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Komatsu 930E-4SE Dump Truck Shop Manual A30587-A30677 – PDF DOWNLOAD
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Komatsu 930E-4SE Dump Truck Shop Manual
SERIAL NUMBERS : A30587 – A30677
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Description
Komatsu 930E-4SE Dump Truck Shop Manual
FILE DETAILS:
Komatsu 930E-4SE Dump Truck Shop Manual
Language : English
Pages : 1262
Downloadable : Yes
File Type : PDF
Size: 33.7 MB
Book Code: CEBM020003
DESCRIPTION:
Komatsu 930E-4SE Dump Truck Shop Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
- All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit.
- The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
- All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs).
- All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
TABLE OF CONTENTS:
Komatsu 930E-4SE Dump Truck Shop Manual
COVER................................................................................................................................. 1 FOREWORD.............................................................................................................................. 5 TABLE OF CONTENTS..................................................................................................................... 7 SECTION A GENERAL INFORMATION......................................................................................................... 9 COMPONENTS & SPECIFICATIONS....................................................................................................... 11 MAJOR COMPONENT DESCRIPTIONS.................................................................................................. 11 Truck And Engine.......................................................................................................... 11 Main Alternator........................................................................................................... 11 AC Induction Traction Motorized Wheels.................................................................................... 11 Suspension................................................................................................................ 11 Operator's Cab............................................................................................................ 11 Power Steering............................................................................................................ 11 Dynamic Retarding......................................................................................................... 11 Brake System.............................................................................................................. 11 SPECIFICATIONS................................................................................................................ 13 ENGINE.................................................................................................................... 13 AC ELECTRIC DRIVE SYSTEM.................................................................................................. 13 DYNAMIC RETARDING......................................................................................................... 13 BATTERY ELECTRIC SYSTEM................................................................................................... 13 SERVICE CAPACITIES........................................................................................................ 13 HYDRAULIC SYSTEMS......................................................................................................... 14 SERVICE BRAKES............................................................................................................ 14 STEERING.................................................................................................................. 14 TIRES..................................................................................................................... 14 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.............................................................................. 14 WEIGHT DISTRIBUTION....................................................................................................... 15 SAFETY............................................................................................................................ 17 GENERAL....................................................................................................................... 17 Safety Rules.............................................................................................................. 17 Safety Features........................................................................................................... 17 Fire Extinguisher And First Aid Kit....................................................................................... 17 Clothing And Personal Items............................................................................................... 17 Leaving The Operator’s Seat............................................................................................... 18 Mounting And Dismounting.................................................................................................. 18 Fire Prevention For Fuel And Oil.......................................................................................... 18 Precautions With High Temperature Fluids.................................................................................. 19 Asbestos Dust Hazard Prevention........................................................................................... 19 Prevention Of Injury By Work Equipment.................................................................................... 19 Unauthorized Modification................................................................................................. 19 Precautions When Using ROPS............................................................................................... 19 Precautions For Attachments............................................................................................... 20 Precautions For Starting The Truck........................................................................................ 20 PRECAUTIONS BEFORE OPERATION.................................................................................................. 20 Safety At The Worksite.................................................................................................... 20 Fire Prevention........................................................................................................... 21 Ventilation In Enclosed Areas............................................................................................. 21 Preparing For Operation................................................................................................... 21 Mirrors, Windows And Lights............................................................................................... 21 In The Operator Cab (Before Starting The Engine).......................................................................... 21 Seat Belts................................................................................................................ 21 OPERATING THE TRUCK........................................................................................................... 22 When Starting The Engine.................................................................................................. 22 General Truck Operation................................................................................................... 22 Ensuring Good Visibility.................................................................................................. 22 Traveling................................................................................................................. 23 Traveling In Reverse...................................................................................................... 23 Traveling On Slopes....................................................................................................... 23 Operating On Snow Or Ice.................................................................................................. 23 Avoid Damage To Dump Body................................................................................................. 23 Driving Near High Voltage Cables.......................................................................................... 24 Working On Loose Ground................................................................................................... 24 When Dumping.............................................................................................................. 24 When Loading.............................................................................................................. 24 Parking The Truck......................................................................................................... 24 Towing.................................................................................................................... 24 WORKING NEAR BATTERIES........................................................................................................ 25 Battery Hazard Prevention................................................................................................. 25 Jump Starting With Booster Cables......................................................................................... 26 Jump Starting With Receptacles............................................................................................ 26 BEFORE PERFORMING MAINTENANCE................................................................................................. 27 Stopping The Engine Before Service........................................................................................ 27 Warning Tag............................................................................................................... 27 Proper Tools.............................................................................................................. 27 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 27 Securing The Dump Body.................................................................................................... 28 WHILE PERFORMING MAINTENANCE.................................................................................................. 29 Keep The Truck Clean...................................................................................................... 29 Attachments............................................................................................................... 29 Working Under The Truck................................................................................................... 29 Rotating Fan And Belts.................................................................................................... 29 Waste Materials........................................................................................................... 29 Adding Fuel Or Oil........................................................................................................ 30 Radiator Coolant Level.................................................................................................... 30 Use Of Lighting........................................................................................................... 30 Precautions With The Battery.............................................................................................. 30 Handling High Pressure Hoses.............................................................................................. 30 Precautions With High Pressure Oil........................................................................................ 30 Performing Maintenance Near High Temperature Or High Pressure............................................................. 30 TIRES......................................................................................................................... 31 Handling Tires............................................................................................................ 31 Tire Maintenance.......................................................................................................... 31 Storing Tires After Removal............................................................................................... 31 WHEN REPAIRS ARE NECESSARY.................................................................................................... 32 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS............................................................................ 33 Preliminary Procedures Before Welding or Performing Maintenance........................................................... 33 Engine Shutdown Procedure Before Welding or Performing Maintenance........................................................ 33 CAPACITOR DISCHARGE SYSTEM.................................................................................................... 35 Necessary Tools........................................................................................................... 35 Warnings And Cautions..................................................................................................... 36 Manual DC Link Capacitor Discharge Procedure.............................................................................. 37 Failure of the Discharge System........................................................................................... 39 Manual Discharge of Capacitors............................................................................................ 40 Short Isolated Capacitor Terminals........................................................................................ 42 OPERATING INSTRUCTIONS............................................................................................................ 43 PREPARING FOR OPERATION....................................................................................................... 43 WALK AROUND INSPECTION........................................................................................................ 43 ENGINE START-UP............................................................................................................... 47 AFTER ENGINE HAS STARTED...................................................................................................... 48 PRE-SHIFT BRAKE CHECK (if equipped)........................................................................................... 48 Events.................................................................................................................... 48 OPERATION..................................................................................................................... 49 Description............................................................................................................... 49 Brake Test Exit Criteria.................................................................................................. 49 PERFORMING THE BRAKE TESTS.................................................................................................... 50 Setup..................................................................................................................... 50 Service Brake Test........................................................................................................ 50 Parking Brake Test........................................................................................................ 51 Retard System Test........................................................................................................ 52 EMERGENCY STEERING SYSTEM..................................................................................................... 52 Operation................................................................................................................. 52 Pre-Operation Testing..................................................................................................... 52 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................................................... 53 OPERATING ON THE HAUL ROAD.................................................................................................... 54 STARTING ON A GRADE WITH A LOADED TRUCK....................................................................................... 55 PASSING....................................................................................................................... 55 LOADING....................................................................................................................... 55 Overload Speed Limit Function............................................................................................. 55 DUMPING....................................................................................................................... 56 Raising The Dump Body..................................................................................................... 56 Lowering The Dump Body (When dumping on flat ground):..................................................................... 57 Lowering The Dump Body (When dumping over a berm or into a crusher):...................................................... 57 TOWING........................................................................................................................ 58 Special Wiring Harness.................................................................................................... 58 SAFE PARKING PROCEDURES....................................................................................................... 60 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................................................................. 60 SUDDEN LOSS OF ENGINE POWER................................................................................................... 61 FUEL DEPLETION................................................................................................................ 61 DISABLED TRUCK DUMPING PROCEDURE.............................................................................................. 62 Hookup.................................................................................................................... 62 Raising the Body.......................................................................................................... 62 Lowering the Body......................................................................................................... 62 WARNINGS AND CAUTIONS............................................................................................................. 63 GRADE/SPEED CHART............................................................................................................. 63 KEY SWITCH.................................................................................................................... 63 ROPS/FOPS..................................................................................................................... 63 BATTERIES..................................................................................................................... 64 CAPACITORS.................................................................................................................... 64 CRUSHING HAZARD............................................................................................................... 65 CYLINDER PRESSURE............................................................................................................. 65 FILLING THE HYDRAULIC TANK.................................................................................................... 66 HYDRAULIC OIL PRESSURE........................................................................................................ 66 HOT OIL SPRAY................................................................................................................. 67 WHEEL MOTOR OIL LEVEL......................................................................................................... 67 HOT EXHAUST................................................................................................................... 67 RADIATOR...................................................................................................................... 67 EMERGENCY LADDER.............................................................................................................. 67 ACCUMULATOR DRAIN VALVES...................................................................................................... 67 EMERGENCY DUMP PROCEDURE...................................................................................................... 68 EMERGENCY TOWING PROCEDURE.................................................................................................... 68 WELDING....................................................................................................................... 68 EMERGENCY SHUTDOWN............................................................................................................ 68 INFORMATION DISPLAY........................................................................................................... 69 WIRELESS SIGNALS.............................................................................................................. 69 HIGH VOLTAGE.................................................................................................................. 69 LIFTING INSTRUCTIONS.......................................................................................................... 70 PRODUCT IDENTIFICATION PLATE.................................................................................................. 71 LUBRICATION CHART............................................................................................................. 72 TORQUE TABLES AND CONVERSION CHARTS............................................................................................... 73 STORAGE AND IDLE MACHINE PREPARATION.............................................................................................. 83 SHORT TERM IDLE PERIODS....................................................................................................... 83 PREPARATION FOR STORAGE....................................................................................................... 84 REMOVAL FROM STORAGE.......................................................................................................... 85 RECONDITIONING AN IDLE VEHICLE................................................................................................ 87 ENGINE OPERATION.............................................................................................................. 89 After The Engine Has Started.............................................................................................. 90 ENGINE STORAGE................................................................................................................ 91 Temporary Storage (30 Days Or Less)....................................................................................... 91 Extended Storage (More Than 30 Days)...................................................................................... 91 RESTORING AN ENGINE AFTER EXTENDED STORAGE.................................................................................... 93 ELECTRIC DRIVE TRUCKS......................................................................................................... 94 Storing A Truck That Is Operational....................................................................................... 94 Storing A Truck That Is Not Operational................................................................................... 95 Storing A Major Component................................................................................................. 96 Periodic Inspections...................................................................................................... 96 Placing Equipment Into Service After Storage.............................................................................. 96 SECTION B STRUCTURES.................................................................................................................. 99 SECTION B2 STRUCTURAL COMPONENTS.................................................................................................. 101 STRUCTURAL COMPONENTS......................................................................................................... 103 PREPARATION............................................................................................................... 103 DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY................................................................................. 104 Removal............................................................................................................... 104 Installation.......................................................................................................... 104 RH DECK AND RETARDING GRID................................................................................................ 105 Removal............................................................................................................... 105 Installation.......................................................................................................... 105 LH DECK................................................................................................................... 106 Removal............................................................................................................... 106 Installation.......................................................................................................... 106 CENTER DECK............................................................................................................... 107 Removal............................................................................................................... 107 Installation.......................................................................................................... 107 SECTION B3 DUMP BODY.............................................................................................................. 109 DUMP BODY..................................................................................................................... 111 DUMP BODY................................................................................................................. 111 Removal............................................................................................................... 111 Installation.......................................................................................................... 112 BODY PADS................................................................................................................. 114 Body Pad Shimming Procedure........................................................................................... 115 BODY GUIDE................................................................................................................ 116 HOIST LIMIT SWITCH........................................................................................................ 116 BODY-UP SWITCH............................................................................................................ 116 BODY RETENTION SLING...................................................................................................... 116 ROCK EJECTORS............................................................................................................. 117 Inspection............................................................................................................ 117 SECTION B4 FUEL TANK.............................................................................................................. 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......................................................................................................... 124 Removal............................................................................................................... 124 Installation.......................................................................................................... 124 QUICK FILL FUEL RECEIVERS................................................................................................. 124 SECTION C ENGINE...................................................................................................................... 125 SECTION C2 POWER MODULE........................................................................................................... 127 POWER MODULE.................................................................................................................. 129 PREPARATION FOR REMOVAL................................................................................................... 129 REMOVAL................................................................................................................... 134 INSTALLATION.............................................................................................................. 136 HOOKUP.................................................................................................................... 137 SECTION C3 COOLING SYSTEM......................................................................................................... 139 COOLING SYSTEM................................................................................................................ 141 RADIATOR.................................................................................................................. 141 Removal............................................................................................................... 141 Installation.......................................................................................................... 143 Filling Procedure..................................................................................................... 144 REPAIRING THE RADIATOR.................................................................................................... 144 Internal Inspection................................................................................................... 144 External Cleaning..................................................................................................... 144 Disassembly........................................................................................................... 145 Cleaning and Inspection............................................................................................... 146 Assembly.............................................................................................................. 146 Pressure Testing...................................................................................................... 147 COOLANT SYSTEM TROUBLESHOOTING............................................................................................ 147 SECTION C4 POWER TRAIN............................................................................................................ 149 POWER TRAIN................................................................................................................... 151 ALTERNATOR REMOVAL........................................................................................................ 151 ALTERNATOR INSTALLATION................................................................................................... 153 Measuring Procedure................................................................................................... 153 Joining the Alternator and Engine..................................................................................... 155 ENGINE.................................................................................................................... 156 Removal............................................................................................................... 156 Service............................................................................................................... 156 Installation.......................................................................................................... 156 SECTION C5 AIR CLEANERS........................................................................................................... 157 AIR CLEANERS.................................................................................................................. 159 OPERATION................................................................................................................. 159 SERVICING THE AIR CLEANERS................................................................................................ 159 Replacing The Filter Element.......................................................................................... 159 Cleaning The Main Filter Element...................................................................................... 161 Servicing The Precleaner Section...................................................................................... 162 EVACUATOR VALVES (if equipped)............................................................................................ 163 AIR INTAKE TROUBLESHOOTING................................................................................................ 163 SECTION C7 FAN CLUTCH............................................................................................................. 165 FAN CLUTCH.................................................................................................................... 167 REMOVAL & INSTALLATION TOOLING............................................................................................ 167 DISASSEMBLY............................................................................................................... 170 CLEANING AND INSPECTION................................................................................................... 180 ASSEMBLY.................................................................................................................. 184 TEST PROCEDURE............................................................................................................ 198 SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION).................................................................................... 199 SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM........................................................................................... 201 24VDC ELECTRIC SUPPLY SYSTEM.................................................................................................. 203 ELECTRICAL SYSTEM DESCRIPTION............................................................................................. 203 BATTERIES................................................................................................................. 203 Maintenance and Service............................................................................................... 203 Troubleshooting....................................................................................................... 203 BATTERY SUPPLY SYSTEM..................................................................................................... 205 24VDC Battery Charging Alternator..................................................................................... 205 Batteries............................................................................................................. 205 24VDC Auxiliary Battery Receptacles................................................................................... 205 Battery Disconnect Switches........................................................................................... 206 Isolation Diode....................................................................................................... 206 Engine Start Relay.................................................................................................... 206 24VDC to 12VDC Converter.............................................................................................. 206 24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)....................................................................... 207 Operation............................................................................................................. 207 Pressure Switch....................................................................................................... 207 Check Valve........................................................................................................... 207 Timer Solenoid........................................................................................................ 207 MAINTENANCE............................................................................................................... 208 Prelube System Operation Checks....................................................................................... 208 Check Valve........................................................................................................... 208 Timer Solenoid........................................................................................................ 208 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT................................................................................ 209 24VDC ELECTRIC START SYSTEM................................................................................................... 211 CRANKING MOTORS........................................................................................................... 211 Operation............................................................................................................. 211 Removal............................................................................................................... 211 Installation.......................................................................................................... 211 CRANKING MOTOR TROUBLESHOOTING............................................................................................ 212 Preliminary Inspection................................................................................................ 212 No-Load Test.......................................................................................................... 212 Interpreting Results of Tests......................................................................................... 213 Disassembly........................................................................................................... 213 Cleaning and Inspection............................................................................................... 214 Armature Servicing.................................................................................................... 216 Field Coil Checks..................................................................................................... 216 Field Coil Removal.................................................................................................... 216 SOLENOID CHECKS........................................................................................................... 217 Test.................................................................................................................. 217 Assembly.............................................................................................................. 218 Bearing Replacement:.................................................................................................. 218 Motor Assembly:....................................................................................................... 218 Pinion Clearance...................................................................................................... 219 MAGNETIC SWITCH........................................................................................................... 219 Removal............................................................................................................... 219 Installation.......................................................................................................... 219 Coil Test............................................................................................................. 220 SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS..................................................................................... 221 24 VDC ELECTRICAL SYSTEM COMPONENTS........................................................................................... 223 BRAKE WARNING BUZZER...................................................................................................... 223 AUXILIARY CONTROL CABINET COMPONENTS...................................................................................... 223 Power Distribution Terminals.......................................................................................... 223 Pulse Voltage Modulator (PMV)......................................................................................... 223 Control Power Relay................................................................................................... 223 Auto Lube Timer....................................................................................................... 223 Ground Level Power Relay.............................................................................................. 223 Diode Board - DB1..................................................................................................... 225 Fuse Blocks........................................................................................................... 226 Alarm Indicating Device (AID) System.................................................................................. 226 RELAY BOARDS.............................................................................................................. 229 Relay Boards RB1, RB3, RB4, RB5....................................................................................... 229 Relay Board RB6, RB7, RB8, RB9........................................................................................ 231 Relay Board Functions................................................................................................. 232 BODY-UP SWITCH............................................................................................................ 234 Operation............................................................................................................. 234 Adjustment............................................................................................................ 234 Service............................................................................................................... 234 HOIST LIMIT SWITCH........................................................................................................ 235 Operation............................................................................................................. 235 Adjustment............................................................................................................ 235 Service............................................................................................................... 235 FUSE BLOCKS AND CIRCUIT BREAKERS.......................................................................................... 236 SECTION D11 KOMTRAX PLUS.......................................................................................................... 239 KOMTRAX PLUS.................................................................................................................. 241 KOMTRAX PLUS BASIC FEATURES............................................................................................... 241 Gather Data........................................................................................................... 241 Convert and Record Data............................................................................................... 241 Communicate Data to Off-Board Systems................................................................................. 242 USING KOMTRAX PLUS........................................................................................................ 243 Turning KOMTRAX Plus ON............................................................................................... 243 Normal KOMTRAX Plus Operation......................................................................................... 243 Turning KOMTRAX Plus OFF.............................................................................................. 244 Downloading from the KOMTRAX Plus Controller.......................................................................... 244 KOMTRAX PLUS DATA ITEMS................................................................................................... 245 Fault Codes........................................................................................................... 245 Machine History....................................................................................................... 245 KOMTRAX Plus History.................................................................................................. 245 Snapshots............................................................................................................. 246 Manual Snapshots...................................................................................................... 246 Trends................................................................................................................ 248 Histogram (Load Map) Data............................................................................................. 248 Haul Cycle Data....................................................................................................... 249 Alarm and Snapshot Triggers........................................................................................... 250 Satellite Features.................................................................................................... 250 KOMTRAX PLUS DIAGNOSTIC FEATURES.......................................................................................... 252 Fault History......................................................................................................... 252 LED Digits............................................................................................................ 252 KOMTRAX PLUS CONTROLLER................................................................................................... 252 Removal............................................................................................................... 253 Installation.......................................................................................................... 253 KOMTRAX PLUS SOFTWARE..................................................................................................... 254 VHMS Tool Box Installation............................................................................................ 254 VHMS Setting Tool Installation........................................................................................ 254 PDM Software Installation............................................................................................. 254 KOMTRAX PLUS INITIALIZATION PROCEDURE..................................................................................... 255 CONTROLLER SETUP PROCEDURE............................................................................................ 255 SNAPSHOT PROCEDURE.................................................................................................... 258 DOWNLOAD PROCEDURE.................................................................................................... 259 FTP UPLOAD PROCEDURE.................................................................................................. 260 INITIALIZATION FORMS.................................................................................................. 261 WHEN REPLACING A KOMTRAX PLUS CONTROLLER.................................................................................. 262 KOMTRAX PLUS CONTROLLER CHECKOUT.......................................................................................... 267 Necessary Equipment................................................................................................... 267 Preliminary........................................................................................................... 267 KOMTRAX Plus Controller Checkout Procedure............................................................................ 268 ORBCOMM CONTROLLER (if equipped).......................................................................................... 270 Removal............................................................................................................... 270 Installation.......................................................................................................... 270 SECTION D12 INTERFACE MODULE...................................................................................................... 271 INTERFACE MODULE.............................................................................................................. 273 Removal................................................................................................................... 273 Installation.............................................................................................................. 273 SENSORS....................................................................................................................... 274 Temperature Sensors....................................................................................................... 274 Pressure Sensors.......................................................................................................... 274 INTERFACE MODULE SOFTWARE..................................................................................................... 275 Flashburn Program Installation............................................................................................ 275 Interface Module Application Code Installation............................................................................ 276 Interface Module Realtime Data Monitor Software........................................................................... 276 INTERFACE MODULE CHECKOUT..................................................................................................... 277 Necessary Equipment....................................................................................................... 277 Preliminary............................................................................................................... 278 Check Digital Inputs To The Interface Module.............................................................................. 279 Check Analog Inputs To The Interface Module............................................................................... 282 Check Serial Interfaces To The Interface Module........................................................................... 282 Check Outputs From The Interface Module................................................................................... 283 SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING..................................................................... 285 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING............................................................................. 287 GENERAL................................................................................................................... 287 TROUBLESHOOTING........................................................................................................... 288 Communications Networks............................................................................................... 288 Coaxial Cable......................................................................................................... 288 FAULT CODES............................................................................................................... 288 Fault History......................................................................................................... 288 KOMTRAX Plus LED Display Fault Codes.................................................................................. 289 Chassis Fault Codes................................................................................................... 290 Engine Fault Codes.................................................................................................... 294 FAULT TREE ANALYSIS....................................................................................................... 300 Unable to connect to KOMTRAX Plus from laptop PC...................................................................... 300 Flashing Error Code N4-23 (PLM III Communications Fault).............................................................. 301 Flashing Error Code N4-22 (Engine Communications Fault)............................................................... 302 No Data Received By WebCARE........................................................................................... 303 Coaxial Cable Troubleshooting......................................................................................... 304 SECTION D14 KOMTRAX PLUS FORMS.................................................................................................... 305 KOMTRAX PLUS FORMS............................................................................................................ 307 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 307 KOMTRAX PLUS DATA DOWNLOAD................................................................................................ 308 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................................................... 309 KOMTRAX PLUS INITIALIZATION FORM.......................................................................................... 311 SECTION E ELECTRIC PROPULSION SYSTEM.................................................................................................. 313 SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS.................................................................................. 315 ELECTRICAL PROPULSION SYSTEM COMPONENTS....................................................................................... 317 GENERAL SYSTEM DESCRIPTION................................................................................................ 317 SYSTEM COMPONENTS......................................................................................................... 319 Propulsion System Controller (PSC).................................................................................... 319 Truck Control Interface (TCI)......................................................................................... 320 Diagnostic Information Display (DID) Panel............................................................................ 321 DID Panel Event Codes................................................................................................. 321 PSC SOFTWARE FUNCTIONS.................................................................................................... 340 Input Processing...................................................................................................... 340 State Machine......................................................................................................... 340 DC Link State......................................................................................................... 343 Engine Control........................................................................................................ 344 ALTERNATOR FIELD CONTROL.................................................................................................. 344 Desired Three-Phase Voltage........................................................................................... 344 Desired DC Link Voltage............................................................................................... 344 Self-Load............................................................................................................. 345 Propel Torque Control................................................................................................. 345 Retard Torque Control................................................................................................. 345 Wheel Slide Control................................................................................................... 346 Resistor Grid Control................................................................................................. 346 Chopper Voltage Control............................................................................................... 346 EVENT DETECTION AND PROCESSING............................................................................................ 346 Power-On Tests........................................................................................................ 346 Initiated Tests....................................................................................................... 347 Periodic Tests........................................................................................................ 347 EVENT RESTRICTIONS........................................................................................................ 347 EVENT LOGGING AND STORAGE................................................................................................. 347 Event History Buffer.................................................................................................. 348 Data Packs............................................................................................................ 348 To Record and Save a Data Pack to a Disk.............................................................................. 348 Event Reset........................................................................................................... 349 SERIAL DATA COMMUNICATIONS................................................................................................ 349 PSC - TCI Communications Processing................................................................................... 349 PSC - PTU Communications Processing................................................................................... 349 Inverter Communications Processing.................................................................................... 350 OUTPUT PROCESSING......................................................................................................... 350 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS.................................................................................. 350 Fast Start............................................................................................................ 350 Engine Shutdown/Engine Not Running.................................................................................... 350 Limp Home Mode........................................................................................................ 351 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS..................................................................... 352 ELECTRONIC ACCELERATOR AND RETARD PEDALS.................................................................................. 360 Removal............................................................................................................... 360 Installation.......................................................................................................... 360 Disassembly........................................................................................................... 360 Assembly.............................................................................................................. 360 SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE.......................................................................... 361 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE................................................................................. 363 AC DRIVE SYSTEM MAINTENANCE............................................................................................... 363 NORMAL TRUCK SHUTDOWN PROCEDURE........................................................................................... 364 SHUTDOWN AFTER SYSTEM FAILURE............................................................................................. 364 SYSTEM CHECKOUT........................................................................................................... 365 Battery and Control Circuit Checks - Battery Power OFF................................................................ 365 Battery and Control Circuit Checks - Battery Power ON................................................................. 368 Checks with Key Switch OFF............................................................................................ 369 Checks with Key Switch ON............................................................................................. 369 CPU Battery Checks.................................................................................................... 369 MEMORY BACKUP BATTERY REPLACEMENT......................................................................................... 370 TCI PROGRAMMING........................................................................................................... 370 PSC PROGRAMMING........................................................................................................... 371 INVERTER PROGRAMMING...................................................................................................... 371 CPU RESET................................................................................................................. 371 PSC CHECKOUT.............................................................................................................. 372 PSC Digital Input Checks.............................................................................................. 372 PSC Digital Output Checks............................................................................................. 376 TCI CHECKOUT.............................................................................................................. 377 Modular Mining Communication Port Check............................................................................... 377 TCI Digital Input Checks.............................................................................................. 377 TCI Digital Output Tests.............................................................................................. 383 CALIBRATIONS.............................................................................................................. 385 Speedometer........................................................................................................... 385 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial.................................................................. 385 ERASING EVENTS............................................................................................................ 385 PSC................................................................................................................... 385 TCI................................................................................................................... 386 GATE DRIVER POWER CONVERTER TEST.......................................................................................... 386 LOAD TESTING.............................................................................................................. 387 Preparation........................................................................................................... 387 Alternator Speed Sensor Checks........................................................................................ 387 Battery Boost Check................................................................................................... 387 Brake Circuit Switch Checks........................................................................................... 388 Hoist & Steering Circuit Switch Checks................................................................................ 388 Link Energized Checks................................................................................................. 388 Loadbox Test.......................................................................................................... 390 TROUBLESHOOTING........................................................................................................... 394 PVM Optimum Load Curve Handshaking Troubleshooting.................................................................... 394 Phase Module and Chopper Module Troubleshooting....................................................................... 394 PHASE MODULE REPLACEMENT.................................................................................................. 395 Phase Module Removal.................................................................................................. 395 Phase Module Installation............................................................................................. 395 SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146)................................................................................ 397 Fault Code A001: Left front suspension pressure sensor signal is high......................................................... 399 Related circuit diagram................................................................................................... 399 Fault Code A002: Left front suspension pressure sensor signal is low.......................................................... 400 Related circuit diagram................................................................................................... 400 Fault Code A003: Right front suspension pressure sensor signal is high........................................................ 401 Related circuit diagram................................................................................................... 401 Fault Code A004: Right front suspension pressure sensor signal is low......................................................... 402 Related circuit diagram................................................................................................... 402 Fault Code A005: Left rear suspension pressure sensor signal is high.......................................................... 403 Related circuit diagram................................................................................................... 403 Fault Code A006: Left rear suspension pressure sensor signal is low........................................................... 404 Related circuit diagram................................................................................................... 404 Fault Code A007: Right rear suspension pressure sensor signal is high......................................................... 405 Related circuit diagram................................................................................................... 405 Fault Code A008: Right rear suspension pressure sensor signal is low.......................................................... 406 Related circuit diagram................................................................................................... 406 Fault Code A009: Incline sensor signal is high................................................................................ 407 Related circuit diagram................................................................................................... 407 Fault Code A010: Incline sensor signal is low................................................................................. 408 Related circuit diagram................................................................................................... 408 Fault Code A011: Payload meter speed sensor signal has failed................................................................. 409 Related circuit diagram................................................................................................... 409 Fault Code A013: Body up switch has failed.................................................................................... 410 Related circuit diagram................................................................................................... 410 Fault Code A014: Payload meter checksum computation has failed................................................................ 411 Related circuit diagram................................................................................................... 411 Fault Code A016: Payload meter write to flash memory has failed............................................................... 412 Related circuit diagram................................................................................................... 412 Fault Code A017: Payload meter flash memory read has failed................................................................... 413 Related circuit diagram................................................................................................... 413 Fault Code A018: Right rear flat suspension cylinder warning.................................................................. 414 Related circuit diagram................................................................................................... 415 Fault Code A019: Left rear flat suspension cylinder warning................................................................... 416 Related circuit diagram................................................................................................... 417 Fault Code A022: Carryback load is excessive.................................................................................. 418 Related circuit diagram................................................................................................... 419 Fault Code A026: Payload meter user select switch has failed.................................................................. 420 Related circuit diagram................................................................................................... 420 Fault Code A027: Payload meter user clear switch has failed................................................................... 421 Related circuit diagram................................................................................................... 421 Fault Code A101: High pressure detected across a hydraulic pump filter........................................................ 422 Related circuit diagram................................................................................................... 423 Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level................................... 424 Related circuit diagram................................................................................................... 425 Fault Code A107: GE has generated a propel system caution..................................................................... 426 Related circuit diagram................................................................................................... 427 Fault Code A108: GE has generated a propel system temperature caution......................................................... 428 Related circuit diagram................................................................................................... 429 Fault Code A109: GE has generated a propel system reduced level signal........................................................ 430 Related circuit diagram................................................................................................... 431 Fault Code A115: Low steering precharge pressure is detected.................................................................. 432 Related circuit diagram................................................................................................... 433 Fault Code A123: GE has generated a reduced retarding caution................................................................. 434 Related circuit diagram................................................................................................... 435 Fault Code A124: GE has generated a no propel / no retard warning............................................................. 436 Related circuit diagram................................................................................................... 437 Fault Code A125: GE has generated a no propel warning......................................................................... 438 Related circuit diagram................................................................................................... 439 Fault Code A126: Oil level in the hydraulic tank is low....................................................................... 440 Related circuit diagram................................................................................................... 441 Fault Code A127: IM furnished +5 volt output for sensors is low............................................................... 442 Related circuit diagram................................................................................................... 443 Fault Code A128: IM furnished +5 volt output for sensors is high.............................................................. 444 Related circuit diagram................................................................................................... 445 Fault Code A139, A310: Low fuel level warning................................................................................. 446 Related circuit diagram................................................................................................... 447 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil.... 448 Related circuit diagram................................................................................................... 449 Fault Code A146: Hydraulic temperature sensors cause posting of this faultl................................................... 450 Related circuit diagram................................................................................................... 451 SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216)................................................................................ 453 Fault Code A152: Starter failure.............................................................................................. 454 Related circuit diagram................................................................................................... 455 Fault Code A153: Battery voltage is low with truck in operation............................................................... 456 Related circuit diagram................................................................................................... 457 Fault Code A154: Battery charging voltage is excessive........................................................................ 458 Related circuit diagram................................................................................................... 459 Fault Code A155: Battery charging voltage is low.............................................................................. 460 Related circuit diagram................................................................................................... 461 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level................................. 462 Related circuit diagram................................................................................................... 463 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................ 464 Related circuit diagram................................................................................................... 465 Fault Code A167: Right rear hydraulic oil temperature sensor is low........................................................... 466 Related circuit diagram................................................................................................... 467 Fault Code A168: Left front hydraulic oil temperature sensor is low........................................................... 468 Related circuit diagram................................................................................................... 469 Fault Code A169: Right front hydraulic oil temperature sensor is low.......................................................... 470 Related circuit diagram................................................................................................... 471 Fault Code A170: Left rear hydraulic oil temperature sensor is high........................................................... 472 Related circuit diagram................................................................................................... 472 Fault Code A171: Right rear hydraulic oil temperature sensor is high.......................................................... 473 Related circuit diagram................................................................................................... 473 Fault Code A172: Left front hydraulic oil temperature sensor is high.......................................................... 474 Related circuit diagram................................................................................................... 474 Fault Code A173: Right front hydraulic oil temperature sensor is high......................................................... 475 Related circuit diagram................................................................................................... 475 Fault Code A184: J1939 data link is not connected............................................................................. 476 Related circuit diagram................................................................................................... 477 Fault Code A190: Auto lube control has detected an incomplete lube cycle...................................................... 478 Related circuit diagram................................................................................................... 479 Fault Code A194: Left front hydraulic oil temperature is high................................................................. 480 Related circuit diagram................................................................................................... 481 Fault Code A195: Right front hydraulic oil temperature is high................................................................ 482 Related circuit diagram....................................................................................................... 483 Fault Code A196: Left rear hydraulic oil temperature is high.................................................................. 484 Related circuit diagram....................................................................................................... 485 Fault Code A197: Right rear hydraulic oil temperature is high................................................................. 486 Related circuit diagram....................................................................................................... 487 Fault Code A198: Hoist pressure 1 sensor is high.............................................................................. 488 Related circuit diagram................................................................................................... 488 Fault Code A199: Hoist pressure 2 sensor is high.............................................................................. 489 Related circuit diagram................................................................................................... 489 Fault Code A200: Steering pressure sensor is high............................................................................. 490 Related circuit diagram................................................................................................... 490 Fault Code A201: Brake pressure sensor is high................................................................................ 491 Related circuit diagram................................................................................................... 491 Fault Code A202: Hoist pressure 1 sensor is low............................................................................... 492 Related circuit diagram................................................................................................... 492 Fault Code A203: Hoist pressure 2 sensor is low............................................................................... 493 Related circuit diagram................................................................................................... 493 Fault Code A204: Steering pressure sensor is low.............................................................................. 494 Related circuit diagram................................................................................................... 494 Fault Code A205: Brake pressure sensor is low................................................................................. 495 Related circuit diagram................................................................................................... 495 Fault Code A206: Ambient temperature sensor is high........................................................................... 496 Related circuit diagram................................................................................................... 496 Fault Code A207: Ambient temperature sensor is low............................................................................ 497 Related circuit diagram................................................................................................... 497 Fault Code A212: Bad truck speed signal....................................................................................... 498 Related circuit diagram................................................................................................... 499 Fault Code A213: Parking brake should have applied but is detected as not having applied...................................... 500 Related circuit diagram................................................................................................... 502 Fault Code A214: Parking brake should have released but is detected as not having released.................................... 504 Related circuit diagram................................................................................................... 506 Fault Code A215: Brake auto apply relay circuit is defective.................................................................. 508 Related circuit diagram................................................................................................... 509 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit...................... 510 Related circuit diagram................................................................................................... 511 SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292)................................................................................ 513 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted.................................... 514 Related circuit diagram................................................................................................... 515 Fault Code A230: Parking brake has been requested while truck still moving.................................................... 516 Related circuit diagram................................................................................................... 517 Fault Code A236: Steering accumulator has not properly bled down after 90 seconds............................................. 518 Related circuit diagram................................................................................................... 519 Fault Code A240: The keyswitch input to the interface module is open.......................................................... 520 Related circuit diagram................................................................................................... 521 Fault Code A246: Payload meter reports truck overload......................................................................... 521 Related circuit diagram................................................................................................... 521 Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted............................... 522 Related circuit diagram................................................................................................... 523 Fault Code A250: Battery voltage is low with the truck parked................................................................. 524 Related circuit diagram................................................................................................... 525 Fault Code A252: Start enable output circuit is either open or shorted to ground.............................................. 526 Related circuit diagram................................................................................................... 527 Fault Code A253: Steering bleed circuit is not open while running............................................................. 528 Related circuit diagram................................................................................................... 529 Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open.................................. 530 Related circuit diagram................................................................................................... 531 Fault Code A257: Payload CAN/RPC is not connected............................................................................. 532 Related circuit diagram................................................................................................... 532 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective.............................................. 534 Related circuit diagram................................................................................................... 535 Fault Code A260: Parking brake failure........................................................................................ 536 Related circuit diagram................................................................................................... 537 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................ 538 Related circuit diagram................................................................................................... 539 Fault Code A263: Steering bleed circuit is shorted to ground.................................................................. 540 Related circuit diagram................................................................................................... 541 Fault Code A264: Parking brake relay circuit is defective..................................................................... 542 Related circuit diagram................................................................................................... 543 Fault Code A265: Service brake failure........................................................................................ 544 Related circuit diagram................................................................................................... 546 Fault Code A270: Brake lock switch power supply is not on when required....................................................... 548 Related circuit diagram................................................................................................... 549 Fault Code A272: Brake lock switch power supply is not off when required...................................................... 550 Related circuit diagram................................................................................................... 552 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit....................... 554 Related circuit diagram................................................................................................... 555 Fault Code A274: A brake setting fault has been detected...................................................................... 556 Related circuit diagram................................................................................................... 557 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................ 558 Related circuit diagram................................................................................................... 559 Fault Code A276: The drive system data link is not connected.................................................................. 560 Related circuit diagram................................................................................................... 561 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7............. 562 Related circuit diagram................................................................................................... 563 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set................................... 564 Related circuit diagram................................................................................................... 565 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated...................... 566 Related circuit diagram................................................................................................... 567 Fault Code A285: The parking brake was not set when the key switch was turned off............................................. 568 Related circuit diagram................................................................................................... 569 Fault Code A286: A fault was detected in the shutdown delay relay circuit..................................................... 570 Related circuit diagram................................................................................................... 571 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off......................... 572 Related circuit diagram................................................................................................... 573 SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365)................................................................................ 575 Fault Code A303: Shifter is defective......................................................................................... 576 Related circuit diagram................................................................................................... 577 Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be............ 578 Related circuit diagram................................................................................................... 579 Fault Code A309: No brakes applied when expected.............................................................................. 580 Related circuit diagram................................................................................................... 582 Fault Code A311: Brake lock switch is on when it should not be................................................................ 584 Related circuit diagram................................................................................................... 585 Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings............................................ 586 Related circuit diagram................................................................................................... 586 Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings........................................... 587 Related circuit diagram................................................................................................... 587 Fault Code A315: DC-DC converter 12 volt circuit is low....................................................................... 588 Related circuit diagram................................................................................................... 589 Fault Code A316: Starter engagement has been attempted with engine running.................................................... 590 Related circuit diagram................................................................................................... 591 Fault Code A317: Operation of brake auto apply valve without a detected response.............................................. 592 Related circuit diagram................................................................................................... 594 Fault Code A318: Unexpected power loss to interface module.................................................................... 595 Related circuit diagram................................................................................................... 595 Fault Code A328: Drive system not powered up.................................................................................. 596 Related circuit diagram................................................................................................... 597 Fault Code A350: Overload on output 1B........................................................................................ 598 Related circuit diagram................................................................................................... 599 Fault Code A351: Overload on output 1E........................................................................................ 600 Related circuit diagram................................................................................................... 601 Fault Code A352: Overload on output 1H........................................................................................ 602 Related circuit diagram................................................................................................... 603 Fault Code A353: Overload on output 1J........................................................................................ 604 Related circuit diagram................................................................................................... 605 Fault Code A354: Overload on output 1K........................................................................................ 606 Related circuit diagram................................................................................................... 607 Fault Code A355: Overload on output 1L........................................................................................ 608 Related circuit diagram................................................................................................... 609 Fault Code A356: Overload on output 1M........................................................................................ 610 Related circuit diagram................................................................................................... 611 Fault Code A357: Overload on output 1N........................................................................................ 612 Related circuit diagram................................................................................................... 613 Fault Code A358: Overload on output 1P........................................................................................ 614 Related circuit diagram................................................................................................... 615 Fault Code A359: Overload on output 1R........................................................................................ 616 Related circuit diagram................................................................................................... 617 Fault Code A360: Overload on output 1S........................................................................................ 618 Related circuit diagram................................................................................................... 619 Fault Code A361: Overload on output 1T........................................................................................ 620 Related circuit diagram................................................................................................... 621 Fault Code A362: Overload on output 1U........................................................................................ 622 Related circuit diagram................................................................................................... 623 Fault Code A363: Overload on output 1X........................................................................................ 624 Related circuit diagram................................................................................................... 624 Fault Code A364: Overload on output 1Y........................................................................................ 626 Related circuit diagram................................................................................................... 627 Fault Code A365: Overload on output 1Z........................................................................................ 628 Related circuit diagram................................................................................................... 629 SECTION G REAR AXLE, SPINDLES AND WHEELS.............................................................................................. 631 SECTION G2 TIRES AND RIMS......................................................................................................... 633 TIRES AND RIMS................................................................................................................ 635 WHEEL STUD MAINTENANCE.................................................................................................... 636 FRONT TIRES AND RIMS...................................................................................................... 637 Removal............................................................................................................... 637 Installation.......................................................................................................... 638 REAR TIRES AND RIMS....................................................................................................... 639 Removal............................................................................................................... 639 Installation.......................................................................................................... 640 RIM....................................................................................................................... 641 Tire Removal.......................................................................................................... 641 Tire Installation..................................................................................................... 641 SECTION G3 FRONT WHEEL HUB AND SPINDLE............................................................................................ 643 FRONT WHEEL HUB AND SPINDLE................................................................................................... 645 WHEEL HUB AND SPINDLE ASSEMBLY............................................................................................ 645 Removal............................................................................................................... 645 Spindle Removal Procedure (off of the truck).......................................................................... 648 Installation.......................................................................................................... 650 Disassembly........................................................................................................... 651 Cleaning and Inspection............................................................................................... 653 Assembly.............................................................................................................. 653 Wheel Bearing Adjustment.............................................................................................. 654 Brake Installation.................................................................................................... 655 Seal Assembly Gap Check............................................................................................... 656 WHEEL SPEED SENSOR TESTING................................................................................................ 657 STEERING CYLINDERS........................................................................................................ 658 Spherical Bearing Wear Limits......................................................................................... 658 Removal............................................................................................................... 659 Installation.......................................................................................................... 659 Bearing Replacement (Steering Cylinder and Tie Rod)................................................................... 659 TIE ROD................................................................................................................... 661 Removal............................................................................................................... 661 Installation.......................................................................................................... 661 Disassembly........................................................................................................... 662 Assembly.............................................................................................................. 662 Toe-In Adjustment..................................................................................................... 663 TIE ROD INSPECTION AND TORQUE PROCEDURE................................................................................... 664 Old Style Tie Rod..................................................................................................... 664 New Style Tie Rod..................................................................................................... 665 SECTION G4 REAR AXLE MOUNTING..................................................................................................... 667 REAR AXLE MOUNTING............................................................................................................ 669 PIVOT PIN................................................................................................................. 669 Removal............................................................................................................... 669 Installation.......................................................................................................... 670 PIVOT EYE BEARING......................................................................................................... 671 Removal............................................................................................................... 671 Installation.......................................................................................................... 671 PIVOT EYE REPAIR.......................................................................................................... 671 Removal............................................................................................................... 671 Disassembly........................................................................................................... 671 Assembly.............................................................................................................. 672 Installation.......................................................................................................... 672 ANTI-SWAY BAR............................................................................................................. 672 Removal............................................................................................................... 672 Disassembly........................................................................................................... 673 Cleaning and Inspection............................................................................................... 673 Assembly.............................................................................................................. 673 Installation.......................................................................................................... 673 SECTION G5 REAR AXLE AND WHEEL MOTOR.............................................................................................. 675 REAR AXLE AND WHEEL MOTOR..................................................................................................... 677 REAR AXLE HOUSING......................................................................................................... 677 Preparation........................................................................................................... 677 Removal............................................................................................................... 678 Cleaning and Inspection............................................................................................... 679 Installation.......................................................................................................... 679 BLOWER PRESSURE SWITCH ADJUSTMENT......................................................................................... 679 WHEEL MOTOR............................................................................................................... 680 Preparation........................................................................................................... 680 Removal............................................................................................................... 681 Cleaning and Inspection............................................................................................... 683 Installation.......................................................................................................... 683 WHEEL MOTOR GEAR OIL...................................................................................................... 688 Filtering Requirements................................................................................................ 688 Particle Size Analysis................................................................................................ 688 Flushing.............................................................................................................. 688 Oil Sample Analysis................................................................................................... 689 ELEMENT SPECIFICATION CHARTS.............................................................................................. 690 SECTION H HYDRAIR® II SUSPENSIONS..................................................................................................... 693 SECTION H2 FRONT SUSPENSIONS...................................................................................................... 695 FRONT SUSPENSION.............................................................................................................. 697 Removal................................................................................................................... 697 Installation.............................................................................................................. 698 Inspection................................................................................................................ 703 LOWER BEARING & SEALS..................................................................................................... 704 Removal............................................................................................................... 704 Installation.......................................................................................................... 704 MAJOR SUSPENSION REBUILD.................................................................................................. 705 Disassembly........................................................................................................... 705 Assembly.............................................................................................................. 706 SUSPENSION PRESSURE TEST.................................................................................................. 707 SECTION H3 REAR SUSPENSIONS....................................................................................................... 709 REAR SUSPENSIONS.............................................................................................................. 711 SUSPENSION CYLINDER....................................................................................................... 712 Removal............................................................................................................... 712 Installation.......................................................................................................... 714 Disassembly........................................................................................................... 714 Cleaning and Inspection............................................................................................... 715 Assembly.............................................................................................................. 715 SUSPENSION PRESSURE TEST.................................................................................................. 717 SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES.............................................................................. 719 SUSPENSION OILING AND CHARGING PROCEDURE...................................................................................... 721 GENERAL................................................................................................................... 721 EQUIPMENT LIST............................................................................................................ 721 HYDRAIR® CHARGING KIT..................................................................................................... 722 Installation of Charging Kit.......................................................................................... 722 Removal of Charging Kit............................................................................................... 722 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................................... 723 FRONT SUSPENSION.......................................................................................................... 723 Front Suspension Oiling............................................................................................... 723 Front Suspension Nitrogen Charging.................................................................................... 725 REAR SUSPENSION........................................................................................................... 726 Rear Suspension Oiling................................................................................................ 727 Rear Suspension Nitrogen Charging..................................................................................... 729 OIL AND NITROGEN SPECIFICATIONS CHARTS........................................................................................ 730 SECTION J BRAKE CIRCUIT............................................................................................................... 731 SECTION J2 BRAKE CIRCUIT.......................................................................................................... 733 BRAKE CIRCUIT................................................................................................................. 735 SERVICE BRAKE CIRCUIT..................................................................................................... 735 PARKING BRAKE CIRCUIT..................................................................................................... 737 BRAKE LOCK CIRCUIT........................................................................................................ 737 SECONDARY BRAKING AND AUTOMATIC APPLY..................................................................................... 738 WARNING CIRCUIT........................................................................................................... 738 SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE........................................................................................ 741 BRAKE CIRCUIT COMPONENT SERVICE............................................................................................... 743 BRAKE VALVE............................................................................................................... 743 Rebuild Criteria...................................................................................................... 743 Removal............................................................................................................... 744 Installation.......................................................................................................... 744 Disassembly........................................................................................................... 745 Cleaning and Inspection............................................................................................... 748 Assembly.............................................................................................................. 748 Regulator Sleeve O-Ring Installation.................................................................................. 749 BRAKE VALVE BENCH TEST AND ADJUSTMENT..................................................................................... 751 Test Setup Procedure.................................................................................................. 752 Brake Valve Output Pressure Adjustment................................................................................ 752 Final Test and Adjustment............................................................................................. 753 Installing Brake Pedal Actuator Assembly to Brake Valve............................................................... 753 Installing Retard Pedal To Brake Pedal................................................................................ 753 DUAL RELAY VALVE.......................................................................................................... 754 Removal............................................................................................................... 754 Installation.......................................................................................................... 754 Disassembly........................................................................................................... 754 Cleaning and Inspection............................................................................................... 755 Assembly.............................................................................................................. 756 DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT................................................................................ 757 Test Setup Procedure.................................................................................................. 758 Relay Valve Output Pressure Adjustment................................................................................ 758 BRAKE MANIFOLD............................................................................................................ 759 Removal............................................................................................................... 759 Installation.......................................................................................................... 759 Disassembly........................................................................................................... 759 Cleaning and Inspection............................................................................................... 760 Assembly.............................................................................................................. 760 BRAKE ACCUMULATORS........................................................................................................ 760 Brake Accumulator Bleeddown Procedure................................................................................. 760 Removal............................................................................................................... 761 Installation.......................................................................................................... 761 Disassembly........................................................................................................... 762 Cleaning and Inspection............................................................................................... 763 Assembly.............................................................................................................. 763 Accumulator Charging Procedure........................................................................................ 765 Precharge Maintenance................................................................................................. 767 Accumulator Storage Procedures........................................................................................ 768 Bladder Storage Procedures............................................................................................ 768 Installing A Bladder Accumulator From Storage......................................................................... 768 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................................................... 769 Removal............................................................................................................... 769 Installation.......................................................................................................... 769 Disassembly........................................................................................................... 769 Lever Adjustments..................................................................................................... 769 Potentiometer Check................................................................................................... 770 Assembly.............................................................................................................. 770 SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE...................................................................................... 773 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................................................. 775 REQUIRED EQUIPMENT........................................................................................................ 776 INITIAL SYSTEM SETUP...................................................................................................... 777 BRAKE LOCK / SECONDARY BRAKE CHECK-OUT.................................................................................... 778 PARKING BRAKE CHECK-OUT................................................................................................... 779 SERVICE BRAKE CHECK-OUT................................................................................................... 780 LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT......................................................................... 781 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART........................................................................... 782 HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET......................................................................... 784 SECTION J5 WET DISC BRAKE ASSEMBLY................................................................................................ 787 WET DISC BRAKE ASSEMBLY....................................................................................................... 789 OPERATION................................................................................................................. 789 BRAKE DISC WEAR INSPECTION................................................................................................ 790 BRAKE REBUILD............................................................................................................. 791 Disassembly........................................................................................................... 791 Cleaning and Inspection............................................................................................... 795 Assembly.............................................................................................................. 796 Floating Ring Seal Assembly & Installation............................................................................ 801 WET DISC BRAKE BLEEDING PROCEDURE......................................................................................... 805 SECTION J7 PARKING BRAKE.......................................................................................................... 807 PARKING BRAKE................................................................................................................. 809 OPERATION................................................................................................................. 809 MAINTENANCE............................................................................................................... 810 Inspection............................................................................................................ 810 Removal............................................................................................................... 810 Installation.......................................................................................................... 811 Disassembly........................................................................................................... 811 Cleaning and Inspection............................................................................................... 811 Assembly.............................................................................................................. 813 Cleaning and Inspecting New Discs..................................................................................... 814 PARKING BRAKE BLEEDING PROCEDURE.......................................................................................... 815 SECTION L HYDRAULIC SYSTEM............................................................................................................ 817 SECTION L2 HYDRAULIC SYSTEM....................................................................................................... 819 HYDRAULIC SYSTEM.............................................................................................................. 821 HYDRAULIC PUMP MODULE..................................................................................................... 821 HOIST CIRCUIT OPERATION................................................................................................... 822 STEERING CIRCUIT OPERATION................................................................................................ 824 DISC BRAKE COOLING SYSTEM................................................................................................. 826 SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR...................................................................................... 829 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................................................. 831 HOIST PUMP................................................................................................................ 831 Removal............................................................................................................... 831 Installation.......................................................................................................... 833 Inspection............................................................................................................ 838 Assembly.............................................................................................................. 838 HYDRAULIC TANK............................................................................................................ 844 Removal............................................................................................................... 844 Installation.......................................................................................................... 845 HYDRAULIC TANK BREATHERS.................................................................................................. 845 HYDRAULIC TANK STRAINERS.................................................................................................. 846 Removal............................................................................................................... 846 Inspect and Clean..................................................................................................... 846 Installation.......................................................................................................... 846 SECTION L4 STEERING CIRCUIT....................................................................................................... 847 STEERING CIRCUIT.............................................................................................................. 849 STEERING CIRCUIT OPERATION................................................................................................ 849 COMPONENT DESCRIPTION..................................................................................................... 850 Steering Control Unit................................................................................................. 850 Bleeddown Manifold.................................................................................................... 851 Steering Accumulator Bleed Down Solenoid.............................................................................. 851 Relief Valves......................................................................................................... 853 Hoist Up Limit Solenoid............................................................................................... 853 Steering Accumulators................................................................................................. 853 Low Precharge Warning Switch.......................................................................................... 853 High Pressure Filter.................................................................................................. 853 Quick Disconnect Ports................................................................................................ 853 Flow Amplifier........................................................................................................ 855 FLOW AMPLIFIER SYSTEM OPERATION........................................................................................... 856 No Steer.............................................................................................................. 856 Steering Left......................................................................................................... 858 Steering Right........................................................................................................ 860 No Steer, External Shock Load......................................................................................... 862 STEERING PUMP............................................................................................................. 864 Normal Operation...................................................................................................... 864 PRINCIPLE OF OPERATION.................................................................................................... 866 Full Pump Volume...................................................................................................... 866 Half Pump Volume...................................................................................................... 866 Neutral Position...................................................................................................... 866 Steering Pump......................................................................................................... 867 SECTION L5 STEERING CONTROL UNIT.................................................................................................. 869 STEERING CONTROL UNIT......................................................................................................... 871 REMOVAL................................................................................................................... 871 SPLINE INSPECTION......................................................................................................... 871 INSTALLATION.............................................................................................................. 872 DISASSEMBLY............................................................................................................... 872 CLEANING AND INSPECTION................................................................................................... 873 ASSEMBLY.................................................................................................................. 875 SECTION L6 STEERING CIRCUIT COMPONENT REPAIR...................................................................................... 879 STEERING CIRCUIT COMPONENT REPAIR............................................................................................. 881 BLEEDDOWN MANIFOLD VALVE.................................................................................................. 881 Removal............................................................................................................... 881 Installation.......................................................................................................... 882 FLOW AMPLIFIER............................................................................................................ 883 Removal............................................................................................................... 883 Installation.......................................................................................................... 883 Disassembly........................................................................................................... 883 Assembly.............................................................................................................. 885 STEERING CYLINDERS........................................................................................................ 886 Disassembly........................................................................................................... 887 Piston Seal & Bearing Installation.................................................................................... 887 Assembly.............................................................................................................. 887 Testing............................................................................................................... 887 STEERING AND BRAKE PUMP................................................................................................... 888 Removal............................................................................................................... 888 Installation.......................................................................................................... 889 Disassembly........................................................................................................... 890 Inspection............................................................................................................ 893 Assembly.............................................................................................................. 896 Driveshaft Group...................................................................................................... 897 Rotating Group........................................................................................................ 897 Valve Plate Group..................................................................................................... 898 STEERING ACCUMULATORS..................................................................................................... 900 Removal............................................................................................................... 900 Installation.......................................................................................................... 900 Disassembly........................................................................................................... 901 Cleaning and Inspection............................................................................................... 901 Assembly.............................................................................................................. 902 Leak Testing.......................................................................................................... 904 Charging Procedure.................................................................................................... 905 Precharge Maintenance................................................................................................. 907 Accumulator Storage Procedures........................................................................................ 908 Bladder Storage Procedures............................................................................................ 908 Installing A Bladder Accumulator From Storage......................................................................... 908 TROUBLESHOOTING CHART......................................................................................................... 909 SECTION L7 HOIST CIRCUIT.......................................................................................................... 913 HOIST CIRCUIT................................................................................................................. 915 BASIC OPERATION........................................................................................................... 915 COMPONENT DESCRIPTION..................................................................................................... 916 Hydraulic Tank........................................................................................................ 916 Hydraulic Pump........................................................................................................ 916 High Pressure Filters................................................................................................. 916 Hoist Valve........................................................................................................... 916 Inlet Sections........................................................................................................ 916 Work Ports (Rear) Spool Section....................................................................................... 917 Tank Ports (Front) Spool Section...................................................................................... 917 Hoist Pilot Valve..................................................................................................... 917 Bleeddown Manifold.................................................................................................... 918 Hoist Up Limit Solenoid............................................................................................... 918 Pilot Operated Check Valve............................................................................................ 918 Overcenter Manifold................................................................................................... 918 HOIST CIRCUIT OPERATION....................................................................................................... 919 Float Position Of Pilot Valve With Truck Body On Frame.................................................................... 920 Power Up Operation........................................................................................................ 922 Hold Operation............................................................................................................ 924 Power Down Operation...................................................................................................... 926 Float Operation........................................................................................................... 928 SECTION L8 HOIST CIRCUIT COMPONENT REPAIR......................................................................................... 931 HOIST CIRCUIT COMPONENT REPAIR................................................................................................ 933 HOIST VALVE............................................................................................................... 933 Removal............................................................................................................... 933 Installation.......................................................................................................... 934 O-Ring Replacement.................................................................................................... 934 INLET SECTION............................................................................................................. 935 Cleaning and Inspection............................................................................................... 936 Assembly.............................................................................................................. 936 REAR SPOOL SECTION (Work Ports)........................................................................................... 937 Disassembly........................................................................................................... 937 Cleaning and Inspection............................................................................................... 937 Assembly.............................................................................................................. 939 FRONT SPOOL SECTION (Tank Ports).......................................................................................... 940 Disassembly........................................................................................................... 940 Cleaning and Inspection............................................................................................... 940 Assembly.............................................................................................................. 940 HOIST PILOT VALVE......................................................................................................... 942 Removal............................................................................................................... 942 Installation.......................................................................................................... 942 Disassembly........................................................................................................... 943 Cleaning and Inspection............................................................................................... 944 Assembly.............................................................................................................. 944 HOIST CYLINDERS........................................................................................................... 945 Removal............................................................................................................... 945 Installation.......................................................................................................... 946 Disassembly........................................................................................................... 948 Cleaning and Inspection............................................................................................... 949 Assembly - Quill...................................................................................................... 950 Assembly - Cylinder................................................................................................... 952 Testing............................................................................................................... 952 OVERCENTER VALVE MANIFOLD................................................................................................. 953 SECTION L9 HYDRAULIC SYSTEM FILTERS............................................................................................... 955 HYDRAULIC SYSTEM FILTERS...................................................................................................... 957 HOIST CIRCUIT FILTER...................................................................................................... 957 Filter Element Replacement............................................................................................ 957 Removal - Hoist Circuit Filter........................................................................................ 958 Installation - Hoist Circuit Filter................................................................................... 958 Indicator Switch - Hoist Circuit Filter............................................................................... 958 STEERING CIRCUIT FILTER................................................................................................... 959 Filter Element Replacement............................................................................................ 959 Removal - Steering Circuit Filter..................................................................................... 960 Installation - Steering Circuit Filter................................................................................ 960 Indicator Switch - Steering Circuit Filter............................................................................ 960 INDICATOR SWITCH.......................................................................................................... 960 Test Procedure........................................................................................................ 960 SECTION L10 HYDRAULIC CHECKOUT PROCEDURE.......................................................................................... 963 HYDRAULIC CHECKOUT PROCEDURE.................................................................................................. 965 GENERAL INFORMATION....................................................................................................... 965 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................................... 972 Equipment Requirements................................................................................................ 973 Pump Pressure Control Adjustments..................................................................................... 973 Steering Control Valve and Flow Amplifier Leakage Test................................................................ 974 Bleeddown Manifold Leakage Test....................................................................................... 975 STEERING/BRAKE PUMP STROKE ADJUSTMENT..................................................................................... 976 SHOCK AND SUCTION VALVES.................................................................................................. 976 Equipment Requirements................................................................................................ 976 Pressure Tests........................................................................................................ 976 HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES............................................................. 978 Equipment Requirements................................................................................................ 978 Pressure Gauge Locations.............................................................................................. 978 Brake Cooling Circuit Test............................................................................................ 978 Power Up Relief Pressure Test......................................................................................... 979 Power Down Relief Pressure Test....................................................................................... 980 Counterbalance Valve Pressure Check................................................................................... 981 Counterbalance Valve Adjustment....................................................................................... 982 930E CHECK-OUT PROCEDURE - STEERING SYSTEM DATA SHEET......................................................................... 983 930E CHECK-OUT PROCEDURE - BRAKE COOLING & HOIST SYSTEM DATA SHEET............................................................ 984 SECTION M OPTIONS AND SPECIAL TOOLS................................................................................................... 985 SECTION M7 HOT START SYSTEM....................................................................................................... 987 HOT START SYSTEM.............................................................................................................. 989 SYSTEM OPERATION.......................................................................................................... 989 HEATER INFORMATION........................................................................................................ 990 TROUBLESHOOTING GUIDELINES................................................................................................ 991 SECTION M8 SPECIAL TOOLS.......................................................................................................... 993 HIGH VOLTAGE TOOLS............................................................................................................ 998 0-2000 VDC CUSTOM METER KIT (58B-06-00800).................................................................................... 998 SECTION M19 RADIATOR SHUTTERS.....................................................................................................1001 RADIATOR SHUTTERS.............................................................................................................1003 OPERATION.................................................................................................................1003 Hydraulic Circuit.....................................................................................................1003 Electrical Circuit....................................................................................................1004 MAINTENANCE AND REPAIR....................................................................................................1004 TROUBLESHOOTING...........................................................................................................1005 SECTION M20 PAYLOAD METER III ™...................................................................................................1009 OPERATION SECTION.............................................................................................................1013 Introduction..............................................................................................................1013 Data Summary..........................................................................................................1013 Data Gathering........................................................................................................1013 COMPONENT DESCRIPTION.....................................................................................................1014 System Diagram........................................................................................................1014 Suspension Pressure Sensors...........................................................................................1014 Inclinometer..........................................................................................................1014 Operator Display......................................................................................................1014 Operator Switch.......................................................................................................1015 Speed Input...........................................................................................................1015 Body-Up Switch........................................................................................................1015 Brake Lock Switch.....................................................................................................1015 Payload Meter.........................................................................................................1015 Communications Ports..................................................................................................1015 Key Switch Input......................................................................................................1016 Payload Meter Power...................................................................................................1016 Load Lights...........................................................................................................1016 Wiring and Termination................................................................................................1017 TCI Outputs...........................................................................................................1017 OPERATOR’S DISPLAY AND SWITCH.............................................................................................1018 Reading the Speedometer...............................................................................................1018 Reading the Load Display..............................................................................................1018 Using the Operator ID.................................................................................................1018 Using the Load and Ton Counter........................................................................................1018 Total Ton Counter.....................................................................................................1018 Total Load Counter....................................................................................................1019 Clearing the Counters.................................................................................................1019 Viewing Live Sensor Data..............................................................................................1019 Other Display Messages................................................................................................1019 PAYLOAD OPERATION & CALCULATION...........................................................................................1020 Description of Haul Cycle States......................................................................................1020 Haul Cycle Description................................................................................................1020 Load Calculation......................................................................................................1021 Carry Back............................................................................................................1021 Measurement Accuracy..................................................................................................1021 SOURCES FOR PAYLOAD ERROR.................................................................................................1021 Payload Error.........................................................................................................1021 Loading Conditions....................................................................................................1022 Pressure Sensors......................................................................................................1022 Swingloads............................................................................................................1022 Speed and Distance....................................................................................................1022 HAUL CYCLE DATA...........................................................................................................1022 Haul Cycle Warning Flags..............................................................................................1024 Frame Torque Data.....................................................................................................1025 Sprung Weight Data....................................................................................................1025 Maximum Speed Data....................................................................................................1025 Alarm Records.........................................................................................................1025 Fault Code Data.......................................................................................................1026 PC SOFTWARE OVERVIEW......................................................................................................1027 System Configuration..................................................................................................1027 Installing the PLMIII Software........................................................................................1027 DOWNLOADING DATA..........................................................................................................1028 PLM III SYSTEM CONFIGURATION..............................................................................................1029 Starting Communications...............................................................................................1029 Displayed Payload Units...............................................................................................1029 Time Units............................................................................................................1029 Connection Menu.......................................................................................................1029 Connecting to the Payload Meter.......................................................................................1030 Configure the Payload Meter...........................................................................................1030 Setting the Date and Time.............................................................................................1030 Setting the Truck Type................................................................................................1031 Setting the Gauge Display Units.......................................................................................1031 Setting the Frame Serial Number.......................................................................................1031 Setting the Truck Number..............................................................................................1031 Setting the Komatsu Distributor.......................................................................................1031 Setting the Komatsu Customer..........................................................................................1031 Clean Truck Tare Calibration..........................................................................................1032 Inclinometer Calibration..............................................................................................1032 DATA ANALYSIS.............................................................................................................1033 Creating a Query......................................................................................................1033 Sorting on Truck Unit Number..........................................................................................1033 Sorting on Truck Type.................................................................................................1033 Sorting on Date Range.................................................................................................1034 Sorting on Time Range.................................................................................................1034 Payload Detail Screen.................................................................................................1035 Creating Reports......................................................................................................1035 Summary - one page report.............................................................................................1036 Detailed - multi-page report..........................................................................................1036 Creating Graphs.......................................................................................................1037 Exporting Data........................................................................................................1037 CSV Export............................................................................................................1037 Compressed............................................................................................................1038 Importing Data........................................................................................................1039 Deleting Haul Cycle Records...........................................................................................1039 Viewing Alarms........................................................................................................1040 Deleting Alarm Records................................................................................................1040 TROUBLESHOOTING SECTION.......................................................................................................1041 TROUBLESHOOTING...........................................................................................................1041 Viewing Active Alarms.................................................................................................1041 Real-Time Data Display................................................................................................1041 Testing the Payload Lights............................................................................................1041 Creating Log Files of Inputs..........................................................................................1042 Daily Inspections.....................................................................................................1042 Periodic Maintenance..................................................................................................1042 Abnormal Displays at Power-Up.........................................................................................1043 No Payload Display When Key Switch is Turned ON.......................................................................1044 No Display on Speedometer.............................................................................................1045 No Display on Operator Display........................................................................................1045 No Communications With PC.............................................................................................1046 Load Lights Don’t Light During Loading................................................................................1047 Load Lights Remain ON.................................................................................................1048 Load Lights Remain ON During Dumping..................................................................................1048 Display Doesn't Clear When The Load Is Dumped.........................................................................1048 Calibration Problems..................................................................................................1049 Alarm 1 - Left Front Pressure High....................................................................................1050 Alarm 2 - Left Front Pressure Low.....................................................................................1050 Troubleshoot Wiring to Left Front Suspension..........................................................................1050 Alarm 3 - Right Front Pressure High...................................................................................1051 Alarm 4 - Right Front Pressure Low....................................................................................1051 Troubleshoot Wiring to Right Front Suspension.........................................................................1051 Alarm 5 -Left Rear Pressure High......................................................................................1052 Alarm 6 - Left Rear Pressure Low......................................................................................1052 Troubleshoot Wiring to Left Rear Suspension...........................................................................1052 Alarm 7 - Right Rear Pressure High....................................................................................1053 Alarm 8 - Right Rear Pressure Low.....................................................................................1053 Troubleshoot Wiring to Right Rear Suspension..........................................................................1053 Alarm 9 - Inclinometer High...........................................................................................1054 Alarm 10 - Inclinometer Low...........................................................................................1054 Troubleshoot Inclinometer Wiring......................................................................................1054 Alarm 13 - Body Up Input Failure......................................................................................1055 Alarm 16 - Memory Write Failure.......................................................................................1056 Alarm 17 - Memory Read Failure........................................................................................1056 Alarm 18..............................................................................................................1057 Alarm 19..............................................................................................................1057 Alarm 22..............................................................................................................1057 Operator Switch Doesn't Work..........................................................................................1058 Alarm 26 - User Switch Fault - SELECT.................................................................................1058 Alarm 27 - User Switch Fault - SET....................................................................................1058 Connector Map.........................................................................................................1059 Connectors............................................................................................................1060 PLMIII CHECK OUT PROCEDURE....................................................................................................1061 General Description.......................................................................................................1061 Tools Required............................................................................................................1061 Checkout Procedure........................................................................................................1061 PLMIII CHECKOUT PROCEDURE CONFIRMATION....................................................................................1065 Flashburn Programming.................................................................................................1065 Confirmation Checklist................................................................................................1067 SECTION M31 RESERVE ENGINE OIL SYSTEM.............................................................................................1069 RESERVE ENGINE OIL SYSTEM.....................................................................................................1071 Operation.................................................................................................................1072 LED Monitor Light.........................................................................................................1072 Tank Fill Control (Optional)..............................................................................................1073 Filling Procedure (Remote Fill Feature)...................................................................................1073 SERVICE...................................................................................................................1074 Every 10 Hours, or once each shift:...................................................................................1074 Every 500 Hours.......................................................................................................1074 Changing Oil..........................................................................................................1074 TROUBLESHOOTING...........................................................................................................1075 Circuit Fuse..........................................................................................................1075 SYSTEM ELECTRICAL SCHEMATICS..............................................................................................1076 SECTION N OPERATOR CAB INDEX..........................................................................................................1077 SECTION N2 TRUCK CAB AND COMPONENTS...............................................................................................1079 TRUCK CAB AND COMPONENTS......................................................................................................1081 TRUCK CAB.................................................................................................................1081 Description...........................................................................................................1081 Removal...............................................................................................................1082 Installation..........................................................................................................1083 CAB DOOR..................................................................................................................1084 Removal...............................................................................................................1084 Installation..........................................................................................................1084 Door Jamb Bolt Adjustment.............................................................................................1085 Door Handle Plunger Adjustment........................................................................................1086 Replacing the Door Glass..............................................................................................1087 Replacing the Door Handle or Latch Assembly...........................................................................1091 Replacing the Door Window Regulator...................................................................................1092 Replacing the Door and Door Hinge Seal................................................................................1093 Replacing the Door Opening Seal.......................................................................................1093 GLASS REPLACEMENT (Adhesive-Bonded Windows)...............................................................................1094 Recommended Tools and Supplies........................................................................................1094 Replacement Procedure.................................................................................................1094 WINDSHIELD AND REAR GLASS.................................................................................................1095 Removal...............................................................................................................1095 Installation..........................................................................................................1096 SECTION N3 CAB COMPONENTS.........................................................................................................1097 CAB COMPONENTS................................................................................................................1099 WINDSHIELD WIPERS.........................................................................................................1099 WIPER MOTOR...........................................................................................................1099 Removal...........................................................................................................1099 Installation......................................................................................................1099 WIPER ARM.............................................................................................................1099 Removal...........................................................................................................1099 Installation......................................................................................................1100 WIPER LINKAGE.........................................................................................................1100 Removal...........................................................................................................1100 Installation......................................................................................................1100 WINDSHIELD WASHER.........................................................................................................1101 Operation.............................................................................................................1101 Service...............................................................................................................1101 OPERATOR SEAT.............................................................................................................1102 Seat Belts............................................................................................................1102 Adjustment............................................................................................................1102 Inspection............................................................................................................1103 Removal...............................................................................................................1103 Installation..........................................................................................................1103 PASSENGER SEAT............................................................................................................1104 Inspection............................................................................................................1104 Removal...............................................................................................................1104 Installation..........................................................................................................1104 SECTION N4 HEATER / AIR CONDITIONER...............................................................................................1105 HEATER/AIR CONDITIONER........................................................................................................1107 OPERATION.................................................................................................................1107 Fan Control Knob......................................................................................................1107 Temperature Control Knob..............................................................................................1107 Directional Control Knob..............................................................................................1107 Heater Vents..........................................................................................................1107 COMPONENTS................................................................................................................1108 Fuse and Circuit Breaker..............................................................................................1108 Relays................................................................................................................1108 Heater Core...........................................................................................................1108 Fan Motor And Speed Control...........................................................................................1109 Actuators.............................................................................................................1109 Cab Air Filter........................................................................................................1109 ENVIRONMENTAL IMPACT OF AIR CONDITIONING..................................................................................1112 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES.................................................................................1112 PRINCIPLES OF REFRIGERATION...............................................................................................1112 Air Conditioning......................................................................................................1112 Refrigeration - The Act Of Cooling....................................................................................1113 The Refrigeration Cycle...............................................................................................1113 AIR CONDITIONER SYSTEM COMPONENTS.........................................................................................1114 Compressor (Refrigerant Pump).........................................................................................1114 Service Valves........................................................................................................1114 Condenser.............................................................................................................1114 Receiver-Drier........................................................................................................1114 Expansion Block Valve.................................................................................................1115 Accumulator...........................................................................................................1115 Evaporator............................................................................................................1115 ELECTRICAL CIRCUIT........................................................................................................1116 Thermostat............................................................................................................1116 Compressor Clutch.....................................................................................................1116 Trinary™ Switch.......................................................................................................1117 AIR CONDITIONING SYSTEM SERVICING WARNINGS................................................................................1118 SERVICE TOOLS AND EQUIPMENT...............................................................................................1119 Recovery/Recycle Station..............................................................................................1119 Leak Detector.........................................................................................................1119 Manifold Gauge Set....................................................................................................1120 Installing Manifold Gauge Set.........................................................................................1121 Purging Air From Service Hoses........................................................................................1121 Service Valves........................................................................................................1122 Vacuum Pump...........................................................................................................1122 SYSTEM PERFORMANCE TEST...................................................................................................1123 SYSTEM OIL................................................................................................................1124 Handling and Reusing PAG Oil..........................................................................................1124 Oil Quantity..........................................................................................................1124 Checking System Oil...................................................................................................1124 REFRIGERANT...............................................................................................................1125 Recycled Refrigerant..................................................................................................1125 Reclaimed Refrigerant.................................................................................................1125 Refrigerant Quantity..................................................................................................1126 R-134a Refrigerant Containers.........................................................................................1126 SYSTEM LEAK TESTING.......................................................................................................1126 Electronic Leak Detector..............................................................................................1127 Tracer Dyes...........................................................................................................1127 Soap and Water........................................................................................................1127 RECOVERING AND RECYCLING THE REFRIGERANT..................................................................................1127 Draining Oil from the Previous Recovery Cycle.........................................................................1127 Performing the Recovery Cycle.........................................................................................1127 Performing the Recycling Procedure....................................................................................1128 Evacuating and Charging the A/C System................................................................................1128 SYSTEM REPAIR.............................................................................................................1128 System Flushing.......................................................................................................1128 A/C DRIVE BELT CHECKOUT PROCEDURE.........................................................................................1129 Pulley Alignment......................................................................................................1129 Belt Tension Check....................................................................................................1129 COMPONENT REPLACEMENT.....................................................................................................1131 Hoses and Fittings....................................................................................................1131 Lines.................................................................................................................1131 Expansion Valve.......................................................................................................1131 Receiver-Drier........................................................................................................1131 Thermostat............................................................................................................1131 Compressor............................................................................................................1132 Accumulator...........................................................................................................1132 Clutch................................................................................................................1132 Servicing the Compressor Clutch.......................................................................................1133 Pulley Removal........................................................................................................1135 Clutch Coil Check.....................................................................................................1135 Pulley Installation...................................................................................................1135 Clutch Assembly Installation..........................................................................................1136 EVACUATING THE SYSTEM.....................................................................................................1137 CHARGING THE A/C SYSTEM...................................................................................................1138 TROUBLESHOOTING...........................................................................................................1139 Preliminary Checks....................................................................................................1139 Diagnosis Of Gauge Readings And System Performance....................................................................1139 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS................................................................................1140 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM................................................................................1146 SECTION N5 OPERATOR CAB CONTROLS..................................................................................................1147 OPERATOR CAB CONTROLS.........................................................................................................1150 STEERING COLUMN...........................................................................................................1151 Removal...............................................................................................................1151 Inspection............................................................................................................1151 Installation..........................................................................................................1152 STEERING WHEEL............................................................................................................1152 Removal...............................................................................................................1152 Installation..........................................................................................................1152 STEERING WHEEL AND CONTROLS...............................................................................................1154 Horn Button...........................................................................................................1154 Tilt / Telescope Lever................................................................................................1154 Multi-Function Turn Signal Switch.....................................................................................1154 DYNAMIC RETARDING.........................................................................................................1155 Retarder Lever........................................................................................................1155 Brake/Retarder Pedal..................................................................................................1155 Throttle/Accelerator Pedal............................................................................................1155 GRADE/SPEED CHART.........................................................................................................1156 OVERHEAD PANEL AND DISPLAYS...............................................................................................1157 Speakers..............................................................................................................1157 Warning Alarm Buzzer..................................................................................................1157 Radio/CD Player.......................................................................................................1157 Warning Indicator Light Dimmer Control................................................................................1157 Status/Warning Indicator Light Panel..................................................................................1157 Air Cleaner Restriction Gauges........................................................................................1157 CENTER CONSOLE............................................................................................................1158 Directional Control Lever.............................................................................................1158 Override/Fault Reset Switch...........................................................................................1159 Engine Shutdown Switch................................................................................................1159 Window Control Switches...............................................................................................1159 Hoist Control Lever...................................................................................................1159 Retarder Speed Control (RSC) Adjustment Dial..........................................................................1160 Retarder Speed Control (RSC) Switch...................................................................................1160 Data Store Button.....................................................................................................1161 KOMTRAX Plus Snapshot In Progress Light...............................................................................1161 Link Energized Light..................................................................................................1161 Service Engine Light..................................................................................................1161 12V Auxiliary Power Outlets...........................................................................................1161 DIAGNOSTIC PORTS..........................................................................................................1161 KOMTRAX Plus Diagnostic Port..........................................................................................1161 Interface Module (IM) Diagnostic Port.................................................................................1161 Payload Meter Diagnostic Port.........................................................................................1161 Truck Control Interface (TCI) Diagnostic Port.........................................................................1161 Propulsion System Controller (PSC) Diagnostic Port....................................................................1161 Engine Diagnostic Port (CENSE)........................................................................................1161 Engine Diagnostic Port (QUANTUM)......................................................................................1161 INSTRUMENT PANEL..........................................................................................................1162 Control Symbols.......................................................................................................1162 Key Switch............................................................................................................1164 Air Conditioner Compressor Switch.....................................................................................1164 Rotating Beacon Switch (optional).....................................................................................1164 Heated Mirrors Switch (optional)......................................................................................1164 AC Drive System Rest Switch...........................................................................................1165 Wheel Brake Lock Switch...............................................................................................1165 Hazard Warning Lights.................................................................................................1165 Heater/Air Conditioner Vents..........................................................................................1165 Engine Oil Pressure Gauge.............................................................................................1166 Right Turn Signal Indicator...........................................................................................1166 Digital Tachometer....................................................................................................1166 High Beam Indicator...................................................................................................1166 Speedometer/Payload Meter Display.....................................................................................1166 Left Turn Signal Indicator............................................................................................1166 Coolant Temperature Gauge.............................................................................................1166 Lamp Check Switch.....................................................................................................1166 Light Switch (3-Way)..................................................................................................1166 Ladder Light Switch...................................................................................................1167 Backup Light Switch...................................................................................................1167 Fog Light Switch......................................................................................................1167 Payload Meter Switch..................................................................................................1167 Panel Illumination Light Dimmer Switch................................................................................1167 Hydraulic Oil Temperature Gauge.......................................................................................1167 Engine Hourmeter......................................................................................................1167 Fuel Gauge............................................................................................................1167 OVERHEAD STATUS / WARNING INDICATORS......................................................................................1168 A1. High Hydraulic Oil Temperature....................................................................................1169 B1. Low Steering Pressure.............................................................................................1169 C1. Low Accumulator Precharge Pressure................................................................................1170 D1. Not used..........................................................................................................1170 E1. Low Brake Pressure................................................................................................1170 A2. Low Hydraulic Tank Level..........................................................................................1170 B2. Low Automatic Lubrication System Pressure.........................................................................1170 C2. Circuit Breaker Tripped...........................................................................................1170 D2. Hydraulic Oil Filter Monitor......................................................................................1171 E2. Low Fuel..........................................................................................................1171 A3. Parking Brake.....................................................................................................1171 B3. Service Brake.....................................................................................................1171 C3. Body Up...........................................................................................................1171 D3. Dynamic Retarding.................................................................................................1171 E3. Stop Engine.......................................................................................................1171 A4. Cranking Motor Failure............................................................................................1172 B4. Backup Lights.....................................................................................................1172 C4. Engine Shutdown Timer.............................................................................................1172 D4. Retard Speed Control (RSC) Indicator..............................................................................1172 E4. Check Engine......................................................................................................1172 A5. No Power..........................................................................................................1172 B5. Propulsion System Warning.........................................................................................1172 C5. Propulsion System Temperature.....................................................................................1172 D5. System/Component Failure..........................................................................................1173 E5. Battery Charging System Failure...................................................................................1173 A6. No Propel.........................................................................................................1173 B6. Propel System At Rest.............................................................................................1173 C6. Propel System Not Ready...........................................................................................1173 D6. Reduced Propulsion................................................................................................1173 E6. Retard At Continuous Level........................................................................................1173 REAR AXLE LIGHT BAR.......................................................................................................1174 Backup Lights.........................................................................................................1174 Retard Lights.........................................................................................................1174 Brake Light...........................................................................................................1174 Backup Alarm..........................................................................................................1174 KOMTRAX PLUS..............................................................................................................1175 Operation.............................................................................................................1175 Interface Module......................................................................................................1177 Basic Precautions.....................................................................................................1177 KOMATSU WIRELESS BRIDGE (Optional)........................................................................................1178 General Information...................................................................................................1178 Communication Setup...................................................................................................1178 Switching to the KWB_SETUP Network....................................................................................1178 Setting the Computer Subnet Mask and IP Address.......................................................................1179 Properties............................................................................................................1179 Setting Up the KWB....................................................................................................1180 Adding Encryption.....................................................................................................1180 Final Computer Settings...............................................................................................1180 Data Downloading......................................................................................................1181 Resetting the KWB.....................................................................................................1181 KWB Lights............................................................................................................1181 SECTION P LUBRICATION AND SERVICE.....................................................................................................1183 SECTION P2 LUBRICATION AND SERVICE................................................................................................1185 LUBRICATION AND SERVICE.......................................................................................................1187 GENERAL...................................................................................................................1187 SERVICE CAPACITIES........................................................................................................1187 HYDRAULIC TANK SERVICE....................................................................................................1187 Adding Oil............................................................................................................1187 COOLING SYSTEM SERVICE....................................................................................................1188 Radiator Filling Procedure............................................................................................1188 Coolant Specifications................................................................................................1188 Unacceptable Practices................................................................................................1188 WHEEL MOTOR SERVICE.......................................................................................................1188 RESERVE OIL TANK SERVICE..................................................................................................1189 Filling the Reserve Oil Tank (Remote Fill)............................................................................1189 Inline Screen.........................................................................................................1189 QUICK FILL SERVICE CENTER.................................................................................................1190 LUBRICATION CHART.........................................................................................................1191 10 HOUR (DAILY) INSPECTIONS...............................................................................................1192 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................................1194 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1194 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1194 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................................1197 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................................1199 5000 HOUR MAINTENANCE CHECKS..............................................................................................1199 SECTION P3 AUTOMATIC LUBRICATION SYSTEM...........................................................................................1201 AUTOMATIC LUBRICATION SYSTEM..................................................................................................1203 GENERAL DESCRIPTION.......................................................................................................1203 SYSTEM COMPONENTS.........................................................................................................1205 Filter................................................................................................................1205 Hydraulic Motor and Pump..............................................................................................1205 Grease Reservoir......................................................................................................1205 Pressure Reducing Valve...............................................................................................1205 Flow Control Valve....................................................................................................1205 Solenoid Valve........................................................................................................1205 Vent Valve............................................................................................................1205 Lubrication Cycle Timer...............................................................................................1205 Over Pressure Cut Off Switch..........................................................................................1205 Grease Pressure Failure Switch........................................................................................1205 Injectors.............................................................................................................1205 Relief Valve (unloader valve).........................................................................................1205 SYSTEM OPERATION..........................................................................................................1206 Normal Operation......................................................................................................1206 Lubricant Required For System.........................................................................................1207 System Priming........................................................................................................1207 Filter Assembly.......................................................................................................1207 LUBRICANT PUMP............................................................................................................1208 Pump Housing Oil Level................................................................................................1208 Pump Pressure Control.................................................................................................1208 INJECTORS (SL-1 Series “H”)...............................................................................................1209 Injector Specifications...............................................................................................1209 Injector Adjustment...................................................................................................1209 INJECTOR OPERATION....................................................................................................1210 PREVENTIVE MAINTENANCE PROCEDURES.........................................................................................1211 Daily Lubrication System Inspection...................................................................................1211 250 Hour Inspection...................................................................................................1211 1000 Hour Inspection..................................................................................................1211 SYSTEM CHECKOUT...........................................................................................................1212 Lubrication Controller Check..........................................................................................1212 Lubrication Controller Components.....................................................................................1212 Lubrication Controller Adjustment.....................................................................................1212 SYSTEM TROUBLESHOOTING CHART..................................................................................................1214 SECTION Q ALPHABETICAL INDEX..........................................................................................................1217 SECTION R SYSTEM SCHEMATICS...........................................................................................................1221 HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC.......................................................................1223 HYDRAULIC BRAKE SYSTEM SCHEMATIC..................................................................................................1224 ELECTRICAL SCHEMATICS.............................................................................................................1225
KOMATSU 930E-4SE DUMP TRUCK SHOP MANUAL A30587-A30677 – PDF DOWNLOAD:
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