Komatsu 930E-4SEDump Truck Shop Manual CEBM027102 PDF

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Komatsu 930E-4SEDump Truck Shop Manual CEBM027102 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-4SEDump Truck Shop Manual CEBM027102 –  PDF DOWNLOAD

Language : English
Pages : 1394
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4SEDump Truck Shop Manual CEBM027102 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31165 – A31824

FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
COMPONENTS & SPECIFICATIONS 11
MAJOR COMPONENT DESCRIPTIONS 11
Truck And Engine 11
Main Alternator 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SAFETY 17
GENERAL 17
Safety Rules 17
Safety Features 17
Fire Extinguisher And First Aid Kit 17
Clothing And Personal Items 18
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 19
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 20
Unauthorized Modification 20
Precautions When Using ROPS 20
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 21
Safety At The Worksite 21
Fire Prevention 21
Ventilation In Enclosed Areas 21
Preparing For Operation 22
Mirrors, Windows And Lights 22
In The Operator Cab (Before Starting The Engine) 22
Seat Belts 22
OPERATING THE TRUCK 23
When Starting The Engine 23
General Truck Operation 23
Ensuring Good Visibility 23
Traveling 24
Traveling In Reverse 24
Traveling On Slopes 24
Operating On Snow Or Ice 24
Avoid Damage To Dump Body 24
Driving Near High Voltage Cables 25
Working On Loose Ground 25
When Dumping 25
When Loading 25
Parking The Truck 25
Towing 25
WORKING NEAR BATTERIES 26
Battery Hazard Prevention 26
Jump Starting With Booster Cables 27
Jump Starting With Receptacles 27
BEFORE PERFORMING MAINTENANCE 28
Stopping The Engine Before Service 28
Warning Tag 28
Proper Tools 28
Use of Tie-Off Anchor During Maintenance and Repair 28
Securing The Dump Body 29
WHILE PERFORMING MAINTENANCE 30
Keep The Truck Clean 30
Attachments 30
Working Under The Truck 30
Rotating Fan And Belts 30
Waste Materials 30
Adding Fuel Or Oil 31
Radiator Coolant Level 31
Use Of Lighting 31
Precautions With The Battery 31
Handling High Pressure Hoses 31
Precautions With High Pressure Oil 31
Performing Maintenance Near High Temperature Or High Pressure 31
TIRES 32
Handling Tires 32
Tire Maintenance 32
Storing Tires After Removal 32
WHEN REPAIRS ARE NECESSARY 33
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 34
Preliminary Procedures Before Welding or Performing Maintenance 34
Engine Shutdown Procedure Before Welding or Performing Maintenance 34
CAPACITOR DISCHARGE SYSTEM 36
Necessary Tools 36
Warnings And Cautions 37
Manual DC Link Capacitor Discharge Procedure 38
Failure of the Discharge System 40
Manual Discharge of Capacitors 41
Short Isolated Capacitor Terminals 43
OPERATING INSTRUCTIONS 44
PREPARING FOR OPERATION 44
WALK AROUND INSPECTION 44
RETRACTABLE LADDER SYSTEM (Optional) 48
Description 48
Normal Operation 48
General Safety 48
IN-CAB CONTROL PANEL 49
Digital Display Screen 49
Command Buttons 49
USING THE IN-CAB CONTROL PANEL 50
Raising the Ladder 51
Lowering the Ladder 51
USING THE GROUND LEVEL CONTROL BOX 52
Raising the Ladder 52
Lowering the Ladder 52
EMERGENCY OPERATION 52
ENGINE START-UP 53
AFTER ENGINE HAS STARTED 54
PRE-SHIFT BRAKE CHECK 54
Events 54
OPERATION 55
Description 55
Brake Test Exit Criteria 55
PERFORMING THE BRAKE TESTS 56
Setup 56
Service Brake Test 56
Parking Brake Test 57
Retard System Test 58
EMERGENCY STEERING SYSTEM 58
Operation 58
Pre-Operation Testing 58
MACHINE OPERATION SAFETY PRECAUTIONS 59
OPERATING ON THE HAUL ROAD 60
STARTING ON A GRADE WITH A LOADED TRUCK 61
PASSING 61
LOADING 61
Overload Speed Limit Function 61
DUMPING 62
Raising The Dump Body 62
Lowering The Dump Body (When dumping on flat ground) 63
Lowering The Dump Body (When dumping over a berm or into a crusher) 63
TOWING 64
Special Wiring Harness 64
Towing Procedure 65
SAFE PARKING PROCEDURES 66
NORMAL ENGINE SHUTDOWN PROCEDURE 66
SUDDEN LOSS OF ENGINE POWER 67
FUEL DEPLETION 67
DISABLED TRUCK DUMPING PROCEDURE 68
Hookup 68
Raising the Body 68
Lowering the Body 68
WARNINGS AND CAUTIONS 69
GRADE/SPEED CHART 69
KEY SWITCH 69
ROPS/FOPS 69
BATTERIES 70
CAPACITORS 70
CRUSHING HAZARD 71
CYLINDER PRESSURE 71
FILLING THE HYDRAULIC TANK 72
HYDRAULIC OIL PRESSURE 72
HOT OIL SPRAY 73
WHEEL MOTOR OIL LEVEL 73
HOT EXHAUST 73
RADIATOR 73
EMERGENCY LADDER 73
ACCUMULATOR DRAIN VALVES 73
EMERGENCY DUMP PROCEDURE 74
EMERGENCY TOWING PROCEDURE 74
WELDING 74
EMERGENCY SHUTDOWN 74
INFORMATION DISPLAY 75
WIRELESS SIGNALS 75
HIGH VOLTAGE 75
LIFTING INSTRUCTIONS 76
PRODUCT IDENTIFICATION PLATE 77
LUBRICATION CHART 78
TORQUE TABLES AND CONVERSION CHARTS 79
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 80
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 80
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 81
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 82
STORAGE PROCEDURES AND IDLE MACHINE PREPARATION 89
SHORT TERM IDLE PERIODS 89
PREPARATION FOR STORAGE 90
REMOVAL FROM STORAGE 91
RECONDITIONING AN IDLE VEHICLE 92
ENGINE OPERATION 94
After The Engine Has Started 95
ENGINE STORAGE 96
Temporary Storage (30 Days Or Less) 96
Extended Storage (More Than 30 Days) 96
RESTORING AN ENGINE AFTER EXTENDED STORAGE 97
ELECTRIC DRIVE TRUCKS 98
Storing A Truck That Is Operational 98
Storing A Truck That Is Not Operational 99
Storing A Major Component 99
Periodic Inspections 99
Placing Equipment Into Service After Storage 100
SECTION B STRUCTURES 101
SECTION B2 STRUCTURAL COMPONENTS 103
STRUCTURAL COMPONENTS 105
PREPARATION 105
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 106
Removal 106
Installation 106
RH DECK AND RETARDING GRID 107
Removal 107
Installation 107
LH DECK 108
Removal 108
Installation 108
CENTER DECK 109
Removal 109
Installation 109
SECTION B3 DUMP BODY 111
DUMP BODY 113
DUMP BODY 113
Removal 113
Installation 114
BODY PADS 115
Body Pad Shimming Procedure 116
BODY GUIDE 117
HOIST LIMIT SWITCH 117
BODY-UP SWITCH 117
BODY RETENTION SLING 117
ROCK EJECTORS 118
Inspection 118
SECTION B4 FUEL TANK 119
FUEL TANK 121
FUEL TANK 121
Removal 121
Repair 121
Cleaning 121
Installation 121
FUEL TANK VENT ASSEMBLY 123
Disassembly 123
Assembly 123
FUEL GAUGE SENDER 124
Removal 124
Installation 124
QUICK FILL FUEL RECEIVERS 124
SECTION B4 FUEL TANK 125
FUEL TANK 127
FUEL TANK 127
Removal 127
Repair 127
Cleaning 127
Installation 127
FUEL TANK VENT ASSEMBLY 129
Disassembly 129
Assembly 129
FUEL GAUGE SENDER 130
Removal 130
Installation 130
QUICK FILL FUEL RECEIVERS 130
SECTION C ENGINE INDEX 131
SECTION C2 POWER MODULE 133
POWER MODULE 135
PREPARATION FOR REMOVAL 135
REMOVAL 140
INSTALLATION 142
HOOKUP 143
EXHAUST TUBE INSTALLATION 144
EXHAUST BLANKET INSTALLATION 144
SECTION C3 COOLING SYSTEM 145
COOLING SYSTEM 147
RADIATOR 147
Removal 147
Installation 149
Filling Procedure 150
REPAIRING THE RADIATOR 150
Internal Inspection 150
External Cleaning 150
Disassembly 151
Cleaning and Inspection 152
Assembly 152
Pressure Testing 153
COOLANT SYSTEM TROUBLESHOOTING 153
SECTION C4 POWER TRAIN 155
POWER TRAIN 157
ALTERNATOR REMOVAL 157
ALTERNATOR INSTALLATION 159
Measuring Procedure 159
Joining the Alternator and Engine 161
ENGINE 162
Removal 162
Service 162
Installation 162
SECTION C5 AIR CLEANERS 163
AIR CLEANERS 165
OPERATION 165
SERVICING THE AIR CLEANERS 165
Replacing The Elements 166
AIR CLEANER ASSEMBLY CLEANING 167
Primary Element Cleaning 167
Precleaner Section Cleaning 169
AIR INTAKE TROUBLESHOOTING 170
SECTION C7 FAN CLUTCH 171
FAN CLUTCH 173
REMOVAL & INSTALLATION TOOLING 173
DISASSEMBLY 176
CLEANING AND INSPECTION 186
ASSEMBLY 190
TEST PROCEDURE 205
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 207
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM 209
24VDC ELECTRIC SUPPLY SYSTEM 211
ELECTRICAL SYSTEM DESCRIPTION 211
BATTERIES 211
Maintenance and Service 211
Troubleshooting 211
BATTERY SUPPLY SYSTEM 213
24VDC Battery Charging Alternator 213
Batteries 213
Engine Start Relays 213
24VDC Auxiliary Battery Receptacles 213
Battery Disconnect Switches 213
24VDC to 12VDC Converter 214
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 214
Operation 214
Pressure Switch 214
Check Valve 215
Prelube Timer Solenoid 215
MAINTENANCE 215
Prelube System Operation Checks 215
Check Valve 215
Prelube Timer Solenoid 215
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 216
24VDC ELECTRIC START SYSTEM 218
CRANKING MOTORS 218
Operation 218
Removal 218
Installation 218
CRANKING MOTOR TROUBLESHOOTING 219
Preliminary Inspection 219
No-Load Test 219
Interpreting Results of Tests 220
MAGNETIC SWITCH 221
Removal 221
Installation 221
Coil Test 221
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 223
24 VDC ELECTRICAL SYSTEM COMPONENTS 225
BRAKE WARNING BUZZER 225
AUXILIARY CONTROL CABINET COMPONENTS 225
Power Distribution Terminals 225
Control Power Relay 225
Auto Lube Timer 225
Ground Level Power Relay 225
Diode Board – DB1 227
Fuse Blocks 228
Alarm Indicating Device (AID) System 228
RELAY BOARDS 231
Relay Boards RB1, RB3, RB4, RB5 231
Relay Board RB6, RB7, RB8, RB9 233
Relay Board Functions 234
BODY-UP SWITCH 236
Operation 236
Adjustment 236
Service 236
HOIST LIMIT SWITCH 237
Operation 237
Adjustment 237
Service 237
FUSE BLOCKS AND CIRCUIT BREAKERS 238
SECTION D11 KOMTRAX PLUS 241
KOMTRAX PLUS 243
KOMTRAX PLUS BASIC FEATURES 243
Gather Data 243
Convert and Record Data 243
Communicate Data to Off-Board Systems 244
USING KOMTRAX PLUS 245
Turning KOMTRAX Plus ON 245
Normal KOMTRAX Plus Operation 245
Turning KOMTRAX Plus OFF 246
Downloading from the KOMTRAX Plus Controller 246
KOMTRAX PLUS DATA ITEMS 247
Fault Codes 247
Machine History 247
KOMTRAX Plus History 247
Snapshots 248
Manual Snapshots 248
Trends 250
Histogram (Load Map) Data 250
Haul Cycle Data 251
Alarm and Snapshot Triggers 252
Satellite Features 252
KOMTRAX PLUS DIAGNOSTIC FEATURES 254
Fault History 254
LED Digits 254
KOMTRAX PLUS CONTROLLER 254
Removal 255
Installation 255
KOMTRAX PLUS SOFTWARE 256
VHMS Tool Box Installation 256
VHMS Setting Tool Installation 256
PDM Software Installation 256
KOMTRAX PLUS INITIALIZATION PROCEDURE 257
CONTROLLER SETUP PROCEDURE 257
SNAPSHOT PROCEDURE 260
DOWNLOAD PROCEDURE 261
FTP UPLOAD PROCEDURE 262
INITIALIZATION FORMS 263
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 264
KOMTRAX PLUS CONTROLLER CHECKOUT 269
Necessary Equipment 269
Preliminary 269
KOMTRAX Plus Controller Checkout Procedure 270
ORBCOMM CONTROLLER (if equipped) 272
Removal 272
Installation 272
Troubleshooting 273
SECTION D12 INTERFACE MODULE 279
INTERFACE MODULE 281
INTERFACE MODULE 281
Removal 281
Installation 281
SENSORS 282
Temperature Sensors 282
Pressure Sensors 282
INTERFACE MODULE SOFTWARE 283
Flashburn Program Installation 283
Interface Module Application Code Installation 284
Interface Module Realtime Data Monitor Software 284
INTERFACE MODULE CHECKOUT 285
Necessary Equipment 285
Preliminary 286
Check Digital Inputs To The Interface Module 287
Check Analog Inputs To The Interface Module 290
Check Serial Interfaces To The Interface Module 290
Check Outputs From The Interface Module 291
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 293
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 295
GENERAL 295
Structure and Purpose 295
TROUBLESHOOTING 296
Communications Networks 296
Coaxial Cable 296
FAULT CODES 296
Fault History 296
KOMTRAX Plus LED Display Fault Codes 297
Chassis Fault Codes 298
Engine Fault Codes 303
FAULT TREE ANALYSIS 308
Unable to connect to KOMTRAX Plus from laptop PC 308
Flashing Error Code N4-23 (PLM Communications Fault) 309
Flashing Error Code N4-22 (Engine Communications Fault) 310
No Data Received By WebCARE 311
Coaxial Cable Troubleshooting 312
SECTION D14 KOMTRAX PLUS FORMS 313
KOMTRAX PLUS FORMS 315
KOMTRAX PLUS INITIALIZATION CHECK LIST 315
KOMTRAX PLUS DATA DOWNLOAD 316
KOMTRAX PLUS INITIALIZATION CHECK LIST 317
KOMTRAX PLUS INITIALIZATION FORM 319
SECTION E ELECTRIC PROPULSION SYSTEM 321
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 323
ELECTRICAL PROPULSION SYSTEM COMPONENTS 325
GENERAL SYSTEM DESCRIPTION 325
SYSTEM COMPONENTS 327
Propulsion System Controller (PSC) 327
Truck Control Interface (TCI) 328
Diagnostic Information Display (DID) Panel 329
DID Panel Event Codes 329
PSC SOFTWARE FUNCTIONS 348
Input Processing 348
State Machine 348
DC Link State 351
Engine Control 352
ALTERNATOR FIELD CONTROL 352
Desired Three-Phase Voltage 352
Desired DC Link Voltage 352
Self-Load 353
Propel Torque Control 353
Retard Torque Control 353
Wheel Slide Control 354
Resistor Grid Control 354
Chopper Voltage Control 354
EVENT DETECTION AND PROCESSING 354
Power-On Tests 354
Initiated Tests 355
Periodic Tests 355
EVENT RESTRICTIONS 355
EVENT LOGGING AND STORAGE 355
Event History Buffer 356
Data Packs 356
To Record and Save a Data Pack to a Disk 356
Event Reset 357
SERIAL DATA COMMUNICATIONS 357
PSC – TCI Communications Processing 357
PSC – PTU Communications Processing 357
Inverter Communications Processing 358
OUTPUT PROCESSING 358
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 358
Fast Start 358
Engine Shutdown/Engine Not Running 358
Limp Home Mode 359
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 360
ELECTRONIC ACCELERATOR AND RETARD PEDALS 368
Removal 368
Installation 368
Disassembly 368
Assembly 368
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 369
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 371
AC DRIVE SYSTEM MAINTENANCE 371
NORMAL TRUCK SHUTDOWN PROCEDURE 372
SHUTDOWN AFTER SYSTEM FAILURE 372
SYSTEM CHECKOUT 373
Battery and Control Circuit Checks – Battery Power OFF 373
Battery and Control Circuit Checks – Battery Power ON 376
Checks with Key Switch OFF 377
Checks with Key Switch ON 377
CPU Battery Checks 377
MEMORY BACKUP BATTERY REPLACEMENT 378
TCI PROGRAMMING 378
PSC PROGRAMMING 379
INVERTER PROGRAMMING 379
CPU RESET 379
PSC CHECKOUT 380
PSC Digital Input Checks 380
PSC Digital Output Checks 384
TCI CHECKOUT 385
Modular Mining Communication Port Check 385
TCI Digital Input Checks 385
TCI Digital Output Tests 391
CALIBRATIONS 393
Speedometer 393
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 393
ERASING EVENTS 393
PSC 393
TCI 394
GATE DRIVER POWER CONVERTER TEST 394
LOAD TESTING 395
Preparation 395
Alternator Speed Sensor Checks 395
Battery Boost Check 395
Brake Circuit Switch Checks 396
Hoist & Steering Circuit Switch Checks 396
Link Energized Checks 396
Loadbox Test 398
TROUBLESHOOTING 402
PVM Optimum Load Curve Handshaking Troubleshooting 402
Phase Module and Chopper Module Troubleshooting 402
PHASE MODULE REPLACEMENT 403
Phase Module Removal 403
Phase Module Installation 403
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) 405
Fault Code A001: Left front suspension pressure sensor signal is high 408
Related circuit diagram 408
Fault Code A002: Left front suspension pressure sensor signal is low 409
Related circuit diagram 409
Fault Code A003: Right front suspension pressure sensor signal is high 410
Related circuit diagram 410
Fault Code A004: Right front suspension pressure sensor signal is low 411
Related circuit diagram 411
Fault Code A005: Left rear suspension pressure sensor signal is high 412
Related circuit diagram 412
Fault Code A006: Left rear suspension pressure sensor signal is low 413
Related circuit diagram 413
Fault Code A007: Right rear suspension pressure sensor signal is high 414
Related circuit diagram 414
Fault Code A008: Right rear suspension pressure sensor signal is low 415
Related circuit diagram 415
Fault Code A009: Incline sensor signal is high 416
Related circuit diagram 416
Fault Code A010: Incline sensor signal is low 417
Related circuit diagram 417
Fault Code A011: Payload meter speed sensor signal has failed 418
Related circuit diagram 418
Fault Code A013: Body up switch has failed 419
Related circuit diagram 419
Fault Code A014: Payload meter checksum computation has failed 420
Related circuit diagram 420
Fault Code A016: Payload meter write to flash memory has failed 421
Related circuit diagram 421
Fault Code A017: Payload meter flash memory read has failed 422
Related circuit diagram 422
Fault Code A018: Right rear flat suspension cylinder warning 424
Related circuit diagram 425
Fault Code A019: Left rear flat suspension cylinder warning 426
Related circuit diagram 427
Fault Code A022: Carryback load is excessive 428
Related circuit diagram 429
Fault Code A026: Payload meter user select switch has failed 430
Related circuit diagram 430
Fault Code A027: Payload meter user clear switch has failed 431
Related circuit diagram 431
Fault Code A101: High pressure detected across a hydraulic pump filter 432
Related circuit diagram 434
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 436
Related circuit diagram 437
Fault Code A109: GE has generated a propel system reduced level signal 438
Related circuit diagram 439
Fault Code A111: Low steering pressure warning 440
Fault Code A115: Low steering precharge pressure is detected 442
Related circuit diagram 443
Fault Code A117: Low brake accumulator pressure warning 444
Fault Code A118: Brake pressure is low while brake lock is activated 445
Fault Code A123: GE has generated a reduced retarding caution 446
Related circuit diagram 447
Fault Code A124: GE has generated a no propel / no retard warning 448
Related circuit diagram 449
Fault Code A125: GE has generated a no propel warning 450
Related circuit diagram 451
Fault Code A126: Oil level in the hydraulic tank is low 452
Related circuit diagram 453
Fault Code A127: IM furnished +5 volt output for sensors is low 454
Related circuit diagram 455
Fault Code A128: IM furnished +5 volt output for sensors is high 456
Related circuit diagram 457
Fault Code A139, A310: Low fuel level warning 458
Related circuit diagram 460
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 462
Related circuit diagram 464
Fault Code A146: Hydraulic temperature sensors cause posting of this fault 466
Related circuit diagram 467
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216) 469
Fault Code A152: Starter failure 470
Related circuit diagram 471
Fault Code A153: Battery voltage is low with truck in operation 472
Related circuit diagram 474
Fault Code A154: Battery charging voltage is excessive 476
Related circuit diagram 477
Fault Code A155: Battery charging voltage is low 478
Related circuit diagram 479
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 480
Related circuit diagram 481
Fault Code A166: Left rear hydraulic oil temperature sensor is low 482
Related circuit diagram 483
Fault Code A167: Right rear hydraulic oil temperature sensor is low 484
Related circuit diagram 485
Fault Code A168: Left front hydraulic oil temperature sensor is low 486
Related circuit diagram 487
Fault Code A169: Right front hydraulic oil temperature sensor is low 488
Related circuit diagram 489
Fault Code A170: Left rear hydraulic oil temperature sensor is high 490
Related circuit diagram 490
Fault Code A171: Right rear hydraulic oil temperature sensor is high 491
Related circuit diagram 491
Fault Code A172: Left front hydraulic oil temperature sensor is high 492
Related circuit diagram 492
Fault Code A173: Right front hydraulic oil temperature sensor is high 493
Related circuit diagram 493
Fault Code A184: J1939 data link is not connected 494
Related circuit diagram 495
Fault Code A190: Auto lube control has detected an incomplete lube cycle 496
Related circuit diagram 497
Fault Code A194: Left front hydraulic oil temperature is high 498
Related circuit diagram 499
Fault Code A195: Right front hydraulic oil temperature is high 500
Related circuit diagram 501
Fault Code A196: Left rear hydraulic oil temperature is high 502
Related circuit diagram 503
Fault Code A197: Right rear hydraulic oil temperature is high 504
Related circuit diagram 505
Fault Code A198: Hoist pressure 1 sensor is high 506
Related circuit diagram 506
Fault Code A199: Hoist pressure 2 sensor is high 507
Related circuit diagram 507
Fault Code A200: Steering pressure sensor is high 508
Related circuit diagram 508
Fault Code A201: Brake pressure sensor is high 509
Related circuit diagram 509
Fault Code A202: Hoist pressure 1 sensor is low 510
Related circuit diagram 511
Fault Code A203: Hoist pressure 2 sensor is low 512
Related circuit diagram 513
Fault Code A204: Steering pressure sensor is low 514
Related circuit diagram 515
Fault Code A205: Brake pressure sensor is low 516
Related circuit diagram 517
Fault Code A206: Ambient temperature sensor is high 518
Related circuit diagram 518
Fault Code A207: Ambient temperature sensor is low 519
Related circuit diagram 519
Fault Code A212: Bad truck speed signal 520
Related circuit diagram 521
Fault Code A213: Parking brake should have applied but is detected as not having applied 522
Related circuit diagram 524
Fault Code A214: Parking brake should have released but is detected as not having released 526
Related circuit diagram 528
Fault Code A215: Brake auto apply relay circuit is defective 530
Related circuit diagram 532
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 534
Related circuit diagram 536
SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292) 539
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 542
Related circuit diagram 544
Fault Code A230: Parking brake has been requested while truck still moving 546
Related circuit diagram 547
Fault Code A231: Dump body is up while traveling or intending to travel 548
Fault Code A233: Drive system CAN/RPC Control Link not connected 550
Fault Code A235: Steering accumulator is in the process of being bled down 551
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 552
Related circuit diagram 553
Fault Code A237: The CAN/RPC connection to the display is open 554
Fault Code A240: The keyswitch input to the interface module is open 555
Related circuit diagram 556
Fault Code A246: Payload meter reports truck overload 557
Related circuit diagram 557
Fault Code A247: Low steering pressure warning 558
Fault Code A248: The status indicator module within the display panel is defective 559
Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted 560
Related circuit diagram 561
Fault Code A250: Battery voltage is low with the truck parked 562
Related circuit diagram 564
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 565
Fault Code A252: Start enable output circuit is either open or shorted to ground 566
Related circuit diagram 567
Fault Code A253: Steering bleed circuit is not open while running 568
Related circuit diagram 569
Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open 570
Related circuit diagram 572
Fault Code A257: Payload CAN/RPC is not connected 573
Related circuit diagram 573
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 574
Related circuit diagram 575
Fault Code A260: Parking brake failure 576
Related circuit diagram 578
Fault Code A261: Low brake accumulator pressure warning 579
Fault Code A262: Steering bleed valve circuit open during shutdown 580
Related circuit diagram 582
Fault Code A263: Steering bleed circuit is shorted to ground 584
Related circuit diagram 585
Fault Code A264: Parking brake relay circuit is defective 586
Related circuit diagram 587
Fault Code A265: Service brake failure 588
Related circuit diagram 590
Fault Code A266: Selector lever was not in park while attempting to crank engine 591
Fault Code A267: Parking brake was not set while attempting to crank engine 592
Fault Code A268: Secondary engine shutdown while cranking 593
Fault Code A270: Brake lock switch power supply is not on when required 594
Related circuit diagram 596
Fault Code A271: Shifter not in gear 597
Fault Code A272: Brake lock switch power supply is not off when required 598
Related circuit diagram 600
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 602
Related circuit diagram 603
Fault Code A274: A brake setting fault has been detected 604
Related circuit diagram 605
Fault Code A275: A starter has been detected as engaged without a cranking attempt 606
Related circuit diagram 608
Fault Code A277: Parking brake applied while loading 609
Fault Code A278: Service brake applied while loading 610
Fault Code A279: Low steering pressure switch is defective 611
Fault Code A280: Steering accumulator Bleed Down switch is defective 612
Fault Code A281: Brake lock degradation switch is defective 613
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 614
Related circuit diagram 616
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 618
Related circuit diagram 619
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 620
Related circuit diagram 621
Fault Code A285: The parking brake was not set when the key switch was turned off 622
Related circuit diagram 623
Fault Code A286: A fault was detected in the shutdown delay relay circuit 624
Related circuit diagram 625
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 626
Related circuit diagram 628
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) 631
Fault Code A303: Shifter is defective 632
Related circuit diagram 633
Fault Code A304: Auto lube grease level is low 634
Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be 636
Related circuit diagram 637
Fault Code A307: Both GE inverters are disabled 638
Fault Code A309: No brakes applied when expected 639
Related circuit diagram 641
Fault Code A311: Brake lock switch is on when it should not be 642
Related circuit diagram 643
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 644
Related circuit diagram 644
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 645
Related circuit diagram 645
Fault Code A315: DC-DC converter 12 volt circuit is low 646
Related circuit diagram 647
Fault Code A316: Starter engagement has been attempted with engine running 648
Related circuit diagram 649
Fault Code A317: Operation of brake auto apply valve without a detected response 650
Related circuit diagram 652
Fault Code A318: Unexpected power loss to interface module 653
Related circuit diagram 653
Fault Code A328: Drive system not powered up 654
Related circuit diagram 655
Fault Code A332: Seat belt not buckled 656
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 658
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 659
Fault Code A335: Manual/Auto Apply Pressure Fault 660
Fault Code A350: Overload on output 1B 662
Related circuit diagram 663
Fault Code A351: Overload on output 1E 664
Related circuit diagram 665
Fault Code A352: Overload on output 1H 666
Related circuit diagram 667
Fault Code A353: Overload on output 1J 668
Related circuit diagram 669
Fault Code A354: Overload on output 1K 670
Related circuit diagram 671
Fault Code A355: Overload on output 1L 672
Related circuit diagram 673
Fault Code A356: Overload on output 1M 674
Related circuit diagram 675
Fault Code A357: Overload on output 1N 676
Related circuit diagram 677
Fault Code A358: Overload on output 1P 678
Related circuit diagram 679
Fault Code A359: Overload on output 1R 680
Related circuit diagram 681
Fault Code A360: Overload on output 1S 682
Related circuit diagram 683
Fault Code A361: Overload on output 1T 684
Related circuit diagram 685
Fault Code A362: Overload on output 1U 686
Related circuit diagram 687
Fault Code A363: Overload on output 1X 688
Related circuit diagram 688
Fault Code A364: Overload on output 1Y 690
Related circuit diagram 691
Fault Code A365: Overload on output 1Z 692
Related circuit diagram 693
SECTION G REAR AXLE, SPINDLES AND WHEELS 695
SECTION G2 TIRES AND RIMS 697
TIRES AND RIMS 699
GENERAL PRECAUTIONS 699
RIM COMPONENTS 700
Smart Rim Component Layout 700
WHEEL STUD MAINTENANCE 701
WHEEL STUD INSTALLATION HEIGHT 702
Installation of wheel stud 702
FRONT TIRES AND RIMS 703
Removal 703
Installation 704
REAR TIRES AND RIMS 704
Removal 704
Installation 705
RIM AND TIRE SERVICE 707
Lubricants 707
Tire Inflation 707
Lock Ring Retainer Installation 707
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 708
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 709
Removal (5-Piece Standard Rim) 710
Removal (7-Piece Smart Rim) 713
Removal (5-Piece Smart Rim) 715
Preparation Before Assembly 716
Installation (5-Piece Standard Rim) 717
Installation – Horizontal Mount (Smart Rim) 719
Installation – Vertical Mount (5-Piece Smart Rim) 721
Installation – Vertical Mount (7-Piece Smart Rim) 722
SECTION G3 FRONT WHEEL HUB AND SPINDLE 723
FRONT WHEEL HUB AND SPINDLE 725
WHEEL HUB AND SPINDLE ASSEMBLY 725
Removal 725
Spindle Removal Procedure (off of the truck) 728
Installation 730
Disassembly 731
Cleaning and Inspection 733
Assembly 733
Wheel Bearing Adjustment 734
Brake Installation 735
Seal Assembly Gap Check 736
WHEEL SPEED SENSOR TESTING 737
STEERING CYLINDERS 738
Spherical Bearing Wear Limits 738
Removal 739
Installation 739
Bearing Replacement (Steering Cylinder and Tie Rod) 739
TIE ROD 741
Removal 741
Installation 741
Disassembly 742
Assembly 742
Toe-In Adjustment 743
TIE ROD INSPECTION AND TORQUE PROCEDURE 744
Old Style Tie Rod 744
New Style Tie Rod 745
SECTION G4 REAR AXLE MOUNTING 747
REAR AXLE MOUNTING 749
PIVOT PIN 749
Removal 749
Installation 750
PIVOT EYE BEARING 750
Removal 750
Installation 750
PIVOT EYE REPAIR 751
Removal 751
Installation 751
ANTI-SWAY BAR 752
Removal 752
Disassembly 752
Cleaning and Inspection 752
Assembly 752
Installation 752
SECTION G5 REAR AXLE AND WHEEL MOTOR 755
REAR AXLE AND WHEEL MOTOR 757
REAR AXLE HOUSING 757
Preparation 757
Removal 758
Cleaning and Inspection 759
Installation 759
BLOWER PRESSURE SWITCH ADJUSTMENT 759
WHEEL MOTOR 760
Preparation 760
Removal 761
Cleaning and Inspection 763
Installation 763
WHEEL MOTOR GEAR OIL 768
TEMPERATURE CONSTRAINTS – TRUCK OPERATION 768
PROPER STORAGE AND HANDLING OF GEAR oil TO AVOID CONTAMINATION 768
Filtering Requirements 768
Particle Size Analysis 769
Flushing 769
Spectrographic Oil Sample Analysis 770
ELEMENT SPECIFICATION CHARTS 771
ELEMENT SPECIFICATION CHARTS 771
SECTION H HYDRAIR® II SUSPENSIONS 775
SECTION H2 FRONT SUSPENSIONS 777
FRONT SUSPENSION 779
Removal 779
Installation 780
Inspection 785
LOWER BEARING & SEALS 786
Removal 786
Installation 786
MAJOR SUSPENSION REBUILD 787
Disassembly 787
Assembly 788
SUSPENSION PRESSURE TEST 789
SECTION H3 REAR SUSPENSIONS 791
REAR SUSPENSIONS 793
SUSPENSION CYLINDER 794
Removal 794
Installation 795
Disassembly 796
Cleaning and Inspection 796
Assembly 796
SUSPENSION PRESSURE TEST 798
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES 799
SUSPENSION OILING AND CHARGING PROCEDURES 801
CHECKING FOR IMPROPER SUSPENSION CHARGE 801
GENERAL 802
REQUIRED EQUIPMENT 802
HYDRAIR® CHARGING KIT 803
Installation of Charging Kit 803
Removal of Charging Kit 803
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 804
FRONT SUSPENSION 807
REAR SUSPENSION 809
OIL AND NITROGEN SPECIFICATIONS CHARTS 812
SECTION J BRAKE CIRCUIT 813
SECTION J2 BRAKE CIRCUIT 815
BRAKE CIRCUIT 817
SERVICE BRAKE CIRCUIT 817
PARKING BRAKE CIRCUIT 819
BRAKE LOCK CIRCUIT 819
SECONDARY BRAKING AND AUTOMATIC APPLY 820
WARNING CIRCUIT 820
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 823
BRAKE CIRCUIT COMPONENT SERVICE 825
BRAKE VALVE 825
Rebuild Criteria 825
Removal 826
Installation 826
BRAKE VALVE/PEDAL ASSEMBLY 827
Disassembly 827
Assembly 828
Installation 830
DUAL RELAY VALVE 830
Removal 830
Installation 831
BRAKE MANIFOLD 831
Removal 831
Installation 832
Disassembly 832
Cleaning and Inspection 832
Assembly 832
BRAKE ACCUMULATORS 833
Accumulator charging and storage 833
Temperature during precharge 833
BLADDER BRAKE ACCUMULATORS 834
Brake Accumulator Bleed Down Procedure 834
Removal 834
Installation 835
Disassembly 835
Cleaning and Inspection 837
Assembly 837
Precharge Maintenance 838
Accumulator Storage Procedures 838
Installing A Bladder Accumulator From Storage 839
PISTON BRAKE ACCUMULATORS 839
Brake Accumulator bleed down Procedure 839
Removal 839
Installation 841
Disassembly 842
Cleaning and Inspection 842
Assembly 843
Piston accumulator charging procedure 843
Testing 846
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 846
Removal 846
Installation 846
Disassembly 847
Lever Adjustments 847
Potentiometer Check 847
Assembly 848
FRONT BRAKE COOLING HOSE INSTALLATION 850
Installation 850
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE 853
BRAKE CIRCUIT CHECK-OUT PROCEDURE 855
REQUIRED EQUIPMENT 856
INITIAL SYSTEM SETUP 857
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 858
PARKING BRAKE CHECK-OUT 859
SERVICE BRAKE CHECK-OUT 860
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 861
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 862
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 864
SECTION J5 WET DISC BRAKE ASSEMBLY 867
WET DISC BRAKE ASSEMBLY 869
OPERATION 869
BRAKE DISC WEAR INSPECTION 870
BRAKE REBUILD 871
Disassembly 871
Cleaning and Inspection 875
Assembly 876
Floating Ring Seal Assembly & Installation 881
Brake floating seal assembly and installation 887
WET DISC BRAKE BLEEDING PROCEDURE 894
SECTION J7 PARKING BRAKE 895
PARKING BRAKE 897
OPERATION 897
MAINTENANCE 898
Inspection 898
Removal 898
Installation 899
Disassembly 899
Cleaning and Inspection 899
Assembly 901
Cleaning and Inspecting New Discs 902
PARKING BRAKE BLEEDING PROCEDURE 903
SECTION L HYDRAULIC SYSTEM 905
SECTION L2 HYDRAULIC SYSTEM 907
HYDRAULIC SYSTEM 909
HYDRAULIC PUMP MODULE 909
HOIST CIRCUIT OPERATION 910
STEERING CIRCUIT OPERATION 912
DISC BRAKE COOLING SYSTEM 914
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 917
HYDRAULIC SYSTEM COMPONENT REPAIR 919
HOIST PUMP 919
Removal 919
Installation 921
Inspection 926
Assembly 926
HYDRAULIC TANK 932
Removal 932
Installation 933
HYDRAULIC TANK BREATHERS 933
HYDRAULIC TANK STRAINERS 934
Removal 934
Inspect and Clean 934
Installation 934
SECTION L4 STEERING CIRCUIT 935
STEERING CIRCUIT 937
STEERING CIRCUIT OPERATION 937
COMPONENT DESCRIPTION 938
Steering Control Unit 938
Bleed Down Manifold 939
Steering Accumulator Bleed Down Solenoid 939
Relief Valves 941
Hoist Up Limit Solenoid 941
Steering Accumulators 941
Low Precharge Warning Switch 941
High Pressure Filter 941
Quick Disconnect Ports 941
Flow Amplifier 943
FLOW AMPLIFIER SYSTEM OPERATION 944
No Steer 944
Steering Left 946
Steering Right 948
No Steer, External Shock Load 950
STEERING PUMP 952
Normal Operation 952
High Altitude Operation 952
PRINCIPLE OF OPERATION 954
Full Pump Volume 954
Half Pump Volume 954
Neutral Position 954
Steering Pump 955
SECTION L5 STEERING CONTROL UNIT 957
STEERING CONTROL UNIT 959
REMOVAL 959
SPLINE INSPECTION 960
INSTALLATION 960
DISASSEMBLY 961
CLEANING AND INSPECTION 962
ASSEMBLY 964
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR 969
STEERING CIRCUIT COMPONENT REPAIR 971
BLEEDDOWN MANIFOLD VALVE 971
Removal 971
Installation 972
FLOW AMPLIFIER 973
Removal 973
Installation 973
Disassembly 973
Assembly 975
STEERING CYLINDERS 976
Disassembly 977
Piston Seal & Bearing Installation 977
Assembly 977
Testing 977
STEERING AND BRAKE PUMP 978
Removal 978
Installation 979
Disassembly 980
Inspection 983
Assembly 986
Driveshaft Group 987
Rotating Group 987
Valve Plate Group 988
STEERING ACCUMULATORS 990
Removal 990
Installation 990
Disassembly 991
Cleaning and Inspection 991
Assembly 992
Leak Testing 994
Charging Procedure 995
Precharge Maintenance 997
Accumulator Storage Procedures 998
Bladder Storage Procedures 998
Installing A Bladder Accumulator From Storage 998
TROUBLESHOOTING 999
STEERING CIRCUIT 999
STEERING PUMP 1001
Basic Hydraulic System Checks 1002
System Leakage Check 1003
Steering Pump Troubleshooting Guide 1005
Pump Pressure Control Checks 1008
Pump Fails to Unload 1009
Pump Fails to Develop Pressure 1009
Pump Slow in Developing Pressure 1010
Pump Control Valve Inspection and Troubleshooting 1011
Pump Case Drain Check 1011
Setting Pump Pressure Controls 1013
Adjustment 1014
SECTION L7 HOIST CIRCUIT 1015
HOIST CIRCUIT 1017
BASIC OPERATION 1017
COMPONENT DESCRIPTION 1018
Hydraulic Tank 1018
Hydraulic Pump 1018
High Pressure Filters 1018
Hoist Valve 1018
Inlet Sections 1018
Work Ports (Rear) Spool Section 1019
Tank Ports (Front) Spool Section 1019
Hoist Pilot Valve 1019
Bleeddown Manifold 1020
Hoist Up Limit Solenoid 1020
Pilot Operated Check Valve 1020
Overcenter Manifold 1020
Float Position Of Pilot Valve With Truck Body On Frame 1022
Power Up Operation 1024
Hold Operation 1026
Power Down Operation 1028
Float Operation 1030
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 1033
HOIST CIRCUIT COMPONENT REPAIR 1035
HOIST VALVE 1035
Removal 1035
Installation 1036
O-Ring Replacement 1036
INLET SECTION 1037
Disassembly 1037
Cleaning and Inspection 1038
Assembly 1038
REAR SPOOL SECTION (Work Ports) 1039
Disassembly 1039
Cleaning and Inspection 1039
Assembly 1041
FRONT SPOOL SECTION (Tank Ports) 1042
Disassembly 1042
Cleaning and Inspection 1042
Assembly 1042
HOIST PILOT VALVE 1044
Removal 1044
Installation 1044
Disassembly 1045
Cleaning and Inspection 1046
Assembly 1046
HOIST CYLINDERS 1047
Removal 1047
Installation 1048
Disassembly 1050
Cleaning and Inspection 1051
Assembly – Quill 1052
Assembly – Cylinder 1054
Testing 1054
OVERCENTER VALVE MANIFOLD 1055
SECTION L9 HYDRAULIC SYSTEM FILTERS 1057
HYDRAULIC SYSTEM FILTERS 1059
HOIST CIRCUIT FILTER 1059
Filter Element Replacement 1059
Removal – Hoist Circuit Filter 1060
Installation – Hoist Circuit Filter 1060
Indicator Switch – Hoist Circuit Filter 1060
STEERING CIRCUIT FILTER 1061
Filter Element Replacement 1061
Removal – Steering Circuit Filter 1062
Installation – Steering Circuit Filter 1062
Indicator Switch – Steering Circuit Filter 1062
INDICATOR SWITCH 1062
Test Procedure 1062
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 1065
HYDRAULIC CHECKOUT PROCEDURE 1067
GENERAL INFORMATION 1067
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1074
Equipment Requirements 1075
Pump Pressure Control Adjustments 1075
Steering Control Valve and Flow Amplifier Leakage Test 1076
Bleed Down Manifold Leakage Test 1077
STEERING/BRAKE PUMP STROKE ADJUSTMENT 1078
SHOCK AND SUCTION VALVES 1078
Equipment Requirements 1078
Pressure Tests 1078
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 1080
Equipment Requirements 1080
Pressure Gauge Locations 1080
Brake Cooling Circuit Test 1080
Power Up Relief Pressure Test 1081
Power Down Relief Pressure Test 1082
Counterbalance Valve Pressure Check 1083
Counterbalance Valve Adjustment 1084
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1085
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 1086
SECTION M OPTIONS AND SPECIAL TOOLS 1087
SECTION M7 HOT START SYSTEM 1089
HOT START SYSTEM 1091
SYSTEM OPERATION 1091
HEATER INFORMATION 1092
TROUBLESHOOTING GUIDELINES 1093
SECTION M8 SPECIAL TOOLS 1095
HIGH VOLTAGE TOOLS 1099
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1099
KOMVISION CALIBRATION TOOLS 1101
SECTION M19 RADIATOR SHUTTERS 1103
RADIATOR SHUTTERS 1105
OPERATION 1105
Hydraulic Circuit 1105
Electrical Circuit 1106
MAINTENANCE AND REPAIR 1106
TROUBLESHOOTING 1107
SECTION M20 PAYLOAD METER IV ™ 1111
PAYLOAD METER IV ™ 1113
INTRODUCTION 1113
Data Summary 1113
Data Gathering 1113
COMPONENT DESCRIPTION 1114
Electronic Dash Display 1114
Mode Switches 1114
Brake Lock Switch 1114
PAYLOAD METER IV SOFTWARE AND TOOLS 1115
PAYLOAD METER IV SYSTEM CONFIGURATION 1115
Connecting to the payload meter IV web server 1115
Configuring a static IP address 1115
PAYLOAD METER IV SOFTWARE INSTALLATION 1117
PLM IV SYSTEM CHECKOUT DATA SHEET 1123
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1124
SECTION M31 RESERVE ENGINE OIL SYSTEM 1127
RESERVE ENGINE OIL SYSTEM 1129
Operation 1130
LED Monitor Light 1130
Tank Fill Control (Optional) 1131
Filling Procedure (Remote Fill Feature) 1131
SERVICE 1132
Every 10 Hours, or once each shift: 1132
Every 500 Hours 1132
Changing Oil 1132
TROUBLESHOOTING 1133
Circuit Fuse 1133
SYSTEM ELECTRICAL SCHEMATICS 1134
SECTION M32 RETRACTABLE LADDER SYSTEM 1135
RETRACTABLE LADDER SYSTEM 1139
GENERAL SAFETY 1139
LADDER SYSTEM DESCRIPTION 1139
LADDER SYSTEM OPERATION 1140
Normal Operation 1140
Emergency Operation 1141
Limit Switch Operation 1141
IN-CAB CONTROL PANEL 1142
IN-CAB CONTROL PANEL FEATURES 1143
IN-CAB CONTROL PANEL FUNCTIONS 1144
Timing Control 1144
Ladder System Status 1144
Fault Code Identification 1144
Ladder System Configuration 1144
In-Cab Control Panel Lockout 1144
Automatic Raising 1144
Diagnostics 1145
Maintenance 1145
USING THE IN-CAB CONTROL PANEL 1145
Raising the Ladder 1146
Lowering the Ladder 1146
USING THE GROUND LEVEL CONTROL BOX 1147
Raising the Ladder 1147
Lowering the Ladder 1147
POWER PACK OPERATION 1148
MAINTENANCE 1151
Safety During Maintenance 1151
Unplanned Ladder Movements 1151
Automatic Ladder Raising 1151
Automatic Accumulator Recharging (Ladder in UP position) 1152
PREVENTIVE MAINTENANCE PROCEDURES 1153
Daily Inspection 1153
250 Hour Inspection 1153
5000 Hour Inspection 1153
SERVICING 1154
Check Reservoir Oil Level 1154
Changing RLS Fluid 1154
Cleaning the RLS 1155
RLS DIAGNOSTICS 1155
Description of Diagnostics Features 1155
Continuous System Monitoring 1156
Historic System Data Review 1157
Comms Integrity Monitoring 1157
Log and Service Information 1158
System Event Logs 1158
SECURITY ACCESS LEVELS 1159
Access Level 1 – NONE 1159
Access Level 2 – RESTRICTED 1159
Access Level 3 – COMPLETE 1159
User Access Privileges 1160
USER ID – PASSWORD 1161
Sequential Field Value Selection Options 1161
Password Character Table 1161
USER ID – NEW USER SETUP 1162
SYSTEM FAULTS 1162
Fault Type 1: Communications error 1163
Fault Type 2: 10A/15A fuse blown 1163
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1164
Fault Type 8: Power pack recharge too long 1164
Fault Type 9: Inhibit relay fail 1165
Fault Types 10, 11: Light/Siren relay failure 1165
Fault Type 12: Ladder came off upper limit 1166
Fault Type 13: Ladder did not reach limit 1166
Fault Type 14: Ladder stayed on limit 1167
Fault Type 15: Low oil level 1167
Fault Type 16: System voltage over 18V during movement 1168
Fault Type 17: System voltage under 18V 1168
Fault Type 18: System voltage over 31V 1169
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1169
Fault Type 21: Accumulator recharge > than once/hour 1170
Fault Type 22: System raised by park brake 1170
Fault Types 23, 24: Levels 1 and 2 service overdue 1171
Fault Type 25: Levels 1 and 2 service complete 1171
DATA MANAGEMENT 1172
Log Files 1172
Generating Reports 1173
MENU DIAGRAMS 1179
Controller Config 1179
Contact Information 1179
Show Recent Logs 1179
System Settings 1179
Upload Logs to USB 1179
Diagnostics 1179
SECTION M33 CAMERA SYSTEM 1187
CAMERA SYSTEM 1189
CAMERA SYSTEM 1189
General 1189
Operation 1189
Camera Switch 1190
CAMERA MONITOR 1191
General 1191
CAMERA CONTROLLER 1192
General 1192
Removal 1192
Installation 1192
Camera Controller Connector Pins 1192
CAMERA SWITCHER 1193
General 1193
Removal 1193
Installation 1193
SETUP AND CHECKOUT PROCEDURE 1194
General 1194
STEP 1 – Switch Function 1194
STEP 2 – Monitor System Settings to Default 1194
STEP 4 – Monitor Settings – System Settings Unique 1196
STEP 4 – Monitor Settings – System Settings Unique – Cameras 1198
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay 1200
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode 1201
STEP 7 – Integrated Functions Check 1202
SECTION N OPERATOR CAB 1203
SECTION N2 TRUCK CAB AND COMPONENTS 1205
TRUCK CAB AND COMPONENTS 1207
TRUCK CAB 1207
Description 1207
Removal 1208
Installation 1209
CAB DOOR 1210
Removal 1210
Installation 1210
Door Jamb Bolt Adjustment 1211
Door Handle Plunger Adjustment 1212
Replacing the Door Glass 1213
Replacing the Door Handle or Latch Assembly 1217
Replacing the Door Window Regulator 1218
Replacing the Door and Door Hinge Seal 1219
Replacing the Door Opening Seal 1219
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1220
Recommended Tools and Supplies 1220
Replacement Procedure 1220
WINDSHIELD AND REAR GLASS 1221
Removal 1221
Installation 1222
SECTION N3 OPERATOR AND PASSENGER SEATS 1223
OPERATOR AND PASSENGER SEATS 1224
OPERATOR SEAT (STANDARD SEAT) 1224
Adjustment 1224
Inspection 1225
Removal 1225
Installation 1225
Replacing the Seat Compressor 1226
PASSENGER SEAT (STANDARD SEAT) 1231
Inspection 1231
Removal 1231
Installation 1231
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1232
Removal 1232
Installation 1232
SEAT BELT REPLACEMENT (STANDARD SEATS) 1234
Removal 1234
Installation 1234
OPERATOR SEAT (OPTIONAL SEAT) 1236
Seat Belts 1236
Adjustment 1236
PASSENGER SEAT (OPTIONAL SEAT) 1237
Seat Belts 1237
Adjustment 1237
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1238
General 1238
Removal 1238
SECTION N4 HEATER / AIR CONDITIONER 1243
HEATER/AIR CONDITIONER 1245
OPERATION 1245
Fan Speed Control Knob 1245
Temperature Control Knob 1245
Air Flow Directional Knob 1246
Heater/Air Conditioner Vents 1246
COMPONENTS 1246
Fuse and Circuit Breaker 1246
Relays 1246
Heater Core 1247
Fan Motor And Speed Control 1247
Actuators 1247
Cab Air Filter 1247
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1250
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1250
PRINCIPLES OF REFRIGERATION 1250
Air Conditioning 1250
Refrigeration – The Act Of Cooling 1251
The Refrigeration Cycle 1251
AIR CONDITIONER SYSTEM COMPONENTS 1252
Compressor (Refrigerant Pump) 1252
Service Valves 1252
Condenser 1252
Receiver-Drier 1252
Expansion Block Valve 1253
Accumulator 1253
Evaporator 1253
ELECTRICAL CIRCUIT 1254
Thermostat 1254
Compressor Clutch 1254
Trinary™ Switch 1255
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1256
SERVICE TOOLS AND EQUIPMENT 1257
Recovery/Recycle Station 1257
Leak Detector 1257
Service Valves 1258
Vacuum Pump 1258
Manifold Gauge Set 1259
Installing Manifold Gauge Set 1260
Purging Air From Service Hoses 1260
SYSTEM PERFORMANCE TEST 1261
SYSTEM OIL 1262
Handling and Reusing PAG Oil 1262
Oil Quantity 1262
Checking System Oil 1262
REFRIGERANT 1263
Recycled Refrigerant 1263
Reclaimed Refrigerant 1263
Refrigerant Quantity 1264
R-134a Refrigerant Containers 1264
SYSTEM LEAK TESTING 1264
Electronic Leak Detector 1265
Tracer Dyes 1265
Soap and Water 1265
RECOVERING AND RECYCLING THE REFRIGERANT 1265
Draining Oil from the Previous Recovery Cycle 1265
Performing the Recovery Cycle 1265
Performing the Recycling Procedure 1266
Evacuating and Charging the A/C System 1266
SYSTEM REPAIR 1266
System Flushing 1266
COMPONENT REPLACEMENT 1267
Hoses and Fittings 1267
Lines 1267
Expansion Valve 1267
Receiver-Drier 1267
Thermostat 1267
Compressor 1268
Accumulator 1268
Clutch 1268
EVACUATING THE SYSTEM 1269
CHARGING THE A/C SYSTEM 1270
TROUBLESHOOTING 1271
Preliminary Checks 1271
Diagnosis Of Gauge Readings And System Performance 1271
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1272
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1278
SECTION N5 OPERATOR CAB AND CONTROLS 1279
OPERATOR CAB AND CONTROLS 1282
STEERING COLUMN 1283
Removal 1283
Inspection 1283
Installation 1284
STEERING WHEEL 1284
Removal 1284
Installation 1284
STEERING WHEEL AND CONTROLS 1286
Horn Button 1286
Tilt / Telescope Lever 1286
Multi-Function Turn Signal Switch 1286
DYNAMIC RETARDING 1287
Retarder Lever 1287
Brake/Retarder Pedal 1287
Throttle/Accelerator Pedal 1287
GRADE/SPEED CHART 1288
OVERHEAD PANEL AND DISPLAYS 1289
CENTER CONSOLE 1290
Directional Control Lever 1290
Override/Fault Reset Switch 1291
Engine Shutdown Switch 1291
Window Control Switches 1291
Hoist Control Lever 1291
Retarder Speed Control (RSC) Adjustment Dial 1292
Retarder Speed Control (RSC) Switch 1292
Data Store Button 1293
KOMTRAX Plus Snapshot In Progress Light 1293
Link Energized Light 1293
Service Engine Light 1293
12V Auxiliary Power Outlets 1293
Fire Suppression Control Outlet 1293
Communication Radio Outlet 1293
DIAGNOSTIC PORTS 1293
KOMTRAX Plus Diagnostic Port 1293
Interface Module (IM) Diagnostic Port 1293
Payload Meter Diagnostic Port 1293
Truck Control Interface (TCI) Diagnostic Port 1293
Propulsion System Controller (PSC) Diagnostic Port 1293
Engine Diagnostic Port (CENSE) 1293
Engine Diagnostic Port (QUANTUM) 1293
INSTRUMENT PANEL 1294
Control Symbols 1294
Key Switch 1296
Rotating Beacon Light Switch (optional) 1296
Heated Mirror Switch (optional) 1296
AC Drive System Rest Switch 1296
Wheel Brake Lock Switch 1297
Hazard Warning Light Switch 1297
Heater/Air Conditioner Vents 1297
Engine Oil Pressure Gauge 1297
Right Turn Signal Indicator 1297
Digital Tachometer 1297
High Beam Indicator 1297
Speedometer/Payload Meter Display 1297
Left Turn Signal Indicator 1298
Coolant Temperature Gauge 1298
Lamp Check Switch 1298
Light Switch (3-Way) 1298
Ladder Light Switch 1298
Backup Light Switch 1298
Fog Light Switch 1299
Payload Meter Switch 1299
Panel Illumination Light Dimmer Switch 1299
Hydraulic Oil Temperature Gauge 1299
Engine Hourmeter 1299
Fuel Gauge 1299
OVERHEAD STATUS / WARNING INDICATORS 1300
A1 High Brake Oil Temperature 1301
B1 Low Steering Pressure 1301
C1 Low Accumulator Precharge Pressure 1302
D1 Not used 1302
E1 Low Brake Pressure 1302
A2 Low Hydraulic Tank Level 1302
B2 Low Automatic Lubrication System Pressure 1302
C2 Circuit Breaker Tripped 1302
D2 Hydraulic Oil Filter Monitor 1303
E2 Low Fuel 1303
A3 Parking Brake 1303
B3 Service Brake 1303
C3 Body Up 1303
D3 Dynamic Retarding 1303
E3 Stop Engine 1304
A4 Cranking Motor Failure 1304
B4 Backup Lights 1304
C4 Engine Shutdown Timer 1304
D4 Retard Speed Control (RSC) Indicator 1304
E4 Check Engine 1304
A5 No Power 1305
B5 Propulsion System Warning 1305
C5 Propulsion System Temperature 1305
D5 System/Component Failure 1305
E5 Battery Charging System Failure 1305
A6 No Propel 1305
B6 Propel System At Rest 1305
C6 Propel System Not Ready 1306
D6 Reduced Propulsion 1306
E6 Retard At Continuous Level 1306
REAR AXLE LIGHT BAR 1307
Backup Lights 1307
Retard Lights 1307
Brake Lights 1307
Backup Alarm 1307
KOMTRAX PLUS 1308
Operation 1308
Interface Module 1310
Basic Precautions 1310
KOMATSU WIRELESS BRIDGE (Optional) 1311
General Information 1311
Communication Setup 1311
Switching to the KWB_SETUP Network 1311
Setting the Computer Subnet Mask and IP Address 1312
Properties 1312
Setting Up the KWB 1313
Adding Encryption 1313
Final Computer Settings 1313
Data Downloading 1314
Resetting the KWB 1314
KWB Lights 1314
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1315
SECTION P2 PERIODIC MAINTENANCE 1317
PERIODIC MAINTENANCE 1319
GENERAL 1319
SERVICE CAPACITIES 1319
HYDRAULIC TANK SERVICE 1319
Adding Oil 1319
COOLING SYSTEM SERVICE 1320
Radiator Filling Procedure 1320
Coolant Specifications 1320
Unacceptable Practices 1320
WHEEL MOTOR SERVICE 1320
RESERVE OIL TANK SERVICE 1321
Filling the Reserve Oil Tank (Remote Fill) 1321
Inline Screen 1321
QUICK FILL SERVICE CENTER 1322
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1324
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1324
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1325
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1327
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1331
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1333
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1333
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1334
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1334
SECTION P3 AUTOMATIC LUBRICATION SYSTEM 1335
AUTOMATIC LUBRICATION SYSTEM 1337
GENERAL DESCRIPTION 1337
SYSTEM COMPONENTS 1339
Filter 1339
Hydraulic Motor and Pump 1339
Grease Reservoir 1339
Pressure Reducing Valve 1339
Flow Control Valve 1339
Solenoid Valve 1339
Vent Valve 1339
Lubrication Cycle Timer 1339
Over Pressure Cut Off Switch 1339
Grease Pressure Failure Switch 1339
Injectors 1339
Relief Valve (unloader valve) 1339
SYSTEM OPERATION 1340
Normal Operation 1340
Lubricant Required For System 1341
System Priming 1341
Filter Assembly 1341
LUBRICANT PUMP 1342
Pump Housing Oil Level 1342
Pump Pressure Control 1342
INJECTORS (SL-1 Series “H”) 1343
Injector Specifications 1343
Injector Adjustment 1343
INJECTOR OPERATION 1344
PREVENTIVE MAINTENANCE PROCEDURES 1345
Daily Lubrication System Inspection 1345
250 Hour Inspection 1345
1000 Hour Inspection 1345
SYSTEM CHECKOUT 1346
Lubrication Controller Check 1346
Lubrication Controller Components 1346
Lubrication Controller Adjustment 1346
SYSTEM TROUBLESHOOTING CHART 1348
SECTION Q ALPHABETICAL INDEX 1351
SECTION R SYSTEM SCHEMATICS 1355

DESCRIPTION:

Komatsu 930E-4SEDump Truck Shop Manual CEBM027102 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31165 – A31824

• FOREWORD
• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
• All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
• When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts in the General Information section of this manual. Specific torques, when provided in the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
• A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
• The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
• The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, see the end of Section A4.
• 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 maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
• To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.
• NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical.
• Exceeding the allowable payload will reduce the expected life of truck components.

G.B 20/12/24