Komatsu 930E-4SE Dump Truck Shop Manual CEBM039000 PDF

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Komatsu 930E-4SE Dump Truck Shop Manual CEBM039000 –  PDF DOWNLOAD

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Komatsu 930E-4SE Dump Truck Shop Manual CEBM039000 –  PDF DOWNLOAD

Language : English
Pages : 1376
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4SE Dump Truck Shop Manual CEBM039000 –  PDF DOWNLOAD

COVER 1
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
When Dumping 24
When Loading 24
Parking The Truck 24
Towing 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump Starting With Jumper Cables 26
Jump Starting With Receptacles 27
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Electrical Systems Isolation 28
Warning Tag 30
Proper Tools 30
Use of Tie-Off Anchor During Maintenance and Repair 30
Securing The Dump Body 30
Jack Point Locations 31
WHILE PERFORMING MAINTENANCE 32
Keep The Truck Clean 32
Attachments 32
Working Under The Truck 32
Rotating Fan And Belts 32
Waste Materials 32
Adding Fuel Or Oil 33
Radiator Coolant Level 33
Use Of Lighting 33
Precautions With The Battery 33
Handling High Pressure Hoses 33
Precautions With High Pressure Oil 33
Performing Maintenance Near High Temperature Or High Pressure 33
TIRES 34
Inspection 34
Maintenance 34
Storage 35
Handling 36
WHEN REPAIRS ARE NECESSARY 37
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 38
Preliminary Procedures Before Welding or Performing Maintenance 38
Engine Shutdown Procedure Before Welding or Performing Maintenance 38
CAPACITOR DISCHARGE SYSTEM 40
Necessary Tools 40
Warnings and Cautions 41
Manual DC Link Capacitor Discharge Procedure 42
Failure of the Discharge System 44
Manual Discharge of Capacitors 45
Short Isolated Capacitor Terminals 47
OPERATING INSTRUCTIONS 48
PREPARING FOR OPERATION 48
WALK AROUND INSPECTION 48
RETRACTABLE LADDER SYSTEM (Optional) 53
Description 53
Normal Operation 53
General Safety 53
IN-CAB CONTROL PANEL 54
Digital Display Screen 54
Command Buttons 54
USING THE IN-CAB CONTROL PANEL 55
Raising the Ladder 56
Lowering the Ladder 56
USING THE GROUND LEVEL CONTROL BOX 57
Raising the Ladder 57
Lowering the Ladder 57
EMERGENCY OPERATION 58
ENGINE START-UP 59
AFTER ENGINE HAS STARTED 60
PRE-SHIFT BRAKE CHECK 61
Events 61
OPERATION 61
Description 61
Brake Test Exit Criteria 62
PERFORMING THE BRAKE TESTS 63
Setup 63
Service Brake Test 63
Parking Brake Test 64
Retard System Test 65
EMERGENCY STEERING SYSTEM 65
Operation 65
Pre-Operation Testing 65
Additional Guidelines 66
MACHINE OPERATION SAFETY PRECAUTIONS 66
OPERATING ON THE HAUL ROAD 68
STARTING ON A GRADE WITH A LOADED TRUCK 69
PASSING 69
LOADING 69
Overload Speed Limit Function 69
DUMPING 70
Raising The Dump Body 70
Lowering The Dump Body (When dumping on flat ground) 71
Lowering The Dump Body (When dumping over a berm or into a crusher) 71
Sudden loss of engine power or loss of drive system function 72
FUEL DEPLETION 72
SAFE PARKING PROCEDURES 73
NORMAL ENGINE SHUTDOWN PROCEDURE 74
DISABLED TRUCK DUMPING PROCEDURE 75
Hookup 75
Raising the Body 75
Lowering the Body 75
HOIST SYSTEM 76
Hookup 76
Dumping Procedure 77
TOWING 77
Special Wiring Harness 78
Towing Procedure 78
SECTION A4 WARNINGS AND CAUTIONS 81
GRADE/SPEED CHART 81
KEY SWITCH 81
ROPS/FOPS 81
BATTERIES 82
ISOLATION BOX 83
PROPEL LOCKOUT LEVER 83
CAPACITORS 84
CRUSHING HAZARD 84
CYLINDER PRESSURE 85
FILLING THE HYDRAULIC TANK 85
HYDRAULIC OIL PRESSURE 86
HOT OIL SPRAY 86
WHEEL MOTOR OIL LEVEL 86
HOT EXHAUST 86
RADIATOR 87
EMERGENCY LADDER 87
ACCUMULATOR DRAIN VALVES 87
EMERGENCY DUMP PROCEDURE 87
EMERGENCY TOWING PROCEDURE 87
WELDING 88
EMERGENCY SHUTDOWN 88
INFORMATION DISPLAY 88
WIRELESS SIGNALS 88
HIGH VOLTAGE 89
LIFTING INSTRUCTIONS 90
PRODUCT IDENTIFICATION PLATE 91
LUBRICATION CHART 92
TOW SOCKET 92
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 92
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 92
TORQUE TABLES AND CONVERSION CHARTS 93
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 94
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 94
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 95
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 96
STORAGE AND IDLE MACHINE PREPARATION A7 9
SHORT TERM IDLE PERIODS 103
PREPARATION FOR STORAGE 104
REMOVAL FROM STORAGE 105
RECONDITIONING AN IDLE VEHICLE 106
ENGINE OPERATION 108
After The Engine Has Started 109
ENGINE STORAGE 110
Temporary Storage (30 Days Or Less) 110
Extended Storage (More Than 30 Days) 110
RESTORING AN ENGINE AFTER EXTENDED STORAGE 111
ELECTRIC DRIVE TRUCKS 112
Storing A Truck That Is Operational 112
Storing A Truck That Is Not Operational 113
Storing A Major Component 113
Periodic Inspections 113
Placing Equipment Into Service After Storage 114
STORAGE PROCEDURES AND IDLE MACHINE PREPARATION 103
SECTION B STRUCTURES INDEX 114
SECTION B2 STRUCTURAL COMPONENTS 117
STRUCTURAL COMPONENTS 119
PREPARATION 119
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 120
Removal 120
Installation 120
RH DECK AND RETARDING GRID 121
Removal 121
Installation 121
LH DECK 122
Removal 122
Installation 122
CENTER DECK 123
Removal 123
Installation 123
SECTION B3 DUMP BODY INDEX 125
DUMP BODY 127
Removal 127
Installation 128
BODY PADS 129
Body Pad Shimming Procedure 130
BODY GUIDE 131
HOIST LIMIT SWITCH 131
BODY-UP SWITCH 131
BODY RETENTION SLING 131
ROCK EJECTORS 132
Inspection 132
SECTION B4 FUEL TANK INDEX 133
FUEL TANK 135
Removal 135
Repair 135
Cleaning 135
Installation 135
FUEL TANK VENT ASSEMBLY 137
Disassembly 137
Assembly 137
FUEL GAUGE SENDER 138
Removal 138
Installation 138
QUICK FILL FUEL RECEIVERS 138
FUEL TANK B4-1 133
SECTION C ENGINE INDEX 139
POWER MODULE C2-3 141
POWER MODULE 143
PREPARATION FOR REMOVAL 143
REMOVAL 148
INSTALLATION 150
HOOKUP 151
EXHAUST TUBE INSTALLATION 152
EXHAUST BLANKET INSTALLATION 152
SECTION C3 COOLING SYSTEM INDEX 153
COOLING SYSTEM C3-3 153
COOLING SYSTEM 155
RADIATOR 155
Removal 155
Installation 157
Filling Procedure 158
REPAIRING THE RADIATOR 158
Internal Inspection 158
External Cleaning 158
Disassembly 159
Cleaning and Inspection 160
Assembly 160
Pressure Testing 161
COOLANT SYSTEM TROUBLESHOOTING 161
SECTION C4 POWER TRAIN INDEX 163
POWER TRAIN 165
ALTERNATOR REMOVAL 165
ALTERNATOR INSTALLATION 167
Measuring Procedure 167
Joining the Alternator and Engine 169
ENGINE 170
Removal 170
Service 170
Installation 170
SECTION C5 AIR CLEANERS INDEX 171
AIR CLEANERS C5-3 171
AIR CLEANERS 173
OPERATION 173
SERVICING THE AIR CLEANERS 173
Replacing The Elements 174
AIR CLEANER ASSEMBLY CLEANING 175
Primary Element Cleaning 175
Precleaner Section Cleaning 177
AIR INTAKE TROUBLESHOOTING 178
SECTION C7 FAN CLUTCH INDEX 179
FAN CLUTCH C7-3 179
FAN CLUTCH 181
REMOVAL & INSTALLATION TOOLING 181
DISASSEMBLY 184
CLEANING AND INSPECTION 194
ASSEMBLY 198
TEST PROCEDURE 213
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 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
System busy light 223
LED Lights 223
AUXILIARY CONTROL CABINET 224
24VDC to 12VDC Converter 224
24 VDC ELECTRICAL SYSTEM COMPONENTS D3-3 239
24 VDC ELECTRICAL SYSTEM COMPONENTS 241
TRUCK SHUTDOWN PROCEDURE 241
BRAKE WARNING BUZZER 241
AUXILIARY CONTROL CABINET COMPONENTS 241
Interface Module 242
Payload Meter 242
24VDC to 12VDC Converter 242
Circuit Breaker (CB60) 242
Communication Interface Module 242
Pump Module Service Light Timer 243
Power Distribution Terminals 243
Ground Terminal 243
Relays 244
Engine Service Light Timer 244
RTMR1 – VEC Block 245
Vehicle Electrical Centers (VEC) 245
VEC-89 246
VEC-90 248
VEC-91 250
MAGNETIC SWITCHES 252
Body position switches (With proximity switch and magnet) 252
Proximity switch operation 252
Service 252
BODY-UP SWITCH 253
Adjusting the Body-Up Switch 253
HOIST LIMIT SWITCH 254
Operation 254
Adjusting the Hoist Limit Switch 255
KOMTRAX PLUS 259
KOMTRAX PLUS BASIC FEATURES 259
Gather Data 259
Convert and Record Data 259
Communicate Data to Off-Board Systems 260
USING KOMTRAX PLUS 261
Turning KOMTRAX Plus ON 261
Normal KOMTRAX Plus Operation 261
Turning KOMTRAX Plus OFF 262
Downloading from the KOMTRAX Plus Controller 262
KOMTRAX PLUS DATA ITEMS 263
Fault Codes 263
Machine History 263
KOMTRAX Plus History 263
Snapshots 264
Manual Snapshots 264
Trends 266
Histogram (Load Map) Data 266
Haul Cycle Data 267
Alarm and Snapshot Triggers 268
Satellite Features 268
KOMTRAX PLUS DIAGNOSTIC FEATURES 270
Fault History 270
LED Digits 270
KOMTRAX PLUS CONTROLLER 270
Removal 271
Installation 271
KOMTRAX PLUS SOFTWARE 272
VHMS Tool Box Installation 272
VHMS Setting Tool Installation 272
PDM Software Installation 272
KOMTRAX PLUS INITIALIZATION PROCEDURE 273
CONTROLLER SETUP PROCEDURE 273
SNAPSHOT PROCEDURE 276
DOWNLOAD PROCEDURE 277
FTP UPLOAD PROCEDURE 278
INITIALIZATION FORMS 279
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS CONTROLLER CHECKOUT 285
Necessary Equipment 285
Preliminary 285
KOMTRAX Plus Controller Checkout Procedure 286
ORBCOMM CONTROLLER (if equipped) 288
Removal 288
Installation 288
Troubleshooting 289
SECTION D11 KOMTRAX PLUS INDEX 257
KOMTRAX PLUS 3 257
SECTION D12 INTERFACE MODULE 2 (IM2) INDEX 295
REQUIRED TOOLS 297
PROGRAMMING THE IM2 297
Updating The Software 297
Configuring The IM2 298
Viewing IM2 Real-Time Data 298
IINTERFACE MODULE CHECKOUT PROCEDURES 299
Checking For IM Fault Codes 299
Checking Digital Inputs To The IM 299
Checking Analog inputs To The IM 302
Checking Serial Communication To The IM 302
Checking Outputs From The IM 303
IM CHECKOUT SHEET 304
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 307
INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING D13-3 307
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES 309
AND TROUBLESHOOTING 309
GENERAL 309
Structure and Purpose 309
TROUBLESHOOTING 310
Communications Networks 310
Coaxial Cable 310
FAULT CODES 310
Fault History 310
KOMTRAX Plus LED Display Fault Codes 311
Chassis Fault Codes 312
Engine Fault Codes 317
FAULT TREE ANALYSIS 322
Unable to connect to KOMTRAX Plus from laptop PC 322
Flashing Error Code N4-23 (PLM Communications Fault) 323
Flashing Error Code N4-22 (Engine Communications Fault) 324
No Data Received By WebCARE 325
Coaxial Cable Troubleshooting 326
SECTION E ELECTRIC PROPULSION SYSTEM INDEX 327
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 329
ELECTRICAL PROPULSION SYSTEM COMPONENTS E2-3 329
ELECTRICAL PROPULSION SYSTEM COMPONENTS 331
GENERAL SYSTEM DESCRIPTION 331
SYSTEM COMPONENTS 333
Drive System Controller (DSC) 333
Diagnostic Information Display (DID) Panel 334
DID Panel Event Codes 334
DSC SOFTWARE FUNCTIONS 362
Input Processing 362
State Machine 362
DC Link State 365
Engine Control 366
ALTERNATOR FIELD CONTROL 366
Desired DC Link Voltage 366
Self-Load 366
Propel Torque Control 367
Retard Torque Control 367
Wheel Slide Control 367
Resistor Grid Control 368
Chopper Voltage Control 368
EVENT DETECTION AND PROCESSING 369
Power-On Tests 369
Initiated Tests 370
Periodic Tests 370
EVENT RESTRICTIONS 370
EVENT LOGGING AND STORAGE 370
Event History Buffer 371
Data Packs 371
Event Reset 371
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 372
Fast Start 372
Engine Shutdown/Engine Not Running 372
Limp Home Mode 372
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 373
ELECTRONIC ACCELERATOR AND RETARD PEDALS 380
Removal 380
Installation 380
Disassembly 380
Assembly 380
PHASE MODULE REPLACEMENT 381
Removal 381
Installation 381
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 383
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE E3-3 383
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 385
AC DRIVE SYSTEM MAINTENANCE 385
NORMAL TRUCK SHUTDOWN PROCEDURE 386
TEST EQUIPMENT 387
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 387
REST MODE ACTIVATION 387
INITIAL CHECKOUT PROCEDURES 388
Circuit Continuity and Resistance Checks 388
Megger Test for Grounds 388
Preparation for Megger Test 389
Megger Test Procedure 390
Troubleshooting for Grounds 391
Low Voltage Power Supply Checks 392
Preparation for Power Supply Checks 392
Power Supply Check Procedure 392
Drive System Controller (DSC) Card Checks 393
Propulsion System Software Installation 393
DSC Manual Test Procedures 396
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 398
Set Truck ID Number 402
Control Cabinet Pressure Switch Check 403
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 404
Verifying DSC Software Version 404
Resetting and Erasing DSC Event Data 405
ENGINE RUNNING TESTS 406
Battery Boost Circuit Verification 406
Selector Switch Check 408
Ground Detection Network Tests 410
Self Load Engine Test (Loadbox) Procedure 414
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 416
DID Panel Display Selection 416
DID Modes Display 418
Function Key F1 – DID Events or Faults Display 419
Function Key F4 – DID Menu Display 422
DID Self Load Engine Test (Loadbox) 423
DID Link Capacitance Test 425
DID Speedometer Test 426
DID View Software Version 427
DID View Overspeed Setting 428
DID View Data Menu 429
DID Inverter Cutout Menu 434
DID Truck Configuration Menu 435
Language Selection 440
VIEWING EVENT AND STATISTICAL DATA 441
Viewing the DSC Event Summary, Trigger Data, and Data Packs 441
Viewing the Statistical Data 443
LOGIC SCREENS 444
DATALOGGER FUNCTION 446
Setting Up the Datalogger 446
Starting the Datalogger 448
UPLOADING DATA 450
Consolidated Truck Data Save 450
USB Drive 451
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 453
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A247) INDEX 505
SECTION E5 TROUBLESHOOTING FAULT CODES (A248-A292) INDEX 559
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 599
SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX 635
SECTION G2 TIRES AND RIMS INDEX 637
TIRES AND RIMS G2-3 637
TIRES AND RIMS 639
GENERAL PRECAUTIONS 639
WHEEL STUD MAINTENANCE 640
WHEEL STUD INSTALLATION HEIGHT 641
FRONT TIRES AND RIMS 642
Removal 642
Installation 643
REAR TIRES AND RIMS 643
Removal 643
Installation 644
RIM COMPONENTS 646
Smart Rim Component Layout 646
RIM AND TIRE SERVICE 647
Lubricants 647
Tire Inflation 647
Lock Ring Retainer Installation 647
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 648
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 649
Removal (5-Piece Standard Rim) 650
Removal (7-Piece Smart Rim) 653
Removal (5-Piece Smart Rim) 655
Preparation Before Assembly 656
Installation (5-Piece Standard Rim) 657
Installation – Horizontal Mount (Smart Rim) 659
Installation – Vertical Mount (5-Piece Smart Rim) 661
Installation – Vertical Mount (7-Piece Smart Rim) 662
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 663
FRONT WHEEL HUB AND SPINDLE G3-3 663
FRONT WHEEL HUB AND SPINDLE 665
WHEEL HUB AND SPINDLE ASSEMBLY 665
Removal 665
Spindle Removal Procedure (off of the truck) 668
Installation 670
Disassembly 671
Cleaning and Inspection 673
Assembly 673
Wheel Bearing Adjustment 674
Brake Installation 675
Seal Assembly Gap Check 676
WHEEL SPEED SENSOR TESTING 677
STEERING CYLINDERS 678
Spherical Bearing Wear Limits 678
Removal 679
Installation 679
Bearing Replacement (Steering Cylinder and Tie Rod) 679
TIE ROD 681
Removal 681
Installation 681
Disassembly 682
Assembly 682
Toe-In Adjustment 683
TIE ROD INSPECTION AND TORQUE PROCEDURE 684
SECTION G4 REAR AXLE MOUNTING INDEX 685
REAR AXLE MOUNTING G4-3 685
REAR AXLE MOUNTING 687
PIVOT PIN 687
Removal 687
Installation 688
PIVOT EYE BEARING 688
Removal 688
Installation 688
PIVOT EYE REPAIR 689
Removal 689
Installation 689
ANTI-SWAY BAR 690
Removal 690
Disassembly 690
Cleaning and Inspection 690
Assembly 690
Installation 690
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 693
REAR AXLE AND WHEEL MOTOR G5-3 693
REAR AXLE AND WHEEL MOTOR 695
REAR AXLE HOUSING 695
Preparation 695
Removal 696
Cleaning and Inspection 697
Installation 697
BLOWER PRESSURE SWITCH ADJUSTMENT 697
WHEEL MOTOR 698
Preparation 698
Removal 699
Cleaning and Inspection 701
Installation 701
WHEEL MOTOR GEAR OIL 706
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 706
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 706
Filtering Requirements 706
Particle Size Analysis 707
Flushing 707
Spectrographic Oil Sample Analysis 708
ELEMENT SPECIFICATION CHARTS 709
SECTION H HYDRAIR® II SUSPENSIONS INDEX 713
SECTION H2 FRONT SUSPENSIONS INDEX 715
FRONT SUSPENSION H2-3 715
LOWER BEARING & SEALS H2-10 715
MAJOR SUSPENSION REBUILD H2-11 715
SUSPENSION PRESSURE TEST H2-13 715
FRONT SUSPENSION 717
Removal 717
Installation 718
Inspection 723
LOWER BEARING & SEALS 724
Removal 724
Installation 724
MAJOR SUSPENSION REBUILD 725
Disassembly 725
Assembly 726
SUSPENSION PRESSURE TEST 727
SECTION H3 REAR SUSPENSIONS INDEX 729
REAR SUSPENSIONS H3-3 729
REAR SUSPENSIONS 731
SUSPENSION CYLINDER 732
Removal 732
Installation 733
Disassembly 734
Cleaning and Inspection 734
Assembly 734
SUSPENSION PRESSURE TEST 736
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 737
SUSPENSION OILING AND CHARGING PROCEDURES H4-3 737
SUSPENSION OILING AND CHARGING PROCEDURES 739
CHECKING FOR IMPROPER SUSPENSION CHARGE 739
GENERAL 740
REQUIRED EQUIPMENT 740
HYDRAIR® CHARGING KIT 741
Installation of Charging Kit 741
Removal of Charging Kit 741
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 742
FRONT SUSPENSION 745
REAR SUSPENSION 747
OIL AND NITROGEN SPECIFICATIONS CHARTS 750
SECTION J BRAKE CIRCUIT INDEX 751
SECTION J2 BRAKE CIRCUIT INDEX 753
BRAKE CIRCUIT J2-3 753
BRAKE CIRCUIT 755
SERVICE BRAKE CIRCUIT 755
PARKING BRAKE CIRCUIT 757
BRAKE LOCK CIRCUIT 757
SECONDARY BRAKING AND AUTOMATIC APPLY 758
WARNING CIRCUIT 758
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 761
BRAKE CIRCUIT COMPONENT SERVICE J3-3 761
BRAKE CIRCUIT COMPONENT SERVICE 763
BRAKE VALVE 763
Rebuild Criteria 763
Removal 764
Installation 764
BRAKE VALVE/PEDAL ASSEMBLY 765
Disassembly 765
Assembly 766
Installation 768
DUAL RELAY VALVE 768
Removal 768
Installation 769
BRAKE MANIFOLD 769
Removal 769
Installation 770
Disassembly 770
Cleaning and Inspection 770
Assembly 770
BRAKE ACCUMULATORS 771
Accumulator charging and storage 771
Temperature during precharge 771
BLADDER BRAKE ACCUMULATORS 772
Brake Accumulator Bleed Down Procedure 772
Removal 772
Installation 773
Disassembly 773
Cleaning and Inspection 775
Assembly 775
Precharge Maintenance 776
Accumulator Storage Procedures 776
Installing A Bladder Accumulator From Storage 777
PISTON BRAKE ACCUMULATORS 777
Brake Accumulator bleed down Procedure 777
Removal 777
Installation 779
Disassembly 780
Cleaning and Inspection 780
Assembly 781
Piston accumulator charging procedure 781
Testing 784
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 784
Removal 784
Installation 784
Disassembly 785
Lever Adjustments 785
Potentiometer Check 785
Assembly 786
FRONT BRAKE COOLING HOSE INSTALLATION 788
Installation 788
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 791
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART J4-13 791
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET J4-15 791
BRAKE CIRCUIT CHECK-OUT PROCEDURE 793
REQUIRED EQUIPMENT 794
INITIAL SYSTEM SETUP 795
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 796
AUTO APPLY (LOW BRAKE PRESSURE) CHECK-OUT 797
SERVICE BRAKES 798
PARKING BRAKES 798
PARKING BRAKE CONTROL LOGIC 799
BRAKE LOCK CONTROL LOGIC 800
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 803
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 805
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 811
WET DISC BRAKE ASSEMBLY J5-3 811
WET DISC BRAKE ASSEMBLY 813
OPERATION 813
BRAKE DISC WEAR INSPECTION 814
BRAKE REBUILD 815
Disassembly 815
Cleaning and Inspection 819
Assembly 820
Brake floating ring seal assembly and installation 825
Brake Floating Seal Assembly and Installation 834
WET DISC BRAKE BLEEDING PROCEDURE 842
SECTION J7 PARKING BRAKE INDEX 843
PARKING BRAKE J7-3 843
PARKING BRAKE 845
OPERATION 845
MAINTENANCE 846
Inspection 846
Removal 846
Installation 847
Disassembly 847
Cleaning and Inspection 847
Assembly 849
Cleaning and Inspecting New Discs 850
PARKING BRAKE BLEEDING PROCEDURE 851
SECTION L HYDRAULIC SYSTEM INDEX 853
SECTION L2 HYDRAULIC SYSTEM INDEX 855
HYDRAULIC SYSTEM L2-3 855
HYDRAULIC SYSTEM 857
HYDRAULIC PUMP MODULE 857
HOIST CIRCUIT OPERATION 858
STEERING CIRCUIT OPERATION 860
DISC BRAKE COOLING SYSTEM 862
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 865
HYDRAULIC SYSTEM COMPONENT REPAIR L3-3 865
HYDRAULIC SYSTEM COMPONENT REPAIR 867
HOIST PUMP 867
Removal 867
Installation 869
Inspection 874
Assembly 874
HOIST PUMP TROUBLESHOOTING GUIDE 879
HYDRAULIC TANK 880
Removal 880
Installation 881
HYDRAULIC TANK STRAINERS 881
Removal 881
Inspect and Clean 883
Installation 883
SECTION L4 STEERING CIRCUIT INDEX 885
STEERING CIRCUIT L4-3 885
STEERING CIRCUIT 887
STEERING CIRCUIT OPERATION 887
COMPONENT DESCRIPTION 888
Steering Control Unit 888
Bleeddown Manifold 889
Steering Accumulator Bleeddown Solenoid 889
Relief Valves 891
Hoist Up Limit Solenoid 891
Steering Accumulators 891
Low Precharge Warning Switch 891
High Pressure Filter 891
Quick Disconnect Ports 891
Flow Amplifier 893
FLOW AMPLIFIER SYSTEM OPERATION 894
No Steer 894
Steering Left 896
Steering Right 898
No Steer, External Shock Load 900
STEERING PUMP 902
Normal Operation 902
High Altitude Operation 902
PRINCIPLE OF OPERATION 904
Full Pump Volume 904
Half Pump Volume 904
Neutral Position 904
Steering Pump 905
SECTION L5 STEERING CONTROL UNIT INDEX 907
STEERING CONTROL UNIT L5-3 907
STEERING CONTROL UNIT 909
REMOVAL 909
SPLINE INSPECTION 910
INSTALLATION 910
DISASSEMBLY 911
CLEANING AND INSPECTION 912
ASSEMBLY 914
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 917
STEERING CIRCUIT COMPONENT REPAIR L6-3 917
STEERING CIRCUIT COMPONENT REPAIR 919
BLEEDDOWN MANIFOLD VALVE 919
Removal 919
Installation 920
FLOW AMPLIFIER 921
Removal 921
Installation 921
STEERING CYLINDERS 922
Disassembly 923
Piston Seal & Bearing Installation 923
Assembly 923
Testing 923
STEERING AND BRAKE PUMP 924
Removal 924
Installation 925
Disassembly 926
Inspection 929
Assembly 932
Driveshaft Group 933
Rotating Group 933
Valve Plate Group 934
PISTON STEERING ACCUMULATORS 936
Removal 936
Installation 937
Disassembly 938
Cleaning and Inspection 938
Assembly 939
Testing 939
TROUBLESHOOTING 940
STEERING CIRCUIT 940
STEERING PUMP 942
Basic Hydraulic System Checks 943
System Leakage Check 944
Steering Pump Troubleshooting Guide 946
Pump Pressure Control Checks 949
Pump Control Valve Inspection and Troubleshooting 952
Pump Case Drain Check 952
Setting Pump Pressure Controls 954
SECTION L7 HOIST CIRCUIT INDEX 957
HOIST CIRCUIT L7-3 957
HOIST CIRCUIT 959
BASIC OPERATION 959
COMPONENT DESCRIPTION 960
Hydraulic Tank 960
Hydraulic Pump 960
High Pressure Filters 960
Hoist Valve 960
Inlet Sections 960
Work Ports (Rear) Spool Section 961
Tank Ports (Front) Spool Section 961
Hoist Pilot Valve 961
Bleeddown Manifold 962
Hoist Up Limit Solenoid 962
Pilot Operated Check Valve 962
Overcenter Manifold 962
HOIST CIRCUIT OPERATION 963
Float Position Of Pilot Valve With Truck Body On Frame 964
Power Up Operation 966
Hold Operation 968
Power Down Operation 970
Float Operation 972
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 975
HOIST CIRCUIT COMPONENT REPAIR L8-3 975
HOIST CIRCUIT COMPONENT REPAIR 977
HOIST VALVE 977
Removal 977
Installation 978
O-Ring Replacement 978
INLET SECTION 979
Disassembly 979
Cleaning and Inspection 980
Assembly 980
REAR SPOOL SECTION (Work Ports) 981
Disassembly 981
Cleaning and Inspection 981
Assembly 983
FRONT SPOOL SECTION (Tank Ports) 984
Disassembly 984
Cleaning and Inspection 984
Assembly 984
HOIST PILOT VALVE 986
Removal 986
Installation 986
Disassembly 987
Cleaning and Inspection 988
Assembly 988
HOIST CYLINDERS 989
Removal 989
Installation 990
Disassembly 992
Cleaning and Inspection 993
Assembly – Quill 994
Assembly – Cylinder 996
Testing 996
OVERCENTER VALVE MANIFOLD 997
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 999
HYDRAULIC SYSTEM FILTERS L9-3 999
HYDRAULIC SYSTEM FILTERS 1001
HOIST CIRCUIT FILTER 1001
Filter Element Replacement 1001
Removal – Hoist Circuit Filter 1002
Installation – Hoist Circuit Filter 1002
Indicator Switch – Hoist Circuit Filter 1002
STEERING CIRCUIT FILTER 1003
Filter Element Replacement 1003
Removal – Steering Circuit Filter 1004
Installation – Steering Circuit Filter 1004
Indicator Switch – Steering Circuit Filter 1004
INDICATOR SWITCH 1004
Test Procedure 1004
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1007
HYDRAULIC CHECKOUT PROCEDURE L10-3 1007
HYDRAULIC CHECKOUT PROCEDURE 1009
GENERAL INFORMATION 1009
Procedure for bleeding down hydraulic brake and steering accumulators 1009
Accumulator precharge procedure (step 1) 1011
Pressure gauge installation (steps 2 and 3) 1012
Initial start-up and flushing (steps 4 through 20) 1013
Steering system checkout and adjustment (steps 21 through 24) 1016
Steering pump with unloader valve adjustment (step 25) 1017
Steering system diagnostic and verification (steps 26 through 30) 1018
Hoist system checkout and adjustment (steps 31 through 33) 1019
Hoist counterbalance valve adjustment (step 34) 1020
Oil cleanliness check (steps 35 & 36) 1021
HYDRAULIC CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1022
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 1025
SECTION M7 HOT START SYSTEM INDEX 1027
HOT START SYSTEM M7-3 1027
SYSTEM OPERATION M7-3 1027
HEATER INFORMATION M7-4 1027
TROUBLESHOOTING GUIDELINES M7-5 1027
HOT START SYSTEM 1029
SYSTEM OPERATION 1029
HEATER INFORMATION 1030
TROUBLESHOOTING GUIDELINES 1031
SECTION M8 SPECIAL TOOLS 1033
HIGH VOLTAGE TOOLS 1037
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1037
KOMVISION CALIBRATION TOOLS 1039
SECTION M19 RADIATOR SHUTTERS INDEX 1041
RADIATOR SHUTTERS M19-3 1041
RADIATOR SHUTTERS 1043
OPERATION 1043
Hydraulic Circuit 1043
Electrical Circuit 1044
MAINTENANCE AND REPAIR 1044
TROUBLESHOOTING 1045
SECTION M20 PAYLOAD METER IV ™ INDEX 1049
PAYLOAD METER IV ™ M20-3 1049
PAYLOAD METER IV ™ 1051
INTRODUCTION 1051
Data Summary 1051
Data Gathering 1051
COMPONENT DESCRIPTION 1052
Electronic Dash Display 1052
Mode Switches 1052
Brake Lock Switch 1052
PAYLOAD METER IV SOFTWARE AND TOOLS 1053
PAYLOAD METER IV SYSTEM CONFIGURATION 1053
Connecting to the payload meter IV web server 1053
Configuring a static IP address 1053
PAYLOAD METER IV SOFTWARE INSTALLATION 1055
INCLINOMETER CALIBRATION AND CLEAN TRUCK TARE 1055
PLM IV SYSTEM CHECKOUT DATA SHEET 1061
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1062
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1065
RESERVE ENGINE OIL SYSTEM M31-3 1065
RESERVE ENGINE OIL SYSTEM 1067
GENERAL 1067
OPERATION 1068
Pumping Unit 1068
LED Monitor Lights 1069
Tank Auto Fill Control 1070
Filling Procedure (Remote Fill Feature) 1070
SERVICE 1071
Every 10 Hours (each shift) 1071
Every 500 Hours 1071
Changing Oil 1071
TROUBLESHOOTING 1072
Circuit Fuses 1072
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1073
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1075
RETRACTABLE LADDER SYSTEM M32-5 1075
RETRACTABLE LADDER SYSTEM 1079
GENERAL SAFETY 1079
LADDER SYSTEM DESCRIPTION 1079
LADDER SYSTEM OPERATION 1080
Normal Operation 1080
Emergency Operation 1081
Limit Switch Operation 1081
IN-CAB CONTROL PANEL 1082
IN-CAB CONTROL PANEL FEATURES 1083
IN-CAB CONTROL PANEL FUNCTIONS 1084
Timing Control 1084
Ladder System Status 1084
Fault Code Identification 1084
Ladder System Configuration 1084
In-Cab Control Panel Lockout 1084
Automatic Raising 1084
Diagnostics 1085
Maintenance 1085
USING THE IN-CAB CONTROL PANEL 1085
Raising the Ladder 1086
Lowering the Ladder 1086
USING THE GROUND LEVEL CONTROL BOX 1087
Raising the Ladder 1087
Lowering the Ladder 1087
POWER PACK OPERATION 1088
MAINTENANCE 1091
Safety During Maintenance 1091
Unplanned Ladder Movements 1091
Automatic Ladder Raising 1091
Automatic Accumulator Recharging (Ladder in UP position) 1092
PREVENTIVE MAINTENANCE PROCEDURES 1093
Daily Inspection 1093
250 Hour Inspection 1093
5000 Hour Inspection 1093
SERVICING 1094
Check Reservoir Oil Level 1094
Changing RLS Fluid 1094
Cleaning the RLS 1095
RLS DIAGNOSTICS 1095
Description of Diagnostics Features 1095
Continuous System Monitoring 1096
Historic System Data Review 1097
Comms Integrity Monitoring 1097
Log and Service Information 1098
System Event Logs 1098
SECURITY ACCESS LEVELS 1099
Access Level 1 – NONE 1099
Access Level 2 – RESTRICTED 1099
Access Level 3 – COMPLETE 1099
User Access Privileges 1100
USER ID – PASSWORD 1101
Sequential Field Value Selection Options 1101
Password Character Table 1101
USER ID – NEW USER SETUP 1102
SYSTEM FAULTS 1102
Fault Type 1: Communications error 1103
Fault Type 2: 10A/15A fuse blown 1103
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1104
Fault Type 8: Power pack recharge too long 1104
Fault Type 9: Inhibit relay fail 1105
Fault Types 10, 11: Light/Siren relay failure 1105
Fault Type 12: Ladder came off upper limit 1106
Fault Type 13: Ladder did not reach limit 1106
Fault Type 14: Ladder stayed on limit 1107
Fault Type 15: Low oil level 1107
Fault Type 16: System voltage over 18V during movement 1108
Fault Type 17: System voltage under 18V 1108
Fault Type 18: System voltage over 31V 1109
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1109
Fault Type 21: Accumulator recharge > than once/hour 1110
Fault Type 22: System raised by park brake 1110
Fault Types 23, 24: Levels 1 and 2 service overdue 1111
Fault Type 25: Levels 1 and 2 service complete 1111
DATA MANAGEMENT 1112
Log Files 1112
Generating Reports 1113
MENU DIAGRAMS 1119
Controller Config 1119
Contact Information 1119
Show Recent Logs 1119
System Settings 1119
Upload Logs to USB 1119
Diagnostics 1119
SECTION M33 KomVision® INDEX 1127
KomVision® M33-3 1127
KomVision® 1129
KomVision® SYSTEM PRECAUTIONS 1129
COMPONENT LOCATIONS 1130
MONITOR PANEL 1134
Brightness Switches 1134
System Power Status Indicator 1134
Force Display Switch 1134
Camera Switches 1135
Monitor Display Mode Switch 1135
Reference Line Display Switch 1135
Lower Body Display Switch 1135
Object Clear Switch 1135
MONITOR DISPLAY 1136
Camera Display Modes 1136
Bird’s Eye Views 1138
Reference Lines 1138
Dump Body Status Display 1138
Error Code Display 1139
Initial Setting Screen 1140
RADAR SYSTEM 1140
Object Detection Range 1140
Object Detection Warnings 1141
Object Clear 1144
START-UP INSPECTION 1144
Camera Inspections 1144
Verify the Radar System is Operational 1144
CLEANING 1145
Monitor Panel And Controller 1145
Cameras 1145
KomVision® SYSTEM SETUP AND CALIBRATION 1146
Password Mode 1146
Maintenance Mode 1147
Main Setting Display 1148
6 Camera Calibration Display 1149
Camera Setting 1159
System State 1161
Error Log Screen 1162
Check Disk Display 1162
MAINTENANCE SCREEN EXPLANATION 1163
Area 1163
Threshold 1164
All Radar Position 1164
RADAR DETAIL 1167
Integration 1167
Explanation of Terms 1168
System I/O Explanation 1169
TESTING AND ADJUSTING 1170
System Adjustment 1170
Initial Setting 1170
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1171
6 Camera Calibration Preparation 1171
Calibration Sheet Unfolding 1174
Folding a Camera Calibration Sheet 1175
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1176
Placement of Front Calibration Sheet 1176
Placement of Left and Right Calibration Sheet 1176
Placement of Rear Calibration Sheet and Adjustment of Left and Right Calibration Sheets 1177
CALIBRATING CAMERAS 1177
Automatic 6 Camera Calibration Operation 1177
Manual 6 Camera Calibration 1181
6 Camera Calibration Outgoing Message, and Screen Correspondence 1183
1 Camera Calibration 1184
1 Camera Calibration Outgoing Message, and Screen Correspondence 1186
RADAR SETTING 1186
Radar Zone Preparation and System Calibration 1186
SECTION N OPERATOR CAB INDEX 1197
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 1199
TRUCK CAB AND COMPONENTS N2-3 1199
TRUCK CAB AND COMPONENTS 1201
TRUCK CAB 1201
Description 1201
Removal 1202
Installation 1203
CAB DOOR 1204
Removal 1204
Installation 1204
Door Jamb Bolt Adjustment 1205
Door Handle Plunger Adjustment 1206
Replacing the Door Glass 1207
Replacing the Door Handle or Latch Assembly 1211
Replacing the Door Window Regulator 1212
Replacing the Door and Door Hinge Seal 1213
Replacing the Door Opening Seal 1213
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1214
Recommended Tools and Supplies 1214
Replacement Procedure 1214
WINDSHIELD AND REAR GLASS 1215
Removal 1215
Installation 1216
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1237
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1217
OPERATOR SEAT (STANDARD SEAT) 1219
Adjustment 1219
Inspection 1220
Removal 1220
Installation 1220
Replacing the Seat Compressor 1221
PASSENGER SEAT (STANDARD SEAT) 1226
Adjustment 1226
Inspection 1227
Removal 1227
Installation 1227
SEAT BELT REPLACEMENT (STANDARD SEAT) 1228
Removal 1228
Installation 1228
OPERATOR SEAT (OPTIONAL SEAT) 1230
Seat Belts 1230
Adjustment 1230
PASSENGER SEAT (OPTIONAL SEAT) 1231
Seat Belts 1231
Adjustment 1231
SEAT BELT REPLACEMENT (OPTIONAL SEAT) 1232
General 1232
Removal 1232
SECTION N4
HEATER / AIR CONDITIONER (PC2600)
INDEX 1237
HEATER/AIR CONDITIONER 1239
OPERATION 1239
Fan Speed Control Knob 1239
Temperature Control Knob 1239
Air Flow Directional Knob 1240
Heater/Air Conditioner Vents 1240
COMPONENTS 1240
Fuse and Circuit Breaker 1240
Relays 1240
Heater Core 1241
Fan Motor And Speed Control 1241
Actuators 1241
Cab Air Filter 1241
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1244
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1244
PRINCIPLES OF REFRIGERATION 1244
Air Conditioning 1244
Refrigeration – The Act Of Cooling 1245
The Refrigeration Cycle 1245
AIR CONDITIONER SYSTEM COMPONENTS 1246
Compressor (Refrigerant Pump) 1246
Service Valves 1246
Condenser 1246
Receiver-Drier 1246
Expansion Block Valve 1247
Accumulator 1247
Evaporator 1247
ELECTRICAL CIRCUIT 1248
Thermostat 1248
Compressor Clutch 1248
Trinary™ Switch 1249
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1250
SERVICE TOOLS AND EQUIPMENT 1251
Recovery/Recycle Station 1251
Leak Detector 1251
Service Valves 1252
Vacuum Pump 1252
Manifold Gauge Set 1253
Installing Manifold Gauge Set 1254
Purging Air From Service Hoses 1254
SYSTEM PERFORMANCE TEST 1255
SYSTEM OIL 1256
Handling and Reusing PAG Oil 1256
Oil Quantity 1256
Checking System Oil 1256
REFRIGERANT 1257
Recycled Refrigerant 1257
Reclaimed Refrigerant 1257
Refrigerant Quantity 1258
R-134a Refrigerant Containers 1258
SYSTEM LEAK TESTING 1258
Electronic Leak Detector 1259
Tracer Dyes 1259
Soap and Water 1259
RECOVERING AND RECYCLING THE REFRIGERANT 1259
Draining Oil from the Previous Recovery Cycle 1259
Performing the Recovery Cycle 1259
Performing the Recycling Procedure 1260
Evacuating and Charging the A/C System 1260
SYSTEM REPAIR 1260
System Flushing 1260
COMPONENT REPLACEMENT 1261
Hoses and Fittings 1261
Lines 1261
Expansion Valve 1261
Receiver-Drier 1261
Thermostat 1261
Compressor 1262
Accumulator 1262
Clutch 1262
EVACUATING THE SYSTEM 1263
CHARGING THE A/C SYSTEM 1264
TROUBLESHOOTING 1265
Preliminary Checks 1265
Diagnosis Of Gauge Readings And System Performance 1265
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1266
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1272
SECTION N5 OPERATOR CAB AND CONTROLS INDEX 1273
OPERATOR CAB AND CONTROLS 5 1273
OPERATOR CAB AND CONTROLS 1277
STEERING COLUMN 1278
Removal 1278
Inspection 1278
Installation 1279
STEERING WHEEL 1279
Removal 1279
Installation 1279
STEERING WHEEL AND CONTROLS 1280
Horn Button 1280
Tilt / Telescope Lever 1280
Multi-Function Turn Signal Switch 1280
DYNAMIC RETARDING 1281
Retarder Lever 1281
Service Brake/Retarder Pedal 1281
Throttle/Accelerator Pedal 1281
GRADE/SPEED CHART 1282
OVERHEAD PANEL AND DISPLAYS 1283
CENTER CONSOLE 1284
Directional Control Lever 1284
Override/Fault Reset Switch 1285
Engine Stop Switch 1285
LH Window Control Switch 1285
RH Window Control Switch 1285
Hoist Control Lever 1285
Raising The Dump Body 1285
Lowering The Dump Body 1285
Retard Speed Control (RSC) Adjust Dial 1286
Retard Speed Control (RSC) Switch 1286
Data Store Button 1286
12V Auxiliary Power Outlets 1286
Fire Suppression Control Outlet 1286
Communication Radio Outlet 1286
DIAGNOSTIC PORTS 1287
KOMTRAX Plus Diagnostic Port 1287
Interface Module (IM) Diagnostic Port 1287
Payload Meter Diagnostic Port 1287
Drive System Or Modular Mining 1287
Drive System Controller (DSC) Diagnostic Port 1287
Engine Diagnostic Port (CENSE) 1287
Engine Diagnostic Port (QUANTUM) 1287
HEATER / AIR CONDITIONER 1288
Fan Speed Control Knob 1288
Temperature Control Knob 1288
Air Flow Directional Knob 1288
Heater/Air Conditioner Vents 1288
INSTRUMENT PANEL 1289
Control Symbols 1289
Cab/Air Conditioner Vents 1291
Status Indicator Light Panel 1291
Hydraulic Oil Temperature Gauge 1291
Coolant Temperature Gauge 1291
Speedometer/Digital Display 1291
Fuel Level Gauge 1291
Drive System Temperature Gauge 1291
Hazard Warning Light Switch 1291
Pre-Shift Brake Test Switch 1292
Wheel Brake Lock Control 1292
Rest Switch 1292
Engine Warm Up Switch 1293
Heated Mirror Switch 1293
Rotating Beacon Light Switch (Optional) 1293
Key Switch 1293
Starting 1293
Warning Light 1294
Digital Display Contrast Buttons 1294
Turn Signal Indicators 1294
Panel Light Dimmer 1294
Mode Switches 1294
Fog Light Switch 1294
Manual Backup Switch 1294
Headlight/Panel Illumination Light Switch 1295
STATUS INDICATOR LIGHT PANEL 1296
REAR AXLE LIGHT BAR 1299
Backup Lights 1299
Retard Lights 1299
Brake Lights 1299
Backup Alarm 1299
DIGITAL DISPLAY OPERATION 1300
Toggling Through Main Level Screens 1300
Toggling Through Warning Screens 1301
Entering Payload Meter Data 1302
KOMTRAX PLUS 1303
Operation 1303
Interface Module 1305
Basic Precautions 1305
KOMATSU WIRELESS BRIDGE (KWB) General information 1306
Required software and tools 1306
Configuring the Bullet wireless radio 1307
Installing the Bullet wireless radio 1310
Configuring the NanoStation access point 1311
Testing the connection 1314
Changing a service computer’s IP address 1315
SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX 1317
SECTION P2 PERIODIC MAINTENANCE INDEX 1319
PERIODIC MAINTENANCE P2-3 1319
PERIODIC MAINTENANCE 1321
GENERAL 1321
SERVICE CAPACITIES 1321
HYDRAULIC TANK SERVICE 1321
Adding Oil 1321
COOLING SYSTEM SERVICE 1322
Radiator Filling Procedure 1322
Coolant Specifications 1322
Unacceptable Practices 1322
WHEEL MOTOR SERVICE 1322
RESERVE OIL TANK SERVICE 1323
Filling the Reserve Oil Tank (Remote Fill) 1323
Inline Screen 1323
QUICK FILL SERVICE CENTER 1324
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1326
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1326
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1327
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1329
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1333
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1335
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1335
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1336
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1336
INJECTOR OPERATION 1346
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1337
AUTOMATIC LUBRICATION SYSTEM P3-3 1337
AUTOMATIC LUBRICATION SYSTEM 1339
GENERAL DESCRIPTION 1339
SYSTEM COMPONENTS 1341
Filter 1341
Hydraulic Motor and Pump 1341
Grease Reservoir 1341
Pressure Reducing Valve 1341
Flow Control Valve 1341
Solenoid Valve 1341
Vent Valve 1341
Grease Pressure Failure Switch 1341
Injectors 1341
Interface Module 1341
Relief Valve (unloader valve) 1341
SYSTEM OPERATION 1342
Normal Operation 1342
Lubricant Required For System 1343
Filter Assembly 1343
System Priming 1343
LUBRICANT PUMP 1344
Pump Housing Oil Level 1344
Pump Pressure Control 1344
INJECTORS (SL-1 Series “H”) 1345
Injector Specifications 1345
Injector Adjustment 1345
PREVENTIVE MAINTENANCE PROCEDURES 1347
Daily Lubrication System Inspection 1347
250 Hour Inspection 1347
1000 Hour Inspection 1347
SYSTEM CHECKOUT 1348
Pump Priming Procedure 1348
System Priming Procedure 1349
Lubrication Cycle Operation 1349
AUTOLUBE TROUBLESHOOTING CHART 1350
SECTION R SYSTEM SCHEMATICS INDEX 1353

DESCRIPTION:

Komatsu 930E-4SE Dump Truck Shop Manual CEBM039000 –  PDF DOWNLOAD

G.B 20/12/24