Komatsu 930E-4 Dump Truck Shop Manual CEBM024503 PDF

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Komatsu 930E-4 Dump Truck Shop Manual CEBM024503 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-4 Dump Truck Shop Manual CEBM024503 –  PDF DOWNLOAD

Language : English
Pages : 1346
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4 Dump Truck Shop Manual CEBM024503 –  PDF DOWNLOAD

Serial Number

• A31056-A31162

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
COMPONENTS & SPECIFICATIONS 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
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
Working On Loose Ground 24
When Dumping 24
When Loading 24
Parking The Truck 24
Towing 24
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump Starting With Booster Cables 26
Jump Starting With Receptacles 26
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Use of Tie-Off Anchor During Maintenance and Repair 27
Securing The Dump Body 28
WHILE PERFORMING MAINTENANCE 29
Keep The Truck Clean 29
Attachments 29
Working Under The Truck 29
Rotating Fan And Belts 29
Waste Materials 29
Adding Fuel Or Oil 30
Radiator Coolant Level 30
Use Of Lighting 30
Precautions With The Battery 30
Handling High Pressure Hoses 30
Precautions With High Pressure Oil 30
Performing Maintenance Near High Temperature Or High Pressure 30
TIRES 31
Handling Tires 31
Tire Maintenance 31
Storing Tires After Removal 31
WHEN REPAIRS ARE NECESSARY 32
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 33
Preliminary Procedures Before Welding or Performing Maintenance 33
Engine Shutdown Procedure Before Welding or Performing Maintenance 33
CAPACITOR DISCHARGE SYSTEM 35
Necessary Tools 35
Warnings And Cautions 36
Manual DC Link Capacitor Discharge Procedure 37
Failure of the Discharge System 39
Manual Discharge of Capacitors 40
Short Isolated Capacitor Terminals 42
OPERATING INSTRUCTIONS 43
PREPARING FOR OPERATION 43
WALK AROUND INSPECTION 43
RETRACTABLE LADDER SYSTEM (Optional) 47
Description 47
Normal Operation 47
General Safety 47
IN-CAB CONTROL PANEL 48
Digital Display Screen 48
Command Buttons 48
USING THE IN-CAB CONTROL PANEL 49
Raising the Ladder 50
Lowering the Ladder 50
USING THE GROUND LEVEL CONTROL BOX 51
Raising the Ladder 51
Lowering the Ladder 51
EMERGENCY OPERATION 51
ENGINE START-UP 52
AFTER ENGINE HAS STARTED 53
PRE-SHIFT BRAKE CHECK 53
Events 53
OPERATION 54
Description 54
Brake Test Exit Criteria 54
PERFORMING THE BRAKE TESTS 55
Setup 55
Service Brake Test 55
Parking Brake Test 56
Retard System Test 57
EMERGENCY STEERING SYSTEM 57
Operation 57
Pre-Operation Testing 57
MACHINE OPERATION SAFETY PRECAUTIONS 58
OPERATING ON THE HAUL ROAD 59
STARTING ON A GRADE WITH A LOADED TRUCK 60
PASSING 60
LOADING 60
Overload Speed Limit Function 60
DUMPING 61
Raising The Dump Body 61
Lowering The Dump Body (When dumping on flat ground) 62
Lowering The Dump Body (When dumping over a berm or into a crusher) 62
TOWING 63
Special Wiring Harness 63
SAFE PARKING PROCEDURES 65
NORMAL ENGINE SHUTDOWN PROCEDURE 65
SUDDEN LOSS OF ENGINE POWER 66
FUEL DEPLETION 66
DISABLED TRUCK DUMPING PROCEDURE 67
Hookup 67
Raising the Body 67
Lowering the Body 67
WARNINGS AND CAUTIONS 69
GRADE/SPEED CHART 69
KEY SWITCH 69
ROPS/FOPS 69
BATTERIES 70
CAPACITORS 70
CRUSHING HAZARD 71
CYLINDER PRESSURE 71
FILLING THE HYDRAULIC TANK 72
HYDRAULIC OIL PRESSURE 72
HOT OIL SPRAY 73
WHEEL MOTOR OIL LEVEL 73
HOT EXHAUST 73
RADIATOR 73
EMERGENCY LADDER 73
ACCUMULATOR DRAIN VALVES 73
EMERGENCY DUMP PROCEDURE 74
EMERGENCY TOWING PROCEDURE 74
WELDING 74
EMERGENCY SHUTDOWN 74
INFORMATION DISPLAY 75
WIRELESS SIGNALS 75
HIGH VOLTAGE 75
LIFTING INSTRUCTIONS 76
PRODUCT IDENTIFICATION PLATE 77
LUBRICATION CHART 78
TORQUE TABLES AND CONVERSION CHARTS 79
STORAGE AND IDLE MACHINE PREPARATION 89
SHORT TERM IDLE PERIODS 89
PREPARATION FOR STORAGE 90
REMOVAL FROM STORAGE 91
RECONDITIONING AN IDLE VEHICLE 93
ENGINE OPERATION 95
After The Engine Has Started 96
ENGINE STORAGE 97
Temporary Storage (30 Days Or Less) 97
Extended Storage (More Than 30 Days) 97
RESTORING AN ENGINE AFTER EXTENDED STORAGE 99
ELECTRIC DRIVE TRUCKS 100
Storing A Truck That Is Operational 100
Storing A Truck That Is Not Operational 101
Storing A Major Component 102
Periodic Inspections 102
Placing Equipment Into Service After Storage 102
SECTION B STRUCTURES 105
SECTION B2 STRUCTURAL COMPONENTS 107
STRUCTURAL COMPONENTS 109
PREPARATION 109
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 110
Removal 110
Installation 110
RH DECK AND RETARDING GRID 111
Removal 111
Installation 111
LH DECK 112
Removal 112
Installation 112
CENTER DECK 113
Removal 113
Installation 113
SECTION B3 DUMP BODY 115
DUMP BODY 117
DUMP BODY 117
Removal 117
Installation 118
BODY PADS 119
Body Pad Shimming Procedure 120
BODY GUIDE 121
HOIST LIMIT SWITCH 121
BODY-UP SWITCH 121
BODY RETENTION SLING 121
ROCK EJECTORS 122
Inspection 122
SECTION B4 FUEL TANK 123
FUEL TANK 125
FUEL TANK 125
Removal 125
Repair 125
Cleaning 125
Installation 125
FUEL TANK VENT ASSEMBLY 127
Disassembly 127
Assembly 127
FUEL GAUGE SENDER 128
Removal 128
Installation 128
QUICK FILL FUEL RECEIVERS 128
SECTION C ENGINE 129
SECTION C2 POWER MODULE 131
POWER MODULE 133
PREPARATION FOR REMOVAL 133
REMOVAL 138
INSTALLATION 140
HOOKUP 141
SECTION C3 COOLING SYSTEM 143
COOLING SYSTEM 145
RADIATOR 145
Removal 145
Installation 147
Filling Procedure 148
REPAIRING THE RADIATOR 148
Internal Inspection 148
External Cleaning 148
Disassembly 149
Cleaning and Inspection 150
Assembly 150
Pressure Testing 151
COOLANT SYSTEM TROUBLESHOOTING 151
SECTION C4 POWER TRAIN 153
POWER TRAIN 155
ALTERNATOR REMOVAL 155
ALTERNATOR INSTALLATION 157
Measuring Procedure 157
Joining the Alternator and Engine 159
ENGINE 160
Removal 160
Service 160
Installation 160
SECTION C5 AIR CLEANERS 161
AIR CLEANERS 163
OPERATION 163
SERVICING THE AIR CLEANERS 163
Replacing The Elements 164
AIR CLEANER ASSEMBLY CLEANING 165
Primary Element Cleaning 165
Precleaner Section Cleaning 167
AIR INTAKE TROUBLESHOOTING 168
SECTION C7 FAN CLUTCH 169
FAN CLUTCH 171
REMOVAL & INSTALLATION TOOLING 171
DISASSEMBLY 174
CLEANING AND INSPECTION 184
ASSEMBLY 188
TEST PROCEDURE 202
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 203
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM 205
24VDC ELECTRIC SUPPLY SYSTEM 207
ELECTRICAL SYSTEM DESCRIPTION 207
BATTERIES 207
Maintenance and Service 207
Troubleshooting 207
BATTERY SUPPLY SYSTEM 209
24VDC Battery Charging Alternator 209
Batteries 209
Engine Start Relays 209
24VDC Auxiliary Battery Receptacles 209
Battery Disconnect Switches 209
24VDC to 12VDC Converter 210
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 210
Operation 210
Pressure Switch 210
Check Valve 211
Timer Solenoid 211
MAINTENANCE 211
Prelube System Operation Checks 211
Check Valve 211
Timer Solenoid 211
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 212
24VDC ELECTRIC START SYSTEM 214
CRANKING MOTORS 214
Operation 214
Removal 214
Installation 214
CRANKING MOTOR TROUBLESHOOTING 215
Preliminary Inspection 215
No-Load Test 215
Interpreting Results of Tests 216
Disassembly 216
Cleaning and Inspection 217
Armature Servicing 219
Field Coil Checks 219
Field Coil Removal 219
SOLENOID CHECKS 220
Test 220
Assembly 221
Bearing Replacement: 221
Motor Assembly: 221
Pinion Clearance 222
MAGNETIC SWITCH 222
Removal 222
Installation 222
Coil Test 223
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 225
24 VDC ELECTRICAL SYSTEM COMPONENTS 227
BRAKE WARNING BUZZER 227
AUXILIARY CONTROL CABINET COMPONENTS 227
Power Distribution Terminals 227
Control Power Relay 227
Auto Lube Timer 227
Ground Level Power Relay 227
Diode Board – DB1 229
Fuse Blocks 230
Alarm Indicating Device (AID) System 230
RELAY BOARDS 233
Relay Boards RB1, RB3, RB4, RB5 233
Relay Board RB6, RB7, RB8, RB9 235
Relay Board Functions 236
BODY-UP SWITCH 238
Operation 238
Adjustment 238
Service 238
HOIST LIMIT SWITCH 239
Operation 239
Adjustment 239
Service 239
FUSE BLOCKS AND CIRCUIT BREAKERS 240
SECTION D11 KOMTRAX PLUS 243
KOMTRAX PLUS 245
KOMTRAX PLUS BASIC FEATURES 245
Gather Data 245
Convert and Record Data 245
Communicate Data to Off-Board Systems 246
USING KOMTRAX PLUS 247
Turning KOMTRAX Plus ON 247
Normal KOMTRAX Plus Operation 247
Turning KOMTRAX Plus OFF 248
Downloading from the KOMTRAX Plus Controller 248
KOMTRAX PLUS DATA ITEMS 249
Fault Codes 249
Machine History 249
KOMTRAX Plus History 249
Snapshots 250
Manual Snapshots 250
Trends 252
Histogram (Load Map) Data 252
Haul Cycle Data 253
Alarm and Snapshot Triggers 254
Satellite Features 254
KOMTRAX PLUS DIAGNOSTIC FEATURES 256
Fault History 256
LED Digits 256
KOMTRAX PLUS CONTROLLER 256
Removal 257
Installation 257
KOMTRAX PLUS SOFTWARE 258
VHMS Tool Box Installation 258
VHMS Setting Tool Installation 258
PDM Software Installation 258
KOMTRAX PLUS INITIALIZATION PROCEDURE 259
CONTROLLER SETUP PROCEDURE 259
SNAPSHOT PROCEDURE 262
DOWNLOAD PROCEDURE 263
FTP UPLOAD PROCEDURE 264
INITIALIZATION FORMS 265
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 266
KOMTRAX PLUS CONTROLLER CHECKOUT 271
Necessary Equipment 271
Preliminary 271
KOMTRAX Plus Controller Checkout Procedure 272
ORBCOMM CONTROLLER (if equipped) 274
Removal 274
Installation 274
SECTION D12 INTERFACE MODULE 275
INTERFACE MODULE 277
Removal 277
Installation 277
SENSORS 278
Temperature Sensors 278
Pressure Sensors 278
INTERFACE MODULE SOFTWARE 279
Flashburn Program Installation 279
Interface Module Application Code Installation 280
Interface Module Realtime Data Monitor Software 280
INTERFACE MODULE CHECKOUT 281
Necessary Equipment 281
Preliminary 282
Check Digital Inputs To The Interface Module 283
Check Analog Inputs To The Interface Module 286
Check Serial Interfaces To The Interface Module 286
Check Outputs From The Interface Module 287
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 289
INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 291
GENERAL 291
TROUBLESHOOTING 292
Communications Networks 292
Coaxial Cable 292
FAULT CODES 292
Fault History 292
KOMTRAX Plus LED Display Fault Codes 293
Chassis Fault Codes 294
Engine Fault Codes 298
FAULT TREE ANALYSIS 304
Unable to connect to KOMTRAX Plus from laptop PC 304
Flashing Error Code N4-23 (PLM III Communications Fault) 305
Flashing Error Code N4-22 (Engine Communications Fault) 306
No Data Received By WebCARE 307
Coaxial Cable Troubleshooting 308
SECTION D14 KOMTRAX PLUS FORMS 309
KOMTRAX PLUS FORMS 311
KOMTRAX PLUS INITIALIZATION CHECK LIST 311
KOMTRAX PLUS DATA DOWNLOAD 312
KOMTRAX PLUS INITIALIZATION CHECK LIST 313
KOMTRAX PLUS INITIALIZATION FORM 315
SECTION E ELECTRIC PROPULSION SYSTEM 317
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 319
ELECTRICAL PROPULSION SYSTEM COMPONENTS 321
GENERAL SYSTEM DESCRIPTION 321
SYSTEM COMPONENTS 323
Propulsion System Controller (PSC) 323
Truck Control Interface (TCI) 324
Diagnostic Information Display (DID) Panel 325
DID Panel Event Codes 325
PSC SOFTWARE FUNCTIONS 344
Input Processing 344
State Machine 344
DC Link State 347
Engine Control 348
ALTERNATOR FIELD CONTROL 348
Desired Three-Phase Voltage 348
Desired DC Link Voltage 348
Self-Load 349
Propel Torque Control 349
Retard Torque Control 349
Wheel Slide Control 350
Resistor Grid Control 350
Chopper Voltage Control 350
EVENT DETECTION AND PROCESSING 350
Power-On Tests 350
Initiated Tests 351
Periodic Tests 351
EVENT RESTRICTIONS 351
EVENT LOGGING AND STORAGE 351
Event History Buffer 352
Data Packs 352
To Record and Save a Data Pack to a Disk 352
Event Reset 353
SERIAL DATA COMMUNICATIONS 353
PSC – TCI Communications Processing 353
PSC – PTU Communications Processing 353
Inverter Communications Processing 354
OUTPUT PROCESSING 354
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 354
Fast Start 354
Engine Shutdown/Engine Not Running 354
Limp Home Mode 355
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 356
ELECTRONIC ACCELERATOR AND RETARD PEDALS 364
Removal 364
Installation 364
Disassembly 364
Assembly 364
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 365
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 367
AC DRIVE SYSTEM MAINTENANCE 367
NORMAL TRUCK SHUTDOWN PROCEDURE 368
SHUTDOWN AFTER SYSTEM FAILURE 368
SYSTEM CHECKOUT 369
Battery and Control Circuit Checks – Battery Power OFF 369
Battery and Control Circuit Checks – Battery Power ON 372
Checks with Key Switch OFF 373
Checks with Key Switch ON 373
CPU Battery Checks 373
MEMORY BACKUP BATTERY REPLACEMENT 374
TCI PROGRAMMING 374
PSC PROGRAMMING 375
INVERTER PROGRAMMING 375
CPU RESET 375
PSC CHECKOUT 376
PSC Digital Input Checks 376
PSC Digital Output Checks 380
TCI CHECKOUT 381
Modular Mining Communication Port Check 381
TCI Digital Input Checks 381
TCI Digital Output Tests 387
CALIBRATIONS 389
Speedometer 389
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 389
ERASING EVENTS 389
PSC 389
TCI 390
GATE DRIVER POWER CONVERTER TEST 390
LOAD TESTING 391
Preparation 391
Alternator Speed Sensor Checks 391
Battery Boost Check 391
Brake Circuit Switch Checks 392
Hoist & Steering Circuit Switch Checks 392
Link Energized Checks 392
Loadbox Test 394
TROUBLESHOOTING 398
PVM Optimum Load Curve Handshaking Troubleshooting 398
Phase Module and Chopper Module Troubleshooting 398
PHASE MODULE REPLACEMENT 399
Phase Module Removal 399
Phase Module Installation 399
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) 401
Fault Code A001: Left front suspension pressure sensor signal is high 403
Related circuit diagram 403
Fault Code A002: Left front suspension pressure sensor signal is low 404
Related circuit diagram 404
Fault Code A003: Right front suspension pressure sensor signal is high 405
Related circuit diagram 405
Fault Code A004: Right front suspension pressure sensor signal is low 406
Related circuit diagram 406
Fault Code A005: Left rear suspension pressure sensor signal is high 407
Related circuit diagram 407
Fault Code A006: Left rear suspension pressure sensor signal is low 408
Related circuit diagram 408
Fault Code A007: Right rear suspension pressure sensor signal is high 409
Related circuit diagram 409
Fault Code A008: Right rear suspension pressure sensor signal is low 410
Related circuit diagram 410
Fault Code A009: Incline sensor signal is high 411
Related circuit diagram 411
Fault Code A010: Incline sensor signal is low 412
Related circuit diagram 412
Fault Code A011: Payload meter speed sensor signal has failed 413
Related circuit diagram 413
Fault Code A013: Body up switch has failed 414
Related circuit diagram 414
Fault Code A014: Payload meter checksum computation has failed 415
Related circuit diagram 415
Fault Code A016: Payload meter write to flash memory has failed 416
Related circuit diagram 416
Fault Code A017: Payload meter flash memory read has failed 417
Related circuit diagram 417
Fault Code A018: Right rear flat suspension cylinder warning 418
Related circuit diagram 419
Fault Code A019: Left rear flat suspension cylinder warning 420
Related circuit diagram 421
Fault Code A022: Carryback load is excessive 422
Related circuit diagram 423
Fault Code A026: Payload meter user select switch has failed 424
Related circuit diagram 424
Fault Code A027: Payload meter user clear switch has failed 425
Related circuit diagram 425
Fault Code A101: High pressure detected across a hydraulic pump filter 426
Related circuit diagram 427
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 428
Related circuit diagram 429
Fault Code A107: GE has generated a propel system caution 430
Related circuit diagram 431
Fault Code A108: GE has generated a propel system temperature caution 432
Related circuit diagram 433
Fault Code A109: GE has generated a propel system reduced level signal 434
Related circuit diagram 435
Fault Code A115: Low steering precharge pressure is detected 436
Related circuit diagram 437
Fault Code A123: GE has generated a reduced retarding caution 438
Related circuit diagram 439
Fault Code A124: GE has generated a no propel / no retard warning 440
Related circuit diagram 441
Fault Code A125: GE has generated a no propel warning 442
Related circuit diagram 443
Fault Code A126: Oil level in the hydraulic tank is low 444
Related circuit diagram 445
Fault Code A127: IM furnished +5 volt output for sensors is low 446
Related circuit diagram 447
Fault Code A128: IM furnished +5 volt output for sensors is high 448
Related circuit diagram 449
Fault Code A139, A310: Low fuel level warning 450
Related circuit diagram 451
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 452
Related circuit diagram 453
Fault Code A146: Hydraulic temperature sensors cause posting of this faultl 454
Related circuit diagram 455
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216) 457
Fault Code A152: Starter failure 458
Related circuit diagram 459
Fault Code A153: Battery voltage is low with truck in operation 460
Related circuit diagram 461
Fault Code A154: Battery charging voltage is excessive 462
Related circuit diagram 463
Fault Code A155: Battery charging voltage is low 464
Related circuit diagram 465
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 466
Related circuit diagram 467
Fault Code A166: Left rear hydraulic oil temperature sensor is low 468
Related circuit diagram 469
Fault Code A167: Right rear hydraulic oil temperature sensor is low 470
Related circuit diagram 471
Fault Code A168: Left front hydraulic oil temperature sensor is low 472
Related circuit diagram 473
Fault Code A169: Right front hydraulic oil temperature sensor is low 474
Related circuit diagram 475
Fault Code A170: Left rear hydraulic oil temperature sensor is high 476
Related circuit diagram 476
Fault Code A171: Right rear hydraulic oil temperature sensor is high 477
Related circuit diagram 477
Fault Code A172: Left front hydraulic oil temperature sensor is high 478
Related circuit diagram 478
Fault Code A173: Right front hydraulic oil temperature sensor is high 479
Related circuit diagram 479
Fault Code A184: J1939 data link is not connected 480
Related circuit diagram 481
Fault Code A190: Auto lube control has detected an incomplete lube cycle 482
Related circuit diagram 483
Fault Code A194: Left front hydraulic oil temperature is high 484
Related circuit diagram 485
Fault Code A195: Right front hydraulic oil temperature is high 486
Related circuit diagram 487
Fault Code A196: Left rear hydraulic oil temperature is high 488
Related circuit diagram 489
Fault Code A197: Right rear hydraulic oil temperature is high 490
Related circuit diagram 491
Fault Code A198: Hoist pressure 1 sensor is high 492
Related circuit diagram 492
Fault Code A199: Hoist pressure 2 sensor is high 493
Related circuit diagram 493
Fault Code A200: Steering pressure sensor is high 494
Related circuit diagram 494
Fault Code A201: Brake pressure sensor is high 495
Related circuit diagram 495
Fault Code A202: Hoist pressure 1 sensor is low 496
Related circuit diagram 496
Fault Code A203: Hoist pressure 2 sensor is low 497
Related circuit diagram 497
Fault Code A204: Steering pressure sensor is low 498
Related circuit diagram 498
Fault Code A205: Brake pressure sensor is low 499
Related circuit diagram 499
Fault Code A206: Ambient temperature sensor is high 500
Related circuit diagram 500
Fault Code A207: Ambient temperature sensor is low 501
Related circuit diagram 501
Fault Code A212: Bad truck speed signal 502
Related circuit diagram 503
Fault Code A213: Parking brake should have applied but is detected as not having applied 504
Related circuit diagram 506
Fault Code A214: Parking brake should have released but is detected as not having released 508
Related circuit diagram 510
Fault Code A215: Brake auto apply relay circuit is defective 512
Related circuit diagram 513
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 514
Related circuit diagram 515
SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292) 517
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 518
Related circuit diagram 519
Fault Code A230: Parking brake has been requested while truck still moving 520
Related circuit diagram 521
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 522
Related circuit diagram 523
Fault Code A240: The keyswitch input to the interface module is open 524
Related circuit diagram 525
Fault Code A246: Payload meter reports truck overload 525
Related circuit diagram 525
Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted 526
Related circuit diagram 527
Fault Code A250: Battery voltage is low with the truck parked 528
Related circuit diagram 529
Fault Code A252: Start enable output circuit is either open or shorted to ground 530
Related circuit diagram 531
Fault Code A253: Steering bleed circuit is not open while running 532
Related circuit diagram 533
Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open 534
Related circuit diagram 535
Fault Code A257: Payload CAN/RPC is not connected 536
Related circuit diagram 536
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 538
Related circuit diagram 539
Fault Code A260: Parking brake failure 540
Related circuit diagram 541
Fault Code A262: Steering bleed valve circuit open during shutdown 542
Related circuit diagram 543
Fault Code A263: Steering bleed circuit is shorted to ground 544
Related circuit diagram 545
Fault Code A264: Parking brake relay circuit is defective 546
Related circuit diagram 547
Fault Code A265: Service brake failure 548
Related circuit diagram 550
Fault Code A270: Brake lock switch power supply is not on when required 552
Related circuit diagram 553
Fault Code A272: Brake lock switch power supply is not off when required 554
Related circuit diagram 556
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 558
Related circuit diagram 559
Fault Code A274: A brake setting fault has been detected 560
Related circuit diagram 561
Fault Code A275: A starter has been detected as engaged without a cranking attempt 562
Related circuit diagram 563
Fault Code A276: The drive system data link is not connected 564
Related circuit diagram 565
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 566
Related circuit diagram 567
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 568
Related circuit diagram 569
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 570
Related circuit diagram 571
Fault Code A285: The parking brake was not set when the key switch was turned off 572
Related circuit diagram 573
Fault Code A286: A fault was detected in the shutdown delay relay circuit 574
Related circuit diagram 575
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 576
Related circuit diagram 577
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) 579
Fault Code A303: Shifter is defective 580
Related circuit diagram 581
Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be 582
Related circuit diagram 583
Fault Code A309: No brakes applied when expected 584
Related circuit diagram 586
Fault Code A311: Brake lock switch is on when it should not be 588
Related circuit diagram 589
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 590
Related circuit diagram 590
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 591
Related circuit diagram 591
Fault Code A315: DC-DC converter 12 volt circuit is low 592
Related circuit diagram 593
Fault Code A316: Starter engagement has been attempted with engine running 594
Related circuit diagram 595
Fault Code A317: Operation of brake auto apply valve without a detected response 596
Related circuit diagram 598
Fault Code A318: Unexpected power loss to interface module 599
Related circuit diagram 599
Fault Code A328: Drive system not powered up 600
Related circuit diagram 601
Fault Code A350: Overload on output 1B 602
Related circuit diagram 603
Fault Code A351: Overload on output 1E 604
Related circuit diagram 605
Fault Code A352: Overload on output 1H 606
Related circuit diagram 607
Fault Code A353: Overload on output 1J 608
Related circuit diagram 609
Fault Code A354: Overload on output 1K 610
Related circuit diagram 611
Fault Code A355: Overload on output 1L 612
Related circuit diagram 613
Fault Code A356: Overload on output 1M 614
Related circuit diagram 615
Fault Code A357: Overload on output 1N 616
Related circuit diagram 617
Fault Code A358: Overload on output 1P 618
Related circuit diagram 619
Fault Code A359: Overload on output 1R 620
Related circuit diagram 621
Fault Code A360: Overload on output 1S 622
Related circuit diagram 623
Fault Code A361: Overload on output 1T 624
Related circuit diagram 625
Fault Code A362: Overload on output 1U 626
Related circuit diagram 627
Fault Code A363: Overload on output 1X 628
Related circuit diagram 628
Fault Code A364: Overload on output 1Y 630
Related circuit diagram 631
Fault Code A365: Overload on output 1Z 632
Related circuit diagram 633
SECTION G REAR AXLE, SPINDLES AND WHEELS 635
SECTION G2 TIRES AND RIMS 637
TIRES AND RIMS 639
WHEEL STUD MAINTENANCE 640
FRONT TIRES AND RIMS 641
Removal 641
Installation 642
REAR TIRES AND RIMS 643
Removal 643
Installation 644
RIM 645
Tire Removal 645
Tire Installation 645
SECTION G3 FRONT WHEEL HUB AND SPINDLE 647
FRONT WHEEL HUB AND SPINDLE 649
WHEEL HUB AND SPINDLE ASSEMBLY 649
Removal 649
Spindle Removal Procedure (off of the truck) 652
Installation 654
Disassembly 655
Cleaning and Inspection 657
Assembly 657
Wheel Bearing Adjustment 658
Brake Installation 659
Seal Assembly Gap Check 660
WHEEL SPEED SENSOR TESTING 661
STEERING CYLINDERS 662
Spherical Bearing Wear Limits 662
Removal 663
Installation 663
Bearing Replacement (Steering Cylinder and Tie Rod) 663
TIE ROD 665
Removal 665
Installation 665
Disassembly 666
Assembly 666
Toe-In Adjustment 667
TIE ROD INSPECTION AND TORQUE PROCEDURE 668
Old Style Tie Rod 668
New Style Tie Rod 669
SECTION G4 REAR AXLE MOUNTING 671
REAR AXLE MOUNTING 673
PIVOT PIN 673
Removal 673
Installation 674
PIVOT EYE BEARING 674
Removal 674
Installation 674
PIVOT EYE REPAIR 675
Removal 675
Installation 675
ANTI-SWAY BAR 676
Removal 676
Disassembly 676
Cleaning and Inspection 676
Assembly 676
Installation 676
SECTION G5 REAR AXLE AND WHEEL MOTOR 679
REAR AXLE AND WHEEL MOTOR 681
REAR AXLE HOUSING 681
Preparation 681
Removal 682
Cleaning and Inspection 683
Installation 683
BLOWER PRESSURE SWITCH ADJUSTMENT 683
WHEEL MOTOR 684
Preparation 684
Removal 685
Cleaning and Inspection 687
Installation 687
WHEEL MOTOR GEAR OIL 692
Filtering Requirements 692
Particle Size Analysis 692
Flushing 692
Oil Sample Analysis 693
ELEMENT SPECIFICATION CHARTS 694
SECTION H HYDRAIR® II SUSPENSIONS 697
SECTION H2 FRONT SUSPENSIONS 699
FRONT SUSPENSION 701
Removal 701
Installation 702
Inspection 707
LOWER BEARING & SEALS 708
Removal 708
Installation 708
MAJOR SUSPENSION REBUILD 709
Disassembly 709
Assembly 710
SUSPENSION PRESSURE TEST 711
SECTION H3 REAR SUSPENSIONS 713
REAR SUSPENSIONS 715
SUSPENSION CYLINDER 716
Removal 716
Installation 718
Disassembly 718
Cleaning and Inspection 719
Assembly 719
SUSPENSION PRESSURE TEST 721
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES 723
SUSPENSION OILING AND CHARGING PROCEDURE 725
GENERAL 725
EQUIPMENT LIST 725
HYDRAIR® CHARGING KIT 726
Installation of Charging Kit 726
Removal of Charging Kit 726
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 727
FRONT SUSPENSION 727
Front Suspension Oiling 727
Front Suspension Nitrogen Charging 729
REAR SUSPENSION 730
Rear Suspension Oiling 731
Rear Suspension Nitrogen Charging 733
OIL AND NITROGEN SPECIFICATIONS CHARTS 734
SECTION J BRAKE CIRCUIT 735
SECTION J2 BRAKE CIRCUIT 737
BRAKE CIRCUIT 739
SERVICE BRAKE CIRCUIT 739
PARKING BRAKE CIRCUIT 741
BRAKE LOCK CIRCUIT 741
SECONDARY BRAKING AND AUTOMATIC APPLY 742
WARNING CIRCUIT 742
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 745
BRAKE CIRCUIT COMPONENT SERVICE 747
BRAKE VALVE 747
Rebuild Criteria 747
Removal 748
Installation 748
Disassembly 749
Cleaning and Inspection 752
Assembly 752
Regulator Sleeve O-Ring Installation 753
BRAKE VALVE BENCH TEST AND ADJUSTMENT 755
Test Setup Procedure 756
Brake Valve Output Pressure Adjustment 756
Final Test and Adjustment 757
Installing Brake Pedal Actuator Assembly to Brake Valve 757
Installing Retard Pedal To Brake Pedal 757
DUAL RELAY VALVE 758
Removal 758
Installation 758
Disassembly 758
Cleaning and Inspection 759
Assembly 760
DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT 761
Test Setup Procedure 762
Relay Valve Output Pressure Adjustment 762
BRAKE MANIFOLD 763
Removal 763
Installation 763
Disassembly 763
Cleaning and Inspection 764
Assembly 764
BRAKE ACCUMULATORS 764
Brake Accumulator Bleeddown Procedure 764
Removal 765
Installation 765
Disassembly 766
Cleaning and Inspection 767
Assembly 767
Accumulator Charging Procedure 769
Precharge Maintenance 771
Accumulator Storage Procedures 772
Bladder Storage Procedures 772
Installing A Bladder Accumulator From Storage 772
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 773
Removal 773
Installation 773
Disassembly 773
Lever Adjustments 773
Potentiometer Check 774
Assembly 774
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE 777
BRAKE CIRCUIT CHECK-OUT PROCEDURE 779
REQUIRED EQUIPMENT 780
INITIAL SYSTEM SETUP 781
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 782
PARKING BRAKE CHECK-OUT 783
SERVICE BRAKE CHECK-OUT 784
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 785
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 786
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 788
SECTION J5 WET DISC BRAKE ASSEMBLY 791
WET DISC BRAKE ASSEMBLY 793
OPERATION 793
BRAKE DISC WEAR INSPECTION 794
BRAKE REBUILD 795
Disassembly 795
Cleaning and Inspection 799
Assembly 800
Floating Ring Seal Assembly & Installation 805
WET DISC BRAKE BLEEDING PROCEDURE 809
SECTION J7 PARKING BRAKE 811
PARKING BRAKE 813
OPERATION 813
MAINTENANCE 814
Inspection 814
Removal 814
Installation 815
Disassembly 815
Cleaning and Inspection 815
Assembly 817
Cleaning and Inspecting New Discs 818
PARKING BRAKE BLEEDING PROCEDURE 819
SECTION L HYDRAULIC SYSTEM 821
SECTION L2 HYDRAULIC SYSTEM 823
HYDRAULIC SYSTEM 825
HYDRAULIC PUMP MODULE 825
HOIST CIRCUIT OPERATION 826
STEERING CIRCUIT OPERATION 828
DISC BRAKE COOLING SYSTEM 830
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 833
HYDRAULIC SYSTEM COMPONENT REPAIR 835
HOIST PUMP 835
Removal 835
Installation 837
Inspection 842
Assembly 842
HYDRAULIC TANK 848
Removal 848
Installation 849
HYDRAULIC TANK BREATHERS 849
HYDRAULIC TANK STRAINERS 850
Removal 850
Inspect and Clean 850
Installation 850
SECTION L4 STEERING CIRCUIT 851
STEERING CIRCUIT 853
STEERING CIRCUIT OPERATION 853
COMPONENT DESCRIPTION 854
Steering Control Unit 854
Bleeddown Manifold 855
Steering Accumulator Bleed Down Solenoid 855
Relief Valves 857
Hoist Up Limit Solenoid 857
Steering Accumulators 857
Low Precharge Warning Switch 857
High Pressure Filter 857
Quick Disconnect Ports 857
Flow Amplifier 859
FLOW AMPLIFIER SYSTEM OPERATION 860
No Steer 860
Steering Left 862
Steering Right 864
No Steer, External Shock Load 866
STEERING PUMP 868
Normal Operation 868
PRINCIPLE OF OPERATION 870
Full Pump Volume 870
Half Pump Volume 870
Neutral Position 870
Steering Pump 871
SECTION L5 STEERING CONTROL UNIT 873
STEERING CONTROL UNIT 875
REMOVAL 875
SPLINE INSPECTION 875
INSTALLATION 876
DISASSEMBLY 876
CLEANING AND INSPECTION 877
ASSEMBLY 879
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR 883
STEERING CIRCUIT COMPONENT REPAIR 885
BLEEDDOWN MANIFOLD VALVE 885
Removal 885
Installation 886
FLOW AMPLIFIER 887
Removal 887
Installation 887
Disassembly 887
Assembly 889
STEERING CYLINDERS 890
Disassembly 891
Piston Seal & Bearing Installation 891
Assembly 891
Testing 891
STEERING AND BRAKE PUMP 892
Removal 892
Installation 893
Disassembly 894
Inspection 897
Assembly 900
Driveshaft Group 901
Rotating Group 901
Valve Plate Group 902
STEERING ACCUMULATORS 904
Removal 904
Installation 904
Disassembly 905
Cleaning and Inspection 905
Assembly 906
Leak Testing 908
Charging Procedure 909
Precharge Maintenance 911
Accumulator Storage Procedures 912
Bladder Storage Procedures 912
Installing A Bladder Accumulator From Storage 912
TROUBLESHOOTING CHART 913
SECTION L7 HOIST CIRCUIT 917
HOIST CIRCUIT 919
BASIC OPERATION 919
COMPONENT DESCRIPTION 920
Hydraulic Tank 920
Hydraulic Pump 920
High Pressure Filters 920
Hoist Valve 920
Inlet Sections 920
Work Ports (Rear) Spool Section 921
Tank Ports (Front) Spool Section 921
Hoist Pilot Valve 921
Bleeddown Manifold 922
Hoist Up Limit Solenoid 922
Pilot Operated Check Valve 922
Overcenter Manifold 922
HOIST CIRCUIT OPERATION 923
Float Position Of Pilot Valve With Truck Body On Frame 924
Power Up Operation 926
Hold Operation 928
Power Down Operation 930
Float Operation 932
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 935
HOIST CIRCUIT COMPONENT REPAIR 937
HOIST VALVE 937
Removal 937
Installation 938
O-Ring Replacement 938
INLET SECTION 939
Disassembly 939
Cleaning and Inspection 940
Assembly 940
REAR SPOOL SECTION (Work Ports) 941
Disassembly 941
Cleaning and Inspection 941
Assembly 943
FRONT SPOOL SECTION (Tank Ports) 944
Disassembly 944
Cleaning and Inspection 944
Assembly 944
HOIST PILOT VALVE 946
Removal 946
Installation 946
Disassembly 947
Cleaning and Inspection 948
Assembly 948
HOIST CYLINDERS 949
Removal 949
Installation 950
Disassembly 952
Cleaning and Inspection 953
Assembly – Quill 954
Assembly – Cylinder 956
Testing 956
OVERCENTER VALVE MANIFOLD 957
SECTION L9 HYDRAULIC SYSTEM FILTERS 959
HYDRAULIC SYSTEM FILTERS 961
HOIST CIRCUIT FILTER 961
Filter Element Replacement 961
Removal – Hoist Circuit Filter 962
Installation – Hoist Circuit Filter 962
Indicator Switch – Hoist Circuit Filter 962
STEERING CIRCUIT FILTER 963
Filter Element Replacement 963
Removal – Steering Circuit Filter 964
Installation – Steering Circuit Filter 964
Indicator Switch – Steering Circuit Filter 964
INDICATOR SWITCH 964
Test Procedure 964
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 967
HYDRAULIC CHECKOUT PROCEDURE 969
GENERAL INFORMATION 969
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 976
Equipment Requirements 977
Pump Pressure Control Adjustments 977
Steering Control Valve and Flow Amplifier Leakage Test 978
Bleeddown Manifold Leakage Test 979
STEERING/BRAKE PUMP STROKE ADJUSTMENT 980
SHOCK AND SUCTION VALVES 980
Equipment Requirements 980
Pressure Tests 980
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 982
Equipment Requirements 982
Pressure Gauge Locations 982
Brake Cooling Circuit Test 982
Power Up Relief Pressure Test 983
Power Down Relief Pressure Test 984
Counterbalance Valve Pressure Check 985
Counterbalance Valve Adjustment 986
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 987
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 988
SECTION M OPTIONS AND SPECIAL TOOLS 989
SECTION M7 HOT START SYSTEM 991
HOT START SYSTEM 993
SYSTEM OPERATION 993
HEATER INFORMATION 994
TROUBLESHOOTING GUIDELINES 995
SECTION M8 SPECIAL TOOLS 997
HIGH VOLTAGE TOOLS 1001
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1001
SECTION M19 RADIATOR SHUTTERS 1005
RADIATOR SHUTTERS 1007
OPERATION 1007
Hydraulic Circuit 1007
Electrical Circuit 1008
MAINTENANCE AND REPAIR 1008
TROUBLESHOOTING 1009
SECTION M20 PAYLOAD METER III ™ 1013
OPERATION SECTION 1017
Introduction 1017
Data Summary 1017
Data Gathering 1017
COMPONENT DESCRIPTION 1018
System Diagram 1018
Suspension Pressure Sensors 1018
Inclinometer 1018
Operator Display 1018
Operator Switch 1019
Speed Input 1019
Body-Up Switch 1019
Brake Lock Switch 1019
Payload Meter 1019
Communications Ports 1019
Key Switch Input 1020
Payload Meter Power 1020
Load Lights 1020
Wiring and Termination 1021
TCI Outputs 1021
OPERATOR’S DISPLAY AND SWITCH 1022
Reading the Speedometer 1022
Reading the Load Display 1022
Using the Operator ID 1022
Using the Load and Ton Counter 1022
Total Ton Counter 1022
Total Load Counter 1023
Clearing the Counters 1023
Viewing Live Sensor Data 1023
Other Display Messages 1023
PAYLOAD OPERATION & CALCULATION 1024
Description of Haul Cycle States 1024
Haul Cycle Description 1024
Load Calculation 1025
Carry Back 1025
Measurement Accuracy 1025
SOURCES FOR PAYLOAD ERROR 1025
Payload Error 1025
Loading Conditions 1026
Pressure Sensors 1026
Swingloads 1026
Speed and Distance 1026
HAUL CYCLE DATA 1026
Haul Cycle Warning Flags 1028
Frame Torque Data 1029
Sprung Weight Data 1029
Maximum Speed Data 1029
Alarm Records 1029
Fault Code Data 1030
PC SOFTWARE OVERVIEW 1031
System Configuration 1031
Installing the PLMIII Software 1031
DOWNLOADING DATA 1032
PLM III SYSTEM CONFIGURATION 1033
Starting Communications 1033
Displayed Payload Units 1033
Time Units 1033
Connection Menu 1033
Connecting to the Payload Meter 1034
Configure the Payload Meter 1034
Setting the Date and Time 1034
Setting the Truck Type 1035
Setting the Gauge Display Units 1035
Setting the Frame Serial Number 1035
Setting the Truck Number 1035
Setting the Komatsu Distributor 1035
Setting the Komatsu Customer 1035
Clean Truck Tare Calibration 1036
Inclinometer Calibration 1036
DATA ANALYSIS 1037
Creating a Query 1037
Sorting on Truck Unit Number 1037
Sorting on Truck Type 1037
Sorting on Date Range 1038
Sorting on Time Range 1038
Payload Detail Screen 1039
Creating Reports 1039
Summary – one page report 1040
Detailed – multi-page report 1040
Creating Graphs 1041
Exporting Data 1041
CSV Export 1041
Compressed 1042
Importing Data 1043
Deleting Haul Cycle Records 1043
Viewing Alarms 1044
Deleting Alarm Records 1044
TROUBLESHOOTING SECTION 1045
TROUBLESHOOTING 1045
Viewing Active Alarms 1045
Real-Time Data Display 1045
Testing the Payload Lights 1045
Creating Log Files of Inputs 1046
Daily Inspections 1046
Periodic Maintenance 1046
Abnormal Displays at Power-Up 1047
No Payload Display When Key Switch is Turned ON 1048
No Display on Speedometer 1049
No Display on Operator Display 1049
No Communications With PC 1050
Load Lights Don’t Light During Loading 1051
Load Lights Remain ON 1052
Load Lights Remain ON During Dumping 1052
Display Doesn’t Clear When The Load Is Dumped 1052
Calibration Problems 1053
Alarm 1 – Left Front Pressure High 1054
Alarm 2 – Left Front Pressure Low 1054
Troubleshoot Wiring to Left Front Suspension 1054
Alarm 3 – Right Front Pressure High 1055
Alarm 4 – Right Front Pressure Low 1055
Troubleshoot Wiring to Right Front Suspension 1055
Alarm 5 -Left Rear Pressure High 1056
Alarm 6 – Left Rear Pressure Low 1056
Troubleshoot Wiring to Left Rear Suspension 1056
Alarm 7 – Right Rear Pressure High 1057
Alarm 8 – Right Rear Pressure Low 1057
Troubleshoot Wiring to Right Rear Suspension 1057
Alarm 9 – Inclinometer High 1058
Alarm 10 – Inclinometer Low 1058
Troubleshoot Inclinometer Wiring 1058
Alarm 13 – Body Up Input Failure 1059
Alarm 16 – Memory Write Failure 1060
Alarm 17 – Memory Read Failure 1060
Alarm 18 1061
Alarm 19 1061
Alarm 22 1061
Operator Switch Doesn’t Work 1062
Alarm 26 – User Switch Fault – SELECT 1062
Alarm 27 – User Switch Fault – SET 1062
Connector Map 1063
Connectors 1064
PLMIII CHECK OUT PROCEDURE 1065
General Description 1065
Tools Required 1065
Checkout Procedure 1065
PLMIII CHECKOUT PROCEDURE CONFIRMATION 1069
Flashburn Programming 1069
Confirmation Checklist 1071
SECTION M31 RESERVE ENGINE OIL SYSTEM 1073
RESERVE ENGINE OIL SYSTEM 1075
Operation 1076
LED Monitor Light 1076
Tank Fill Control (Optional) 1077
Filling Procedure (Remote Fill Feature) 1077
SERVICE 1078
Every 10 Hours, or once each shift: 1078
Every 500 Hours 1078
Changing Oil 1078
TROUBLESHOOTING 1079
Circuit Fuse 1079
SYSTEM ELECTRICAL SCHEMATICS 1080
SECTION M32 RETRACTABLE LADDER SYSTEM 1081
RETRACTABLE LADDER SYSTEM 1086
GENERAL SAFETY 1086
LADDER SYSTEM DESCRIPTION 1086
LADDER SYSTEM OPERATION 1086
Normal Operation 1086
Emergency Operation 1088
Limit Switch Operation 1088
IN-CAB CONTROL PANEL 1088
IN-CAB CONTROL PANEL FEATURES 1090
Digital Display Screen 1090
Command Buttons 1090
IN-CAB CONTROL PANEL FUNCTIONS 1092
Timing Control 1092
Ladder System Status 1092
Fault Code Identification 1092
Ladder System Configuration 1093
In-Cab Control Panel Lockout 1093
Automatic Raising 1093
Diagnostics 1093
Maintenance 1093
USING THE IN-CAB CONTROL PANEL 1094
Raising the Ladder 1094
Lowering the Ladder 1095
USING THE GROUND LEVEL CONTROL BOX 1096
Raising the Ladder 1096
Lowering the Ladder 1096
POWER PACK OPERATION 1097
MAINTENANCE 1101
Safety During Maintenance 1101
Unplanned Ladder Movements 1101
Automatic Ladder Raising 1101
Automatic Accumulator Recharging (Ladder in UP position) 1102
PREVENTIVE MAINTENANCE PROCEDURES 1103
Daily Inspection 1103
250 Hour Inspection 1103
5000 Hour Inspection 1103
SERVICING 1104
Check Reservoir Oil Level 1104
Changing RLS Fluid 1104
Cleaning the RLS 1105
RLS DIAGNOSTICS 1105
Description of Diagnostics Features 1105
Continuous System Monitoring 1106
Historic System Data Review 1107
Comms Integrity Monitoring 1107
Log and Service Information 1107
System Event Logs 1108
SECURITY ACCESS LEVELS 1109
Access Level 1 – NONE 1109
Access Level 2 – RESTRICTED 1109
Access Level 3 – COMPLETE 1109
User Access Privileges 1110
USER ID – PASSWORD 1111
Sequential Field Value Selection Options 1111
Password Character Table 1111
USER ID – NEW USER SETUP 1112
SYSTEM FAULTS 1112
Fault Type 1: Communications error 1113
Fault Type 2: 10A/15A fuse blown 1113
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1114
Fault Type 8: Power pack recharge too long 1114
Fault Type 9: Inhibit relay fail 1115
Fault Types 10, 11: Light/Siren relay failure 1115
Fault Type 12: Ladder came off upper limit 1116
Fault Type 13: Ladder did not reach limit 1116
Fault Type 14: Ladder stayed on limit 1117
Fault Type 15: Low oil level 1117
Fault Type 16: System voltage over 18V during movement 1118
Fault Type 17: System voltage under 18V 1118
Fault Type 18: System voltage over 31V 1119
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1119
Fault Type 21: Accumulator recharge > than once/hour 1120
Fault Type 22: System raised by park brake 1120
Fault Types 23, 24: Levels 1 and 2 service overdue 1121
Fault Type 25: Levels 1 and 2 service complete 1121
DATA MANAGEMENT 1122
Log Files 1122
Generating Reports 1123
MENU DIAGRAMS 1129
Controller Config 1129
Contact Information 1129
Show Recent Logs 1129
System Settings 1129
Upload Logs to USB 1129
Diagnostics 1129
SECTION M33 CAMERA SYSTEM 1137
CAMERA SYSTEM 1138
CAMERA SYSTEM 1138
General 1138
Operation 1138
Camera Switch 1139
CAMERA MONITOR 1140
General 1140
CAMERA CONTROLLER 1141
General 1141
Removal 1141
Installation 1141
Camera Controller Connector Pins 1141
CAMERA SWITCHER 1142
General 1142
Removal 1142
Installation 1142
SETUP AND CHECKOUT PROCEDURE 1143
General 1143
STEP 1 – Switch Function 1143
STEP 2 – Monitor System Settings to Default 1143
STEP 4 – Monitor Settings – System Settings Unique 1145
STEP 4 – Monitor Settings – System Settings Unique – Cameras 1147
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay 1149
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode 1150
STEP 7 – Integrated Functions Check 1151
SECTION N OPERATOR CAB 1153
SECTION N2 TRUCK CAB AND COMPONENTS 1155
TRUCK CAB AND COMPONENTS 1157
TRUCK CAB 1157
Description 1157
Removal 1158
Installation 1159
CAB DOOR 1160
Removal 1160
Installation 1160
Door Jamb Bolt Adjustment 1161
Door Handle Plunger Adjustment 1162
Replacing the Door Glass 1163
Replacing the Door Handle or Latch Assembly 1167
Replacing the Door Window Regulator 1168
Replacing the Door and Door Hinge Seal 1169
Replacing the Door Opening Seal 1169
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1170
Recommended Tools and Supplies 1170
Replacement Procedure 1170
WINDSHIELD AND REAR GLASS 1171
Removal 1171
Installation 1172
SECTION N3 CAB COMPONENTS 1173
CAB COMPONENTS 1175
WINDSHIELD WIPERS 1175
WIPER MOTOR 1175
Removal 1175
Installation 1175
WIPER ARM 1175
Removal 1175
Installation 1176
WIPER LINKAGE 1176
Removal 1176
Installation 1176
WINDSHIELD WASHER 1177
Operation 1177
Service 1177
OPERATOR SEAT (STANDARD SEAT) 1178
Adjustment 1178
Inspection 1179
Removal 1179
Installation 1179
Replacing the Seat Compressor 1180
PASSENGER SEAT (STANDARD SEAT) 1185
Inspection 1185
Removal 1185
Installation 1185
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1186
Removal 1186
Installation 1186
SEAT BELT REPLACEMENT (STANDARD SEATS – 58E-57-00500) 1188
Removal 1188
Installation 1188
OPERATOR SEAT (OPTIONAL SEAT) 1190
Seat Belts 1190
Adjustment 1190
PASSENGER SEAT (OPTIONAL SEAT) 1191
Seat Belts 1191
Adjustment 1191
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1192
General 1192
Removal 1192
SECTION N4 HEATER / AIR CONDITIONER 1197
HEATER/AIR CONDITIONER 1199
OPERATION 1199
Fan Speed Control Knob 1199
Temperature Control Knob 1199
Air Flow Directional Knob 1200
Heater/Air Conditioner Vents 1200
COMPONENTS 1200
Fuse and Circuit Breaker 1200
Relays 1200
Heater Core 1201
Fan Motor And Speed Control 1201
Actuators 1201
Cab Air Filter 1201
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1204
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1204
PRINCIPLES OF REFRIGERATION 1204
Air Conditioning 1204
Refrigeration – The Act Of Cooling 1205
The Refrigeration Cycle 1205
AIR CONDITIONER SYSTEM COMPONENTS 1206
Compressor (Refrigerant Pump) 1206
Service Valves 1206
Condenser 1206
Receiver-Drier 1206
Expansion Block Valve 1207
Accumulator 1207
Evaporator 1207
ELECTRICAL CIRCUIT 1208
Thermostat 1208
Compressor Clutch 1208
Trinary™ Switch 1209
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1210
SERVICE TOOLS AND EQUIPMENT 1211
Recovery/Recycle Station 1211
Leak Detector 1211
Manifold Gauge Set 1212
Installing Manifold Gauge Set 1213
Purging Air From Service Hoses 1213
Service Valves 1214
Vacuum Pump 1214
SYSTEM PERFORMANCE TEST 1215
SYSTEM OIL 1216
Handling and Reusing PAG Oil 1216
Oil Quantity 1216
Checking System Oil 1216
REFRIGERANT 1217
Recycled Refrigerant 1217
Reclaimed Refrigerant 1217
Refrigerant Quantity 1218
R-134a Refrigerant Containers 1218
SYSTEM LEAK TESTING 1218
Electronic Leak Detector 1219
Tracer Dyes 1219
Soap and Water 1219
RECOVERING AND RECYCLING THE REFRIGERANT 1219
Draining Oil from the Previous Recovery Cycle 1219
Performing the Recovery Cycle 1219
Performing the Recycling Procedure 1220
Evacuating and Charging the A/C System 1220
SYSTEM REPAIR 1220
System Flushing 1220
COMPONENT REPLACEMENT 1221
Hoses and Fittings 1221
Lines 1221
Expansion Valve 1221
Receiver-Drier 1221
Thermostat 1221
Compressor 1222
Accumulator 1222
Clutch 1222
EVACUATING THE SYSTEM 1223
CHARGING THE A/C SYSTEM 1224
TROUBLESHOOTING 1225
Preliminary Checks 1225
Diagnosis Of Gauge Readings And System Performance 1225
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1226
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1232
SECTION N5 OPERATOR CAB AND CONTROLS 1233
OPERATOR CAB AND CONTROLS 1236
STEERING COLUMN 1237
Removal 1237
Inspection 1237
Installation 1238
STEERING WHEEL 1238
Removal 1238
Installation 1238
STEERING WHEEL AND CONTROLS 1240
Horn Button 1240
Tilt / Telescope Lever 1240
Multi-Function Turn Signal Switch 1240
DYNAMIC RETARDING 1241
Retarder Lever 1241
Brake/Retarder Pedal 1241
Throttle/Accelerator Pedal 1241
GRADE/SPEED CHART 1242
OVERHEAD PANEL AND DISPLAYS 1243
CENTER CONSOLE 1244
Directional Control Lever 1244
Override/Fault Reset Switch 1245
Engine Shutdown Switch 1245
Window Control Switches 1245
Hoist Control Lever 1245
Retarder Speed Control (RSC) Adjustment Dial 1246
Retarder Speed Control (RSC) Switch 1246
Data Store Button 1247
KOMTRAX Plus Snapshot In Progress Light 1247
Link Energized Light 1247
Service Engine Light 1247
12V Auxiliary Power Outlets 1247
Fire Suppression Control Outlet 1247
Communication Radio Outlet 1247
DIAGNOSTIC PORTS 1247
KOMTRAX Plus Diagnostic Port 1247
Interface Module (IM) Diagnostic Port 1247
Payload Meter Diagnostic Port 1247
Truck Control Interface (TCI) Diagnostic Port 1247
Propulsion System Controller (PSC) Diagnostic Port 1247
Engine Diagnostic Port (CENSE) 1247
Engine Diagnostic Port (QUANTUM) 1247
INSTRUMENT PANEL 1248
Control Symbols 1248
Key Switch 1250
Rotating Beacon Light Switch (optional) 1250
Heated Mirror Switch (optional) 1250
AC Drive System Rest Switch 1250
Wheel Brake Lock Switch 1251
Hazard Warning Light Switch 1251
Heater/Air Conditioner Vents 1251
Engine Oil Pressure Gauge 1251
Right Turn Signal Indicator 1251
Digital Tachometer 1251
High Beam Indicator 1251
Speedometer/Payload Meter Display 1251
Left Turn Signal Indicator 1252
Coolant Temperature Gauge 1252
Lamp Check Switch 1252
Light Switch (3-Way) 1252
Ladder Light Switch 1252
Backup Light Switch 1252
Fog Light Switch 1253
Payload Meter Switch 1253
Panel Illumination Light Dimmer Switch 1253
Hydraulic Oil Temperature Gauge 1253
Engine Hourmeter 1253
Fuel Gauge 1253
OVERHEAD STATUS / WARNING INDICATORS 1254
A1 High Brake Oil Temperature 1255
B1 Low Steering Pressure 1255
C1 Low Accumulator Precharge Pressure 1256
D1 Not used 1256
E1 Low Brake Pressure 1256
A2 Low Hydraulic Tank Level 1256
B2 Low Automatic Lubrication System Pressure 1256
C2 Circuit Breaker Tripped 1256
D2 Hydraulic Oil Filter Monitor 1257
E2 Low Fuel 1257
A3 Parking Brake 1257
B3 Service Brake 1257
C3 Body Up 1257
D3 Dynamic Retarding 1257
E3 Stop Engine 1258
A4 Cranking Motor Failure 1258
B4 Backup Lights 1258
C4 Engine Shutdown Timer 1258
D4 Retard Speed Control (RSC) Indicator 1258
E4 Check Engine 1258
A5 No Power 1259
B5 Propulsion System Warning 1259
C5 Propulsion System Temperature 1259
D5 System/Component Failure 1259
E5 Battery Charging System Failure 1259
A6 No Propel 1259
B6 Propel System At Rest 1259
C6 Propel System Not Ready 1260
D6 Reduced Propulsion 1260
E6 Retard At Continuous Level 1260
D7 Brake Test Light 1260
E7 Maintenance Monitor 1260
8 Brake Test Switch 1260
REAR AXLE LIGHT BAR 1261
Backup Lights 1261
Retard Lights 1261
Brake Lights 1261
Backup Alarm 1261
KOMTRAX PLUS 1262
Operation 1262
Interface Module 1264
Basic Precautions 1264
KOMATSU WIRELESS BRIDGE (Optional) 1265
General Information 1265
Communication Setup 1265
Switching to the KWB_SETUP Network 1265
Setting the Computer Subnet Mask and IP Address 1266
Properties 1266
Setting Up the KWB 1267
Adding Encryption 1267
Final Computer Settings 1267
Data Downloading 1268
Resetting the KWB 1268
KWB Lights 1268
SECTION P LUBRICATION AND SERVICE 1269
SECTION P2 LUBRICATION AND SERVICE 1271
LUBRICATION AND SERVICE 1273
GENERAL 1273
SERVICE CAPACITIES 1273
HYDRAULIC TANK SERVICE 1273
Adding Oil 1273
COOLING SYSTEM SERVICE 1274
Radiator Filling Procedure 1274
Coolant Specifications 1274
Unacceptable Practices 1274
WHEEL MOTOR SERVICE 1274
RESERVE OIL TANK SERVICE 1275
Filling the Reserve Oil Tank (Remote Fill) 1275
Inline Screen 1275
QUICK FILL SERVICE CENTER 1276
LUBRICATION CHART 1277
10 HOUR (DAILY) INSPECTIONS 1278
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1280
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1280
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1280
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1283
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1285
5000 HOUR MAINTENANCE CHECKS 1285
SECTION P3 AUTOMATIC LUBRICATION SYSTEM 1287
AUTOMATIC LUBRICATION SYSTEM 1289
GENERAL DESCRIPTION 1289
SYSTEM COMPONENTS 1291
Filter 1291
Hydraulic Motor and Pump 1291
Grease Reservoir 1291
Pressure Reducing Valve 1291
Flow Control Valve 1291
Solenoid Valve 1291
Vent Valve 1291
Lubrication Cycle Timer 1291
Over Pressure Cut Off Switch 1291
Grease Pressure Failure Switch 1291
Injectors 1291
Relief Valve (unloader valve) 1291
SYSTEM OPERATION 1292
Normal Operation 1292
Lubricant Required For System 1293
System Priming 1293
Filter Assembly 1293
LUBRICANT PUMP 1294
Pump Housing Oil Level 1294
Pump Pressure Control 1294
INJECTORS (SL-1 Series “H”) 1295
Injector Specifications 1295
Injector Adjustment 1295
INJECTOR OPERATION 1296
PREVENTIVE MAINTENANCE PROCEDURES 1297
Daily Lubrication System Inspection 1297
250 Hour Inspection 1297
1000 Hour Inspection 1297
SYSTEM CHECKOUT 1298
Lubrication Controller Check 1298
Lubrication Controller Components 1298
Lubrication Controller Adjustment 1298
SYSTEM TROUBLESHOOTING CHART 1300
SECTION Q ALPHABETICAL INDEX 1303
SECTION R SYSTEM SCHEMATICS 1307
HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC 1309
HYDRAULIC BRAKE SYSTEM SCHEMATIC 1310
ELECTRICAL SCHEMATICS 1311

DESCRIPTION:

Komatsu 930E-4 Dump Truck Shop Manual CEBM024503 –  PDF DOWNLOAD

Serial Number

• A31056-A31162

• 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 Nm (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.