Komatsu 930E- 4SE DUMP TRUCK Shop Manual CEBM030102 PDF

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Komatsu 930E- 4SE DUMP TRUCK Shop Manual CEBM030102 –  PDF DOWNLOAD

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Komatsu 930E- 4SE DUMP TRUCK Shop Manual CEBM030102 –  PDF DOWNLOAD

Language : English
Pages : 1412
Downloadable : Yes
File Type : PDF

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14

TABLE OF CONTENTS:

Komatsu 930E- 4SE DUMP TRUCK Shop Manual CEBM030102 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31875 and up

FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
SECTION A2 COMPONENTS & SPECIFICATIONS 11
MAJOR COMPONENT DESCRIPTIONS 11
Truck And Engine 11
Main Alternator 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SECTION A3 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 Jumper Cables 26
Jump Starting With Receptacles 26
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Electrical Systems Isolation 27
Warning Tag 29
Proper Tools 29
Use of Tie-Off Anchor During Maintenance and Repair 29
Securing The Dump Body 29
Jack Point Locations 30
WHILE PERFORMING MAINTENANCE 31
Keep The Truck Clean 31
Attachments 31
Working Under The Truck 31
Rotating Fan And Belts 31
Waste Materials 31
Adding Fuel Or Oil 32
Radiator Coolant Level 32
Use Of Lighting 32
Precautions With The Battery 32
Handling High Pressure Hoses 32
Precautions With High Pressure Oil 32
Performing Maintenance Near High Temperature Or High Pressure 32
TIRES 33
Inspection 33
Maintenance 33
Storage 34
Handling 35
WHEN REPAIRS ARE NECESSARY 36
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 37
Preliminary Procedures Before Welding or Performing Maintenance 37
Engine Shutdown Procedure Before Welding or Performing Maintenance 37
CAPACITOR DISCHARGE SYSTEM 39
Necessary Tools 39
Warnings and Cautions 40
Manual DC Link Capacitor Discharge Procedure 41
Failure of the Discharge System 43
Manual Discharge of Capacitors 44
Short Isolated Capacitor Terminals 46
SECTION A3 OPERATING INSTRUCTIONS 47
PREPARING FOR OPERATION 47
WALK AROUND INSPECTION 47
RETRACTABLE LADDER SYSTEM (Optional) 52
Description 52
Normal Operation 52
General Safety 52
IN-CAB CONTROL PANEL 53
Digital Display Screen 53
Command Buttons 53
USING THE IN-CAB CONTROL PANEL 54
Raising the Ladder 55
Lowering the Ladder 55
USING THE GROUND LEVEL CONTROL BOX 56
Raising the Ladder 56
Lowering the Ladder 56
EMERGENCY OPERATION 57
ENGINE START-UP 58
AFTER ENGINE HAS STARTED 59
PRE-SHIFT BRAKE CHECK 60
Events 60
OPERATION 60
Description 60
Brake Test Exit Criteria 61
PERFORMING THE BRAKE TESTS 62
Setup 62
Service Brake Test 62
Parking Brake Test 63
Retard System Test 64
EMERGENCY STEERING SYSTEM 64
Operation 64
Pre-Operation Testing 64
Additional Guidelines 65
MACHINE OPERATION SAFETY PRECAUTIONS 65
OPERATING ON THE HAUL ROAD 66
STARTING ON A GRADE WITH A LOADED TRUCK 67
PASSING 67
LOADING 67
Overload Speed Limit Function 67
DUMPING 68
Raising The Dump Body 68
Lowering The Dump Body (When dumping on flat ground) 69
Lowering The Dump Body (When dumping over a berm or into a crusher) 69
Sudden loss of engine power or loss of drive system function 70
FUEL DEPLETION 70
SAFE PARKING PROCEDURES 71
NORMAL ENGINE SHUTDOWN PROCEDURE 71
DISABLED TRUCK DUMPING PROCEDURE 73
Hookup 73
Raising the Body 73
Lowering the Body 73
HOIST SYSTEM 74
Hookup 74
Dumping Procedure 75
TOWING 75
Special Wiring Harness 76
Towing Procedure 76
SECTION A4 WARNINGS AND CAUTIONS 79
GRADE/SPEED CHART 79
KEY SWITCH 79
ROPS/FOPS 79
BATTERIES 80
ISOLATION BOX 81
PROPEL LOCKOUT LEVER 81
CAPACITORS 82
CRUSHING HAZARD 82
CYLINDER PRESSURE 83
FILLING THE HYDRAULIC TANK 83
HYDRAULIC OIL PRESSURE 84
HOT OIL SPRAY 84
WHEEL MOTOR OIL LEVEL 84
HOT EXHAUST 84
RADIATOR 85
EMERGENCY LADDER 85
ACCUMULATOR DRAIN VALVES 85
EMERGENCY DUMP PROCEDURE 85
EMERGENCY TOWING PROCEDURE 85
WELDING 86
EMERGENCY SHUTDOWN 86
INFORMATION DISPLAY 86
WIRELESS SIGNALS 86
HIGH VOLTAGE 87
LIFTING INSTRUCTIONS 88
PRODUCT IDENTIFICATION PLATE 89
LUBRICATION CHART 90
TOW SOCKET 90
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 90
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 91
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 92
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 92
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 93
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 94
SECTION A7 STORAGE PROCEDURES AND IDLE MACHINE PREPARATION 101
SHORT TERM IDLE PERIODS 101
PREPARATION FOR STORAGE 102
REMOVAL FROM STORAGE 103
RECONDITIONING AN IDLE VEHICLE 105
ENGINE OPERATION 107
After The Engine Has Started 108
ENGINE STORAGE 109
Temporary Storage (30 Days Or Less) 109
Extended Storage (More Than 30 Days) 109
RESTORING AN ENGINE AFTER EXTENDED STORAGE 111
ELECTRIC DRIVE TRUCKS 112
Storing A Truck That Is Operational 112
Storing A Truck That Is Not Operational 113
Storing A Major Component 114
Periodic Inspections 114
Placing Equipment Into Service After Storage 114
SECTION B STRUCTURES INDEX 117
SECTION B2 STRUCTURAL COMPONENTS INDEX 119
STRUCTURAL COMPONENTS 121
PREPARATION 121
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 122
Removal 122
Installation 122
RH DECK AND RETARDING GRID 123
Removal 123
Installation 123
LH DECK 124
Removal 124
Installation 124
CENTER DECK 125
Removal 125
Installation 125
SECTION B3 DUMP BODY INDEX 127
DUMP BODY 129
DUMP BODY 129
Removal 129
Installation 130
BODY PADS 131
Body Pad Shimming Procedure 132
BODY GUIDE 133
HOIST LIMIT SWITCH 133
BODY-UP SWITCH 133
BODY RETENTION SLING 133
ROCK EJECTORS 134
Inspection 134
SECTION B4 FUEL TANK INDEX 135
FUEL TANK 137
FUEL TANK 137
Removal 137
Repair 137
Cleaning 137
Installation 137
FUEL TANK VENT ASSEMBLY 139
Disassembly 139
Assembly 139
FUEL GAUGE SENDER 140
Removal 140
Installation 140
QUICK FILL FUEL RECEIVERS 140
SECTION C ENGINE INDEX 141
SECTION C2 POWER MODULE INDEX 143
POWER MODULE 145
PREPARATION FOR REMOVAL 145
REMOVAL 150
INSTALLATION 152
HOOKUP 153
EXHAUST TUBE INSTALLATION 154
EXHAUST BLANKET INSTALLATION 154
SECTION C3 COOLING SYSTEM INDEX 155
COOLING SYSTEM 157
RADIATOR 157
Removal 157
Installation 159
Filling Procedure 160
REPAIRING THE RADIATOR 160
Internal Inspection 160
External Cleaning 160
Disassembly 161
Cleaning and Inspection 162
Assembly 162
Pressure Testing 163
COOLANT SYSTEM TROUBLESHOOTING 163
SECTION C4 POWER TRAIN INDEX 165
POWER TRAIN 167
ALTERNATOR REMOVAL 167
ALTERNATOR INSTALLATION 169
Measuring Procedure 169
Joining the Alternator and Engine 171
ENGINE 172
Removal 172
Service 172
Installation 172
SECTION C5 AIR CLEANERS INDEX 173
AIR CLEANERS 175
OPERATION 175
SERVICING THE AIR CLEANERS 175
Replacing The Elements 176
AIR CLEANER ASSEMBLY CLEANING 177
Primary Element Cleaning 177
Precleaner Section Cleaning 179
AIR INTAKE TROUBLESHOOTING 180
SECTION C7 FAN CLUTCH INDEX 181
FAN CLUTCH 183
REMOVAL & INSTALLATION TOOLING 183
DISASSEMBLY 186
CLEANING AND INSPECTION 196
ASSEMBLY 200
TEST PROCEDURE 214
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 215
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 217
24VDC ELECTRIC SUPPLY SYSTEM 219
ELECTRICAL SYSTEM DESCRIPTION 219
BATTERIES 219
Maintenance and Service 219
Troubleshooting 219
BATTERY SUPPLY SYSTEM 221
24VDC Battery Charging Alternator 221
Battery Box 221
Removal 221
Installation 222
Battery Control Box 222
24VDC Auxiliary Battery Receptacles 222
Engine Start Relay 222
ISOLATION BOX ASSEMBLY 222
Engine Shutdown Switch 222
Access Ladder Light Switch 222
Battery Disconnect Switches 222
Propel Lockout Lever 223
LED Lights 223
AUXILIARY CONTROL CABINET 224
24VDC to 12VDC Converter 224
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 225
Operation 225
Engine Oil Pressure Switch 226
Check Valve 226
MAINTENANCE 226
Prelube System Operation Checks 226
Check Valve 226
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 227
24VDC ELECTRIC START SYSTEM 229
CRANKING MOTORS 229
Operation 229
Removal 229
Installation 229
CRANKING MOTOR TROUBLESHOOTING 230
Preliminary Inspection 230
No-Load Test 230
Interpreting Results of Tests 231
Disassembly 231
Cleaning and Inspection 232
Armature Servicing 234
Field Coil Checks 234
Field Coil Removal 234
SOLENOID CHECKS 235
Test 235
Assembly 236
Bearing Replacement: 236
Motor Assembly: 236
Pinion Clearance 237
MAGNETIC SWITCH 237
Removal 237
Installation 237
Coil Test 238
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 239
24 VDC ELECTRICAL SYSTEM COMPONENTS 241
TRUCK SHUTDOWN PROCEDURE 241
BRAKE WARNING BUZZER 241
AUXILIARY CONTROL CABINET COMPONENTS 241
Interface Module 242
Payload Meter 242
24VDC to 12VDC Converter 242
Circuit Breaker (CB60) 242
Communication Interface Module 242
Pump Module Service Light Timer 243
Power Distribution Terminals 243
Ground Terminal 243
Relays 244
Engine Service Light Timer 244
RTMR1 – VEC Block 245
Vehicle Electrical Centers (VEC) 245
VEC-89 246
VEC-90 248
VEC-91 250
MAGNETIC SWITCHES 252
Body position switches (With proximity switch and magnet) 252
Proximity switch operation 252
Service 252
BODY-UP SWITCH 253
Adjusting the Body-Up Switch 253
HOIST LIMIT SWITCH 254
Operation 254
Adjusting the Hoist Limit Switch 255
SECTION D11 KOMTRAX PLUS INDEX 257
KOMTRAX PLUS 259
KOMTRAX PLUS BASIC FEATURES 259
Gather Data 259
Convert and Record Data 259
Communicate Data to Off-Board Systems 260
USING KOMTRAX PLUS 261
Turning KOMTRAX Plus ON 261
Normal KOMTRAX Plus Operation 261
Turning KOMTRAX Plus OFF 262
Downloading from the KOMTRAX Plus Controller 262
KOMTRAX PLUS DATA ITEMS 263
Fault Codes 263
Machine History 263
KOMTRAX Plus History 263
Snapshots 264
Manual Snapshots 264
Trends 266
Histogram (Load Map) Data 266
Haul Cycle Data 267
Alarm and Snapshot Triggers 268
Satellite Features 268
KOMTRAX PLUS DIAGNOSTIC FEATURES 270
Fault History 270
LED Digits 270
KOMTRAX PLUS CONTROLLER 270
Removal 271
Installation 271
KOMTRAX PLUS SOFTWARE 272
VHMS Tool Box Installation 272
VHMS Setting Tool Installation 272
PDM Software Installation 272
KOMTRAX PLUS INITIALIZATION PROCEDURE 273
CONTROLLER SETUP PROCEDURE 273
SNAPSHOT PROCEDURE 276
DOWNLOAD PROCEDURE 277
FTP UPLOAD PROCEDURE 278
INITIALIZATION FORMS 279
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS CONTROLLER CHECKOUT 285
Necessary Equipment 285
Preliminary 285
KOMTRAX Plus Controller Checkout Procedure 286
ORBCOMM CONTROLLER (if equipped) 288
Removal 288
Installation 288
Troubleshooting 289
SECTION D12 INTERFACE MODULE INDEX 295
INTERFACE MODULE 297
Removal 297
Installation 297
SENSORS 298
Temperature Sensors 298
Pressure Sensors 298
INTERFACE MODULE SOFTWARE 299
Flashburn Program Installation 299
Interface Module Application Code Installation 300
Interface Module Realtime Data Monitor Software 300
INTERFACE MODULE CHECKOUT 301
Necessary Equipment 301
Preliminary 302
Check Digital Inputs To The Interface Module 303
Check Analog Inputs To The Interface Module 307
Check Serial Interfaces To The Interface Module 307
Check Outputs From The Interface Module 308
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 313
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 315
GENERAL 315
Structure and Purpose 315
TROUBLESHOOTING 316
Communications Networks 316
Coaxial Cable 316
FAULT CODES 316
Fault History 316
KOMTRAX Plus LED Display Fault Codes 317
Chassis Fault Codes 318
Engine Fault Codes 323
FAULT TREE ANALYSIS 328
Unable to connect to KOMTRAX Plus from laptop PC 328
Flashing Error Code N4-23 (PLM III Communications Fault) 329
Flashing Error Code N4-22 (Engine Communications Fault) 330
No Data Received By WebCARE 331
Coaxial Cable Troubleshooting 332
SECTION D14 KOMTRAX PLUS FORMS INDEX 333
KOMTRAX PLUS FORMS 335
KOMTRAX PLUS INITIALIZATION CHECK LIST 335
KOMTRAX PLUS DATA DOWNLOAD 336
KOMTRAX PLUS INITIALIZATION CHECK LIST 337
KOMTRAX PLUS INITIALIZATION FORM 339
SECTION E ELECTRIC PROPULSION SYSTEM INDEX 341
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 343
ELECTRICAL PROPULSION SYSTEM COMPONENTS 345
GENERAL SYSTEM DESCRIPTION 345
SYSTEM COMPONENTS 347
Drive System Controller (DSC) 347
Diagnostic Information Display (DID) Panel 348
DID Panel Event Codes 348
DSC SOFTWARE FUNCTIONS 376
Input Processing 376
State Machine 376
DC Link State 379
Engine Control 380
ALTERNATOR FIELD CONTROL 380
Desired DC Link Voltage 380
Self-Load 380
Propel Torque Control 381
Retard Torque Control 381
Wheel Slide Control 381
Resistor Grid Control 382
Chopper Voltage Control 382
EVENT DETECTION AND PROCESSING 382
Power-On Tests 382
Initiated Tests 383
Periodic Tests 383
EVENT RESTRICTIONS 383
EVENT LOGGING AND STORAGE 383
Event History Buffer 384
Data Packs 384
Event Reset 384
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 385
Fast Start 385
Engine Shutdown/Engine Not Running 385
Limp Home Mode 385
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 386
ELECTRONIC ACCELERATOR AND RETARD PEDALS 393
Removal 393
Installation 393
Disassembly 393
Assembly 393
PHASE MODULE REPLACEMENT 394
Removal 394
Installation 394
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 395
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 397
AC DRIVE SYSTEM MAINTENANCE 397
NORMAL TRUCK SHUTDOWN PROCEDURE 398
TEST EQUIPMENT 399
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 399
REST MODE ACTIVATION 399
INITIAL CHECKOUT PROCEDURES 400
Circuit Continuity and Resistance Checks 400
Megger Test for Grounds 400
Preparation for Megger Test 401
Megger Test Procedure 402
Troubleshooting for Grounds 403
Low Voltage Power Supply Checks 404
Preparation for Power Supply Checks 404
Power Supply Check Procedure 404
Drive System Controller (DSC) Card Checks 405
Propulsion System Software Installation 405
DSC Manual Test Procedures 408
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 410
Set Truck ID Number 414
Control Cabinet Pressure Switch Check 415
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 416
Verifying DSC Software Version 416
Resetting and Erasing DSC Event Data 418
ENGINE RUNNING TESTS 419
Battery Boost Circuit Verification 419
Selector Switch Check 421
Ground Detection Network Tests 423
Self Load Engine Test (Loadbox) Procedure 427
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 429
DID Panel Display Selection 429
DID Modes Display 431
Function Key F1 – DID Events or Faults Display 432
Function Key F4 – DID Menu Display 435
DID Self Load Engine Test (Loadbox) 436
DID Link Capacitance Test 438
DID Speedometer Test 439
DID View Software Version 440
DID View Overspeed Setting 441
DID View Data Menu 442
DID Inverter Cutout Menu 447
DID Truck Configuration Menu 448
Language Selection 453
VIEWING EVENT AND STATISTICAL DATA 454
Viewing the DSC Event Summary, Trigger Data, and Data Packs 454
Viewing the Statistical Data 456
LOGIC SCREENS 457
DATALOGGER FUNCTION 459
Setting Up the Datalogger 459
Starting the Datalogger 461
UPLOADING DATA 463
Consolidated Truck Data Save 463
USB Drive 464
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 465
Fault Code A001: Left front suspension pressure sensor signal is high 467
Related circuit diagram 467
Fault Code A002: Left front suspension pressure sensor signal is low 468
Related circuit diagram 468
Fault Code A003: Right front suspension pressure sensor signal is high 469
Related circuit diagram 469
Fault Code A004: Right front suspension pressure sensor signal is low 470
Related circuit diagram 470
Fault Code A005: Left rear suspension pressure sensor signal is high 471
Related circuit diagram 471
Fault Code A006: Left rear suspension pressure sensor signal is low 472
Related circuit diagram 472
Fault Code A007: Right rear suspension pressure sensor signal is high 473
Related circuit diagram 473
Fault Code A008: Right rear suspension pressure sensor signal is low 474
Related circuit diagram 474
Fault Code A009: Incline sensor signal is high 475
Related circuit diagram 475
Fault Code A010: Incline sensor signal is low 476
Related circuit diagram 476
Fault Code A011: Payload meter speed sensor signal has failed 477
Related circuit diagram 477
Fault Code A013: Body up switch has failed 478
Related circuit diagram 478
Fault Code A014: Payload meter checksum computation has failed 479
Related circuit diagram 479
Fault Code A016: Payload meter write to flash memory has failed 480
Related circuit diagram 480
Fault Code A017: Payload meter flash memory read has failed 480
Related circuit diagram 480
Fault Code A018: Right rear flat suspension cylinder warning 481
Related circuit diagram 482
Fault Code A019: Left rear flat suspension cylinder warning 483
Related circuit diagram 484
Fault Code A022: Carryback load is excessive 485
Related circuit diagram 486
Fault Code A101: High pressure detected across a hydraulic pump filter 487
Related circuit diagram 489
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 491
Related circuit diagram 492
Fault Code A109: GE has generated a propel system reduced level signal 493
Related circuit diagram 493
Fault Code A111 & A247: Low steering pressure warning 494
Related circuit diagram 495
Fault Code A115: Low steering precharge pressure is detected 496
Related circuit diagram 497
Fault Code A117 & A261: Low brake accumulator pressure warning 498
Related circuit diagram 499
Fault Code A118: Brake pressure is low while brake lock is activated 500
Related circuit diagram 501
Fault Code A123: GE has generated a reduced retarding caution 502
Related circuit diagram 502
Fault Code A124: GE has generated a no propel / no retard warning 504
Related circuit diagram 505
Fault Code A125: GE has generated a no propel warning 506
Related circuit diagram 506
Fault Code A126: Oil level in the hydraulic tank is low 507
Related circuit diagram 507
Fault Code A127: IM furnished +5 volt output for sensors is low 508
Related circuit diagram 509
Fault Code A128: IM furnished +5 volt output for sensors is high 510
Related circuit diagram 511
Fault Code A139 & A310: Low fuel level warning 512
Related circuit diagram 513
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 514
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 515
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A247) INDEX 517
Fault Code A152: Starter failure 519
Fault Code A153: Battery voltage is low with truck in operation 520
Fault Code A154: Battery charging voltage is excessive 521
Fault Code A155: Battery charging voltage is low 522
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 523
Fault Code A166: Left rear hydraulic oil temp sensor is low 524
Fault Code A167: Right rear hydraulic oil temp sensor is low 525
Fault Code A168: Left front hydraulic oil temp sensor is low 526
Fault Code A169: Right front hydraulic oil temp sensor is low 527
Fault Code A170: Left rear hydraulic oil temp sensor is high 528
Fault Code A171: Right rear hydraulic oil temp sensor is high 529
Fault Code A172: Left front hydraulic oil temp sensor is high 530
Fault Code A173: Right front hydraulic oil temp sensor is high 531
Fault Code A184: J1939 data link is not connected 532
Fault Code A190: Auto lube control has detected an incomplete lube cycle 533
Fault Code A194: Left front hydraulic oil temperature is high 534
Fault Code A195: Right front hydraulic oil temperature is high 535
Fault Code A196: Left rear hydraulic oil temperature is high 536
Fault Code A197: Right rear hydraulic oil temperature is high 537
Fault Code A198: Hoist pressure 1 sensor is high 538
Fault Code A199: Hoist pressure 2 sensor is high 538
Fault Code A200: Steering pressure sensor is high 539
Fault Code A201: Brake pressure sensor is high 540
Fault Code A202: Hoist pressure 1 sensor is low 541
Fault Code A203: Hoist pressure 2 sensor is low 542
Fault Code A204: Steering pressure sensor is low 543
Fault Code A205: Brake pressure sensor is low 544
Fault Code A206: Ambient temperature sensor is high 545
Fault Code A207: Ambient temperature sensor is low 546
Fault Code A212: Bad truck speed signal 547
Fault Code A213: Parking brake should have applied but is detected as not having applied 548
Fault Code A214: Parking brake should have released but is detected as not having released 550
Fault Code A215: The brake auto apply relay circuit is defective 552
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 553
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 554
Fault Code A230: Parking brake has been requested while truck still moving 555
Fault Code A231: Dump body is up while traveling or intending to travel 556
Fault Code A233: Drive system CAN/RPC Control Link not connected 558
Fault Code A235: Steering accumulator is in the process of being bled down 559
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 560
Fault Code A237: The CAN/RPC connection to the display is open 561
Fault Code A240: The keyswitch input to the interface module is open 562
Fault Code A242: The fuel gauge within the display panel is defective 563
Fault Code A243: The engine coolant temp gauge within the display panel is defective 564
Fault Code A244: The drive system temp gauge within the display panel is defective 565
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 566
Fault Code A246: Payload meter reports truck overload 567
Fault Code A247 & A111: Low steering pressure warning 568
Related circuit diagram 569
SECTION E5 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX 571
Fault Code A248: The status indicator module within the display panel is defective 573
Fault Code A249: The red warning lamp within the display panel is shorted 574
Fault Code A250: Battery voltage is low with the truck parked 575
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 577
Fault Code A252: Start enable output circuit is either open or shorted to ground 578
Fault Code A253: Steering bleed circuit is not open while running 579
Fault Code A255: IM has detected a fault on IM output 1N 580
Fault Code A256: The red warning lamp in the ACTIA display but driven by IM, is open 581
Fault Code A257: Payload CAN/RPC is not connected 582
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 583
Fault Code A260: Parking brake failure 584
Fault Code A261 & A117: Low brake accumulator pressure warning 585
Fault Code A262: Steering bleed valve circuit open during shutdown 586
Fault Code A264: Parking brake relay circuit is defective 587
Fault Code A265: Service brake failure 588
Fault Code A266: Selector lever was not in park while attempting to crank engine 589
Fault Code A267: Parking brake was not set while attempting to crank engine 590
Fault Code A268: Secondary engine shutdown while cranking 591
Fault Code A270: Brake lock switch power supply is not on when required 592
Fault Code A271: Shifter not in gear 594
Fault Code A272: Brake lock switch power supply is not off when required 595
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 597
Fault Code A274: A brake setting fault has been detected 598
Fault Code A275: A starter has been detected as engaged without a cranking attempt 599
Fault Code A277: Parking brake applied while loading 600
Fault Code A278: Service brake applied while loading 601
Fault Code A279: Low steering pressure switch is defective 602
Fault Code A280: Steering accumulator bleed down switch is defective 603
Fault Code A281: Brake lock degradation switch is defective 604
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 605
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 606
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 607
Fault Code A285: The parking brake was not set when the key switch was turned off 608
Fault Code A286: A fault was detected in the shutdown delay relay circuit 609
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 610
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 611
Fault Code A303: Shifter is defective 613
Fault Code A304: Auto lube grease level is low 614
Fault Code A307: Both GE inverters are disabled 615
Fault Code A309: No brakes applied when expected 616
Fault Code A310 & A139: Low fuel level warning 617
Fault Code A311: Brake lock switch is on when it should not be 618
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 619
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 620
Fault Code A315: DC-DC converter 12 volt circuit is low 621
Fault Code A316: Starter engagement has been attempted with engine running 622
Fault Code A317: Operation of brake auto apply circuit without a detected response 623
Fault Code A318: Unexpected power loss to interface module 624
Fault Code A328: Drive system not powered up 625
Fault Code A332: Seat belt not buckled 626
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 627
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 628
Fault Code A335: Manual/Auto Apply Pressure Fault 629
Fault Code A350: Overload on output 1B 630
Fault Code A351: Overload on output 1E 631
Fault Code A352: Overload on output 1H 632
Fault Code A353: Overload on output 1J 633
Fault Code A354: Overload on output 1K 634
Fault Code A355: Overload on output 1L 635
Fault Code A356: Overload on output 1M 636
Fault Code A357: Overload on output 1N 637
Fault Code A358: Overload on output 1P 638
Fault Code A359: Overload on output 1R 639
Fault Code A360: Overload on output 1S 640
Fault Code A361: Overload on output 1T 641
Fault Code A362: Overload on output 1U 642
Fault Code A363: Overload on output 1X 643
Fault Code A364: Overload on output 1Y 644
Fault Code A365: Overload on output 1Z 645
SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX 647
SECTION G2 TIRES AND RIMS INDEX 649
TIRES AND RIMS 651
GENERAL PRECAUTIONS 651
RIM COMPONENTS 652
Smart Rim Component Layout 652
WHEEL STUD MAINTENANCE 653
FRONT TIRES AND RIMS 654
Removal 654
Installation 655
REAR TIRES AND RIMS 655
Removal 655
Installation 656
RIM AND TIRE SERVICE 658
Lubricants 658
Tire Inflation 658
Lock Ring Retainer Installation 658
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 659
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 660
Removal (5-Piece Standard Rim) 661
Removal (7-Piece Smart Rim) 664
Removal (5-Piece Smart Rim) 666
Preparation Before Assembly 667
Installation (5-Piece Standard Rim) 668
Installation – Horizontal Mount (Smart Rim) 670
Installation – Vertical Mount (5-Piece Smart Rim) 672
Installation – Vertical Mount (7-Piece Smart Rim) 673
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 675
FRONT WHEEL HUB AND SPINDLE 677
WHEEL HUB AND SPINDLE ASSEMBLY 677
Removal 677
Spindle Removal Procedure (off of the truck) 680
Installation 682
Disassembly 683
Cleaning and Inspection 685
Assembly 685
Wheel Bearing Adjustment 686
Brake Installation 687
Seal Assembly Gap Check 688
WHEEL SPEED SENSOR TESTING 689
STEERING CYLINDERS 690
Spherical Bearing Wear Limits 690
Removal 691
Installation 691
Bearing Replacement (Steering Cylinder and Tie Rod) 691
TIE ROD 693
Removal 693
Installation 693
Disassembly 694
Assembly 694
Toe-In Adjustment 695
TIE ROD INSPECTION AND TORQUE PROCEDURE 696
SECTION G4 REAR AXLE MOUNTING INDEX 697
REAR AXLE MOUNTING 699
PIVOT PIN 699
Removal 699
Installation 700
PIVOT EYE BEARING 700
Removal 700
Installation 700
PIVOT EYE REPAIR 701
Removal 701
Installation 701
ANTI-SWAY BAR 702
Removal 702
Disassembly 702
Cleaning and Inspection 702
Assembly 702
Installation 702
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 705
REAR AXLE AND WHEEL MOTOR 707
REAR AXLE HOUSING 707
Preparation 707
Removal 708
Cleaning and Inspection 709
Installation 709
BLOWER PRESSURE SWITCH ADJUSTMENT 709
WHEEL MOTOR 710
Preparation 710
Removal 711
Cleaning and Inspection 713
Installation 713
WHEEL MOTOR GEAR OIL 718
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 718
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 718
Filtering Requirements 718
Particle Size Analysis 719
Flushing 719
Spectrographic Oil Sample Analysis 720
SECTION H HYDRAIR® II SUSPENSIONS INDEX 725
SECTION H2 FRONT SUSPENSIONS INDEX 727
FRONT SUSPENSION 729
Removal 729
Installation 730
Inspection 735
LOWER BEARING & SEALS 736
Removal 736
Installation 736
MAJOR SUSPENSION REBUILD 737
Disassembly 737
Assembly 738
SUSPENSION PRESSURE TEST 739
SECTION H3 REAR SUSPENSIONS INDEX 741
REAR SUSPENSIONS 743
SUSPENSION CYLINDER 744
Removal 744
Installation 745
Disassembly 746
Cleaning and Inspection 746
Assembly 746
SUSPENSION PRESSURE TEST 748
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 749
SUSPENSION OILING AND CHARGING PROCEDURES 751
CHECKING FOR IMPROPER SUSPENSION CHARGE 751
GENERAL 752
REQUIRED EQUIPMENT 752
HYDRAIR® CHARGING KIT 753
Installation of Charging Kit 753
Removal of Charging Kit 753
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 754
FRONT SUSPENSION 757
REAR SUSPENSION 759
OIL AND NITROGEN SPECIFICATIONS CHARTS 762
SECTION J BRAKE CIRCUIT INDEX 763
SECTION J2 BRAKE CIRCUIT INDEX 765
BRAKE CIRCUIT 767
SERVICE BRAKE CIRCUIT 767
PARKING BRAKE CIRCUIT 769
BRAKE LOCK CIRCUIT 769
SECONDARY BRAKING AND AUTOMATIC APPLY 770
WARNING CIRCUIT 770
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 773
BRAKE CIRCUIT COMPONENT SERVICE 775
BRAKE VALVE 775
Rebuild Criteria 775
Removal 776
Installation 776
BRAKE VALVE/PEDAL ASSEMBLY 777
Disassembly 777
Assembly 778
Installation 780
DUAL RELAY VALVE 780
Removal 780
Installation 781
BRAKE MANIFOLD 781
Removal 781
Installation 782
Disassembly 782
Cleaning and Inspection 782
Assembly 782
BRAKE ACCUMULATORS 783
Accumulator charging and storage 783
Temperature during precharge 783
BLADDER BRAKE ACCUMULATORS 784
Brake Accumulator Bleed Down Procedure 784
Removal 784
Installation 785
Disassembly 785
Cleaning and Inspection 787
Assembly 787
Precharge Maintenance 788
Accumulator Storage Procedures 788
Installing A Bladder Accumulator From Storage 789
PISTON BRAKE ACCUMULATORS 789
Brake Accumulator bleed down Procedure 789
Removal 789
Installation 791
Disassembly 793
Cleaning and Inspection 793
Assembly 794
Piston accumulator charging procedure 794
Testing 797
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 797
Removal 797
Installation 797
Disassembly 798
Lever Adjustments 798
Potentiometer Check 798
Assembly 799
FRONT BRAKE COOLING HOSE INSTALLATION 801
Installation 801
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 805
BRAKE CIRCUIT CHECK-OUT PROCEDURE 807
REQUIRED EQUIPMENT 808
INITIAL SYSTEM SETUP 809
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 810
AUTO APPLY (LOW BRAKE PRESSURE) CHECK-OUT 811
SERVICE BRAKES 812
PARKING BRAKES 812
PARKING BRAKE CONTROL LOGIC 813
BRAKE LOCK CONTROL LOGIC 814
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 817
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 819
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 825
WET DISC BRAKE ASSEMBLY 827
OPERATION 827
BRAKE DISC WEAR INSPECTION 828
BRAKE REBUILD 829
Disassembly 829
Cleaning and Inspection 833
Assembly 834
Floating Ring Seal Assembly & Installation 839
WET DISC BRAKE BLEEDING PROCEDURE 843
SECTION J7 PARKING BRAKE INDEX 845
PARKING BRAKE 847
OPERATION 847
MAINTENANCE 848
Inspection 848
Removal 848
Installation 849
Disassembly 849
Cleaning and Inspection 849
Assembly 851
Cleaning and Inspecting New Discs 852
PARKING BRAKE BLEEDING PROCEDURE 853
SECTION L HYDRAULIC SYSTEM INDEX 855
SECTION L2 HYDRAULIC SYSTEM INDEX 857
HYDRAULIC SYSTEM 859
HYDRAULIC PUMP MODULE 859
HOIST CIRCUIT OPERATION 860
STEERING CIRCUIT OPERATION 862
DISC BRAKE COOLING SYSTEM 864
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 867
HYDRAULIC SYSTEM COMPONENT REPAIR 869
HOIST PUMP 869
Removal 869
Installation 871
Inspection 876
Assembly 876
HOIST PUMP TROUBLESHOOTING GUIDE 881
HYDRAULIC TANK 882
Removal 882
Installation 883
HYDRAULIC TANK STRAINERS 883
Removal 883
Inspect and Clean 885
Installation 885
SECTION L4 STEERING CIRCUIT INDEX 887
STEERING CIRCUIT 889
STEERING CIRCUIT OPERATION 889
COMPONENT DESCRIPTION 890
Steering Control Unit 890
Bleeddown Manifold 891
Steering Accumulator Bleeddown Solenoid 891
Relief Valves 893
Hoist Up Limit Solenoid 893
Steering Accumulators 893
Low Precharge Warning Switch 893
High Pressure Filter 893
Quick Disconnect Ports 893
Flow Amplifier 895
FLOW AMPLIFIER SYSTEM OPERATION 896
No Steer 896
Steering Left 898
Steering Right 900
No Steer, External Shock Load 902
STEERING PUMP 904
Normal Operation 904
High Altitude Operation 904
PRINCIPLE OF OPERATION 906
Full Pump Volume 906
Half Pump Volume 906
Neutral Position 906
Steering Pump 907
SECTION L5 STEERING CONTROL UNIT INDEX 909
STEERING CONTROL UNIT 911
REMOVAL 911
SPLINE INSPECTION 911
INSTALLATION 912
DISASSEMBLY 912
CLEANING AND INSPECTION 913
ASSEMBLY 915
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 919
STEERING CIRCUIT COMPONENT REPAIR 921
BLEEDDOWN MANIFOLD VALVE 921
Removal 921
Installation 922
FLOW AMPLIFIER 923
Removal 923
Installation 923
STEERING CYLINDERS 924
Disassembly 925
Piston Seal & Bearing Installation 925
Assembly 925
Testing 925
STEERING AND BRAKE PUMP 926
Removal 926
Installation 927
Disassembly 928
Inspection 931
Assembly 934
Driveshaft Group 935
Rotating Group 935
Valve Plate Group 936
PISTON STEERING ACCUMULATORS 938
Removal 938
Installation 939
Disassembly 940
Cleaning and Inspection 940
Assembly 941
Testing 941
TROUBLESHOOTING 942
STEERING CIRCUIT 942
STEERING PUMP 944
Basic Hydraulic System Checks 945
System Leakage Check 946
Steering Pump Troubleshooting Guide 948
Pump Pressure Control Checks 951
Pump Control Valve Inspection and Troubleshooting 954
Pump Case Drain Check 954
Setting Pump Pressure Controls 956
SECTION L7 HOIST CIRCUIT INDEX 959
HOIST CIRCUIT 961
BASIC OPERATION 961
COMPONENT DESCRIPTION 962
Hydraulic Tank 962
Hydraulic Pump 962
High Pressure Filters 962
Hoist Valve 962
Inlet Sections 962
Work Ports (Rear) Spool Section 963
Tank Ports (Front) Spool Section 963
Hoist Pilot Valve 963
Bleeddown Manifold 964
Hoist Up Limit Solenoid 964
Pilot Operated Check Valve 964
Overcenter Manifold 964
HOIST CIRCUIT OPERATION 965
Float Position Of Pilot Valve With Truck Body On Frame 966
Power Up Operation 968
Hold Operation 970
Power Down Operation 972
Float Operation 974
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 977
HOIST CIRCUIT COMPONENT REPAIR 979
HOIST VALVE 979
Removal 979
Installation 980
O-Ring Replacement 980
INLET SECTION 981
Disassembly 981
Cleaning and Inspection 982
Assembly 982
REAR SPOOL SECTION (Work Ports) 983
Disassembly 983
Cleaning and Inspection 983
Assembly 985
FRONT SPOOL SECTION (Tank Ports) 986
Disassembly 986
Cleaning and Inspection 986
Assembly 986
HOIST PILOT VALVE 988
Removal 988
Installation 988
Disassembly 989
Cleaning and Inspection 990
Assembly 990
HOIST CYLINDERS 991
Removal 991
Installation 992
Disassembly 994
Cleaning and Inspection 995
Assembly – Quill 996
Assembly – Cylinder 998
Testing 998
OVERCENTER VALVE MANIFOLD 999
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 1001
HYDRAULIC SYSTEM FILTERS 1003
HOIST CIRCUIT FILTER 1003
Filter Element Replacement 1003
Removal – Hoist Circuit Filter 1004
Installation – Hoist Circuit Filter 1004
Indicator Switch – Hoist Circuit Filter 1004
STEERING CIRCUIT FILTER 1005
Filter Element Replacement 1005
Removal – Steering Circuit Filter 1006
Installation – Steering Circuit Filter 1006
Indicator Switch – Steering Circuit Filter 1006
INDICATOR SWITCH 1006
Test Procedure 1006
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1009
HYDRAULIC CHECKOUT PROCEDURE 1011
GENERAL INFORMATION 1011
Procedure for bleeding down hydraulic brake and steering accumulators 1011
Accumulator precharge procedure (step 1) 1012
Pressure gauge installation (steps 2 and 3) 1013
Initial start-up and flushing (steps 4 through 20) 1013
Steering system checkout and adjustment (steps 21 through 24) 1017
Steering pump with unloader valve adjustment (step 25) 1018
Steering system diagnostic and verification (steps 26 through 30) 1019
Hoist system checkout and adjustment (steps 31 through 33) 1020
Hoist counterbalance valve adjustment (step 34) 1020
Oil cleanliness check (steps 35 & 36) 1021
HYDRAULIC CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1023
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 1027
SECTION M7 HOT START SYSTEM INDEX 1029
HOT START SYSTEM 1031
SYSTEM OPERATION 1031
HEATER INFORMATION 1032
TROUBLESHOOTING GUIDELINES 1033
SECTION M8 SPECIAL TOOLS 1035
HIGH VOLTAGE TOOLS 1039
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1039
KomVision calibration tools 1041
SECTION M19 RADIATOR SHUTTERS INDEX 1043
RADIATOR SHUTTERS 1045
OPERATION 1045
Hydraulic Circuit 1045
Electrical Circuit 1046
MAINTENANCE AND REPAIR 1046
TROUBLESHOOTING 1047
SECTION M20 PAYLOAD METER IV ™ INDEX 1051
INTRODUCTION 1053
Data Summary 1053
Data Gathering 1053
COMPONENT DESCRIPTION 1054
Electronic Dash Display 1054
Mode Switches 1054
Brake Lock Switch 1054
PAYLOAD METER IV SOFTWARE AND TOOLS 1055
PAYLOAD METER IV SYSTEM CONFIGURATION 1055
Connecting to the payload meter IV web server 1055
Configuring a static IP address 1055
PAYLOAD METER IV SOFTWARE INSTALLATION 1057
PLM IV SYSTEM CHECKOUT DATA SHEET 1063
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1064
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1067
RESERVE ENGINE OIL SYSTEM 1069
GENERAL 1069
OPERATION 1070
Pumping Unit 1070
LED Monitor Lights 1071
Tank Auto Fill Control 1072
Filling Procedure (Remote Fill Feature) 1072
SERVICE 1073
Every 10 Hours (each shift) 1073
Every 500 Hours 1073
Changing Oil 1073
TROUBLESHOOTING 1074
Circuit Fuses 1074
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1075
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1077
RETRACTABLE LADDER SYSTEM 1081
GENERAL SAFETY 1081
LADDER SYSTEM DESCRIPTION 1081
LADDER SYSTEM OPERATION 1082
Normal Operation 1082
Emergency Operation 1083
Limit Switch Operation 1083
IN-CAB CONTROL PANEL 1084
IN-CAB CONTROL PANEL FEATURES 1085
IN-CAB CONTROL PANEL FUNCTIONS 1086
Timing Control 1086
Ladder System Status 1086
Fault Code Identification 1086
Ladder System Configuration 1086
In-Cab Control Panel Lockout 1086
Automatic Raising 1086
Diagnostics 1087
Maintenance 1087
USING THE IN-CAB CONTROL PANEL 1087
Raising the Ladder 1088
Lowering the Ladder 1088
USING THE GROUND LEVEL CONTROL BOX 1089
Raising the Ladder 1089
Lowering the Ladder 1089
POWER PACK OPERATION 1090
MAINTENANCE 1093
Safety During Maintenance 1093
Unplanned Ladder Movements 1093
Automatic Ladder Raising 1093
Automatic Accumulator Recharging (Ladder in UP position) 1094
PREVENTIVE MAINTENANCE PROCEDURES 1095
Daily Inspection 1095
250 Hour Inspection 1095
5000 Hour Inspection 1095
SERVICING 1096
Check Reservoir Oil Level 1096
Changing RLS Fluid 1096
Cleaning the RLS 1097
RLS DIAGNOSTICS 1097
Description of Diagnostics Features 1097
Continuous System Monitoring 1098
Historic System Data Review 1099
Comms Integrity Monitoring 1099
Log and Service Information 1100
System Event Logs 1100
SECURITY ACCESS LEVELS 1101
Access Level 1 – NONE 1101
Access Level 2 – RESTRICTED 1101
Access Level 3 – COMPLETE 1101
User Access Privileges 1102
USER ID – PASSWORD 1103
Sequential Field Value Selection Options 1103
Password Character Table 1103
USER ID – NEW USER SETUP 1104
SYSTEM FAULTS 1104
Fault Type 1: Communications error 1105
Fault Type 2: 10A/15A fuse blown 1105
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1106
Fault Type 8: Power pack recharge too long 1106
Fault Type 9: Inhibit relay fail 1107
Fault Types 10, 11: Light/Siren relay failure 1107
Fault Type 12: Ladder came off upper limit 1108
Fault Type 13: Ladder did not reach limit 1108
Fault Type 14: Ladder stayed on limit 1109
Fault Type 15: Low oil level 1109
Fault Type 16: System voltage over 18V during movement 1110
Fault Type 17: System voltage under 18V 1110
Fault Type 18: System voltage over 31V 1111
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1111
Fault Type 21: Accumulator recharge > than once/hour 1112
Fault Type 22: System raised by park brake 1112
Fault Types 23, 24: Levels 1 and 2 service overdue 1113
Fault Type 25: Levels 1 and 2 service complete 1113
DATA MANAGEMENT 1114
Log Files 1114
Generating Reports 1115
MENU DIAGRAMS 1121
Controller Config 1121
Contact Information 1121
Show Recent Logs 1121
System Settings 1121
Upload Logs to USB 1121
Diagnostics 1121
SECTION M33 KomVision® INDEX 1129
KomVision® 1131
KomVision® SYSTEM PRECAUTIONS 1131
COMPONENT LOCATIONS 1132
MONITOR PANEL 1136
Brightness Switches 1136
System Power Status Indicator 1136
Force Display Switch 1136
Camera Switches 1137
Monitor Display Mode Switch 1137
Reference Line Display Switch 1137
Lower Body Display Switch 1137
Object Clear Switch 1137
MONITOR DISPLAY 1138
Camera Display Modes 1138
Bird’s Eye Views 1140
Reference Lines 1140
Dump Body Status Display 1140
Error Code Display 1141
Initial Setting Screen 1142
RADAR SYSTEM 1142
Object Detection Range 1142
Object Detection Warnings 1143
Object Clear 1146
START-UP INSPECTION 1146
Camera Inspections 1146
Verify the Radar System is Operational 1146
CLEANING 1147
Monitor Panel And Controller 1147
Cameras 1147
KomVision® SYSTEM SETUP AND CALIBRATION 1148
Password Mode 1148
Maintenance Mode 1149
Main Setting Display 1150
6 Camera Calibration Display 1151
Camera Setting 1161
System State 1163
Error Log Screen 1164
Check Disk Display 1164
MAINTENANCE SCREEN EXPLANATION 1165
Area 1165
Threshold 1166
All Radar Position 1166
RADAR DETAIL 1169
Integration 1169
Explanation of Terms 1170
System I/O Explanation 1171
TESTING AND ADJUSTING 1172
System Adjustment 1172
Initial Setting 1172
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1173
6 Camera Calibration Preparation 1173
Calibration Sheet Unfolding 1176
Folding a Camera Calibration Sheet 1177
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1178
Placement of Front Calibration Sheet 1178
Placement of Left and Right Calibration Sheet 1178
Placement of Rear Calibration Sheet and Adjustment of Left and Right Calibration Sheets 1179
CALIBRATING CAMERAS 1179
Automatic 6 Camera Calibration Operation 1179
Manual 6 Camera Calibration 1183
6 Camera Calibration Outgoing Message, and Screen Correspondence 1185
1 Camera Calibration 1186
1 Camera Calibration Outgoing Message, and Screen Correspondence 1188
RADAR SETTING 1188
Radar Zone Preparation and System Calibration 1188
SECTION N OPERATOR CAB INDEX 1199
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 1201
TRUCK CAB AND COMPONENTS 1203
TRUCK CAB 1203
Description 1203
Removal 1204
Installation 1205
CAB DOOR 1206
Removal 1206
Installation 1206
Door Jamb Bolt Adjustment 1207
Door Handle Plunger Adjustment 1208
Replacing the Door Glass 1209
Replacing the Door Handle or Latch Assembly 1213
Replacing the Door Window Regulator 1214
Replacing the Door and Door Hinge Seal 1215
Replacing the Door Opening Seal 1215
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1216
Recommended Tools and Supplies 1216
Replacement Procedure 1216
WINDSHIELD AND REAR GLASS 1217
Removal 1217
Installation 1218
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1219
OPERATOR SEAT (STANDARD SEAT) 1221
Adjustment 1221
Inspection 1222
Removal 1222
Installation 1222
Replacing the Seat Compressor 1223
PASSENGER SEAT (STANDARD SEAT) 1228
Adjustment 1228
Inspection 1229
Removal 1229
Installation 1229
SEAT BELT REPLACEMENT (STANDARD SEAT) 1230
Removal 1230
Installation 1230
OPERATOR SEAT (OPTIONAL SEAT) 1232
Seat Belts 1232
Adjustment 1232
PASSENGER SEAT (OPTIONAL SEAT) 1233
Seat Belts 1233
Adjustment 1233
SEAT BELT REPLACEMENT (OPTIONAL SEAT) 1234
General 1234
Removal 1234
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1239
HEATER/AIR CONDITIONER 1241
OPERATION 1241
Fan Speed Control Knob 1241
Temperature Control Knob 1241
Air Flow Directional Knob 1242
Heater/Air Conditioner Vents 1242
COMPONENTS 1242
Fuse and Circuit Breaker 1242
Relays 1242
Heater Core 1243
Fan Motor And Speed Control 1243
Actuators 1243
Cab Air Filter 1243
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1246
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1246
PRINCIPLES OF REFRIGERATION 1246
Air Conditioning 1246
Refrigeration – The Act Of Cooling 1247
The Refrigeration Cycle 1247
AIR CONDITIONER SYSTEM COMPONENTS 1248
Compressor (Refrigerant Pump) 1248
Service Valves 1248
Condenser 1248
Receiver-Drier 1248
Expansion Block Valve 1249
Accumulator 1249
Evaporator 1249
ELECTRICAL CIRCUIT 1250
Thermostat 1250
Compressor Clutch 1250
Trinary™ Switch 1251
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1252
SERVICE TOOLS AND EQUIPMENT 1253
Recovery/Recycle Station 1253
Leak Detector 1253
Service Valves 1254
Vacuum Pump 1254
Manifold Gauge Set 1255
Installing Manifold Gauge Set 1256
Purging Air From Service Hoses 1256
SYSTEM PERFORMANCE TEST 1257
SYSTEM OIL 1258
Handling and Reusing PAG Oil 1258
Oil Quantity 1258
Checking System Oil 1258
REFRIGERANT 1259
Recycled Refrigerant 1259
Reclaimed Refrigerant 1259
Refrigerant Quantity 1260
R-134a Refrigerant Containers 1260
SYSTEM LEAK TESTING 1260
Electronic Leak Detector 1261
Tracer Dyes 1261
Soap and Water 1261
RECOVERING AND RECYCLING THE REFRIGERANT 1261
Draining Oil from the Previous Recovery Cycle 1261
Performing the Recovery Cycle 1261
Performing the Recycling Procedure 1262
Evacuating and Charging the A/C System 1262
SYSTEM REPAIR 1262
System Flushing 1262
COMPONENT REPLACEMENT 1263
Hoses and Fittings 1263
Lines 1263
Expansion Valve 1263
Receiver-Drier 1263
Thermostat 1263
Compressor 1264
Accumulator 1264
Clutch 1264
EVACUATING THE SYSTEM 1265
CHARGING THE A/C SYSTEM 1266
TROUBLESHOOTING 1267
Preliminary Checks 1267
Diagnosis Of Gauge Readings And System Performance 1267
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1268
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1274
SECTION N5 OPERATOR CAB AND CONTROLS INDEX 1275
OPERATOR CAB AND CONTROLS 1279
STEERING COLUMN 1280
Removal 1280
Inspection 1280
Installation 1281
STEERING WHEEL 1281
Removal 1281
Installation 1281
STEERING WHEEL AND CONTROLS 1282
Horn Button 1282
Tilt / Telescope Lever 1282
Multi-Function Turn Signal Switch 1282
DYNAMIC RETARDING 1283
Retarder Lever 1283
Service Brake/Retarder Pedal 1283
Throttle/Accelerator Pedal 1283
GRADE/SPEED CHART 1284
OVERHEAD PANEL AND DISPLAYS 1285
CENTER CONSOLE 1286
Directional Control Lever 1286
Override/Fault Reset Switch 1287
Engine Stop Switch 1287
LH Window Control Switch 1287
RH Window Control Switch 1287
Hoist Control Lever 1287
Raising The Dump Body 1287
Lowering The Dump Body 1287
Retard Speed Control (RSC) Adjust Dial 1288
Retard Speed Control (RSC) Switch 1288
Data Store Button 1288
12V Auxiliary Power Outlets 1288
Fire Suppression Control Outlet 1288
Communication Radio Outlet 1288
DIAGNOSTIC PORTS 1289
KOMTRAX Plus Diagnostic Port 1289
Interface Module (IM) Diagnostic Port 1289
Payload Meter Diagnostic Port 1289
Drive System Or Modular Mining 1289
Drive System Controller (DSC) Diagnostic Port 1289
Engine Diagnostic Port (CENSE) 1289
Engine Diagnostic Port (QUANTUM) 1289
HEATER / AIR CONDITIONER 1290
Fan Speed Control Knob 1290
Temperature Control Knob 1290
Air Flow Directional Knob 1290
Heater/Air Conditioner Vents 1290
INSTRUMENT PANEL 1291
Control Symbols 1291
Cab/Air Conditioner Vents 1293
Status Indicator Light Panel 1293
Hydraulic Oil Temperature Gauge 1293
Coolant Temperature Gauge 1293
Speedometer/Digital Display 1293
Fuel Level Gauge 1293
Drive System Temperature Gauge 1293
Hazard Warning Light Switch 1293
Pre-Shift Brake Test Switch 1294
Wheel Brake Lock Control 1294
Rest Switch 1294
Engine Warm Up Switch 1295
Heated Mirror Switch 1295
Rotating Beacon Light Switch (Optional) 1295
Key Switch 1295
Starting 1295
Warning Light 1296
Digital Display Contrast Buttons 1296
Turn Signal Indicators 1296
Panel Light Dimmer 1296
Mode Switches 1296
Fog Light Switch 1296
Manual Backup Switch 1296
Headlight/Panel Illumination Light Switch 1297
STATUS INDICATOR LIGHT PANEL 1298
REAR AXLE LIGHT BAR 1301
Backup Lights 1301
Retard Lights 1301
Brake Lights 1301
Backup Alarm 1301
DIGITAL DISPLAY OPERATION 1302
Toggling Through Main Level Screens 1302
Toggling Through Warning Screens 1303
Entering Payload Meter Data 1304
KOMTRAX PLUS 1305
Operation 1305
Interface Module 1307
Basic Precautions 1307
KOMATSU WIRELESS BRIDGE (KWB) General information 1308
Required software and tools 1308
Configuring the Bullet wireless radio 1309
Installing the Bullet wireless radio 1312
Configuring the NanoStation access point 1313
Testing the connection 1316
Changing a service computer’s IP address 1317
SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX 1319
SECTION P2 PERIODIC MAINTENANCE INDEX 1321
PERIODIC MAINTENANCE 1323
GENERAL 1323
SERVICE CAPACITIES 1323
HYDRAULIC TANK SERVICE 1323
Adding Oil 1323
COOLING SYSTEM SERVICE 1324
Radiator Filling Procedure 1324
Coolant Specifications 1324
Unacceptable Practices 1324
WHEEL MOTOR SERVICE 1324
RESERVE OIL TANK SERVICE 1325
Filling the Reserve Oil Tank (Remote Fill) 1325
Inline Screen 1325
QUICK FILL SERVICE CENTER 1326
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1328
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1328
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1329
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1331
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1335
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1337
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1337
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1338
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1338
INJECTOR OPERATION 1348
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1339
AUTOMATIC LUBRICATION SYSTEM 1341
GENERAL DESCRIPTION 1341
SYSTEM COMPONENTS 1343
Filter 1343
Hydraulic Motor and Pump 1343
Grease Reservoir 1343
Pressure Reducing Valve 1343
Flow Control Valve 1343
Solenoid Valve 1343
Vent Valve 1343
Grease Pressure Failure Switch 1343
Injectors 1343
Interface Module 1343
Relief Valve (unloader valve) 1343
SYSTEM OPERATION 1344
Normal Operation 1344
Lubricant Required For System 1345
Filter Assembly 1345
System Priming 1345
LUBRICANT PUMP 1346
Pump Housing Oil Level 1346
Pump Pressure Control 1346
INJECTORS (SL-1 Series “H”) 1347
Injector Specifications 1347
Injector Adjustment 1347
PREVENTIVE MAINTENANCE PROCEDURES 1349
Daily Lubrication System Inspection 1349
250 Hour Inspection 1349
1000 Hour Inspection 1349
SYSTEM CHECKOUT 1350
Pump Priming Procedure 1350
System Priming Procedure 1351
Lubrication Cycle Operation 1351
AUTOLUBE TROUBLESHOOTING CHART 1352
SECTION R SYSTEM SCHEMATICS INDEX 1355

DESCRIPTION:

Komatsu 930E- 4SE DUMP TRUCK Shop Manual CEBM030102 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31875 and up

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

G.B  21/12/24