Komatsu 930E-4SE Dump Truck Parts Manual CEBM030103 – PDF DOWNLOAD

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Komatsu 930E-4SE Dump Truck Parts Manual CEBM030103 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-4SE Dump Truck Parts Manual CEBM030103 – PDF DOWNLOAD

Language : English
Pages :1390
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4SE Dump Truck Parts Manual CEBM030103 – PDF DOWNLOAD

• A31875 – A32193

COVER 1
SECTION A GENERAL INFORMATION 9
Section A2 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
SECTION A2 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 SAFETY 17
GENERAL 17
Safety Rules 17
Safety Features 17
Fire Extinguisher And First Aid Kit 17
Clothing And Personal Items 17
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Unauthorized Modification 19
Precautions When Using ROPS 19
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 20
Safety At The Worksite 20
Fire Prevention 21
Ventilation In Enclosed Areas 21
Preparing For Operation 21
Mirrors, Windows And Lights 21
In The Operator Cab (Before Starting The Engine) 21
Seat Belts 21
OPERATING THE TRUCK 22
When Starting The Engine 22
General Truck Operation 22
Ensuring Good Visibility 22
Traveling 23
Traveling In Reverse 23
Traveling On Slopes 23
Operating On Snow Or Ice 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 24
When Dumping 24
When Loading 24
Parking The Truck 24
Towing 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump Starting With Jumper Cables 26
Jump Starting With Receptacles 27
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Electrical Systems Isolation 28
Warning Tag 30
Proper Tools 30
Use of Tie-Off Anchor During Maintenance and Repair 30
Securing The Dump Body 30
Jack Point Locations 31
WHILE PERFORMING MAINTENANCE 32
Keep The Truck Clean 32
Attachments 32
Working Under The Truck 32
Rotating Fan And Belts 32
Waste Materials 32
Adding Fuel Or Oil 33
Radiator Coolant Level 33
Use Of Lighting 33
Precautions With The Battery 33
Handling High Pressure Hoses 33
Precautions With High Pressure Oil 33
Performing Maintenance Near High Temperature Or High Pressure 33
TIRES 34
Inspection 34
Maintenance 34
Storage 35
Handling 36
WHEN REPAIRS ARE NECESSARY 37
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 38
Preliminary Procedures Before Welding or Performing Maintenance 38
Engine Shutdown Procedure Before Welding or Performing Maintenance 38
CAPACITOR DISCHARGE SYSTEM 40
Necessary Tools 40
Warnings and Cautions 41
Manual DC Link Capacitor Discharge Procedure 42
Failure of the Discharge System 44
Manual Discharge of Capacitors 45
Short Isolated Capacitor Terminals 47
SECTION A3 OPERATING INSTRUCTIONS 48
PREPARING FOR OPERATION 48
WALK AROUND INSPECTION 48
RETRACTABLE LADDER SYSTEM (Optional) 53
Description 53
Normal Operation 53
General Safety 53
IN-CAB CONTROL PANEL 54
Digital Display Screen 54
Command Buttons 54
USING THE IN-CAB CONTROL PANEL 55
Raising the Ladder 56
Lowering the Ladder 56
USING THE GROUND LEVEL CONTROL BOX 57
Raising the Ladder 57
Lowering the Ladder 57
EMERGENCY OPERATION 58
ENGINE START-UP 59
AFTER ENGINE HAS STARTED 60
PRE-SHIFT BRAKE CHECK 61
Events 61
OPERATION 61
Description 61
Brake Test Exit Criteria 62
PERFORMING THE BRAKE TESTS 63
Setup 63
Service Brake Test 63
Parking Brake Test 64
Retard System Test 65
EMERGENCY STEERING SYSTEM 65
Operation 65
Pre-Operation Testing 65
Additional Guidelines 66
MACHINE OPERATION SAFETY PRECAUTIONS 66
OPERATING ON THE HAUL ROAD 68
STARTING ON A GRADE WITH A LOADED TRUCK 69
PASSING 69
LOADING 69
Overload Speed Limit Function 69
DUMPING 70
Raising The Dump Body 70
Lowering The Dump Body (When dumping on flat ground) 71
Lowering The Dump Body (When dumping over a berm or into a crusher) 71
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION 72
FUEL DEPLETION 72
SAFE PARKING PROCEDURES 73
NORMAL ENGINE SHUTDOWN PROCEDURE 74
DISABLED TRUCK DUMPING PROCEDURE 75
Hookup 75
Raising the Body 75
Lowering the Body 75
HOIST SYSTEM 76
Hookup 76
Dumping Procedure 77
TOWING 77
Special Wiring Harness 78
Towing Procedure 78
SECTION A4 WARNINGS AND CAUTIONS 81
GRADE/SPEED CHART 81
KEY SWITCH 81
ROPS/FOPS 81
BATTERIES 82
ISOLATION BOX 83
PROPEL LOCKOUT LEVER 83
CAPACITORS 84
CRUSHING HAZARD 84
CYLINDER PRESSURE 85
FILLING THE HYDRAULIC TANK 85
HYDRAULIC OIL PRESSURE 86
HOT OIL SPRAY 86
WHEEL MOTOR OIL LEVEL 86
HOT EXHAUST 86
RADIATOR 87
EMERGENCY LADDER 87
ACCUMULATOR DRAIN VALVES 87
EMERGENCY DUMP PROCEDURE 87
EMERGENCY TOWING PROCEDURE 87
WELDING 88
EMERGENCY SHUTDOWN 88
INFORMATION DISPLAY 88
WIRELESS SIGNALS 88
HIGH VOLTAGE 89
LIFTING INSTRUCTIONS 90
PRODUCT IDENTIFICATION PLATE 91
LUBRICATION CHART 92
TOW SOCKET 92
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 92
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 93
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 94
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 94
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 95
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 96
SECTION A7 STORAGE PROCEDURES AND IDEL MACHINE PREPARATION 103
STORAGE PROCEDURES AND IDLE MACHINE PREPARATION 103
SHORT TERM IDLE PERIODS 103
PREPARATION FOR STORAGE 104
REMOVAL FROM STORAGE 105
RECONDITIONING AN IDLE VEHICLE 106
ENGINE OPERATION 108
After The Engine Has Started 109
ENGINE STORAGE 110
Temporary Storage (30 Days Or Less) 110
Extended Storage (More Than 30 Days) 110
RESTORING AN ENGINE AFTER EXTENDED STORAGE 111
ELECTRIC DRIVE TRUCKS 112
Storing A Truck That Is Operational 112
Storing A Truck That Is Not Operational 113
Storing A Major Component 113
Periodic Inspections 113
Placing Equipment Into Service After Storage 114
SECTION B STRUCTURES 115
SECTION B2 STRUCTURAL COMPONENTS INDEX 117
STRUCTURAL COMPONENTS 119
PREPARATION 119
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 120
Removal 120
Installation 120
RH DECK AND RETARDING GRID 121
Removal 121
Installation 121
LH DECK 122
Removal 122
Installation 122
CENTER DECK 123
Removal 123
Installation 123
SECTION B3 DUMP BODY INDEX 125
DUMP BODY 127
DUMP BODY 127
Removal 127
Installation 128
BODY PADS 129
Body Pad Shimming Procedure 130
BODY GUIDE 131
HOIST LIMIT SWITCH 131
BODY-UP SWITCH 131
BODY RETENTION SLING 131
ROCK EJECTORS 132
Inspection 132
SECTION B4 FUEL TANK INDEX 133
FUEL TANK 135
FUEL TANK 135
Removal 135
Repair 135
Cleaning 135
Installation 135
FUEL TANK VENT ASSEMBLY 137
Disassembly 137
Assembly 137
FUEL GAUGE SENDER 138
Removal 138
Installation 138
QUICK FILL FUEL RECEIVERS 138
SECTION C ENGINE 139
SECTION C2 POWER MODULE INDEX 141
POWER MODULE 143
PREPARATION FOR REMOVAL 143
REMOVAL 148
INSTALLATION 150
HOOKUP 151
EXHAUST TUBE INSTALLATION 152
EXHAUST BLANKET INSTALLATION 152
SECTION C3 COOLING SYSTEM INDEX 153
COOLING SYSTEM 155
RADIATOR 155
Removal 155
Installation 157
Filling Procedure 158
REPAIRING THE RADIATOR 158
Internal Inspection 158
External Cleaning 158
Disassembly 159
Cleaning and Inspection 160
Assembly 160
Pressure Testing 161
COOLANT SYSTEM TROUBLESHOOTING 161
SECTION C4 POWER TRAIN INDEX 163
POWER TRAIN 165
ALTERNATOR REMOVAL 165
ALTERNATOR INSTALLATION 167
Measuring Procedure 167
Joining the Alternator and Engine 169
ENGINE 170
Removal 170
Service 170
Installation 170
SECTION C5 AIR CLEANERS INDEX 171
AIR CLEANERS 173
OPERATION 173
SERVICING THE AIR CLEANERS 173
Replacing The Elements 174
AIR CLEANER ASSEMBLY CLEANING 175
Primary Element Cleaning 175
Precleaner Section Cleaning 177
AIR INTAKE TROUBLESHOOTING 178
SECTION C7 FAN CLUTCH INDEX 179
FAN CLUTCH 181
REMOVAL & INSTALLATION TOOLING 181
DISASSEMBLY 184
CLEANING AND INSPECTION 194
ASSEMBLY 198
TEST PROCEDURE 213
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 215
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 217
24VDC ELECTRIC SUPPLY SYSTEM 219
ELECTRICAL SYSTEM DESCRIPTION 219
BATTERIES 219
Maintenance and Service 219
Troubleshooting 219
BATTERY SUPPLY SYSTEM 221
24VDC Battery Charging Alternator 221
Battery Box 221
Removal 221
Installation 222
Battery Control Box 222
24VDC Auxiliary Battery Receptacles 222
Engine Start Relay 222
ISOLATION BOX ASSEMBLY 222
Engine Shutdown Switch 222
Access Ladder Light Switch 222
Battery Disconnect Switches 222
Propel Lockout Lever 223
LED Lights 223
AUXILIARY CONTROL CABINET 224
24VDC to 12VDC Converter 224
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 225
Operation 225
Engine Oil Pressure Switch 226
Check Valve 226
MAINTENANCE 226
Prelube System Operation Checks 226
Check Valve 226
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 227
24VDC ELECTRIC START SYSTEM 229
CRANKING MOTORS 229
Operation 229
Removal 229
Installation 229
CRANKING MOTOR TROUBLESHOOTING 230
Preliminary Inspection 230
No-Load Test 230
Interpreting Results of Tests 231
Disassembly 231
Cleaning and Inspection 232
Armature Servicing 234
Field Coil Checks 234
Field Coil Removal 234
SOLENOID CHECKS 235
Test 235
Assembly 236
Bearing Replacement: 236
Motor Assembly: 236
Pinion Clearance 237
MAGNETIC SWITCH 237
Removal 237
Installation 237
Coil Test 238
SECTION D3 24 VDC ELECTRICAL SYSTEM COMPONENTS INDEX 239
24 VDC ELECTRICAL SYSTEM COMPONENTS 241
TRUCK SHUTDOWN PROCEDURE 241
BRAKE WARNING BUZZER 241
AUXILIARY CONTROL CABINET COMPONENTS 241
Interface Module 242
Payload Meter 242
24VDC to 12VDC Converter 242
Circuit Breaker (CB60) 242
Communication Interface Module 242
Pump Module Service Light Timer 243
Power Distribution Terminals 243
Ground Terminal 243
Relays 244
Engine Service Light Timer 244
RTMR1 – VEC Block 245
Vehicle Electrical Centers (VEC) 245
VEC-89 246
VEC-90 248
VEC-91 250
MAGNETIC SWITCHES 252
Body position switches (With proximity switch and magnet) 252
Proximity switch operation 252
Service 252
BODY-UP SWITCH 253
Adjusting the Body-Up Switch 253
HOIST LIMIT SWITCH 254
Operation 254
Adjusting the Hoist Limit Switch 255
KOMTRAX PLUS 259
KOMTRAX PLUS BASIC FEATURES 259
Gather Data 259
Convert and Record Data 259
Communicate Data to Off-Board Systems 260
USING KOMTRAX PLUS 261
Turning KOMTRAX Plus ON 261
Normal KOMTRAX Plus Operation 261
Turning KOMTRAX Plus OFF 262
Downloading from the KOMTRAX Plus Controller 262
KOMTRAX PLUS DATA ITEMS 263
Fault Codes 263
Machine History 263
KOMTRAX Plus History 263
Snapshots 264
Manual Snapshots 264
Trends 266
Histogram (Load Map) Data 266
Haul Cycle Data 267
Alarm and Snapshot Triggers 268
Satellite Features 268
KOMTRAX PLUS DIAGNOSTIC FEATURES 270
Fault History 270
LED Digits 270
KOMTRAX PLUS CONTROLLER 270
Removal 271
Installation 271
KOMTRAX PLUS SOFTWARE 272
VHMS Tool Box Installation 272
VHMS Setting Tool Installation 272
PDM Software Installation 272
KOMTRAX PLUS INITIALIZATION PROCEDURE 273
CONTROLLER SETUP PROCEDURE 273
SNAPSHOT PROCEDURE 276
DOWNLOAD PROCEDURE 277
FTP UPLOAD PROCEDURE 278
INITIALIZATION FORMS 279
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS CONTROLLER CHECKOUT 285
Necessary Equipment 285
Preliminary 285
KOMTRAX Plus Controller Checkout Procedure 286
ORBCOMM CONTROLLER (if equipped) 288
Removal 288
Installation 288
Troubleshooting 289
SECTION D11 KOMTRAX PLUS INDEX 257
SECTION D11 KOMTRAX PLUS INDEX 257
KOMTRAX PLUS 259
KOMTRAX PLUS BASIC FEATURES 259
Gather Data 259
Convert and Record Data 259
Communicate Data to Off-Board Systems 260
USING KOMTRAX PLUS 261
Turning KOMTRAX Plus ON 261
Normal KOMTRAX Plus Operation 261
Turning KOMTRAX Plus OFF 262
Downloading from the KOMTRAX Plus Controller 262
KOMTRAX PLUS DATA ITEMS 263
Fault Codes 263
Machine History 263
KOMTRAX Plus History 263
Snapshots 264
Manual Snapshots 264
Trends 266
Hisogram (Load Map) Data 266
Haul Cycle Data 267
Alarm and Snapshot Triggers 268
Satellite Features 268
KOMTRAX PLUS DIAGNOSTIC FEATURES 270
Fault History 270
LED Digits 270
KOMTRAX PLUS CONTROLLER 270
Removal 271
Installation 271
KOMTRAX PLUS SOFTWARE 272
VHMS Tool Box Installation 272
VHMS Setting Tool Installation 272
PDM Software Installation 272
KOMTRAX PLUS INITIALIZATION PROCEDURE 273
CONTROLLER SETUP PROCEDURE 273
SNAPSHOT PROCEDURE 276
DOWNLOAD PROCEDURE 277
FTP UPLOAD PROCEDURE 278
INITIALIZATION FORMS 279
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS CONTROLLER CHECKOUT 285
Necessary Equipment 285
Preliminary 285
KOMTRAX Plus Controller Checkout Procedure 286
ORBCOMM CONTROLLER (if equipped) 288
Removal 288
Installation 288
Troubleshooting 289
SECTION D12 INTERFACE MODULE INDEX 295
INTERFACE MODULE 297
Removal 297
Installation 297
SENSORS 298
Temperature Sensors 298
Pressure Sensors 298
INTERFACE MODULE SOFTWARE 299
Flashburn Program Installation 299
Interface Module Application Code Installation 300
Interface Module Realtime Data Monitor Software 300
INTERFACE MODULE CHECKOUT 301
Necessary Equipment 301
Preliminary 302
Check Digital Inputs To The Interface Module 303
Check Analog Inputs To The Interface Module 307
Check Serial Interfaces To The Interface Module 307
Check Outputs From The Interface Module 308
IM SYSTEM CHECK-OUT PROCEDURE DATA SHEET 309
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 313
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 315
GENERAL 315
Structure and Purpose 315
TROUBLESHOOTING 316
Communications Networks 316
Coaxial Cable 316
FAULT CODES 316
Fault History 316
KOMTRAX Plus LED Display Fault Codes 317
Chassis Fault Codes 318
Engine Fault Codes 323
FAULT TREE ANALYSIS 328
Unable to connect to KOMTRAX Plus from laptop PC 328
Flashing Error Code N4-23 (PLM Communications Fault) 329
Flashing Error Code N4-22 (Engine Communications Fault) 330
No Data Received By WebCARE 331
Coaxial Cable Troubleshooting 332
SECTION D14 KOMTRAX PLUS FORMS INDEX 333
KOMTRAX PLUS FORMS 335
KOMTRAX PLUS INITIALIZATION CHECK LIST 335
KOMTRAX PLUS DATA DOWNLOAD 336
KOMTRAX PLUS INITIALIZATION CHECK LIST 337
KOMTRAX PLUS INITIALIZATION FORM 339
SECTION E ELECTRIC PROPULSION SYSTEM 341
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 343
ELECTRICAL PROPULSION SYSTEM COMPONENTS 345
GENERAL SYSTEM DESCRIPTION 345
SYSTEM COMPONENTS 347
Drive System Controller (DSC) 347
Diagnostic Information Display (DID) Panel 348
DID Panel Event Codes 348
DSC SOFTWARE FUNCTIONS 376
Input Processing 376
State Machine 376
DC Link State 379
Engine Control 380
ALTERNATOR FIELD CONTROL 380
Desired DC Link Voltage 380
Self-Load 380
Propel Torque Control 381
Retard Torque Control 381
Wheel Slide Control 381
Resistor Grid Control 382
Chopper Voltage Control 382
EVENT DETECTION AND PROCESSING 383
Power-On Tests 383
Initiated Tests 384
Periodic Tests 384
EVENT RESTRICTIONS 384
EVENT LOGGING AND STORAGE 384
Event History Buffer 385
Data Packs 385
Event Reset 385
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 386
Fast Start 386
Engine Shutdown/Engine Not Running 386
Limp Home Mode 386
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 387
ELECTRONIC ACCELERATOR AND RETARD PEDALS 394
Removal 394
Installation 394
Disassembly 394
Assembly 394
PHASE MODULE REPLACEMENT 395
Removal 395
Installation 395
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 397
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 399
AC DRIVE SYSTEM MAINTENANCE 399
NORMAL TRUCK SHUTDOWN PROCEDURE 400
TEST EQUIPMENT 401
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 401
REST MODE ACTIVATION 401
INITIAL CHECKOUT PROCEDURES 402
Circuit Continuity and Resistance Checks 402
Megger Test for Grounds 402
Preparation for Megger Test 403
Megger Test Procedure 404
Troubleshooting for Grounds 406
Low Voltage Power Supply Checks 407
Preparation for Power Supply Checks 407
Power Supply Check Procedure 407
Drive System Controller (DSC) Card Checks 408
Propulsion System Software Installation 408
DSC Manual Test Procedures 411
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 413
Set Truck ID Number 417
Control Cabinet Pressure Switch Check 418
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 419
Verifying DSC Software Version 419
Resetting and Erasing DSC Event Data 420
ENGINE RUNNING TESTS 421
Battery Boost Circuit Verification 421
Selector Switch Check 423
Ground Detection Network Tests 425
Self Load Engine Test (Loadbox) Procedure 429
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 431
DID Panel Display Selection 431
DID Modes Display 433
Function Key F1 – DID Events or Faults Display 434
Function Key F4 – DID Menu Display 437
DID Self Load Engine Test (Loadbox) 438
DID Link Capacitance Test 440
DID Speedometer Test 441
DID View Software Version 442
DID View Overspeed Setting 443
DID View Data Menu 444
DID Inverter Cutout Menu 449
DID Truck Configuration Menu 450
Language Selection 455
VIEWING EVENT AND STATISTICAL DATA 456
Viewing the DSC Event Summary, Trigger Data, and Data Packs 456
Viewing the Statistical Data 458
LOGIC SCREENS 459
DATALOGGER FUNCTION 461
Setting Up the Datalogger 461
Starting the Datalogger 463
UPLOADING DATA 465
Consolidated Truck Data Save 465
USB Drive 466
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 467
Fault Code A001: Left front suspension pressure sensor signal is high 469
Related circuit diagram 469
Fault Code A002: Left front suspension pressure sensor signal is low 470
Related circuit diagram 470
Fault Code A003: Right front suspension pressure sensor signal is high 471
Related circuit diagram 471
Fault Code A004: Right front suspension pressure sensor signal is low 472
Related circuit diagram 472
Fault Code A005: Left rear suspension pressure sensor signal is high 473
Related circuit diagram 473
Fault Code A006: Left rear suspension pressure sensor signal is low 474
Related circuit diagram 474
Fault Code A007: Right rear suspension pressure sensor signal is high 475
Related circuit diagram 475
Fault Code A008: Right rear suspension pressure sensor signal is low 476
Related circuit diagram 476
Fault Code A009: Incline sensor signal is high 477
Related circuit diagram 477
Fault Code A010: Incline sensor signal is low 478
Related circuit diagram 478
Fault Code A011: Payload meter speed sensor signal has failed 479
Related circuit diagram 479
Fault Code A013: Body up switch has failed 480
Related circuit diagram 480
Fault Code A014: Payload meter checksum computation has failed 481
Related circuit diagram 481
Fault Code A016: Payload meter write to flash memory has failed 482
Related circuit diagram 482
Fault Code A017: Payload meter flash memory read has failed 482
Related circuit diagram 482
Fault Code A018: Right rear flat suspension cylinder warning 483
Related circuit diagram 484
Fault Code A019: Left rear flat suspension cylinder warning 485
Related circuit diagram 486
Fault Code A022: Carryback load is excessive 487
Related circuit diagram 488
Fault Code A101: High pressure detected across a hydraulic pump filter 489
Related circuit diagram 491
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 493
Related circuit diagram 494
Fault Code A109: GE has generated a propel system reduced level signal 495
Related circuit diagram 495
Fault Code A111 & A247: Low steering pressure warning 496
Related circuit diagram 497
Fault Code A115: Low steering precharge pressure is detected 498
Related circuit diagram 499
Fault Code A117 & A261: Low brake accumulator pressure warning 500
Related circuit diagram 501
Fault Code A118: Brake pressure is low while brake lock is activated 502
Related circuit diagram 503
Fault Code A123: GE has generated a reduced retarding caution 504
Related circuit diagram 504
Fault Code A124: GE has generated a no propel / no retard warning 506
Related circuit diagram 507
Fault Code A125: GE has generated a no propel warning 508
Related circuit diagram 508
Fault Code A126: Oil level in the hydraulic tank is low 509
Related circuit diagram 509
Fault Code A127: IM furnished +5 volt output for sensors is low 510
Related circuit diagram 511
Fault Code A128: IM furnished +5 volt output for sensors is high 512
Related circuit diagram 513
Fault Code A139 & A310: Low fuel level warning 514
Related circuit diagram 515
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 516
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 517
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A247) INDEX 519
Fault Code A152: Starter failure 521
Fault Code A153: Battery voltage is low with truck in operation 522
Fault Code A154: Battery charging voltage is excessive 523
Fault Code A155: Battery charging voltage is low 524
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 525
Fault Code A166: Left rear hydraulic oil temp sensor is low 526
Fault Code A167: Right rear hydraulic oil temp sensor is low 527
Fault Code A168: Left front hydraulic oil temp sensor is low 528
Fault Code A169: Right front hydraulic oil temp sensor is low 529
Fault Code A170: Left rear hydraulic oil temp sensor is high 530
Fault Code A171: Right rear hydraulic oil temp sensor is high 531
Fault Code A172: Left front hydraulic oil temp sensor is high 532
Fault Code A173: Right front hydraulic oil temp sensor is high 533
Fault Code A184: J1939 data link is not connected 534
Fault Code A190: Auto lube control has detected an incomplete lube cycle 535
Fault Code A194: Left front hydraulic oil temperature is high 536
Fault Code A195: Right front hydraulic oil temperature is high 537
Fault Code A196: Left rear hydraulic oil temperature is high 538
Fault Code A197: Right rear hydraulic oil temperature is high 539
Fault Code A198: Hoist pressure 1 sensor is high 540
Fault Code A199: Hoist pressure 2 sensor is high 540
Fault Code A200: Steering pressure sensor is high 541
Fault Code A201: Brake pressure sensor is high 542
Fault Code A202: Hoist pressure 1 sensor is low 543
Fault Code A203: Hoist pressure 2 sensor is low 544
Fault Code A204: Steering pressure sensor is low 545
Fault Code A205: Brake pressure sensor is low 546
Fault Code A206: Ambient temperature sensor is high 547
Fault Code A207: Ambient temperature sensor is low 548
Fault Code A212: Bad truck speed signal 549
Fault Code A213: Parking brake should have applied but is detected as not having applied 550
Fault Code A214: Parking brake should have released but is detected as not having released 552
Fault Code A215: The brake auto apply relay circuit is defective 554
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 555
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 556
Fault Code A230: Parking brake has been requested while truck still moving 557
Fault Code A231: Dump body is up while traveling or intending to travel 558
Fault Code A233: Drive system CAN/RPC Control Link not connected 560
Fault Code A235: Steering accumulator is in the process of being bled down 561
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 562
Fault Code A237: The CAN/RPC connection to the display is open 563
Fault Code A240: The keyswitch input to the interface module is open 564
Fault Code A242: The fuel gauge within the display panel is defective 565
Fault Code A243: The engine coolant temp gauge within the display panel is defective 566
Fault Code A244: The drive system temp gauge within the display panel is defective 567
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 568
Fault Code A246: Payload meter reports truck overload 569
Fault Code A247 & A111: Low steering pressure warning 570
Related circuit diagram 571
SECTION E5 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX 573
Fault Code A248: The status indicator module within the display panel is defective 575
Fault Code A249: The red warning lamp within the display panel is shorted 576
Fault Code A250: Battery voltage is low with the truck parked 577
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 579
Fault Code A252: Start enable output circuit is either open or shorted to ground 580
Fault Code A253: Steering bleed circuit is not open while running 581
Fault Code A255: IM has detected a fault on IM output 1N 582
Fault Code A256: The red warning lamp in the ACTIA display but driven by IM, is open 583
Fault Code A257: Payload CAN/RPC is not connected 584
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 585
Fault Code A260: Parking brake failure 586
Fault Code A261 & A117: Low brake accumulator pressure warning 587
Fault Code A262: Steering bleed valve circuit open during shutdown 588
Fault Code A264: Parking brake relay circuit is defective 589
Fault Code A265: Service brake failure 590
Fault Code A266: Selector lever was not in park while attempting to crank engine 591
Fault Code A267: Parking brake was not set while attempting to crank engine 592
Fault Code A268: Secondary engine shutdown while cranking 593
Fault Code A270: Brake lock switch power supply is not on when required 594
Fault Code A271: Shifter not in gear 596
Fault Code A272: Brake lock switch power supply is not off when required 597
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 599
Fault Code A274: A brake setting fault has been detected 600
Fault Code A275: A starter has been detected as engaged without a cranking attempt 601
Fault Code A277: Parking brake applied while loading 602
Fault Code A278: Service brake applied while loading 603
Fault Code A279: Low steering pressure switch is defective 604
Fault Code A280: Steering accumulator bleed down switch is defective 605
Fault Code A281: Brake lock degradation switch is defective 606
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 607
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 608
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 609
Fault Code A285: The parking brake was not set when the key switch was turned off 610
Fault Code A286: A fault was detected in the shutdown delay relay circuit 611
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 612
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 613
Fault Code A303: Shifter is defective 615
Fault Code A304: Auto lube grease level is low 616
Fault Code A307: Both GE inverters are disabled 617
Fault Code A309: No brakes applied when expected 618
Fault Code A310 & A139: Low fuel level warning 619
Fault Code A311: Brake lock switch is on when it should not be 620
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 621
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 622
Fault Code A315: DC-DC converter 12 volt circuit is low 623
Fault Code A316: Starter engagement has been attempted with engine running 624
Fault Code A317: Operation of brake auto apply circuit without a detected response 625
Fault Code A318: Unexpected power loss to interface module 626
Fault Code A328: Drive system not powered up 627
Fault Code A332: Seat belt not buckled 628
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 629
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 630
Fault Code A335: Manual/Auto Apply Pressure Fault 631
Fault Code A350: Overload on output 1B 632
Fault Code A351: Overload on output 1E 633
Fault Code A352: Overload on output 1H 634
Fault Code A353: Overload on output 1J 635
Fault Code A354: Overload on output 1K 636
Fault Code A355: Overload on output 1L 637
Fault Code A356: Overload on output 1M 638
Fault Code A357: Overload on output 1N 639
Fault Code A358: Overload on output 1P 640
Fault Code A359: Overload on output 1R 641
Fault Code A360: Overload on output 1S 642
Fault Code A361: Overload on output 1T 643
Fault Code A362: Overload on output 1U 644
Fault Code A363: Overload on output 1X 645
Fault Code A364: Overload on output 1Y 646
Fault Code A365: Overload on output 1Z 647
SECTION G REAR AXLE, SPINDLES AND WHEELS 649
SECTION G2 TIRES AND RIMS INDEX 651
TIRES AND RIMS 653
GENERAL PRECAUTIONS 653
WHEEL STUD MAINTENANCE 654
WHEEL STUD INSTALLATION HEIGHT 655
FRONT TIRES AND RIMS 656
Removal 656
Installation 657
REAR TIRES AND RIMS 657
Removal 657
Installation 658
RIM COMPONENTS 660
Smart Rim Component Layout 660
RIM AND TIRE SERVICE 661
Lubricants 661
Tire Inflation 661
Lock Ring Retainer Installation 661
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 662
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 663
Removal (5-Piece Standard Rim) 664
Removal (7-Piece Smart Rim) 667
Removal (5-Piece Smart Rim) 669
Preparation Before Assembly 670
Installation (5-Piece Standard Rim) 671
Installation – Horizontal Mount (Smart Rim) 673
Installation – Vertical Mount (5-Piece Smart Rim) 675
Installation – Vertical Mount (7-Piece Smart Rim) 676
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 677
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 677
FRONT WHEEL HUB AND SPINDLE 679
WHEEL HUB AND SPINDLE ASSEMBLY 679
Removal 679
Spindle Removal Procedure (off of the truck) 682
Installation 684
Disassembly 685
Cleaning and Inspection 687
Assembly 687
Wheel Bearing Adjustment 688
Brake Installation 689
Seal Assembly Gap Check 690
WHEEL SPEED SENSOR TESTING 691
STEERING CYLINDERS 692
Spherical Bearing Wear Limits 692
Removal 693
Installation 693
Bearing Replacement (Steering Cylinder and Tie Rod) 693
TIE ROD 695
Removal 695
Installation 695
Disassembly 696
Assembly 696
Toe-In Adjustment 697
TIE ROD INSPECTION AND TORQUE PROCEDURE 698
SECTION G4 REAR AXLE MOUNTING INDEX 699
REAR AXLE MOUNTING 701
PIVOT PIN 701
Removal 701
Installation 702
PIVOT EYE BEARING 702
Removal 702
Installation 702
PIVOT EYE REPAIR 703
Removal 703
Installation 703
ANTI-SWAY BAR 704
Removal 704
Disassembly 704
Cleaning and Inspection 704
Assembly 704
Installation 704
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 707
REAR AXLE AND WHEEL MOTOR 709
REAR AXLE HOUSING 709
Preparation 709
Removal 710
Cleaning and Inspection 711
Installation 711
BLOWER PRESSURE SWITCH ADJUSTMENT 711
WHEEL MOTOR 712
Preparation 712
Removal 713
Cleaning and Inspection 715
Installation 715
WHEEL MOTOR GEAR OIL 720
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 720
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 720
Filtering Requirements 720
Particle Size Analysis 721
Flushing 721
Spectrographic Oil Sample Analysis 722
ELEMENT SPECIFICATION CHARTS 723
SECTION H HYDRAIR® II SUSPENSIONS 727
SECTION H2 FRONT SUSPENSIONS INDEX 729
FRONT SUSPENSION 731
Removal 731
Installation 732
Inspection 737
LOWER BEARING & SEALS 738
Removal 738
Installation 738
MAJOR SUSPENSION REBUILD 739
Disassembly 739
Assembly 740
SUSPENSION PRESSURE TEST 741
SECTION H3 REAR SUSPENSIONS INDEX 743
REAR SUSPENSIONS 745
SUSPENSION CYLINDER 746
Removal 746
Installation 747
Disassembly 748
Cleaning and Inspection 748
Assembly 748
SUSPENSION PRESSURE TEST 750
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 751
SUSPENSION OILING AND CHARGING PROCEDURES 753
CHECKING FOR IMPROPER SUSPENSION CHARGE 753
GENERAL 754
REQUIRED EQUIPMENT 754
HYDRAIR® CHARGING KIT 755
Installation of Charging Kit 755
Removal of Charging Kit 755
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 756
FRONT SUSPENSION 759
REAR SUSPENSION 761
OIL AND NITROGEN SPECIFICATIONS CHARTS 764
SECTION J BRAKE CIRCUIT 765
SECTION J2 BRAKE CIRCUIT INDEX 767
BRAKE CIRCUIT 769
SERVICE BRAKE CIRCUIT 769
PARKING BRAKE CIRCUIT 771
BRAKE LOCK CIRCUIT 771
SECONDARY BRAKING AND AUTOMATIC APPLY 772
WARNING CIRCUIT 772
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 775
BRAKE CIRCUIT COMPONENT SERVICE 777
BRAKE VALVE 777
Rebuild Criteria 777
Removal 778
Installation 778
BRAKE VALVE/PEDAL ASSEMBLY 779
Disassembly 779
Assembly 780
Installation 782
DUAL RELAY VALVE 782
Removal 782
Installation 783
BRAKE MANIFOLD 783
Removal 783
Installation 784
Disassembly 784
Cleaning and Inspection 784
Assembly 784
BRAKE ACCUMULATORS 785
Accumulator charging and storage 785
Temperature during precharge 785
BLADDER BRAKE ACCUMULATORS 786
Brake Accumulator Bleed Down Procedure 786
Removal 786
Installation 787
Disassembly 787
Cleaning and Inspection 789
Assembly 789
Precharge Maintenance 790
Accumulator Storage Procedures 790
Installing A Bladder Accumulator From Storage 791
PISTON BRAKE ACCUMULATORS 791
Brake Accumulator bleed down Procedure 791
Removal 791
Installation 793
Disassembly 794
Cleaning and Inspection 794
Assembly 795
Piston accumulator charging procedure 795
Testing 798
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 798
Removal 798
Installation 798
Disassembly 799
Lever Adjustments 799
Potentiometer Check 799
Assembly 800
FRONT BRAKE COOLING HOSE INSTALLATION 802
Installation 802
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 805
BRAKE CIRCUIT CHECK-OUT PROCEDURE 807
REQUIRED EQUIPMENT 808
INITIAL SYSTEM SETUP 809
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 810
AUTO APPLY (LOW BRAKE PRESSURE) CHECK-OUT 811
SERVICE BRAKES 812
PARKING BRAKES 812
PARKING BRAKE CONTROL LOGIC 813
BRAKE LOCK CONTROL LOGIC 814
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 817
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 819
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 825
WET DISC BRAKE ASSEMBLY 827
OPERATION 827
BRAKE DISC WEAR INSPECTION 828
BRAKE REBUILD 829
Disassembly 829
Cleaning and Inspection 833
Assembly 834
Brake floating ring seal assembly and installation 839
Brake Floating Seal Assembly and Installation 848
WET DISC BRAKE BLEEDING PROCEDURE 855
SECTION J7 PARKING BRAKE INDEX 857
PARKING BRAKE 859
OPERATION 859
MAINTENANCE 860
Inspection 860
Removal 860
Installation 861
Disassembly 861
Cleaning and Inspection 861
Assembly 863
Cleaning and Inspecting New Discs 864
PARKING BRAKE BLEEDING PROCEDURE 865
SECTION L HYDRAULIC SYSTEM 867
SECTION L2 HYDRAULIC SYSTEM INDEX 869
HYDRAULIC SYSTEM 871
HYDRAULIC PUMP MODULE 871
HOIST CIRCUIT OPERATION 872
STEERING CIRCUIT OPERATION 874
DISC BRAKE COOLING SYSTEM 876
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 879
HYDRAULIC SYSTEM COMPONENT REPAIR 881
HOIST PUMP 881
Removal 881
Installation 883
Inspection 888
Assembly 888
HOIST PUMP TROUBLESHOOTING GUIDE 893
HYDRAULIC TANK 894
Removal 894
Installation 895
HYDRAULIC TANK STRAINERS 895
Removal 895
Inspect and Clean 897
Installation 897
SECTION L4 STEERING CIRCUIT INDEX 899
STEERING CIRCUIT 901
STEERING CIRCUIT OPERATION 901
COMPONENT DESCRIPTION 902
Steering Control Unit 902
Bleeddown Manifold 903
Steering Accumulator Bleeddown Solenoid 903
Relief Valves 905
Hoist Up Limit Solenoid 905
Steering Accumulators 905
Low Precharge Warning Switch 905
High Pressure Filter 905
Quick Disconnect Ports 905
Flow Amplifier 907
FLOW AMPLIFIER SYSTEM OPERATION 908
No Steer 908
Steering Left 910
Steering Right 912
No Steer, External Shock Load 914
STEERING PUMP 916
Normal Operation 916
High Altitude Operation 916
PRINCIPLE OF OPERATION 918
Full Pump Volume 918
Half Pump Volume 918
Neutral Position 918
Steering Pump 919
SECTION L5 STEERING CONTROL UNIT INDEX 921
STEERING CONTROL UNIT 923
REMOVAL 923
SPLINE INSPECTION 924
INSTALLATION 924
DISASSEMBLY 925
CLEANING AND INSPECTION 926
ASSEMBLY 928
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 931
STEERING CIRCUIT COMPONENT REPAIR 933
BLEEDDOWN MANIFOLD VALVE 933
Removal 933
Installation 934
FLOW AMPLIFIER 935
Removal 935
Installation 935
STEERING CYLINDERS 936
Disassembly 937
Piston Seal & Bearing Installation 937
Assembly 937
Testing 937
STEERING AND BRAKE PUMP 938
Removal 938
Installation 939
Disassembly 940
Inspection 943
Assembly 946
Driveshaft Group 947
Rotating Group 947
Valve Plate Group 948
PISTON STEERING ACCUMULATORS 950
Removal 950
Installation 951
Disassembly 952
Cleaning and Inspection 952
Assembly 953
Testing 953
TROUBLESHOOTING 954
STEERING CIRCUIT 954
STEERING PUMP 956
Basic Hydraulic System Checks 957
System Leakage Check 958
Steering Pump Troubleshooting Guide 960
Pump Pressure Control Checks 963
Pump Control Valve Inspection and Troubleshooting 966
Pump Case Drain Check 966
Setting Pump Pressure Controls 968
SECTION L7 HOIST CIRCUIT INDEX 971
HOIST CIRCUIT 973
BASIC OPERATION 973
COMPONENT DESCRIPTION 974
Hydraulic Tank 974
Hydraulic Pump 974
High Pressure Filters 974
Hoist Valve 974
Inlet Sections 974
Work Ports (Rear) Spool Section 975
Tank Ports (Front) Spool Section 975
Hoist Pilot Valve 975
Bleeddown Manifold 976
Hoist Up Limit Solenoid 976
Pilot Operated Check Valve 976
Overcenter Manifold 976
HOIST CIRCUIT OPERATION 977
Float Position Of Pilot Valve With Truck Body On Frame 978
Power Up Operation 980
Hold Operation 982
Power Down Operation 984
Float Operation 986
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 989
HOIST CIRCUIT COMPONENT REPAIR 991
HOIST VALVE 991
Removal 991
Installation 992
O-Ring Replacement 992
INLET SECTION 993
Disassembly 993
Cleaning and Inspection 994
Assembly 994
REAR SPOOL SECTION (Work Ports) 995
Disassembly 995
Cleaning and Inspection 995
Assembly 997
FRONT SPOOL SECTION (Tank Ports) 998
Disassembly 998
Cleaning and Inspection 998
Assembly 998
HOIST PILOT VALVE 1000
Removal 1000
Installation 1000
Disassembly 1001
Cleaning and Inspection 1002
Assembly 1002
HOIST CYLINDERS 1003
Removal 1003
Installation 1004
Disassembly 1006
Cleaning and Inspection 1007
Assembly – Quill 1008
Assembly – Cylinder 1010
Testing 1010
OVERCENTER VALVE MANIFOLD 1011
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 1013
HYDRAULIC SYSTEM FILTERS 1015
HOIST CIRCUIT FILTER 1015
Filter Element Replacement 1015
Removal – Hoist Circuit Filter 1016
Installation – Hoist Circuit Filter 1016
Indicator Switch – Hoist Circuit Filter 1016
STEERING CIRCUIT FILTER 1017
Filter Element Replacement 1017
Removal – Steering Circuit Filter 1018
Installation – Steering Circuit Filter 1018
Indicator Switch – Steering Circuit Filter 1018
INDICATOR SWITCH 1018
Test Procedure 1018
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1021
HYDRAULIC CHECKOUT PROCEDURE 1023
GENERAL INFORMATION 1023
Procedure for bleeding down hydraulic brake and steering accumulators 1023
Accumulator precharge procedure (step 1) 1025
Pressure gauge installation (steps 2 and 3) 1026
Initial start-up and flushing (steps 4 through 20) 1027
Steering system checkout and adjustment (steps 21 through 24) 1030
Steering pump with unloader valve adjustment (step 25) 1031
Steering system diagnostic and verification (steps 26 through 30) 1032
Hoist system checkout and adjustment (steps 31 through 33) 1033
Hoist counterbalance valve adjustment (step 34) 1034
Oil cleanliness check (steps 35 & 36) 1035
HYDRAULIC CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1036
SECTION M OPTIONS AND SPECIAL TOOLS 1039
SECTION M7 HOT START SYSTEM INDEX 1041
HOT START SYSTEM 1043
SYSTEM OPERATION 1043
HEATER INFORMATION 1044
TROUBLESHOOTING GUIDELINES 1045
SECTION M8 SPECIAL TOOLS 1047
HIGH VOLTAGE TOOLS 1051
KOMVISION CALIBRATION TOOLS 1053
SECTION M19 RADIATOR SHUTTERS INDEX 1055
RADIATOR SHUTTERS 1057
OPERATION 1057
Hydraulic Circuit 1057
Electrical Circuit 1058
MAINTENANCE AND REPAIR 1058
TROUBLESHOOTING 1059
SECTION M20 PAYLOAD METER IV ™ INDEX 1063
PAYLOAD METER IV ™ 1065
INTRODUCTION 1065
Data Summary 1065
Data Gathering 1065
COMPONENT DESCRIPTION 1066
Electronic Dash Display 1066
Mode Switches 1066
Brake Lock Switch 1066
PAYLOAD METER IV SOFTWARE AND TOOLS 1067
PAYLOAD METER IV SYSTEM CONFIGURATION 1067
Connecting to the payload meter IV web server 1067
Configuring a static IP address 1067
PAYLOAD METER IV SOFTWARE INSTALLATION 1069
INCLINOMETER CALIBRATION AND CLEAN TRUCK TARE 1069
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1076
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1079
RESERVE ENGINE OIL SYSTEM 1081
GENERAL 1081
OPERATION 1082
Pumping Unit 1082
LED Monitor Lights 1083
Tank Auto Fill Control 1084
Filling Procedure (Remote Fill Feature) 1084
SERVICE 1085
Every 10 Hours (each shift) 1085
Every 500 Hours 1085
Changing Oil 1085
TROUBLESHOOTING 1086
Circuit Fuses 1086
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1087
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1089
RETRACTABLE LADDER SYSTEM 1093
GENERAL SAFETY 1093
LADDER SYSTEM DESCRIPTION 1093
LADDER SYSTEM OPERATION 1094
Normal Operation 1094
Emergency Operation 1095
Limit Switch Operation 1095
IN-CAB CONTROL PANEL 1096
IN-CAB CONTROL PANEL FEATURES 1097
IN-CAB CONTROL PANEL FUNCTIONS 1098
Timing Control 1098
Ladder System Status 1098
Fault Code Identification 1098
Ladder System Configuration 1098
In-Cab Control Panel Lockout 1098
Automatic Raising 1098
Diagnostics 1099
Maintenance 1099
USING THE IN-CAB CONTROL PANEL 1099
Raising the Ladder 1100
Lowering the Ladder 1100
USING THE GROUND LEVEL CONTROL BOX 1101
Raising the Ladder 1101
Lowering the Ladder 1101
POWER PACK OPERATION 1102
MAINTENANCE 1105
Safety During Maintenance 1105
Unplanned Ladder Movements 1105
Automatic Ladder Raising 1105
Automatic Accumulator Recharging (Ladder in UP position) 1106
PREVENTIVE MAINTENANCE PROCEDURES 1107
Daily Inspection 1107
250 Hour Inspection 1107
5000 Hour Inspection 1107
SERVICING 1108
Check Reservoir Oil Level 1108
Changing RLS Fluid 1108
Cleaning the RLS 1109
RLS DIAGNOSTICS 1109
Description of Diagnostics Features 1109
Continuous System Monitoring 1110
Historic System Data Review 1111
Comms Integrity Monitoring 1111
Log and Service Information 1112
System Event Logs 1112
SECURITY ACCESS LEVELS 1113
Access Level 1 – NONE 1113
Access Level 2 – RESTRICTED 1113
Access Level 3 – COMPLETE 1113
User Access Privileges 1114
USER ID – PASSWORD 1115
Sequential Field Value Selection Options 1115
Password Character Table 1115
USER ID – NEW USER SETUP 1116
SYSTEM FAULTS 1116
Fault Type 1: Communications error 1117
Fault Type 2: 10A/15A fuse blown 1117
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1118
Fault Type 8: Power pack recharge too long 1118
Fault Type 9: Inhibit relay fail 1119
Fault Types 10, 11: Light/Siren relay failure 1119
Fault Type 12: Ladder came off upper limit 1120
Fault Type 13: Ladder did not reach limit 1120
Fault Type 14: Ladder stayed on limit 1121
Fault Type 15: Low oil level 1121
Fault Type 16: System voltage over 18V during movement 1122
Fault Type 17: System voltage under 18V 1122
Fault Type 18: System voltage over 31V 1123
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1123
Fault Type 21: Accumulator recharge > than once/hour 1124
Fault Type 22: System raised by park brake 1124
Fault Types 23, 24: Levels 1 and 2 service overdue 1125
Fault Type 25: Levels 1 and 2 service complete 1125
DATA MANAGEMENT 1126
Log Files 1126
Generating Reports 1127
MENU DIAGRAMS 1133
Controller Config 1133
Contact Information 1133
Show Recent Logs 1133
System Settings 1133
Upload Logs to USB 1133
Diagnostics 1133
SECTION M33 KomVision® INDEX 1141
KomVision® 1143
KomVision® SYSTEM PRECAUTIONS 1143
COMPONENT LOCATIONS 1144
MONITOR PANEL 1148
Brightness Switches 1148
System Power Status Indicator 1148
Force Display Switch 1148
Camera Switches 1149
Monitor Display Mode Switch 1149
Reference Line Display Switch 1149
Lower Body Display Switch 1149
Object Clear Switch 1149
MONITOR DISPLAY 1150
Camera Display Modes 1150
Bird’s Eye Views 1152
Reference Lines 1152
Dump Body Status Display 1152
Error Code Display 1153
Initial Setting Screen 1154
RADAR SYSTEM 1154
Object Detection Range 1154
Object Detection Warnings 1155
Object Clear 1158
START-UP INSPECTION 1158
Camera Inspections 1158
Verify the Radar System is Operational 1158
CLEANING 1159
Monitor Panel And Controller 1159
Cameras 1159
KomVision® SYSTEM SETUP AND CALIBRATION 1160
Password Mode 1160
Maintenance Mode 1161
Main Setting Display 1162
6 Camera Calibration Display 1163
Camera Setting 1173
System State 1175
Error Log Screen 1176
Check Disk Display 1176
MAINTENANCE SCREEN EXPLANATION 1177
Area 1177
Threshold 1178
All Radar Position 1178
RADAR DETAIL 1181
Integration 1181
Explanation of Terms 1182
System I/O Explanation 1183
TESTING AND ADJUSTING 1184
System Adjustment 1184
Initial Setting 1184
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1185
6 Camera Calibration Preparation 1185
Calibration Sheet Unfolding 1188
Folding a Camera Calibration Sheet 1189
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1190
Placement of Front Calibration Sheet 1190
Placement of Left and Right Calibration Sheet 1190
Placement of Rear Calibration Sheet and Adjustment of Left and Right Calibration Sheets 1191
CALIBRATING CAMERAS 1191
Automatic 6 Camera Calibration Operation 1191
Manual 6 Camera Calibration 1195
6 Camera Calibration Outgoing Message, and Screen Correspondence 1197
1 Camera Calibration 1198
1 Camera Calibration Outgoing Message, and Screen Correspondence 1200
RADAR SETTING 1200
Radar Zone Preparation and System Calibration 1200
SECTION N OPERATOR CAB 1211
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 1213
TRUCK CAB AND COMPONENTS 1215
TRUCK CAB 1215
Description 1215
Removal 1216
Installation 1217
CAB DOOR 1218
Removal 1218
Installation 1218
Door Jamb Bolt Adjustment 1219
Door Handle Plunger Adjustment 1220
Replacing the Door Glass 1221
Replacing the Door Handle or Latch Assembly 1225
Replacing the Door Window Regulator 1226
Replacing the Door and Door Hinge Seal 1227
Replacing the Door Opening Seal 1227
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1228
Recommended Tools and Supplies 1228
Replacement Procedure 1228
WINDSHIELD AND REAR GLASS 1229
Removal 1229
Installation 1230
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1231
OPERATOR SEAT (STANDARD SEAT) 1233
Adjustment 1233
Inspection 1234
Removal 1234
Installation 1234
Replacing the Seat Compressor 1235
PASSENGER SEAT (STANDARD SEAT) 1240
Adjustment 1240
Inspection 1241
Removal 1241
Installation 1241
SEAT BELT REPLACEMENT (STANDARD SEAT) 1242
Removal 1242
Installation 1242
OPERATOR SEAT (OPTIONAL SEAT) 1244
Seat Belts 1244
Adjustment 1244
PASSENGER SEAT (OPTIONAL SEAT) 1245
Seat Belts 1245
Adjustment 1245
SEAT BELT REPLACEMENT (OPTIONAL SEAT) 1246
General 1246
Removal 1246
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1251
HEATER/AIR CONDITIONER 1253
OPERATION 1253
Fan Speed Control Knob 1253
Temperature Control Knob 1253
Air Flow Directional Knob 1254
Heater/Air Conditioner Vents 1254
COMPONENTS 1254
Fuse and Circuit Breaker 1254
Relays 1254
Heater Core 1255
Fan Motor And Speed Control 1255
Actuators 1255
Cab Air Filter 1255
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1258
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1258
PRINCIPLES OF REFRIGERATION 1258
Air Conditioning 1258
Refrigeration – The Act Of Cooling 1259
The Refrigeration Cycle 1259
AIR CONDITIONER SYSTEM COMPONENTS 1260
Compressor (Refrigerant Pump) 1260
Service Valves 1260
Condenser 1260
Receiver-Drier 1260
Expansion Block Valve 1261
Accumulator 1261
Evaporator 1261
ELECTRICAL CIRCUIT 1262
Thermostat 1262
Compressor Clutch 1262
Trinary™ Switch 1263
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1264
SERVICE TOOLS AND EQUIPMENT 1265
Recovery/Recycle Station 1265
Leak Detector 1265
Service Valves 1266
Vacuum Pump 1266
Manifold Gauge Set 1267
Installing Manifold Gauge Set 1268
Purging Air From Service Hoses 1268
SYSTEM PERFORMANCE TEST 1269
SYSTEM OIL 1270
Handling and Reusing PAG Oil 1270
Oil Quantity 1270
Checking System Oil 1270
REFRIGERANT 1271
Recycled Refrigerant 1271
Reclaimed Refrigerant 1271
Refrigerant Quantity 1272
R-134a Refrigerant Containers 1272
SYSTEM LEAK TESTING 1272
Electronic Leak Detector 1273
Tracer Dyes 1273
Soap and Water 1273
RECOVERING AND RECYCLING THE REFRIGERANT 1273
Draining Oil from the Previous Recovery Cycle 1273
Performing the Recovery Cycle 1273
Performing the Recycling Procedure 1274
Evacuating and Charging the A/C System 1274
SYSTEM REPAIR 1274
System Flushing 1274
COMPONENT REPLACEMENT 1275
Hoses and Fittings 1275
Lines 1275
Expansion Valve 1275
Receiver-Drier 1275
Thermostat 1275
Compressor 1276
Accumulator 1276
Clutch 1276
EVACUATING THE SYSTEM 1277
CHARGING THE A/C SYSTEM 1278
TROUBLESHOOTING 1279
Preliminary Checks 1279
Diagnosis Of Gauge Readings And System Performance 1279
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1280
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1286
SECTION N5 OPERATOR CAB AND CONTROLS INDEX 1287
OPERATOR CAB AND CONTROLS 1291
STEERING COLUMN 1292
Removal 1292
Inspection 1292
Installation 1293
STEERING WHEEL 1293
Removal 1293
Installation 1293
STEERING WHEEL AND CONTROLS 1294
Horn Button 1294
Tilt / Telescope Lever 1294
Multi-Function Turn Signal Switch 1294
DYNAMIC RETARDING 1295
Retarder Lever 1295
Service Brake/Retarder Pedal 1295
Throttle/Accelerator Pedal 1295
GRADE/SPEED CHART 1296
OVERHEAD PANEL AND DISPLAYS 1297
CENTER CONSOLE 1298
Directional Control Lever 1298
Override/Fault Reset Switch 1299
Engine Stop Switch 1299
LH Window Control Switch 1299
RH Window Control Switch 1299
Hoist Control Lever 1299
Raising The Dump Body 1299
Lowering The Dump Body 1299
Retard Speed Control (RSC) Adjust Dial 1300
Retard Speed Control (RSC) Switch 1300
Data Store Button 1300
12V Auxiliary Power Outlets 1300
Fire Suppression Control Outlet 1300
Communication Radio Outlet 1300
DIAGNOSTIC PORTS 1301
KOMTRAX Plus Diagnostic Port 1301
Interface Module (IM) Diagnostic Port 1301
Payload Meter Diagnostic Port 1301
Drive System Or Modular Mining 1301
Drive System Controller (DSC) Diagnostic Port 1301
Engine Diagnostic Port (CENSE) 1301
Engine Diagnostic Port (QUANTUM) 1301
HEATER / AIR CONDITIONER 1302
Fan Speed Control Knob 1302
Temperature Control Knob 1302
Air Flow Directional Knob 1302
Heater/Air Conditioner Vents 1302
INSTRUMENT PANEL 1303
Control Symbols 1303
Cab/Air Conditioner Vents 1305
Status Indicator Light Panel 1305
Hydraulic Oil Temperature Gauge 1305
Coolant Temperature Gauge 1305
Speedometer/Digital Display 1305
Fuel Level Gauge 1305
Drive System Temperature Gauge 1305
Hazard Warning Light Switch 1305
Pre-Shift Brake Test Switch 1306
Wheel Brake Lock Control 1306
Rest Switch 1306
Engine Warm Up Switch 1307
Heated Mirror Switch 1307
Rotating Beacon Light Switch (Optional) 1307
Key Switch 1307
Starting 1307
Warning Light 1308
Digital Display Contrast Buttons 1308
Turn Signal Indicators 1308
Panel Light Dimmer 1308
Mode Switches 1308
Fog Light Switch 1308
Manual Backup Switch 1308
Headlight/Panel Illumination Light Switch 1309
STATUS INDICATOR LIGHT PANEL 1310
REAR AXLE LIGHT BAR 1313
Backup Lights 1313
Retard Lights 1313
Brake Lights 1313
Backup Alarm 1313
DIGITAL DISPLAY OPERATION 1314
Toggling Through Main Level Screens 1314
Toggling Through Warning Screens 1315
Entering Payload Meter Data 1316
KOMTRAX PLUS 1317
Operation 1317
Interface Module 1319
Basic Precautions 1319
KOMATSU WIRELESS BRIDGE (KWB) General information 1320
General information 1320
Required software and tools 1320
Configuring the Bullet wireless radio 1321
Installing the Bullet wireless radio 1324
Configuring the NanoStation access point 1326
Testing the connection 1329
Changing a service computer’s IP address 1330
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1331
SECTION P2 PERIODIC MAINTENANCE INDEX 1333
PERIODIC MAINTENANCE 1335
GENERAL 1335
SERVICE CAPACITIES 1335
HYDRAULIC TANK SERVICE 1335
Adding Oil 1335
COOLING SYSTEM SERVICE 1336
Radiator Filling Procedure 1336
Coolant Specifications 1336
Unacceptable Practices 1336
WHEEL MOTOR SERVICE 1336
RESERVE OIL TANK SERVICE 1337
Filling the Reserve Oil Tank (Remote Fill) 1337
Inline Screen 1337
QUICK FILL SERVICE CENTER 1338
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1340
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1340
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1341
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1343
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1347
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1349
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1349
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1350
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1350
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1351
AUTOMATIC LUBRICATION SYSTEM 1353
GENERAL DESCRIPTION 1353
SYSTEM COMPONENTS 1355
Filter 1355
Hydraulic Motor and Pump 1355
Grease Reservoir 1355
Pressure Reducing Valve 1355
Flow Control Valve 1355
Solenoid Valve 1355
Vent Valve 1355
Grease Pressure Failure Switch 1355
Injectors 1355
Interface Module 1355
Relief Valve (unloader valve) 1355
SYSTEM OPERATION 1356
Normal Operation 1356
Lubricant Required For System 1357
Filter Assembly 1357
System Priming 1357
LUBRICANT PUMP 1358
Pump Housing Oil Level 1358
Pump Pressure Control 1358
INJECTORS (SL-1 Series “H”) 1359
Injector Specifications 1359
Injector Adjustment 1359
INJECTOR OPERATION 1360
PREVENTIVE MAINTENANCE PROCEDURES 1361
Daily Lubrication System Inspection 1361
250 Hour Inspection 1361
1000 Hour Inspection 1361
SYSTEM CHECKOUT 1362
Pump Priming Procedure 1362
System Priming Procedure 1363
Lubrication Cycle Operation 1363
AUTOLUBE TROUBLESHOOTING CHART 1364
SECTION R SYSTEM SCHEMATICS INDEX 1367

DESCRIPTION:

Komatsu 930E-4SE Dump Truck Parts Manual CEBM030103 – PDF DOWNLOAD

• A31875 – A32193

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per- sonnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing 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 ser- viceable 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, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”. “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
  Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 135 Nm (100 ft lbs) torque. All torque specifications have ±10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system.
  The Product Identification Number (vehicle serial number) contains information which will identify the original man- ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo- nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
  To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.