Komatsu 930E-4 DUMP TRUCK Shop Manual CEBM026903 – PDF DOWNLOAD

Description

Komatsu 930E-4 DUMP TRUCK Shop Manual CEBM026903 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-4 DUMP TRUCK Shop Manual CEBM026903 – PDF DOWNLOAD

Language : English
Pages :1370
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E-4 DUMP TRUCK Shop Manual CEBM026903 – PDF DOWNLOAD

SERIAL NUMBERS 930E-4 A31164 – A31689,
A31698, A31700, A31704,
A31718 – A31724

GENERAL

Safety records from most organizations will show that the greatest percentage of accidents are caused by unsafe acts performed by people. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to the proper authority. The following safety rules are provided as a guide for the operator. However, local conditions and regulations may add many more to this list.

TABLE OF CONTENTS:

Komatsu 930E-4 DUMP TRUCK Shop Manual CEBM026903 – PDF DOWNLOAD

SERIAL NUMBERS 930E-4 A31164 – A31689,
A31698, A31700, A31704,
A31718 – A31724

COVER 1
SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENTS & SPECIFICATIONS INDEX 11
MAJOR 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
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 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 19
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 20
Unauthorized Modification 20
Precautions When Using ROPS 20
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 21
Safety At The Worksite 21
Fire Prevention 21
Ventilation In Enclosed Areas 21
Preparing For Operation 22
Mirrors, Windows And Lights 22
In The Operator Cab (Before Starting The Engine) 22
Seat Belts 22
OPERATING THE TRUCK 23
When Starting The Engine 23
General Truck Operation 23
Ensuring Good Visibility 23
Traveling 24
Traveling In Reverse 24
Traveling On Slopes 24
Operating On Snow Or Ice 24
Avoid Damage To Dump Body 24
Driving Near High Voltage Cables 25
Working On Loose Ground 25
When Dumping 25
When Loading 25
Parking The Truck 25
Towing 25
WORKING NEAR BATTERIES 26
Battery Hazard Prevention 26
Jump Starting With Booster Cables 27
Jump Starting With Receptacles 27
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Warning Tag 28
Proper Tools 28
Use of Tie-Off Anchor During Maintenance and Repair 28
Securing The Dump Body 29
WHILE PERFORMING MAINTENANCE 30
Keep The Truck Clean 30
Attachments 30
Working Under The Truck 30
Rotating Fan And Belts 30
Waste Materials 30
Adding Fuel Or Oil 31
Radiator Coolant Level 31
Use Of Lighting 31
Precautions With The Battery 31
Handling High Pressure Hoses 31
Precautions With High Pressure Oil 31
Performing Maintenance Near High Temperature Or High Pressure 31
TIRES 32
Handling Tires 32
Tire Maintenance 32
Storing Tires After Removal 32
WHEN REPAIRS ARE NECESSARY 33
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 34
Preliminary Procedures Before Welding or Performing Maintenance 34
Engine Shutdown Procedure Before Welding or Performing Maintenance 34
CAPACITOR DISCHARGE SYSTEM 36
Necessary Tools 36
Warnings And Cautions 37
Manual DC Link Capacitor Discharge Procedure 38
Failure of the Discharge System 40
Manual Discharge of Capacitors 41
Short Isolated Capacitor Terminals 43
OPERATING INSTRUCTIONS 44
PREPARING FOR OPERATION 44
WALK AROUND INSPECTION 44
RETRACTABLE LADDER SYSTEM (Optional) 48
Description 48
Normal Operation 48
General Safety 48
IN-CAB CONTROL PANEL 49
Digital Display Screen 49
Command Buttons 49
USING THE IN-CAB CONTROL PANEL 50
Raising the Ladder 51
Lowering the Ladder 51
USING THE GROUND LEVEL CONTROL BOX 52
Raising the Ladder 52
Lowering the Ladder 52
EMERGENCY OPERATION 52
ENGINE START-UP 53
AFTER ENGINE HAS STARTED 54
PRE-SHIFT BRAKE CHECK 54
Events 54
OPERATION 55
Description 55
Brake Test Exit Criteria 55
PERFORMING THE BRAKE TESTS 56
Setup 56
Service Brake Test 56
Parking Brake Test 57
Retard System Test 58
EMERGENCY STEERING SYSTEM 58
Operation 58
Pre-Operation Testing 58
MACHINE OPERATION SAFETY PRECAUTIONS 59
OPERATING ON THE HAUL ROAD 60
STARTING ON A GRADE WITH A LOADED TRUCK 61
PASSING 61
LOADING 61
Overload Speed Limit Function 61
DUMPING 62
Raising The Dump Body 62
Lowering The Dump Body (When dumping on flat ground) 63
Lowering The Dump Body (When dumping over a berm or into a crusher) 63
TOWING 64
Special Wiring Harness 64
Towing Procedure 65
SAFE PARKING PROCEDURES 66
NORMAL ENGINE SHUTDOWN PROCEDURE 66
SUDDEN LOSS OF ENGINE POWER 67
FUEL DEPLETION 67
DISABLED TRUCK DUMPING PROCEDURE 68
Hookup 68
Raising the Body 68
Lowering the Body 68
SECTION A4 WARNINGS AND CAUTIONS INDEX 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
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS INDEX 79
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 80
STANDARD TIGHTENING TORQUES For Class 109 Capscrews & Class 10 Nuts 80
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 81
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 82
SECTION A7 STORAGE PROCEDURES AND IDLE MACHINE PREPARATION INDEX 89
SHORT TERM IDLE PERIODS 89
PREPARATION FOR STORAGE 90
REMOVAL FROM STORAGE 91
RECONDITIONING AN IDLE VEHICLE 92
ENGINE OPERATION 94
After The Engine Has Started 95
ENGINE STORAGE 96
Temporary Storage (30 Days Or Less) 96
Extended Storage (More Than 30 Days) 96
RESTORING AN ENGINE AFTER EXTENDED STORAGE 97
ELECTRIC DRIVE TRUCKS 98
Storing A Truck That Is Operational 98
Storing A Truck That Is Not Operational 99
Storing A Major Component 99
Periodic Inspections 99
Placing Equipment Into Service After Storage 100
SECTION B STRUCTURES 101
SECTION B2 STRUCTURAL COMPONENTS INDEX 103
STRUCTURAL COMPONENTS 105
PREPARATION 105
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 106
Removal 106
Installation 106
RH DECK AND RETARDING GRID 107
Removal 107
Installation 107
LH DECK 108
Removal 108
Installation 108
CENTER DECK 109
Removal 109
Installation 109
SECTION B3 DUMP BODY INDEX 111
DUMP BODY 113
DUMP BODY 113
Removal 113
Installation 114
BODY PADS 115
Body Pad Shimming Procedure 116
BODY GUIDE 117
HOIST LIMIT SWITCH 117
BODY-UP SWITCH 117
BODY RETENTION SLING 117
ROCK EJECTORS 118
Inspection 118
SECTION B4 FUEL TANK INDEX (S/N A31164 – A31494) 119
FUEL TANK 121
FUEL TANK 121
Removal 121
Repair 121
Cleaning 121
Installation 121
FUEL TANK VENT ASSEMBLY 123
Disassembly 123
Assembly 123
FUEL GAUGE SENDER (FRONT) 124
Removal 124
Installation 124
QUICK FILL FUEL RECEIVERS (FRONT) 124
SECTION B4 FUEL TANK INDEX (S/N A31496 & UP) 125
FUEL TANK 126
Removal 126
Installation 126
Repair 128
Cleaning 128
FUEL TANK VENT ASSEMBLY 128
Disassembly 128
Assembly 128
FUEL GAUGE SENDER (TOP) 129
Removal 129
Installation 129
Operation 130
Specifications: 130
QUICK FILL FUEL RECEIVERS 131
SECTION C ENGINE 133
SECTION C2 POWER MODULE INDEX 135
POWER MODULE 137
PREPARATION FOR REMOVAL 137
REMOVAL 142
INSTALLATION 144
HOOKUP 145
EXHAUST TUBE INSTALLATION 146
EXHAUST BLANKET INSTALLATION 146
SECTION C3 COOLING SYSTEM INDEX 147
COOLING SYSTEM 149
RADIATOR 149
Removal 149
Installation 151
Filling Procedure 152
REPAIRING THE RADIATOR 152
Internal Inspection 152
External Cleaning 152
Disassembly 153
Cleaning and Inspection 154
Assembly 154
Pressure Testing 155
COOLANT SYSTEM TROUBLESHOOTING 155
SECTION C4 POWER TRAIN INDEX 157
POWER TRAIN 159
ALTERNATOR REMOVAL 159
ALTERNATOR INSTALLATION 161
Measuring Procedure 161
Joining the Alternator and Engine 163
ENGINE 164
Removal 164
Service 164
Installation 164
SECTION C5 AIR CLEANERS INDEX 165
AIR CLEANERS 167
OPERATION 167
SERVICING THE AIR CLEANERS 167
Replacing The Elements 168
AIR CLEANER ASSEMBLY CLEANING 169
Primary Element Cleaning 169
Precleaner Section Cleaning 171
AIR INTAKE TROUBLESHOOTING 172
SECTION C7 FAN CLUTCH INDEX 173
FAN CLUTCH 175
REMOVAL & INSTALLATION TOOLING 175
DISASSEMBLY 178
CLEANING AND INSPECTION 188
ASSEMBLY 192
TEST PROCEDURE 207
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 209
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM INDEX 211
24VDC ELECTRIC SUPPLY SYSTEM 213
ELECTRICAL SYSTEM DESCRIPTION 213
BATTERIES 213
Maintenance and Service 213
Troubleshooting 213
BATTERY SUPPLY SYSTEM 215
24VDC Battery Charging Alternator 215
Batteries 215
Engine Start Relays 215
24VDC Auxiliary Battery Receptacles 215
Battery Disconnect Switches 215
24VDC to 12VDC Converter 216
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 216
Operation 216
Pressure Switch 216
Check Valve 217
Prelube Timer Solenoid 217
MAINTENANCE 217
Prelube System Operation Checks 217
Check Valve 217
Prelube Timer Solenoid 217
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 218
24VDC ELECTRIC START SYSTEM 220
CRANKING MOTORS 220
Operation 220
Removal 220
Installation 220
CRANKING MOTOR TROUBLESHOOTING 221
Preliminary Inspection 221
No-Load Test 221
Interpreting Results of Tests 222
MAGNETIC SWITCH 223
Removal 223
Installation 223
Coil Test 223
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 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 INDEX 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
Troubleshooting 275
SECTION D12 INTERFACE MODULE INDEX 281
INTERFACE MODULE 283
INTERFACE MODULE 283
Removal 283
Installation 283
SENSORS 284
Temperature Sensors 284
Pressure Sensors 284
INTERFACE MODULE SOFTWARE 285
Flashburn Program Installation 285
Interface Module Application Code Installation 286
Interface Module Realtime Data Monitor Software 286
INTERFACE MODULE CHECKOUT 287
Necessary Equipment 287
Preliminary 288
Check Digital Inputs To The Interface Module 289
Check Analog Inputs To The Interface Module 292
Check Serial Interfaces To The Interface Module 292
Check Outputs From The Interface Module 293
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 295
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 297
GENERAL 297
Structure and Purpose 297
TROUBLESHOOTING 298
Communications Networks 298
Coaxial Cable 298
FAULT CODES 298
Fault History 298
KOMTRAX Plus LED Display Fault Codes 299
Chassis Fault Codes 300
Engine Fault Codes 305
FAULT TREE ANALYSIS 310
Unable to connect to KOMTRAX Plus from laptop PC 310
Flashing Error Code N4-23 (PLM Communications Fault) 311
Flashing Error Code N4-22 (Engine Communications Fault) 312
No Data Received By WebCARE 313
Coaxial Cable Troubleshooting 314
SECTION D14 KOMTRAX PLUS FORMS INDEX 315
KOMTRAX PLUS FORMS 317
KOMTRAX PLUS INITIALIZATION CHECK LIST 317
KOMTRAX PLUS DATA DOWNLOAD 318
KOMTRAX PLUS INITIALIZATION CHECK LIST 319
KOMTRAX PLUS INITIALIZATION FORM 321
SECTION E ELECTRIC PROPULSION SYSTEM 323
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 325
ELECTRICAL PROPULSION SYSTEM COMPONENTS 327
GENERAL SYSTEM DESCRIPTION 327
SYSTEM COMPONENTS 329
Propulsion System Controller (PSC) 329
Truck Control Interface (TCI) 330
Diagnostic Information Display (DID) Panel 331
DID Panel Event Codes 331
PSC SOFTWARE FUNCTIONS 350
Input Processing 350
State Machine 350
DC Link State 353
Engine Control 354
ALTERNATOR FIELD CONTROL 354
Desired Three-Phase Voltage 354
Desired DC Link Voltage 354
Self-Load 355
Propel Torque Control 355
Retard Torque Control 355
Wheel Slide Control 356
Resistor Grid Control 356
Chopper Voltage Control 356
EVENT DETECTION AND PROCESSING 356
Power-On Tests 356
Initiated Tests 357
Periodic Tests 357
EVENT RESTRICTIONS 357
EVENT LOGGING AND STORAGE 357
Event History Buffer 358
Data Packs 358
To Record and Save a Data Pack to a Disk 358
Event Reset 359
SERIAL DATA COMMUNICATIONS 359
PSC – TCI Communications Processing 359
PSC – PTU Communications Processing 359
Inverter Communications Processing 360
OUTPUT PROCESSING 360
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 360
Fast Start 360
Engine Shutdown/Engine Not Running 360
Limp Home Mode 361
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 362
ELECTRONIC ACCELERATOR AND RETARD PEDALS 370
Removal 370
Installation 370
Disassembly 370
Assembly 370
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 371
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 373
AC DRIVE SYSTEM MAINTENANCE 373
NORMAL TRUCK SHUTDOWN PROCEDURE 374
SHUTDOWN AFTER SYSTEM FAILURE 374
SYSTEM CHECKOUT 375
Battery and Control Circuit Checks – Battery Power OFF 375
Battery and Control Circuit Checks – Battery Power ON 378
Checks with Key Switch OFF 379
Checks with Key Switch ON 379
CPU Battery Checks 379
MEMORY BACKUP BATTERY REPLACEMENT 380
TCI PROGRAMMING 380
PSC PROGRAMMING 381
INVERTER PROGRAMMING 381
CPU RESET 381
PSC CHECKOUT 382
PSC Digital Input Checks 382
PSC Digital Output Checks 386
TCI CHECKOUT 387
Modular Mining Communication Port Check 387
TCI Digital Input Checks 387
TCI Digital Output Tests 393
CALIBRATIONS 395
Speedometer 395
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 395
ERASING EVENTS 395
PSC 395
TCI 396
GATE DRIVER POWER CONVERTER TEST 396
LOAD TESTING 397
Preparation 397
Alternator Speed Sensor Checks 397
Battery Boost Check 397
Brake Circuit Switch Checks 398
Hoist & Steering Circuit Switch Checks 398
Link Energized Checks 398
Loadbox Test 400
TROUBLESHOOTING 404
PVM Optimum Load Curve Handshaking Troubleshooting 404
Phase Module and Chopper Module Troubleshooting 404
PHASE MODULE REPLACEMENT 405
Phase Module Removal 405
Phase Module Installation 405
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 407
Fault Code A001: Left front suspension pressure sensor signal is high 410
Related circuit diagram 410
Fault Code A002: Left front suspension pressure sensor signal is low 411
Related circuit diagram 411
Fault Code A003: Right front suspension pressure sensor signal is high 412
Related circuit diagram 412
Fault Code A004: Right front suspension pressure sensor signal is low 413
Related circuit diagram 413
Fault Code A005: Left rear suspension pressure sensor signal is high 414
Related circuit diagram 414
Fault Code A006: Left rear suspension pressure sensor signal is low 415
Related circuit diagram 415
Fault Code A007: Right rear suspension pressure sensor signal is high 416
Related circuit diagram 416
Fault Code A008: Right rear suspension pressure sensor signal is low 417
Related circuit diagram 417
Fault Code A009: Incline sensor signal is high 418
Related circuit diagram 418
Fault Code A010: Incline sensor signal is low 419
Related circuit diagram 419
Fault Code A011: Payload meter speed sensor signal has failed 420
Related circuit diagram 420
Fault Code A013: Body up switch has failed 421
Related circuit diagram 421
Fault Code A014: Payload meter checksum computation has failed 422
Related circuit diagram 422
Fault Code A016: Payload meter write to flash memory has failed 423
Related circuit diagram 423
Fault Code A017: Payload meter flash memory read has failed 424
Related circuit diagram 424
Fault Code A018: Right rear flat suspension cylinder warning 426
Related circuit diagram 427
Fault Code A019: Left rear flat suspension cylinder warning 428
Related circuit diagram 429
Fault Code A022: Carryback load is excessive 430
Related circuit diagram 431
Fault Code A026: Payload meter user select switch has failed 432
Related circuit diagram 432
Fault Code A027: Payload meter user clear switch has failed 433
Related circuit diagram 433
Fault Code A101: High pressure detected across a hydraulic pump filter 434
Related circuit diagram 436
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 438
Related circuit diagram 439
Fault Code A109: GE has generated a propel system reduced level signal 440
Related circuit diagram 441
Fault Code A111: Low steering pressure warning 442
Fault Code A115: Low steering precharge pressure is detected 444
Related circuit diagram 445
Fault Code A117: Low brake accumulator pressure warning 446
Fault Code A118: Brake pressure is low while brake lock is activated 447
Fault Code A123: GE has generated a reduced retarding caution 448
Related circuit diagram 449
Fault Code A124: GE has generated a no propel / no retard warning 450
Related circuit diagram 451
Fault Code A125: GE has generated a no propel warning 452
Related circuit diagram 453
Fault Code A126: Oil level in the hydraulic tank is low 454
Related circuit diagram 455
Fault Code A127: IM furnished +5 volt output for sensors is low 456
Related circuit diagram 457
Fault Code A128: IM furnished +5 volt output for sensors is high 458
Related circuit diagram 459
Fault Code A139, A310: Low fuel level warning 460
Related circuit diagram 462
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 464
Related circuit diagram 466
Fault Code A146: Hydraulic temperature sensors cause posting of this fault 468
Related circuit diagram 469
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216) INDEX 471
Fault Code A152: Starter failure 472
Related circuit diagram 473
Fault Code A153: Battery voltage is low with truck in operation 474
Related circuit diagram 476
Fault Code A154: Battery charging voltage is excessive 478
Related circuit diagram 479
Fault Code A155: Battery charging voltage is low 480
Related circuit diagram 481
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 482
Related circuit diagram 483
Fault Code A166: Left rear hydraulic oil temperature sensor is low 484
Related circuit diagram 485
Fault Code A167: Right rear hydraulic oil temperature sensor is low 486
Related circuit diagram 487
Fault Code A168: Left front hydraulic oil temperature sensor is low 488
Related circuit diagram 489
Fault Code A169: Right front hydraulic oil temperature sensor is low 490
Related circuit diagram 491
Fault Code A170: Left rear hydraulic oil temperature sensor is high 492
Related circuit diagram 492
Fault Code A171: Right rear hydraulic oil temperature sensor is high 493
Related circuit diagram 493
Fault Code A172: Left front hydraulic oil temperature sensor is high 494
Related circuit diagram 494
Fault Code A173: Right front hydraulic oil temperature sensor is high 495
Related circuit diagram 495
Fault Code A184: J1939 data link is not connected 496
Related circuit diagram 497
Fault Code A190: Auto lube control has detected an incomplete lube cycle 498
Related circuit diagram 499
Fault Code A194: Left front hydraulic oil temperature is high 500
Related circuit diagram 501
Fault Code A195: Right front hydraulic oil temperature is high 502
Related circuit diagram 503
Fault Code A196: Left rear hydraulic oil temperature is high 504
Related circuit diagram 505
Fault Code A197: Right rear hydraulic oil temperature is high 506
Related circuit diagram 507
Fault Code A198: Hoist pressure 1 sensor is high 508
Related circuit diagram 508
Fault Code A199: Hoist pressure 2 sensor is high 509
Related circuit diagram 509
Fault Code A200: Steering pressure sensor is high 510
Related circuit diagram 510
Fault Code A201: Brake pressure sensor is high 511
Related circuit diagram 511
Fault Code A202: Hoist pressure 1 sensor is low 512
Related circuit diagram 513
Fault Code A203: Hoist pressure 2 sensor is low 514
Related circuit diagram 515
Fault Code A204: Steering pressure sensor is low 516
Related circuit diagram 517
Fault Code A205: Brake pressure sensor is low 518
Related circuit diagram 519
Fault Code A206: Ambient temperature sensor is high 520
Related circuit diagram 520
Fault Code A207: Ambient temperature sensor is low 521
Related circuit diagram 521
Fault Code A212: Bad truck speed signal 522
Related circuit diagram 523
Fault Code A213: Parking brake should have applied but is detected as not having applied 524
Related circuit diagram 526
Fault Code A214: Parking brake should have released but is detected as not having released 528
Related circuit diagram 530
Fault Code A215: Brake auto apply relay circuit is defective 532
Related circuit diagram 534
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 536
Related circuit diagram 538
SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292) INDEX 541
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 544
Related circuit diagram 546
Fault Code A230: Parking brake has been requested while truck still moving 548
Related circuit diagram 549
Fault Code A231: Dump body is up while traveling or intending to travel 550
Fault Code A233: Drive system CAN/RPC Control Link not connected 552
Fault Code A235: Steering accumulator is in the process of being bled down 553
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 554
Related circuit diagram 555
Fault Code A237: The CAN/RPC connection to the display is open 556
Fault Code A240: The keyswitch input to the interface module is open 557
Related circuit diagram 558
Fault Code A246: Payload meter reports truck overload 559
Related circuit diagram 559
Fault Code A247: Low steering pressure warning 560
Fault Code A248: The status indicator module within the display panel is defective 561
Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted 562
Related circuit diagram 563
Fault Code A250: Battery voltage is low with the truck parked 564
Related circuit diagram 566
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 567
Fault Code A252: Start enable output circuit is either open or shorted to ground 568
Related circuit diagram 569
Fault Code A253: Steering bleed circuit is not open while running 570
Related circuit diagram 571
Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open 572
Related circuit diagram 574
Fault Code A257: Payload CAN/RPC is not connected 575
Related circuit diagram 575
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 576
Related circuit diagram 577
Fault Code A260: Parking brake failure 578
Related circuit diagram 580
Fault Code A261: Low brake accumulator pressure warning 581
Fault Code A262: Steering bleed valve circuit open during shutdown 582
Related circuit diagram 584
Fault Code A263: Steering bleed circuit is shorted to ground 586
Related circuit diagram 587
Fault Code A264: Parking brake relay circuit is defective 588
Related circuit diagram 589
Fault Code A265: Service brake failure 590
Related circuit diagram 592
Fault Code A266: Selector lever was not in park while attempting to crank engine 593
Fault Code A267: Parking brake was not set while attempting to crank engine 594
Fault Code A268: Secondary engine shutdown while cranking 595
Fault Code A270: Brake lock switch power supply is not on when required 596
Related circuit diagram 598
Fault Code A271: Shifter not in gear 599
Fault Code A272: Brake lock switch power supply is not off when required 600
Related circuit diagram 602
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 604
Related circuit diagram 605
Fault Code A274: A brake setting fault has been detected 606
Related circuit diagram 607
Fault Code A275: A starter has been detected as engaged without a cranking attempt 608
Related circuit diagram 610
Fault Code A277: Parking brake applied while loading 611
Fault Code A278: Service brake applied while loading 612
Fault Code A279: Low steering pressure switch is defective 613
Fault Code A280: Steering accumulator Bleed Down switch is defective 614
Fault Code A281: Brake lock degradation switch is defective 615
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 616
Related circuit diagram 618
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 620
Related circuit diagram 621
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 622
Related circuit diagram 623
Fault Code A285: The parking brake was not set when the key switch was turned off 624
Related circuit diagram 625
Fault Code A286: A fault was detected in the shutdown delay relay circuit 626
Related circuit diagram 627
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 628
Related circuit diagram 630
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 633
Fault Code A303: Shifter is defective 634
Related circuit diagram 635
Fault Code A304: Auto lube grease level is low 636
Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be 638
Related circuit diagram 639
Fault Code A307: Both GE inverters are disabled 640
Fault Code A309: No brakes applied when expected 641
Related circuit diagram 643
Fault Code A311: Brake lock switch is on when it should not be 644
Related circuit diagram 645
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 646
Related circuit diagram 646
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 647
Related circuit diagram 647
Fault Code A315: DC-DC converter 12 volt circuit is low 648
Related circuit diagram 649
Fault Code A316: Starter engagement has been attempted with engine running 650
Related circuit diagram 651
Fault Code A317: Operation of brake auto apply valve without a detected response 652
Related circuit diagram 654
Fault Code A318: Unexpected power loss to interface module 655
Related circuit diagram 655
Fault Code A328: Drive system not powered up 656
Related circuit diagram 657
Fault Code A332: Seat belt not buckled 658
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 660
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 661
Fault Code A335: Manual/Auto Apply Pressure Fault 662
Fault Code A350: Overload on output 1B 664
Related circuit diagram 665
Fault Code A351: Overload on output 1E 666
Related circuit diagram 667
Fault Code A352: Overload on output 1H 668
Related circuit diagram 669
Fault Code A353: Overload on output 1J 670
Related circuit diagram 671
Fault Code A354: Overload on output 1K 672
Related circuit diagram 673
Fault Code A355: Overload on output 1L 674
Related circuit diagram 675
Fault Code A356: Overload on output 1M 676
Related circuit diagram 677
Fault Code A357: Overload on output 1N 678
Related circuit diagram 679
Fault Code A358: Overload on output 1P 680
Related circuit diagram 681
Fault Code A359: Overload on output 1R 682
Related circuit diagram 683
Fault Code A360: Overload on output 1S 684
Related circuit diagram 685
Fault Code A361: Overload on output 1T 686
Related circuit diagram 687
Fault Code A362: Overload on output 1U 688
Related circuit diagram 689
Fault Code A363: Overload on output 1X 690
Related circuit diagram 690
Fault Code A364: Overload on output 1Y 692
Related circuit diagram 693
Fault Code A365: Overload on output 1Z 694
Related circuit diagram 695
SECTION G REAR AXLE, SPINDLES AND WHEELS 697
SECTION G2 TIRES AND RIMS INDEX 699
TIRES AND RIMS 701
GENERAL PRECAUTIONS 701
WHEEL STUD MAINTENANCE 702
WHEEL STUD INSTALLATION HEIGHT 703
FRONT TIRES AND RIMS 704
Removal 704
Installation 705
REAR TIRES AND RIMS 705
Removal 705
Installation 706
RIM COMPONENTS 708
Smart Rim Component Layout 708
RIM AND TIRE SERVICE 709
Lubricants 709
Tire Inflation 709
Lock Ring Retainer Installation 709
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 710
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 711
Removal (5-Piece Standard Rim) 712
Removal (7-Piece Smart Rim) 715
Removal (5-Piece Smart Rim) 717
Preparation Before Assembly 718
Installation (5-Piece Standard Rim) 719
Installation – Horizontal Mount (Smart Rim) 721
Installation – Vertical Mount (5-Piece Smart Rim) 723
Installation – Vertical Mount (7-Piece Smart Rim) 724
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 725
FRONT WHEEL HUB AND SPINDLE 727
WHEEL HUB AND SPINDLE ASSEMBLY 727
Removal 727
Spindle Removal Procedure (off of the truck) 730
Installation 732
Disassembly 733
Cleaning and Inspection 735
Assembly 735
Wheel Bearing Adjustment 736
Brake Installation 737
Seal Assembly Gap Check 738
WHEEL SPEED SENSOR TESTING 739
STEERING CYLINDERS 740
Spherical Bearing Wear Limits 740
Removal 741
Installation 741
Bearing Replacement (Steering Cylinder and Tie Rod) 741
TIE ROD 743
Removal 743
Installation 743
Disassembly 744
Assembly 744
Toe-In Adjustment 745
TIE ROD INSPECTION AND TORQUE PROCEDURE 746
Old Style Tie Rod 746
New Style Tie Rod 747
SECTION G4 REAR AXLE MOUNTING INDEX 749
REAR AXLE MOUNTING 751
PIVOT PIN 751
Removal 751
Installation 752
PIVOT EYE BEARING 752
Removal 752
Installation 752
PIVOT EYE REPAIR 753
Removal 753
Installation 753
ANTI-SWAY BAR 754
Removal 754
Disassembly 754
Cleaning and Inspection 754
Assembly 754
Installation 754
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 757
REAR AXLE AND WHEEL MOTOR 759
REAR AXLE HOUSING 759
Preparation 759
Removal 760
Cleaning and Inspection 761
Installation 761
BLOWER PRESSURE SWITCH ADJUSTMENT 761
WHEEL MOTOR 762
Preparation 762
Removal 763
Cleaning and Inspection 765
Installation 765
WHEEL MOTOR GEAR OIL 770
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 770
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 770
Filtering Requirements 770
Particle Size Analysis 771
Flushing 771
Spectrographic Oil Sample Analysis 772
ELEMENT SPECIFICATION CHARTS 773
SECTION H HYDRAIR® II SUSPENSIONS 777
SECTION H2 FRONT SUSPENSIONS INDEX 779
FRONT SUSPENSION 781
Removal 781
Installation 782
Inspection 787
LOWER BEARING & SEALS 788
Removal 788
Installation 788
MAJOR SUSPENSION REBUILD 789
Disassembly 789
Assembly 790
SUSPENSION PRESSURE TEST 791
SECTION H3 REAR SUSPENSIONS INDEX 793
REAR SUSPENSIONS 795
SUSPENSION CYLINDER 796
Removal 796
Installation 797
Disassembly 798
Cleaning and Inspection 798
Assembly 798
SUSPENSION PRESSURE TEST 800
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 801
SUSPENSION OILING AND CHARGING PROCEDURES 803
CHECKING FOR IMPROPER SUSPENSION CHARGE 803
GENERAL 804
REQUIRED EQUIPMENT 804
HYDRAIR® CHARGING KIT 805
Installation of Charging Kit 805
Removal of Charging Kit 805
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 806
FRONT SUSPENSION 809
REAR SUSPENSION 812
OIL AND NITROGEN SPECIFICATIONS CHARTS 815
SECTION J BRAKE CIRCUIT 817
SECTION J2 BRAKE CIRCUIT INDEX 819
BRAKE CIRCUIT 821
SERVICE BRAKE CIRCUIT 821
PARKING BRAKE CIRCUIT 823
BRAKE LOCK CIRCUIT 823
SECONDARY BRAKING AND AUTOMATIC APPLY 824
WARNING CIRCUIT 824
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 827
BRAKE CIRCUIT COMPONENT SERVICE 829
BRAKE VALVE 829
Rebuild Criteria 829
Removal 830
Installation 830
BRAKE VALVE/PEDAL ASSEMBLY 831
Disassembly 831
Assembly 832
Installation 834
DUAL RELAY VALVE 834
Removal 834
Installation 835
BRAKE MANIFOLD 835
Removal 835
Installation 836
Disassembly 836
Cleaning and Inspection 836
Assembly 836
BRAKE ACCUMULATORS 837
Accumulator charging and storage 837
Temperature during precharge 837
BLADDER BRAKE ACCUMULATORS 838
Brake Accumulator Bleed Down Procedure 838
Removal 838
Installation 839
Disassembly 839
Cleaning and Inspection 841
Assembly 841
Precharge Maintenance 842
Accumulator Storage Procedures 842
Installing A Bladder Accumulator From Storage 843
PISTON BRAKE ACCUMULATORS 843
Brake Accumulator bleed down Procedure 843
Removal 843
Installation 845
Disassembly 846
Cleaning and Inspection 846
Assembly 847
Piston accumulator charging procedure 847
Testing 850
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 850
Removal 850
Installation 850
Disassembly 851
Lever Adjustments 851
Potentiometer Check 851
Assembly 852
FRONT BRAKE COOLING HOSE INSTALLATION 854
Installation 854
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 857
BRAKE CIRCUIT CHECK-OUT PROCEDURE 859
REQUIRED EQUIPMENT 860
INITIAL SYSTEM SETUP 861
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 862
PARKING BRAKE CHECK-OUT 863
SERVICE BRAKE CHECK-OUT 864
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 865
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 866
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 868
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 869
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 871
WET DISC BRAKE ASSEMBLY 873
OPERATION 873
BRAKE DISC WEAR INSPECTION 874
BRAKE REBUILD 875
Disassembly 875
Cleaning and Inspection 879
Assembly 880
Brake floating ring seal assembly and installation 885
Brake Floating Seal Assembly and Installation 894
WET DISC BRAKE BLEEDING PROCEDURE 901
SECTION J7 PARKING BRAKE INDEX 903
PARKING BRAKE 905
OPERATION 905
MAINTENANCE 906
Inspection 906
Removal 906
Installation 907
Disassembly 907
Cleaning and Inspection 907
Assembly 909
Cleaning and Inspecting New Discs 910
PARKING BRAKE BLEEDING PROCEDURE 911
SECTION L HYDRAULIC SYSTEM 913
SECTION L2 HYDRAULIC SYSTEM INDEX 915
HYDRAULIC SYSTEM 917
HYDRAULIC PUMP MODULE 917
HOIST CIRCUIT OPERATION 918
STEERING CIRCUIT OPERATION 920
DISC BRAKE COOLING SYSTEM 922
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 925
HYDRAULIC SYSTEM COMPONENT REPAIR 927
HOIST PUMP 927
Removal 927
Installation 929
Inspection 934
Assembly 934
HOIST PUMP TROUBLESHOOTING GUIDE 939
HYDRAULIC TANK 940
Removal 940
Installation 941
HYDRAULIC TANK BREATHERS 941
HYDRAULIC TANK STRAINERS 942
Removal 942
Inspect and Clean 942
Installation 942
SECTION L4 STEERING CIRCUIT INDEX 943
STEERING CIRCUIT 945
STEERING CIRCUIT OPERATION 945
COMPONENT DESCRIPTION 946
Steering Control Unit 946
Bleed Down Manifold 947
Steering Accumulator Bleed Down Solenoid 947
Relief Valves 949
Hoist Up Limit Solenoid 949
Steering Accumulators 949
Low Precharge Warning Switch 949
High Pressure Filter 949
Quick Disconnect Ports 949
Flow Amplifier 951
FLOW AMPLIFIER SYSTEM OPERATION 952
No Steer 952
Steering Left 954
Steering Right 956
No Steer, External Shock Load 958
STEERING PUMP 960
Normal Operation 960
High Altitude Operation 960
PRINCIPLE OF OPERATION 962
Full Pump Volume 962
Half Pump Volume 962
Neutral Position 962
Steering Pump 963
SECTION L5 STEERING CONTROL UNIT INDEX 965
STEERING CONTROL UNIT 967
REMOVAL 967
SPLINE INSPECTION 968
INSTALLATION 968
DISASSEMBLY 969
CLEANING AND INSPECTION 970
ASSEMBLY 972
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 975
STEERING CIRCUIT COMPONENT REPAIR 977
BLEEDDOWN MANIFOLD VALVE 977
Removal 977
Installation 978
FLOW AMPLIFIER 979
Removal 979
Installation 979
Disassembly 979
Assembly 981
STEERING CYLINDERS 982
Disassembly 983
Piston Seal & Bearing Installation 983
Assembly 983
Testing 983
STEERING AND BRAKE PUMP 984
Removal 984
Installation 985
Disassembly 986
Inspection 989
Assembly 992
Driveshaft Group 993
Rotating Group 993
Valve Plate Group 994
STEERING ACCUMULATORS 996
Removal 996
Installation 996
Disassembly 997
Cleaning and Inspection 997
Assembly 998
Leak Testing1000
Charging Procedure1001
Precharge Maintenance1003
Accumulator Storage Procedures1004
Bladder Storage Procedures1004
Installing A Bladder Accumulator From Storage1004
TROUBLESHOOTING1005
STEERING CIRCUIT1005
STEERING PUMP1007
Basic Hydraulic System Checks1008
System Leakage Check1009
Steering Pump Troubleshooting Guide1011
Pump Pressure Control Checks1014
Pump Fails to Unload1015
Pump Fails to Develop Pressure1015
Pump Slow in Developing Pressure1016
Pump Control Valve Inspection and Troubleshooting1017
Pump Case Drain Check1017
Setting Pump Pressure Controls1019
Adjustment1020
SECTION L7 HOIST CIRCUIT INDEX1021
HOIST CIRCUIT1023
BASIC OPERATION1023
COMPONENT DESCRIPTION1024
Hydraulic Tank1024
Hydraulic Pump1024
High Pressure Filters1024
Hoist Valve1024
Inlet Sections1024
Work Ports (Rear) Spool Section1025
Tank Ports (Front) Spool Section1025
Hoist Pilot Valve1025
Bleeddown Manifold1026
Hoist Up Limit Solenoid1026
Pilot Operated Check Valve1026
Overcenter Manifold1026
HOIST CIRCUIT OPERATION1027
Float Position Of Pilot Valve With Truck Body On Frame1028
Power Up Operation1030
Hold Operation1032
Power Down Operation1034
Float Operation1036
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX1039
HOIST CIRCUIT COMPONENT REPAIR1041
HOIST VALVE1041
Removal1041
Installation1042
O-Ring Replacement1042
INLET SECTION1043
Disassembly1043
Cleaning and Inspection1044
Assembly1044
REAR SPOOL SECTION (Work Ports)1045
Disassembly1045
Cleaning and Inspection1045
Assembly1047
FRONT SPOOL SECTION (Tank Ports)1048
Disassembly1048
Cleaning and Inspection1048
Assembly1048
HOIST PILOT VALVE1050
Removal1050
Installation1050
Disassembly1051
Cleaning and Inspection1052
Assembly1052
HOIST CYLINDERS1053
Removal1053
Installation1054
Disassembly1056
Cleaning and Inspection1057
Assembly – Quill1058
Assembly – Cylinder1060
Testing1060
OVERCENTER VALVE MANIFOLD1061
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX1063
HYDRAULIC SYSTEM FILTERS1065
HOIST CIRCUIT FILTER1065
Filter Element Replacement1065
Removal – Hoist Circuit Filter1066
Installation – Hoist Circuit Filter1066
Indicator Switch – Hoist Circuit Filter1066
STEERING CIRCUIT FILTER1067
Filter Element Replacement1067
Removal – Steering Circuit Filter1068
Installation – Steering Circuit Filter1068
Indicator Switch – Steering Circuit Filter1068
INDICATOR SWITCH1068
Test Procedure1068
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX1071
HYDRAULIC CHECKOUT PROCEDURE1073
GENERAL INFORMATION1073
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE1080
Equipment Requirements1081
Pump Pressure Control Adjustments1081
Steering Control Valve and Flow Amplifier Leakage Test1082
Bleed Down Manifold Leakage Test1083
STEERING/BRAKE PUMP STROKE ADJUSTMENT1084
SHOCK AND SUCTION VALVES1084
Equipment Requirements1084
Pressure Tests1084
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES1086
Equipment Requirements1086
Pressure Gauge Locations1086
Brake Cooling Circuit Test1086
Power Up Relief Pressure Test1087
Power Down Relief Pressure Test1088
Counterbalance Valve Pressure Check1089
Counterbalance Valve Adjustment1090
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET1091
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET1092
SECTION M OPTIONS AND SPECIAL TOOLS1093
SECTION M7 HOT START SYSTEM INDEX1095
HOT START SYSTEM1097
SYSTEM OPERATION1097
HEATER INFORMATION1098
TROUBLESHOOTING GUIDELINES1099
SECTION M8 SPECIAL TOOLS INDEX1101
HIGH VOLTAGE TOOLS1105
0-2000 VDC CUSTOM METER KIT (58B-06-00800)1105
KOMVISION CALIBRATION TOOLS1107
SECTION M19 RADIATOR SHUTTERS INDEX1109
RADIATOR SHUTTERS1111
OPERATION1111
Hydraulic Circuit1111
Electrical Circuit1112
MAINTENANCE AND REPAIR1112
TROUBLESHOOTING1113
SECTION M20 PAYLOAD METER IV ™ INDEX1117
PAYLOAD METER IV ™1119
INTRODUCTION1119
Data Summary1119
Data Gathering1119
COMPONENT DESCRIPTION1120
Electronic Dash Display1120
Mode Switches1120
Brake Lock Switch1120
PAYLOAD METER IV SOFTWARE AND TOOLS1121
PAYLOAD METER IV SYSTEM CONFIGURATION1121
Connecting to the payload meter IV web server1121
Configuring a static IP address1121
PAYLOAD METER IV SOFTWARE INSTALLATION1123
INCLINOMETER CALIBRATION AND CLEAN TRUCK TARE1123
PLM IV SYSTEM CHECKOUT DATA SHEET1129
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS1130
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX1133
RESERVE ENGINE OIL SYSTEM1135
Operation1136
LED Monitor Light1136
Tank Fill Control (Optional)1137
Filling Procedure (Remote Fill Feature)1137
SERVICE1138
Every 10 Hours, or once each shift:1138
Every 500 Hours1138
Changing Oil1138
TROUBLESHOOTING1139
Circuit Fuse1139
SYSTEM ELECTRICAL SCHEMATICS1140
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX1141
RETRACTABLE LADDER SYSTEM1145
GENERAL SAFETY1145
LADDER SYSTEM DESCRIPTION1145
LADDER SYSTEM OPERATION1146
Normal Operation1146
Emergency Operation1147
Limit Switch Operation1147
IN-CAB CONTROL PANEL1148
IN-CAB CONTROL PANEL FEATURES1149
IN-CAB CONTROL PANEL FUNCTIONS1150
Timing Control1150
Ladder System Status1150
Fault Code Identification1150
Ladder System Configuration1150
In-Cab Control Panel Lockout1150
Automatic Raising1150
Diagnostics1151
Maintenance1151
USING THE IN-CAB CONTROL PANEL1151
Raising the Ladder1152
Lowering the Ladder1152
USING THE GROUND LEVEL CONTROL BOX1153
Raising the Ladder1153
Lowering the Ladder1153
POWER PACK OPERATION1154
MAINTENANCE1157
Safety During Maintenance1157
Unplanned Ladder Movements1157
Automatic Ladder Raising1157
Automatic Accumulator Recharging (Ladder in UP position)1158
PREVENTIVE MAINTENANCE PROCEDURES1159
Daily Inspection1159
250 Hour Inspection1159
5000 Hour Inspection1159
SERVICING1160
Check Reservoir Oil Level1160
Changing RLS Fluid1160
Cleaning the RLS1161
RLS DIAGNOSTICS1161
Description of Diagnostics Features1161
Continuous System Monitoring1162
Historic System Data Review1163
Comms Integrity Monitoring1163
Log and Service Information1164
System Event Logs1164
SECURITY ACCESS LEVELS1165
Access Level 1 – NONE1165
Access Level 2 – RESTRICTED1165
Access Level 3 – COMPLETE1165
User Access Privileges1166
USER ID – PASSWORD1167
Sequential Field Value Selection Options1167
Password Character Table1167
USER ID – NEW USER SETUP1168
SYSTEM FAULTS1168
Fault Type 1: Communications error1169
Fault Type 2: 10A/15A fuse blown1169
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected1170
Fault Type 8: Power pack recharge too long1170
Fault Type 9: Inhibit relay fail1171
Fault Types 10, 11: Light/Siren relay failure1171
Fault Type 12: Ladder came off upper limit1172
Fault Type 13: Ladder did not reach limit1172
Fault Type 14: Ladder stayed on limit1173
Fault Type 15: Low oil level1173
Fault Type 16: System voltage over 18V during movement1174
Fault Type 17: System voltage under 18V1174
Fault Type 18: System voltage over 31V1175
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)1175
Fault Type 21: Accumulator recharge > than once/hour1176
Fault Type 22: System raised by park brake1176
Fault Types 23, 24: Levels 1 and 2 service overdue1177
Fault Type 25: Levels 1 and 2 service complete1177
DATA MANAGEMENT1178
Log Files1178
Generating Reports1179
MENU DIAGRAMS1185
Controller Config1185
Contact Information1185
Show Recent Logs1185
System Settings1185
Upload Logs to USB1185
Diagnostics1185
SECTION M33 CAMERA SYSTEM INDEX1193
CAMERA SYSTEM1195
CAMERA SYSTEM1195
General1195
Operation1195
Camera Switch1196
CAMERA MONITOR1197
General1197
CAMERA CONTROLLER1198
General1198
Removal1198
Installation1198
Camera Controller Connector Pins1198
CAMERA SWITCHER1199
General1199
Removal1199
Installation1199
SETUP AND CHECKOUT PROCEDURE1200
General1200
STEP 1 – Switch Function1200
STEP 2 – Monitor System Settings to Default1200
STEP 4 – Monitor Settings – System Settings Unique1202
STEP 4 – Monitor Settings – System Settings Unique – Cameras1204
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay1206
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode1207
STEP 7 – Integrated Functions Check1208
SECTION N OPERATOR CAB1209
SECTION N2 TRUCK CAB AND COMPONENTS INDEX1211
TRUCK CAB AND COMPONENTS1213
TRUCK CAB1213
Description1213
Removal1214
Installation1215
CAB DOOR1216
Removal1216
Installation1216
Door Jamb Bolt Adjustment1217
Door Handle Plunger Adjustment1218
Replacing the Door Glass1219
Replacing the Door Handle or Latch Assembly1223
Replacing the Door Window Regulator1224
Replacing the Door and Door Hinge Seal1225
Replacing the Door Opening Seal1225
GLASS REPLACEMENT (Adhesive-Bonded Windows)1226
Recommended Tools and Supplies1226
Replacement Procedure1226
WINDSHIELD AND REAR GLASS1227
Removal1227
Installation1228
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX1229
OPERATOR AND PASSENGER SEATS1230
OPERATOR SEAT (STANDARD SEAT)1230
Adjustment1230
Inspection1231
Removal1231
Installation1231
Replacing the Seat Compressor1232
PASSENGER SEAT (STANDARD SEAT)1237
Inspection1237
Removal1237
Installation1237
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230)1238
Removal1238
Installation1238
SEAT BELT REPLACEMENT (STANDARD SEATS)1240
Removal1240
Installation1240
OPERATOR SEAT (OPTIONAL SEAT)1242
Seat Belts1242
Adjustment1242
PASSENGER SEAT (OPTIONAL SEAT)1243
Seat Belts1243
Adjustment1243
SEAT BELT REPLACEMENT (OPTIONAL SEATS)1244
General1244
Removal1244
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX1249
HEATER/AIR CONDITIONER1251
OPERATION1251
Fan Speed Control Knob1251
Temperature Control Knob1251
Air Flow Directional Knob1252
Heater/Air Conditioner Vents1252
COMPONENTS1252
Fuse and Circuit Breaker1252
Relays1252
Heater Core1253
Fan Motor And Speed Control1253
Actuators1253
Cab Air Filter1253
ENVIRONMENTAL IMPACT OF AIR CONDITIONING1256
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES1256
PRINCIPLES OF REFRIGERATION1256
Air Conditioning1256
Refrigeration – The Act Of Cooling1257
The Refrigeration Cycle1257
AIR CONDITIONER SYSTEM COMPONENTS1258
Compressor (Refrigerant Pump)1258
Service Valves1258
Condenser1258
Receiver-Drier1258
Expansion Block Valve1259
Accumulator1259
Evaporator1259
ELECTRICAL CIRCUIT1260
Thermostat1260
Compressor Clutch1260
Trinary™ Switch1261
AIR CONDITIONING SYSTEM SERVICING WARNINGS1262
SERVICE TOOLS AND EQUIPMENT1263
Recovery/Recycle Station1263
Leak Detector1263
Service Valves1264
Vacuum Pump1264
Manifold Gauge Set1265
Installing Manifold Gauge Set1266
Purging Air From Service Hoses1266
SYSTEM PERFORMANCE TEST1267
SYSTEM OIL1268
Handling and Reusing PAG Oil1268
Oil Quantity1268
Checking System Oil1268
REFRIGERANT1269
Recycled Refrigerant1269
Reclaimed Refrigerant1269
Refrigerant Quantity1270
R-134a Refrigerant Containers1270
SYSTEM LEAK TESTING1270
Electronic Leak Detector1271
Tracer Dyes1271
Soap and Water1271
RECOVERING AND RECYCLING THE REFRIGERANT1271
Draining Oil from the Previous Recovery Cycle1271
Performing the Recovery Cycle1271
Performing the Recycling Procedure1272
Evacuating and Charging the A/C System1272
SYSTEM REPAIR1272
System Flushing1272
COMPONENT REPLACEMENT1273
Hoses and Fittings1273
Lines1273
Expansion Valve1273
Receiver-Drier1273
Thermostat1273
Compressor1274
Accumulator1274
Clutch1274
EVACUATING THE SYSTEM1275
CHARGING THE A/C SYSTEM1276
TROUBLESHOOTING1277
Preliminary Checks1277
Diagnosis Of Gauge Readings And System Performance1277
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS1278
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM1284
SECTION N5 OPERATOR CAB AND CONTROLS INDEX1285
OPERATOR CAB AND CONTROLS1288
STEERING COLUMN1289
Removal1289
Inspection1289
Installation1290
STEERING WHEEL1290
Removal1290
Installation1290
STEERING WHEEL AND CONTROLS1292
Horn Button1292
Tilt / Telescope Lever1292
Multi-Function Turn Signal Switch1292
DYNAMIC RETARDING1293
Retarder Lever1293
Brake/Retarder Pedal1293
Throttle/Accelerator Pedal1293
GRADE/SPEED CHART1294
OVERHEAD PANEL AND DISPLAYS1295
CENTER CONSOLE1296
Directional Control Lever1296
Override/Fault Reset Switch1297
Engine Shutdown Switch1297
Window Control Switches1297
Hoist Control Lever1297
Retarder Speed Control (RSC) Adjustment Dial1298
Retarder Speed Control (RSC) Switch1298
Data Store Button1299
KOMTRAX Plus Snapshot In Progress Light1299
Link Energized Light1299
Service Engine Light1299
12V Auxiliary Power Outlets1299
Fire Suppression Control Outlet1299
Communication Radio Outlet1299
DIAGNOSTIC PORTS1299
KOMTRAX Plus Diagnostic Port1299
Interface Module (IM) Diagnostic Port1299
Payload Meter Diagnostic Port1299
Truck Control Interface (TCI) Diagnostic Port1299
Propulsion System Controller (PSC) Diagnostic Port1299
Engine Diagnostic Port (CENSE)1299
Engine Diagnostic Port (QUANTUM)1299
INSTRUMENT PANEL1300
Control Symbols1300
Key Switch1302
Rotating Beacon Light Switch (optional)1302
Heated Mirror Switch (optional)1302
AC Drive System Rest Switch1302
Wheel Brake Lock Switch1303
Hazard Warning Light Switch1303
Heater/Air Conditioner Vents1303
Engine Oil Pressure Gauge1303
Right Turn Signal Indicator1303
Digital Tachometer1303
High Beam Indicator1303
Speedometer/Payload Meter Display1303
Left Turn Signal Indicator1304
Coolant Temperature Gauge1304
Lamp Check Switch1304
Light Switch (3-Way)1304
Ladder Light Switch1304
Backup Light Switch1304
Fog Light Switch1305
Payload Meter Switch1305
Panel Illumination Light Dimmer Switch1305
Hydraulic Oil Temperature Gauge1305
Engine Hourmeter1305
Fuel Gauge1305
OVERHEAD STATUS / WARNING INDICATORS1306
A1 High Brake Oil Temperature1307
B1 Low Steering Pressure1307
C1 Low Accumulator Precharge Pressure1308
D1 Not used1308
E1 Low Brake Pressure1308
A2 Low Hydraulic Tank Level1308
B2 Low Automatic Lubrication System Pressure1308
C2 Circuit Breaker Tripped1308
D2 Hydraulic Oil Filter Monitor1309
E2 Low Fuel1309
A3 Parking Brake1309
B3 Service Brake1309
C3 Body Up1309
D3 Dynamic Retarding1309
E3 Stop Engine1310
A4 Cranking Motor Failure1310
B4 Backup Lights1310
C4 Engine Shutdown Timer1310
D4 Retard Speed Control (RSC) Indicator1310
E4 Check Engine1310
A5 No Power1311
B5 Propulsion System Warning1311
C5 Propulsion System Temperature1311
D5 System/Component Failure1311
E5 Battery Charging System Failure1311
A6 No Propel1311
B6 Propel System At Rest1311
C6 Propel System Not Ready1312
D6 Reduced Propulsion1312
E6 Retard At Continuous Level1312
D7 Brake Test Light1312
E7 Maintenance Monitor1312
8 Brake Test Switch1312
REAR AXLE LIGHT BAR1313
Backup Lights1313
Retard Lights1313
Brake Lights1313
Backup Alarm1313
KOMTRAX PLUS1314
Operation1314
Interface Module1316
Basic Precautions1316
KOMATSU WIRELESS BRIDGE (Optional)1317
General Information1317
Communication Setup1317
Switching to the KWB_SETUP Network1317
Setting the Computer Subnet Mask and IP Address1318
Properties1318
Setting Up the KWB1319
Adding Encryption1319
Final Computer Settings1319
Data Downloading1320
Resetting the KWB1320
KWB Lights1320
SECTION P LUBRICATION AND PERIODIC MAINTENANCE1321
SECTION P2 LUBRICATION AND SERVICE INDEX1323
LUBRICATION AND SERVICE1325
GENERAL1325
SERVICE CAPACITIES1325
HYDRAULIC TANK SERVICE1325
Adding Oil1325
COOLING SYSTEM SERVICE1326
Radiator Filling Procedure1326
Coolant Specifications1326
Unacceptable Practices1326
WHEEL MOTOR SERVICE1326
RESERVE OIL TANK SERVICE1327
Filling the Reserve Oil Tank (Remote Fill)1327
Inline Screen1327
QUICK FILL SERVICE CENTER1328
LUBRICATION CHART1329
10 HOUR (DAILY) INSPECTIONS1330
50 HOUR LUBRICATION AND MAINTENANCE CHECKS1332
100 HOUR LUBRICATION AND MAINTENANCE CHECKS1332
250 HOUR LUBRICATION AND MAINTENANCE CHECKS1332
500 HOUR LUBRICATION AND MAINTENANCE CHECKS1335
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS1337
5000 HOUR MAINTENANCE CHECKS1337
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX1339
AUTOMATIC LUBRICATION SYSTEM1341
GENERAL DESCRIPTION1341
SYSTEM COMPONENTS1343
Filter1343
Hydraulic Motor and Pump1343
Grease Reservoir1343
Pressure Reducing Valve1343
Flow Control Valve1343
Solenoid Valve1343
Vent Valve1343
Lubrication Cycle Timer1343
Over Pressure Cut Off Switch1343
Grease Pressure Failure Switch1343
Injectors1343
Relief Valve (unloader valve)1343
SYSTEM OPERATION1344
Normal Operation1344
Lubricant Required For System1345
System Priming1345
Filter Assembly1345
LUBRICANT PUMP1346
Pump Housing Oil Level1346
Pump Pressure Control1346
INJECTORS (SL-1 Series “H”)1347
Injector Specifications1347
Injector Adjustment1347
INJECTOR OPERATION1348
PREVENTIVE MAINTENANCE PROCEDURES1349
Daily Lubrication System Inspection1349
250 Hour Inspection1349
1000 Hour Inspection1349
SYSTEM CHECKOUT1350
Lubrication Controller Check1350
Lubrication Controller Components1350
Lubrication Controller Adjustment1350
SYSTEM TROUBLESHOOTING CHART1352
SECTION R SYSTEM SCHEMATICS1355

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24