Hydraulic System Checks 967
System Leakage Check 968
Steering Pump Troubleshooting Guide 970
Pump Pressure Control Checks 973
Pump Control Valve Inspection and Troubleshooting 976
Pump Case Drain Check 976
Setting Pump Pressure Controls 978
SECTION L7 HOIST CIRCUIT INDEX 981
HOIST CIRCUIT 983
BASIC OPERATION 983
COMPONENT DESCRIPTION 984
Hydraulic Tank 984
Hydraulic Pump 984
High Pressure Filters 984
Hoist Valve 984
Inlet Sections 984
Work Ports (Rear) Spool Section 985
Tank Ports (Front) Spool Section 985
Hoist Pilot Valve 985
Bleeddown Manifold 986
Hoist Up Limit Solenoid 986
Pilot Operated Check Valve 986
Overcenter Manifold 986
HOIST CIRCUIT OPERATION 987
Float Position Of Pilot Valve With Truck Body On Frame 988
Power Up Operation 990
Hold Operation 992
Power Down Operation 994
Float Operation 996
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 999
HOIST CIRCUIT COMPONENT REPAIR 1001
HOIST VALVE 1001
Removal 1001
Installation 1002
O-Ring Replacement 1002
INLET SECTION 1003
Disassembly 1003
Cleaning and Inspection 1004
Assembly 1004
REAR SPOOL SECTION (Work Ports) 1005
Disassembly 1005
Cleaning and Inspection 1005
Assembly 1007
FRONT SPOOL SECTION (Tank Ports) 1008
Disassembly 1008
Cleaning and Inspection 1008
Assembly 1008
HOIST PILOT VALVE 1010
Removal 1010
Installation 1010
Disassembly 1011
Cleaning and Inspection 1012
Assembly 1012
HOIST CYLINDERS 1013
Removal 1013
Installation 1014
Disassembly 1016
Cleaning and Inspection 1017
Assembly – Quill 1018
Assembly – Cylinder 1020
Testing 1020
OVERCENTER VALVE MANIFOLD 1021
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 1023
HYDRAULIC SYSTEM FILTERS 1025
HOIST CIRCUIT FILTER 1025
Filter Element Replacement 1025
Removal – Hoist Circuit Filter 1026
Installation – Hoist Circuit Filter 1026
Indicator Switch – Hoist Circuit Filter 1026
STEERING CIRCUIT FILTER 1027
Filter Element Replacement 1027
Removal – Steering Circuit Filter 1028
Installation – Steering Circuit Filter 1028
Indicator Switch – Steering Circuit Filter 1028
INDICATOR SWITCH 1028
Test Procedure 1028
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1031
HYDRAULIC CHECKOUT PROCEDURE 1033
GENERAL INFORMATION 1033
Procedure for bleeding down hydraulic brake and steering accumulators 1033
Accumulator precharge procedure (step 1) 1035
Pressure gauge installation (steps 2 and 3) 1036
Initial start-up and flushing (steps 4 through 20) 1037
Steering system checkout and adjustment (steps 21 through 24) 1040
Steering pump with unloader valve adjustment (step 25) 1041
Steering system diagnostic and verification (steps 26 through 30) 1042
Hoist system checkout and adjustment (steps 31 through 33) 1043
Hoist counterbalance valve adjustment (step 34) 1044
Oil cleanliness check (steps 35 & 36) 1045
HYDRAULIC CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1046
SECTION M OPTIONS AND SPECIAL TOOLS 1049
SECTION M7 HOT START SYSTEM INDEX 1051
HOT START SYSTEM 1053
SYSTEM OPERATION 1053
HEATER INFORMATION 1054
TROUBLESHOOTING GUIDELINES 1055
SECTION M8 SPECIAL TOOLS 1057
HIGH VOLTAGE TOOLS 1061
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1061
KOMVISION CALIBRATION TOOLS 1063
SECTION M19 RADIATOR SHUTTERS INDEX 1065
RADIATOR SHUTTERS 1067
OPERATION 1067
Hydraulic Circuit 1067
Electrical Circuit 1068
MAINTENANCE AND REPAIR 1068
TROUBLESHOOTING 1069
SECTION M20 PAYLOAD METER IV ™ INDEX 1073
PAYLOAD METER IV ™ 1075
INTRODUCTION 1075
Data Summary 1075
Data Gathering 1075
COMPONENT DESCRIPTION 1076
Electronic Dash Display 1076
Mode Switches 1076
Brake Lock Switch 1076
PAYLOAD METER IV SOFTWARE AND TOOLS 1077
PAYLOAD METER IV SYSTEM CONFIGURATION 1077
Connecting to the payload meter IV web server 1077
Configuring a static IP address 1077
PAYLOAD METER IV SOFTWARE INSTALLATION 1079
INCLINOMETER CALIBRATION AND CLEAN TRUCK TARE 1079
PLM IV SYSTEM CHECKOUT DATA SHEET 1085
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1086
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1089
RESERVE ENGINE OIL SYSTEM 1091
GENERAL 1091
OPERATION 1092
Pumping Unit 1092
LED Monitor Lights 1093
Tank Auto Fill Control 1094
Filling Procedure (Remote Fill Feature) 1094
SERVICE 1095
Every 10 Hours (each shift) 1095
Every 500 Hours 1095
Changing Oil 1095
TROUBLESHOOTING 1096
Circuit Fuses 1096
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1097
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1099
RETRACTABLE LADDER SYSTEM 1103
GENERAL SAFETY 1103
LADDER SYSTEM DESCRIPTION 1103
LADDER SYSTEM OPERATION 1104
Normal Operation 1104
Emergency Operation 1105
Limit Switch Operation 1105
IN-CAB CONTROL PANEL 1106
IN-CAB CONTROL PANEL FEATURES 1107
IN-CAB CONTROL PANEL FUNCTIONS 1108
Timing Control 1108
Ladder System Status 1108
Fault Code Identification 1108
Ladder System Configuration 1108
In-Cab Control Panel Lockout 1108
Automatic Raising 1108
Diagnostics 1109
Maintenance 1109
USING THE IN-CAB CONTROL PANEL 1109
Raising the Ladder 1110
Lowering the Ladder 1110
USING THE GROUND LEVEL CONTROL BOX 1111
Raising the Ladder 1111
Lowering the Ladder 1111
POWER PACK OPERATION 1112
MAINTENANCE 1115
Safety During Maintenance 1115
Unplanned Ladder Movements 1115
Automatic Ladder Raising 1115
Automatic Accumulator Recharging (Ladder in UP position) 1116
PREVENTIVE MAINTENANCE PROCEDURES 1117
Daily Inspection 1117
250 Hour Inspection 1117
5000 Hour Inspection 1117
SERVICING 1118
Check Reservoir Oil Level 1118
Changing RLS Fluid 1118
Cleaning the RLS 1119
RLS DIAGNOSTICS 1119
Description of Diagnostics Features 1119
Continuous System Monitoring 1120
Historic System Data Review 1121
Comms Integrity Monitoring 1121
Log and Service Information 1122
System Event Logs 1122
SECURITY ACCESS LEVELS 1123
Access Level 1 – NONE 1123
Access Level 2 – RESTRICTED 1123
Access Level 3 – COMPLETE 1123
User Access Privileges 1124
USER ID – PASSWORD 1125
Sequential Field Value Selection Options 1125
Password Character Table 1125
USER ID – NEW USER SETUP 1126
SYSTEM FAULTS 1126
Fault Type 1: Communications error 1127
Fault Type 2: 10A/15A fuse blown 1127
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1128
Fault Type 8: Power pack recharge too long 1128
Fault Type 9: Inhibit relay fail 1129
Fault Types 10, 11: Light/Siren relay failure 1129
Fault Type 12: Ladder came off upper limit 1130
Fault Type 13: Ladder did not reach limit 1130
Fault Type 14: Ladder stayed on limit 1131
Fault Type 15: Low oil level 1131
Fault Type 16: System voltage over 18V during movement 1132
Fault Type 17: System voltage under 18V 1132
Fault Type 18: System voltage over 31V 1133
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1133
Fault Type 21: Accumulator recharge > than once/hour 1134
Fault Type 22: System raised by park brake 1134
Fault Types 23, 24: Levels 1 and 2 service overdue 1135
Fault Type 25: Levels 1 and 2 service complete 1135
DATA MANAGEMENT 1136
Log Files 1136
Generating Reports 1137
MENU DIAGRAMS 1143
Controller Config 1143
Contact Information 1143
Show Recent Logs 1143
System Settings 1143
Upload Logs to USB 1143
Diagnostics 1143
SECTION M33 KomVision® INDEX 1151
KomVision® 1153
KomVision® SYSTEM PRECAUTIONS 1153
COMPONENT LOCATIONS 1154
MONITOR PANEL 1158
Brightness Switches 1158
System Power Status Indicator 1158
Force Display Switch 1158
Camera Switches 1159
Monitor Display Mode Switch 1159
Reference Line Display Switch 1159
Lower Body Display Switch 1159
Object Clear Switch 1159
MONITOR DISPLAY 1160
Camera Display Modes 1160
Bird’s Eye Views 1162
Reference Lines 1162
Dump Body Status Display 1162
Error Code Display 1163
Initial Setting Screen 1164
RADAR SYSTEM 1164
Object Detection Range 1164
Object Detection Warnings 1165
Object Clear 1168
START-UP INSPECTION 1168
Camera Inspections 1168
Verify the Radar System is Operational 1168
CLEANING 1169
Monitor Panel And Controller 1169
Cameras 1169
KomVision® SYSTEM SETUP AND CALIBRATION 1170
Password Mode 1170
Maintenance Mode 1171
Main Setting Display 1172
6 Camera Calibration Display 1173
Camera Setting 1183
System State 1185
Error Log Screen 1186
Check Disk Display 1186
MAINTENANCE SCREEN EXPLANATION 1187
Area 1187
Threshold 1188
All Radar Position 1188
RADAR DETAIL 1191
Integration 1191
Explanation of Terms 1192
System I/O Explanation 1193
TESTING AND ADJUSTING 1194
System Adjustment 1194
Initial Setting 1194
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1195
6 Camera Calibration Preparation 1195
Calibration Sheet Unfolding 1198
Folding a Camera Calibration Sheet 1199
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1200
Placement of Front Calibration Sheet 1200
Placement of Left and Right Calibration Sheet 1200
Placement of Rear Calibration Sheet and Adjustment of Left and Right Calibration Sheets 1201
CALIBRATING CAMERAS 1201
Automatic 6 Camera Calibration Operation 1201
Manual 6 Camera Calibration 1205
6 Camera Calibration Outgoing Message, and Screen Correspondence 1207
1 Camera Calibration 1208
1 Camera Calibration Outgoing Message, and Screen Correspondence 1210
RADAR SETTING 1210
Radar Zone Preparation and System Calibration 1210
SECTION N OPERATOR CAB 1221
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 1223
TRUCK CAB AND COMPONENTS 1225
TRUCK CAB 1225
Description 1225
Removal 1226
Installation 1227
CAB DOOR 1228
Removal 1228
Installation 1228
Door Jamb Bolt Adjustment 1229
Door Handle Plunger Adjustment 1230
Replacing the Door Glass 1231
Replacing the Door Handle or Latch Assembly 1235
Replacing the Door Window Regulator 1236
Replacing the Door and Door Hinge Seal 1237
Replacing the Door Opening Seal 1237
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1238
Recommended Tools and Supplies 1238
Replacement Procedure 1238
WINDSHIELD AND REAR GLASS 1239
Removal 1239
Installation 1240
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1261
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1241
OPERATOR SEAT (STANDARD SEAT) 1243
Adjustment 1243
Inspection 1244
Removal 1244
Installation 1244
Replacing the Seat Compressor 1245
PASSENGER SEAT (STANDARD SEAT) 1250
Adjustment 1250
Inspection 1251
Removal 1251
Installation 1251
SEAT BELT REPLACEMENT (STANDARD SEAT) 1252
Removal 1252
Installation 1252
OPERATOR SEAT (OPTIONAL SEAT) 1254
Seat Belts 1254
Adjustment 1254
PASSENGER SEAT (OPTIONAL SEAT) 1256
Seat Belts 1256
Adjustment 1256
SEAT BELT REPLACEMENT (OPTIONAL SEAT) 1257
General 1257
Removal 1257
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1261
HEATER/AIR CONDITIONER 1263
OPERATION 1263
Fan Speed Control Knob 1263
Temperature Control Knob 1263
Air Flow Directional Knob 1264
Heater/Air Conditioner Vents 1264
COMPONENTS 1264
Fuse and Circuit Breaker 1264
Relays 1264
Heater Core 1265
Fan Motor And Speed Control 1265
Actuators 1265
Cab Air Filter 1265
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1268
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1268
PRINCIPLES OF REFRIGERATION 1268
Air Conditioning 1268
Refrigeration – The Act Of Cooling 1269
The Refrigeration Cycle 1269
AIR CONDITIONER SYSTEM COMPONENTS 1270
Compressor (Refrigerant Pump) 1270
Service Valves 1270
Condenser 1270
Receiver-Drier 1270
Expansion Block Valve 1271
Accumulator 1271
Evaporator 1271
ELECTRICAL CIRCUIT 1272
Thermostat 1272
Compressor Clutch 1272
Trinary™ Switch 1273
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1274
SERVICE TOOLS AND EQUIPMENT 1275
Recovery/Recycle Station 1275
Leak Detector 1275
Service Valves 1276
Vacuum Pump 1276
Manifold Gauge Set 1277
Installing Manifold Gauge Set 1278
Purging Air From Service Hoses 1278
SYSTEM PERFORMANCE TEST 1279
SYSTEM OIL 1280
Handling and Reusing PAG Oil 1280
Oil Quantity 1280
Checking System Oil 1280
REFRIGERANT 1281
Recycled Refrigerant 1281
Reclaimed Refrigerant 1281
Refrigerant Quantity 1282
R-134a Refrigerant Containers 1282
SYSTEM LEAK TESTING 1282
Electronic Leak Detector 1283
Tracer Dyes 1283
Soap and Water 1283
RECOVERING AND RECYCLING THE REFRIGERANT 1283
Draining Oil from the Previous Recovery Cycle 1283
Performing the Recovery Cycle 1283
Performing the Recycling Procedure 1284
Evacuating and Charging the A/C System 1284
SYSTEM REPAIR 1284
System Flushing 1284
COMPONENT REPLACEMENT 1285
Hoses and Fittings 1285
Lines 1285
Expansion Valve 1285
Receiver-Drier 1285
Thermostat 1285
Compressor 1286
Accumulator 1286
Clutch 1286
EVACUATING THE SYSTEM 1287
CHARGING THE A/C SYSTEM 1288
TROUBLESHOOTING 1289
Preliminary Checks 1289
Diagnosis Of Gauge Readings And System Performance 1289
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1290
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1296
SECTION N5 OPERATOR CAB AND CONTROLS INDEX 1297
OPERATOR CAB AND CONTROLS 1301
STEERING COLUMN 1302
Removal 1302
Inspection 1302
Installation 1303
STEERING WHEEL 1303
Removal 1303
Installation 1303
STEERING WHEEL AND CONTROLS 1304
Horn Button 1304
Tilt / Telescope Lever 1304
Multi-Function Turn Signal Switch 1304
DYNAMIC RETARDING 1305
Retarder Lever 1305
Service Brake/Retarder Pedal 1305
Throttle/Accelerator Pedal 1305
GRADE/SPEED CHART 1306
OVERHEAD PANEL AND DISPLAYS 1307
CENTER CONSOLE 1308
Directional Control Lever 1308
Override/Fault Reset Switch 1309
Engine Stop Switch 1309
LH Window Control Switch 1309
RH Window Control Switch 1309
Hoist Control Lever 1309
Raising The Dump Body 1309
Lowering The Dump Body 1309
Retard Speed Control (RSC) Adjust Dial 1310
Retard Speed Control (RSC) Switch 1310
Data Store Button 1310
12V Auxiliary Power Outlets 1310
Fire Suppression Control Outlet 1310
Communication Radio Outlet 1310
DIAGNOSTIC PORTS 1311
KOMTRAX Plus Diagnostic Port 1311
Interface Module (IM) Diagnostic Port 1311
Payload Meter Diagnostic Port 1311
Drive System Or Modular Mining 1311
Drive System Controller (DSC) Diagnostic Port 1311
Engine Diagnostic Port (CENSE) 1311
Engine Diagnostic Port (QUANTUM) 1311
HEATER / AIR CONDITIONER 1312
Fan Speed Control Knob 1312
Temperature Control Knob 1312
Air Flow Directional Knob 1312
Heater/Air Conditioner Vents 1312
INSTRUMENT PANEL 1313
Control Symbols 1313
Cab/Air Conditioner Vents 1315
Status Indicator Light Panel 1315
Hydraulic Oil Temperature Gauge 1315
Coolant Temperature Gauge 1315
Speedometer/Digital Display 1315
Fuel Level Gauge 1315
Drive System Temperature Gauge 1315
Hazard Warning Light Switch 1315
Pre-Shift Brake Test Switch 1316
Wheel Brake Lock Control 1316
Rest Switch 1316
Engine Warm Up Switch 1317
Heated Mirror Switch 1317
Rotating Beacon Light Switch (Optional) 1317
Key Switch 1317
Starting 1317
Warning Light 1318
Digital Display Contrast Buttons 1318
Turn Signal Indicators 1318
Panel Light Dimmer 1318
Mode Switches 1318
Fog Light Switch 1318
Manual Backup Switch 1318
Headlight/Panel Illumination Light Switch 1319
STATUS INDICATOR LIGHT PANEL 1320
REAR AXLE LIGHT BAR 1323
Backup Lights 1323
Retard Lights 1323
Brake Lights 1323
Backup Alarm 1323
DIGITAL DISPLAY OPERATION 1324
Toggling Through Main Level Screens 1324
Toggling Through Warning Screens 1325
Entering Payload Meter Data 1326
KOMTRAX PLUS 1327
Operation 1327
Interface Module 1329
Basic Precautions 1329
KOMATSU WIRELESS BRIDGE (KWB) General information 1330
Required software and tools 1330
Configuring the Bullet wireless radio 1331
Installing the Bullet wireless radio 1334
Configuring the NanoStation access point 1336
Testing the connection 1339
Changing a service computer’s IP address 1340
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1341
SECTION P2 PERIODIC MAINTENANCE INDEX 1343
PERIODIC MAINTENANCE 1345
GENERAL 1345
SERVICE CAPACITIES 1345
HYDRAULIC TANK SERVICE 1345
Adding Oil 1345
COOLING SYSTEM SERVICE 1346
Radiator Filling Procedure 1346
Coolant Specifications 1346
Unacceptable Practices 1346
WHEEL MOTOR SERVICE 1346
RESERVE OIL TANK SERVICE 1347
Filling the Reserve Oil Tank (Remote Fill) 1347
Inline Screen 1347
QUICK FILL SERVICE CENTER 1348
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1350
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1350
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1351
EVERY 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1351
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1353
EVERY 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1353
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1357
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1359
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1359
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1360
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1360
INJECTOR OPERATION 1370
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1361
AUTOMATIC LUBRICATION SYSTEM 1363
GENERAL DESCRIPTION 1363
SYSTEM COMPONENTS 1365
Filter 1365
Hydraulic Motor and Pump 1365
Grease Reservoir 1365
Pressure Reducing Valve 1365
Flow Control Valve 1365
Solenoid Valve 1365
Vent Valve 1365
Grease Pressure Failure Switch 1365
Injectors 1365
Interface Module 1365
Relief Valve (unloader valve) 1365
SYSTEM OPERATION 1366
Normal Operation 1366
Lubricant Required For System 1367
Filter Assembly 1367
System Priming 1367
LUBRICANT PUMP 1368
Pump Housing Oil Level 1368
Pump Pressure Control 1368
INJECTORS (SL-1 Series “H”) 1369
Injector Specifications 1369
Injector Adjustment 1369
PREVENTIVE MAINTENANCE PROCEDURES 1371
Daily Lubrication System Inspection 1371
250 Hour Inspection 1371
1000 Hour Inspection 1371
SYSTEM CHECKOUT 1372
Pump Priming Procedure 1372
System Priming Procedure 1373
Lubrication Cycle Operation 1373
AUTOLUBE TROUBLESHOOTING CHART 1374
SECTION R SYSTEM SCHEMATICS 1377

DESCRIPTION:

Komatsu 930E-4 Dump Truck Parts Manual CEBM030303 PDF DOWNLOAD

• A31879 and up
• A31880 and up
• A31882 and up
• A31990 and up
• A31992 and up

FOREWORD:

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently.

All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.

The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually.

For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.

The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.

When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.

A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.

The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.

The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW.

The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload.

To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.

G.B 18/12/24