Komatsu 930E-4SE Dump Truck Shop Manual CEBM020003 – PDF DOWNLOAD
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Komatsu 930E-4SE Dump Truck Shop Manual CEBM020003 – PDF DOWNLOAD
Language : English
Pages : 1262
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
Komatsu 930E-4SE Dump Truck Shop Manual CEBM020003 – PDF DOWNLOAD
SN A30587-A30677
COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
COMPONENTS & SPECIFICATIONS 11
MAJOR COMPONENT DESCRIPTIONS 11
Truck And Engine 11
Main Alternator 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SAFETY 17
GENERAL 17
Safety Rules 17
Safety Features 17
Fire Extinguisher And First Aid Kit 17
Clothing And Personal Items 17
Leaving The Operator’s Seat 18
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 19
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Unauthorized Modification 19
Precautions When Using ROPS 19
Precautions For Attachments 20
Precautions For Starting The Truck 20
PRECAUTIONS BEFORE OPERATION 20
Safety At The Worksite 20
Fire Prevention 21
Ventilation In Enclosed Areas 21
Preparing For Operation 21
Mirrors, Windows And Lights 21
In The Operator Cab (Before Starting The Engine) 21
Seat Belts 21
OPERATING THE TRUCK 22
When Starting The Engine 22
General Truck Operation 22
Ensuring Good Visibility 22
Traveling 23
Traveling In Reverse 23
Traveling On Slopes 23
Operating On Snow Or Ice 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 24
Working On Loose Ground 24
When Dumping 24
When Loading 24
Parking The Truck 24
Towing 24
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Jump Starting With Booster Cables 26
Jump Starting With Receptacles 26
BEFORE PERFORMING MAINTENANCE 27
Stopping The Engine Before Service 27
Warning Tag 27
Proper Tools 27
Use of Tie-Off Anchor During Maintenance and Repair 27
Securing The Dump Body 28
WHILE PERFORMING MAINTENANCE 29
Keep The Truck Clean 29
Attachments 29
Working Under The Truck 29
Rotating Fan And Belts 29
Waste Materials 29
Adding Fuel Or Oil 30
Radiator Coolant Level 30
Use Of Lighting 30
Precautions With The Battery 30
Handling High Pressure Hoses 30
Precautions With High Pressure Oil 30
Performing Maintenance Near High Temperature Or High Pressure 30
TIRES 31
Handling Tires 31
Tire Maintenance 31
Storing Tires After Removal 31
WHEN REPAIRS ARE NECESSARY 32
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 33
Preliminary Procedures Before Welding or Performing Maintenance 33
Engine Shutdown Procedure Before Welding or Performing Maintenance 33
CAPACITOR DISCHARGE SYSTEM 35
Necessary Tools 35
Warnings And Cautions 36
Manual DC Link Capacitor Discharge Procedure 37
Failure of the Discharge System 39
Manual Discharge of Capacitors 40
Short Isolated Capacitor Terminals 42
OPERATING INSTRUCTIONS 43
PREPARING FOR OPERATION 43
WALK AROUND INSPECTION 43
ENGINE START-UP 47
AFTER ENGINE HAS STARTED 48
PRE-SHIFT BRAKE CHECK (if equipped) 48
Events 48
OPERATION 49
Description 49
Brake Test Exit Criteria 49
PERFORMING THE BRAKE TESTS 50
Setup 50
Service Brake Test 50
Parking Brake Test 51
Retard System Test 52
EMERGENCY STEERING SYSTEM 52
Operation 52
Pre-Operation Testing 52
MACHINE OPERATION SAFETY PRECAUTIONS 53
OPERATING ON THE HAUL ROAD 54
STARTING ON A GRADE WITH A LOADED TRUCK 55
PASSING 55
LOADING 55
Overload Speed Limit Function 55
DUMPING 56
Raising The Dump Body 56
Lowering The Dump Body (When dumping on flat ground): 57
Lowering The Dump Body (When dumping over a berm or into a crusher): 57
TOWING 58
Special Wiring Harness 58
SAFE PARKING PROCEDURES 60
NORMAL ENGINE SHUTDOWN PROCEDURE 60
SUDDEN LOSS OF ENGINE POWER 61
FUEL DEPLETION 61
DISABLED TRUCK DUMPING PROCEDURE 62
Hookup 62
Raising the Body 62
Lowering the Body 62
WARNINGS AND CAUTIONS 63
GRADE/SPEED CHART 63
KEY SWITCH 63
ROPS/FOPS 63
BATTERIES 64
CAPACITORS 64
CRUSHING HAZARD 65
CYLINDER PRESSURE 65
FILLING THE HYDRAULIC TANK 66
HYDRAULIC OIL PRESSURE 66
HOT OIL SPRAY 67
WHEEL MOTOR OIL LEVEL 67
HOT EXHAUST 67
RADIATOR 67
EMERGENCY LADDER 67
ACCUMULATOR DRAIN VALVES 67
EMERGENCY DUMP PROCEDURE 68
EMERGENCY TOWING PROCEDURE 68
WELDING 68
EMERGENCY SHUTDOWN 68
INFORMATION DISPLAY 69
WIRELESS SIGNALS 69
HIGH VOLTAGE 69
LIFTING INSTRUCTIONS 70
PRODUCT IDENTIFICATION PLATE 71
LUBRICATION CHART 72
TORQUE TABLES AND CONVERSION CHARTS 73
STORAGE AND IDLE MACHINE PREPARATION 83
SHORT TERM IDLE PERIODS 83
PREPARATION FOR STORAGE 84
REMOVAL FROM STORAGE 85
RECONDITIONING AN IDLE VEHICLE 87
ENGINE OPERATION 89
After The Engine Has Started 90
ENGINE STORAGE 91
Temporary Storage (30 Days Or Less) 91
Extended Storage (More Than 30 Days) 91
RESTORING AN ENGINE AFTER EXTENDED STORAGE 93
ELECTRIC DRIVE TRUCKS 94
Storing A Truck That Is Operational 94
Storing A Truck That Is Not Operational 95
Storing A Major Component 96
Periodic Inspections 96
Placing Equipment Into Service After Storage 96
SECTION B STRUCTURES 99
SECTION B2 STRUCTURAL COMPONENTS 101
STRUCTURAL COMPONENTS 103
PREPARATION 103
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 104
Removal 104
Installation 104
RH DECK AND RETARDING GRID 105
Removal 105
Installation 105
LH DECK 106
Removal 106
Installation 106
CENTER DECK 107
Removal 107
Installation 107
SECTION B3 DUMP BODY 109
DUMP BODY 111
DUMP BODY 111
Removal 111
Installation 112
BODY PADS 114
Body Pad Shimming Procedure 115
BODY GUIDE 116
HOIST LIMIT SWITCH 116
BODY-UP SWITCH 116
BODY RETENTION SLING 116
ROCK EJECTORS 117
Inspection 117
SECTION B4 FUEL TANK 119
FUEL TANK 121
FUEL TANK 121
Removal 121
Repair 121
Cleaning 121
Installation 121
FUEL TANK VENT ASSEMBLY 123
Disassembly 123
Assembly 123
FUEL GAUGE SENDER 124
Removal 124
Installation 124
QUICK FILL FUEL RECEIVERS 124
SECTION C ENGINE 125
SECTION C2 POWER MODULE 127
POWER MODULE 129
PREPARATION FOR REMOVAL 129
REMOVAL 134
INSTALLATION 136
HOOKUP 137
SECTION C3 COOLING SYSTEM 139
COOLING SYSTEM 141
RADIATOR 141
Removal 141
Installation 143
Filling Procedure 144
REPAIRING THE RADIATOR 144
Internal Inspection 144
External Cleaning 144
Disassembly 145
Cleaning and Inspection 146
Assembly 146
Pressure Testing 147
COOLANT SYSTEM TROUBLESHOOTING 147
SECTION C4 POWER TRAIN 149
POWER TRAIN 151
ALTERNATOR REMOVAL 151
ALTERNATOR INSTALLATION 153
Measuring Procedure 153
Joining the Alternator and Engine 155
ENGINE 156
Removal 156
Service 156
Installation 156
SECTION C5 AIR CLEANERS 157
AIR CLEANERS 159
OPERATION 159
SERVICING THE AIR CLEANERS 159
Replacing The Filter Element 159
Cleaning The Main Filter Element 161
Servicing The Precleaner Section 162
EVACUATOR VALVES (if equipped) 163
AIR INTAKE TROUBLESHOOTING 163
SECTION C7 FAN CLUTCH 165
FAN CLUTCH 167
REMOVAL & INSTALLATION TOOLING 167
DISASSEMBLY 170
CLEANING AND INSPECTION 180
ASSEMBLY 184
TEST PROCEDURE 198
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 199
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM 201
24VDC ELECTRIC SUPPLY SYSTEM 203
ELECTRICAL SYSTEM DESCRIPTION 203
BATTERIES 203
Maintenance and Service 203
Troubleshooting 203
BATTERY SUPPLY SYSTEM 205
24VDC Battery Charging Alternator 205
Batteries 205
24VDC Auxiliary Battery Receptacles 205
Battery Disconnect Switches 206
Isolation Diode 206
Engine Start Relay 206
24VDC to 12VDC Converter 206
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 207
Operation 207
Pressure Switch 207
Check Valve 207
Timer Solenoid 207
MAINTENANCE 208
Prelube System Operation Checks 208
Check Valve 208
Timer Solenoid 208
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 209
24VDC ELECTRIC START SYSTEM 211
CRANKING MOTORS 211
Operation 211
Removal 211
Installation 211
CRANKING MOTOR TROUBLESHOOTING 212
Preliminary Inspection 212
No-Load Test 212
Interpreting Results of Tests 213
Disassembly 213
Cleaning and Inspection 214
Armature Servicing 216
Field Coil Checks 216
Field Coil Removal 216
SOLENOID CHECKS 217
Test 217
Assembly 218
Bearing Replacement: 218
Motor Assembly: 218
Pinion Clearance 219
MAGNETIC SWITCH 219
Removal 219
Installation 219
Coil Test 220
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 221
24 VDC ELECTRICAL SYSTEM COMPONENTS 223
BRAKE WARNING BUZZER 223
AUXILIARY CONTROL CABINET COMPONENTS 223
Power Distribution Terminals 223
Pulse Voltage Modulator (PMV) 223
Control Power Relay 223
Auto Lube Timer 223
Ground Level Power Relay 223
Diode Board – DB1 225
Fuse Blocks 226
Alarm Indicating Device (AID) System 226
RELAY BOARDS 229
Relay Boards RB1, RB3, RB4, RB5 229
Relay Board RB6, RB7, RB8, RB9 231
Relay Board Functions 232
BODY-UP SWITCH 234
Operation 234
Adjustment 234
Service 234
HOIST LIMIT SWITCH 235
Operation 235
Adjustment 235
Service 235
FUSE BLOCKS AND CIRCUIT BREAKERS 236
SECTION D11 KOMTRAX PLUS 239
KOMTRAX PLUS 241
KOMTRAX PLUS BASIC FEATURES 241
Gather Data 241
Convert and Record Data 241
Communicate Data to Off-Board Systems 242
USING KOMTRAX PLUS 243
Turning KOMTRAX Plus ON 243
Normal KOMTRAX Plus Operation 243
Turning KOMTRAX Plus OFF 244
Downloading from the KOMTRAX Plus Controller 244
KOMTRAX PLUS DATA ITEMS 245
Fault Codes 245
Machine History 245
KOMTRAX Plus History 245
Snapshots 246
Manual Snapshots 246
Trends 248
Histogram (Load Map) Data 248
Haul Cycle Data 249
Alarm and Snapshot Triggers 250
Satellite Features 250
KOMTRAX PLUS DIAGNOSTIC FEATURES 252
Fault History 252
LED Digits 252
KOMTRAX PLUS CONTROLLER 252
Removal 253
Installation 253
KOMTRAX PLUS SOFTWARE 254
VHMS Tool Box Installation 254
VHMS Setting Tool Installation 254
PDM Software Installation 254
KOMTRAX PLUS INITIALIZATION PROCEDURE 255
CONTROLLER SETUP PROCEDURE 255
SNAPSHOT PROCEDURE 258
DOWNLOAD PROCEDURE 259
FTP UPLOAD PROCEDURE 260
INITIALIZATION FORMS 261
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 262
KOMTRAX PLUS CONTROLLER CHECKOUT 267
Necessary Equipment 267
Preliminary 267
KOMTRAX Plus Controller Checkout Procedure 268
ORBCOMM CONTROLLER (if equipped) 270
Removal 270
Installation 270
SECTION D12 INTERFACE MODULE 271
INTERFACE MODULE 273
Removal 273
Installation 273
SENSORS 274
Temperature Sensors 274
Pressure Sensors 274
INTERFACE MODULE SOFTWARE 275
Flashburn Program Installation 275
Interface Module Application Code Installation 276
Interface Module Realtime Data Monitor Software 276
INTERFACE MODULE CHECKOUT 277
Necessary Equipment 277
Preliminary 278
Check Digital Inputs To The Interface Module 279
Check Analog Inputs To The Interface Module 282
Check Serial Interfaces To The Interface Module 282
Check Outputs From The Interface Module 283
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 285
INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING 287
GENERAL 287
TROUBLESHOOTING 288
Communications Networks 288
Coaxial Cable 288
FAULT CODES 288
Fault History 288
KOMTRAX Plus LED Display Fault Codes 289
Chassis Fault Codes 290
Engine Fault Codes 294
FAULT TREE ANALYSIS 300
Unable to connect to KOMTRAX Plus from laptop PC 300
Flashing Error Code N4-23 (PLM III Communications Fault) 301
Flashing Error Code N4-22 (Engine Communications Fault) 302
No Data Received By WebCARE 303
Coaxial Cable Troubleshooting 304
SECTION D14 KOMTRAX PLUS FORMS 305
KOMTRAX PLUS FORMS 307
KOMTRAX PLUS INITIALIZATION CHECK LIST 307
KOMTRAX PLUS DATA DOWNLOAD 308
KOMTRAX PLUS INITIALIZATION CHECK LIST 309
KOMTRAX PLUS INITIALIZATION FORM 311
SECTION E ELECTRIC PROPULSION SYSTEM 313
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 315
ELECTRICAL PROPULSION SYSTEM COMPONENTS 317
GENERAL SYSTEM DESCRIPTION 317
SYSTEM COMPONENTS 319
Propulsion System Controller (PSC) 319
Truck Control Interface (TCI) 320
Diagnostic Information Display (DID) Panel 321
DID Panel Event Codes 321
PSC SOFTWARE FUNCTIONS 340
Input Processing 340
State Machine 340
DC Link State 343
Engine Control 344
ALTERNATOR FIELD CONTROL 344
Desired Three-Phase Voltage 344
Desired DC Link Voltage 344
Self-Load 345
Propel Torque Control 345
Retard Torque Control 345
Wheel Slide Control 346
Resistor Grid Control 346
Chopper Voltage Control 346
EVENT DETECTION AND PROCESSING 346
Power-On Tests 346
Initiated Tests 347
Periodic Tests 347
EVENT RESTRICTIONS 347
EVENT LOGGING AND STORAGE 347
Event History Buffer 348
Data Packs 348
To Record and Save a Data Pack to a Disk 348
Event Reset 349
SERIAL DATA COMMUNICATIONS 349
PSC – TCI Communications Processing 349
PSC – PTU Communications Processing 349
Inverter Communications Processing 350
OUTPUT PROCESSING 350
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 350
Fast Start 350
Engine Shutdown/Engine Not Running 350
Limp Home Mode 351
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 352
ELECTRONIC ACCELERATOR AND RETARD PEDALS 360
Removal 360
Installation 360
Disassembly 360
Assembly 360
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 361
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 363
AC DRIVE SYSTEM MAINTENANCE 363
NORMAL TRUCK SHUTDOWN PROCEDURE 364
SHUTDOWN AFTER SYSTEM FAILURE 364
SYSTEM CHECKOUT 365
Battery and Control Circuit Checks – Battery Power OFF 365
Battery and Control Circuit Checks – Battery Power ON 368
Checks with Key Switch OFF 369
Checks with Key Switch ON 369
CPU Battery Checks 369
MEMORY BACKUP BATTERY REPLACEMENT 370
TCI PROGRAMMING 370
PSC PROGRAMMING 371
INVERTER PROGRAMMING 371
CPU RESET 371
PSC CHECKOUT 372
PSC Digital Input Checks 372
PSC Digital Output Checks 376
TCI CHECKOUT 377
Modular Mining Communication Port Check 377
TCI Digital Input Checks 377
TCI Digital Output Tests 383
CALIBRATIONS 385
Speedometer 385
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 385
ERASING EVENTS 385
PSC 385
TCI 386
GATE DRIVER POWER CONVERTER TEST 386
LOAD TESTING 387
Preparation 387
Alternator Speed Sensor Checks 387
Battery Boost Check 387
Brake Circuit Switch Checks 388
Hoist & Steering Circuit Switch Checks 388
Link Energized Checks 388
Loadbox Test 390
TROUBLESHOOTING 394
PVM Optimum Load Curve Handshaking Troubleshooting 394
Phase Module and Chopper Module Troubleshooting 394
PHASE MODULE REPLACEMENT 395
Phase Module Removal 395
Phase Module Installation 395
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) 397
Fault Code A001: Left front suspension pressure sensor signal is high 399
Related circuit diagram 399
Fault Code A002: Left front suspension pressure sensor signal is low 400
Related circuit diagram 400
Fault Code A003: Right front suspension pressure sensor signal is high 401
Related circuit diagram 401
Fault Code A004: Right front suspension pressure sensor signal is low 402
Related circuit diagram 402
Fault Code A005: Left rear suspension pressure sensor signal is high 403
Related circuit diagram 403
Fault Code A006: Left rear suspension pressure sensor signal is low 404
Related circuit diagram 404
Fault Code A007: Right rear suspension pressure sensor signal is high 405
Related circuit diagram 405
Fault Code A008: Right rear suspension pressure sensor signal is low 406
Related circuit diagram 406
Fault Code A009: Incline sensor signal is high 407
Related circuit diagram 407
Fault Code A010: Incline sensor signal is low 408
Related circuit diagram 408
Fault Code A011: Payload meter speed sensor signal has failed 409
Related circuit diagram 409
Fault Code A013: Body up switch has failed 410
Related circuit diagram 410
Fault Code A014: Payload meter checksum computation has failed 411
Related circuit diagram 411
Fault Code A016: Payload meter write to flash memory has failed 412
Related circuit diagram 412
Fault Code A017: Payload meter flash memory read has failed 413
Related circuit diagram 413
Fault Code A018: Right rear flat suspension cylinder warning 414
Related circuit diagram 415
Fault Code A019: Left rear flat suspension cylinder warning 416
Related circuit diagram 417
Fault Code A022: Carryback load is excessive 418
Related circuit diagram 419
Fault Code A026: Payload meter user select switch has failed 420
Related circuit diagram 420
Fault Code A027: Payload meter user clear switch has failed 421
Related circuit diagram 421
Fault Code A101: High pressure detected across a hydraulic pump filter 422
Related circuit diagram 423
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 424
Related circuit diagram 425
Fault Code A107: GE has generated a propel system caution 426
Related circuit diagram 427
Fault Code A108: GE has generated a propel system temperature caution 428
Related circuit diagram 429
Fault Code A109: GE has generated a propel system reduced level signal 430
Related circuit diagram 431
Fault Code A115: Low steering precharge pressure is detected 432
Related circuit diagram 433
Fault Code A123: GE has generated a reduced retarding caution 434
Related circuit diagram 435
Fault Code A124: GE has generated a no propel / no retard warning 436
Related circuit diagram 437
Fault Code A125: GE has generated a no propel warning 438
Related circuit diagram 439
Fault Code A126: Oil level in the hydraulic tank is low 440
Related circuit diagram 441
Fault Code A127: IM furnished +5 volt output for sensors is low 442
Related circuit diagram 443
Fault Code A128: IM furnished +5 volt output for sensors is high 444
Related circuit diagram 445
Fault Code A139, A310: Low fuel level warning 446
Related circuit diagram 447
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 448
Related circuit diagram 449
Fault Code A146: Hydraulic temperature sensors cause posting of this faultl 450
Related circuit diagram 451
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216) 453
Fault Code A152: Starter failure 454
Related circuit diagram 455
Fault Code A153: Battery voltage is low with truck in operation 456
Related circuit diagram 457
Fault Code A154: Battery charging voltage is excessive 458
Related circuit diagram 459
Fault Code A155: Battery charging voltage is low 460
Related circuit diagram 461
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 462
Related circuit diagram 463
Fault Code A166: Left rear hydraulic oil temperature sensor is low 464
Related circuit diagram 465
Fault Code A167: Right rear hydraulic oil temperature sensor is low 466
Related circuit diagram 467
Fault Code A168: Left front hydraulic oil temperature sensor is low 468
Related circuit diagram 469
Fault Code A169: Right front hydraulic oil temperature sensor is low 470
Related circuit diagram 471
Fault Code A170: Left rear hydraulic oil temperature sensor is high 472
Related circuit diagram 472
Fault Code A171: Right rear hydraulic oil temperature sensor is high 473
Related circuit diagram 473
Fault Code A172: Left front hydraulic oil temperature sensor is high 474
Related circuit diagram 474
Fault Code A173: Right front hydraulic oil temperature sensor is high 475
Related circuit diagram 475
Fault Code A184: J1939 data link is not connected 476
Related circuit diagram 477
Fault Code A190: Auto lube control has detected an incomplete lube cycle 478
Related circuit diagram 479
Fault Code A194: Left front hydraulic oil temperature is high 480
Related circuit diagram 481
Fault Code A195: Right front hydraulic oil temperature is high 482
Related circuit diagram 483
Fault Code A196: Left rear hydraulic oil temperature is high 484
Related circuit diagram 485
Fault Code A197: Right rear hydraulic oil temperature is high 486
Related circuit diagram 487
Fault Code A198: Hoist pressure 1 sensor is high 488
Related circuit diagram 488
Fault Code A199: Hoist pressure 2 sensor is high 489
Related circuit diagram 489
Fault Code A200: Steering pressure sensor is high 490
Related circuit diagram 490
Fault Code A201: Brake pressure sensor is high 491
Related circuit diagram 491
Fault Code A202: Hoist pressure 1 sensor is low 492
Related circuit diagram 492
Fault Code A203: Hoist pressure 2 sensor is low 493
Related circuit diagram 493
Fault Code A204: Steering pressure sensor is low 494
Related circuit diagram 494
Fault Code A205: Brake pressure sensor is low 495
Related circuit diagram 495
Fault Code A206: Ambient temperature sensor is high 496
Related circuit diagram 496
Fault Code A207: Ambient temperature sensor is low 497
Related circuit diagram 497
Fault Code A212: Bad truck speed signal 498
Related circuit diagram 499
Fault Code A213: Parking brake should have applied but is detected as not having applied 500
Related circuit diagram 502
Fault Code A214: Parking brake should have released but is detected as not having released 504
Related circuit diagram 506
Fault Code A215: Brake auto apply relay circuit is defective 508
Related circuit diagram 509
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 510
Related circuit diagram 511
SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292) 513
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 514
Related circuit diagram 515
Fault Code A230: Parking brake has been requested while truck still moving 516
Related circuit diagram 517
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 518
Related circuit diagram 519
Fault Code A240: The keyswitch input to the interface module is open 520
Related circuit diagram 521
Fault Code A246: Payload meter reports truck overload 521
Related circuit diagram 521
Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted 522
Related circuit diagram 523
Fault Code A250: Battery voltage is low with the truck parked 524
Related circuit diagram 525
Fault Code A252: Start enable output circuit is either open or shorted to ground 526
Related circuit diagram 527
Fault Code A253: Steering bleed circuit is not open while running 528
Related circuit diagram 529
Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open 530
Related circuit diagram 531
Fault Code A257: Payload CAN/RPC is not connected 532
Related circuit diagram 532
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 534
Related circuit diagram 535
Fault Code A260: Parking brake failure 536
Related circuit diagram 537
Fault Code A262: Steering bleed valve circuit open during shutdown 538
Related circuit diagram 539
Fault Code A263: Steering bleed circuit is shorted to ground 540
Related circuit diagram 541
Fault Code A264: Parking brake relay circuit is defective 542
Related circuit diagram 543
Fault Code A265: Service brake failure 544
Related circuit diagram 546
Fault Code A270: Brake lock switch power supply is not on when required 548
Related circuit diagram 549
Fault Code A272: Brake lock switch power supply is not off when required 550
Related circuit diagram 552
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 554
Related circuit diagram 555
Fault Code A274: A brake setting fault has been detected 556
Related circuit diagram 557
Fault Code A275: A starter has been detected as engaged without a cranking attempt 558
Related circuit diagram 559
Fault Code A276: The drive system data link is not connected 560
Related circuit diagram 561
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 562
Related circuit diagram 563
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 564
Related circuit diagram 565
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 566
Related circuit diagram 567
Fault Code A285: The parking brake was not set when the key switch was turned off 568
Related circuit diagram 569
Fault Code A286: A fault was detected in the shutdown delay relay circuit 570
Related circuit diagram 571
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 572
Related circuit diagram 573
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) 575
Fault Code A303: Shifter is defective 576
Related circuit diagram 577
Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be 578
Related circuit diagram 579
Fault Code A309: No brakes applied when expected 580
Related circuit diagram 582
Fault Code A311: Brake lock switch is on when it should not be 584
Related circuit diagram 585
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 586
Related circuit diagram 586
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 587
Related circuit diagram 587
Fault Code A315: DC-DC converter 12 volt circuit is low 588
Related circuit diagram 589
Fault Code A316: Starter engagement has been attempted with engine running 590
Related circuit diagram 591
Fault Code A317: Operation of brake auto apply valve without a detected response 592
Related circuit diagram 594
Fault Code A318: Unexpected power loss to interface module 595
Related circuit diagram 595
Fault Code A328: Drive system not powered up 596
Related circuit diagram 597
Fault Code A350: Overload on output 1B 598
Related circuit diagram 599
Fault Code A351: Overload on output 1E 600
Related circuit diagram 601
Fault Code A352: Overload on output 1H 602
Related circuit diagram 603
Fault Code A353: Overload on output 1J 604
Related circuit diagram 605
Fault Code A354: Overload on output 1K 606
Related circuit diagram 607
Fault Code A355: Overload on output 1L 608
Related circuit diagram 609
Fault Code A356: Overload on output 1M 610
Related circuit diagram 611
Fault Code A357: Overload on output 1N 612
Related circuit diagram 613
Fault Code A358: Overload on output 1P 614
Related circuit diagram 615
Fault Code A359: Overload on output 1R 616
Related circuit diagram 617
Fault Code A360: Overload on output 1S 618
Related circuit diagram 619
Fault Code A361: Overload on output 1T 620
Related circuit diagram 621
Fault Code A362: Overload on output 1U 622
Related circuit diagram 623
Fault Code A363: Overload on output 1X 624
Related circuit diagram 624
Fault Code A364: Overload on output 1Y 626
Related circuit diagram 627
Fault Code A365: Overload on output 1Z 628
Related circuit diagram 629
SECTION G REAR AXLE, SPINDLES AND WHEELS 631
SECTION G2 TIRES AND RIMS 633
TIRES AND RIMS 635
WHEEL STUD MAINTENANCE 636
FRONT TIRES AND RIMS 637
Removal 637
Installation 638
REAR TIRES AND RIMS 639
Removal 639
Installation 640
RIM 641
Tire Removal 641
Tire Installation 641
SECTION G3 FRONT WHEEL HUB AND SPINDLE 643
FRONT WHEEL HUB AND SPINDLE 645
WHEEL HUB AND SPINDLE ASSEMBLY 645
Removal 645
Spindle Removal Procedure (off of the truck) 648
Installation 650
Disassembly 651
Cleaning and Inspection 653
Assembly 653
Wheel Bearing Adjustment 654
Brake Installation 655
Seal Assembly Gap Check 656
WHEEL SPEED SENSOR TESTING 657
STEERING CYLINDERS 658
Spherical Bearing Wear Limits 658
Removal 659
Installation 659
Bearing Replacement (Steering Cylinder and Tie Rod) 659
TIE ROD 661
Removal 661
Installation 661
Disassembly 662
Assembly 662
Toe-In Adjustment 663
TIE ROD INSPECTION AND TORQUE PROCEDURE 664
Old Style Tie Rod 664
New Style Tie Rod 665
SECTION G4 REAR AXLE MOUNTING 667
REAR AXLE MOUNTING 669
PIVOT PIN 669
Removal 669
Installation 670
PIVOT EYE BEARING 671
Removal 671
Installation 671
PIVOT EYE REPAIR 671
Removal 671
Disassembly 671
Assembly 672
Installation 672
ANTI-SWAY BAR 672
Removal 672
Disassembly 673
Cleaning and Inspection 673
Assembly 673
Installation 673
SECTION G5 REAR AXLE AND WHEEL MOTOR 675
REAR AXLE AND WHEEL MOTOR 677
REAR AXLE HOUSING 677
Preparation 677
Removal 678
Cleaning and Inspection 679
Installation 679
BLOWER PRESSURE SWITCH ADJUSTMENT 679
WHEEL MOTOR 680
Preparation 680
Removal 681
Cleaning and Inspection 683
Installation 683
WHEEL MOTOR GEAR OIL 688
Filtering Requirements 688
Particle Size Analysis 688
Flushing 688
Oil Sample Analysis 689
ELEMENT SPECIFICATION CHARTS 690
SECTION H HYDRAIR® II SUSPENSIONS 693
SECTION H2 FRONT SUSPENSIONS 695
FRONT SUSPENSION 697
Removal 697
Installation 698
Inspection 703
LOWER BEARING & SEALS 704
Removal 704
Installation 704
MAJOR SUSPENSION REBUILD 705
Disassembly 705
Assembly 706
SUSPENSION PRESSURE TEST 707
SECTION H3 REAR SUSPENSIONS 709
REAR SUSPENSIONS 711
SUSPENSION CYLINDER 712
Removal 712
Installation 714
Disassembly 714
Cleaning and Inspection 715
Assembly 715
SUSPENSION PRESSURE TEST 717
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES 719
SUSPENSION OILING AND CHARGING PROCEDURE 721
GENERAL 721
EQUIPMENT LIST 721
HYDRAIR® CHARGING KIT 722
Installation of Charging Kit 722
Removal of Charging Kit 722
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 723
FRONT SUSPENSION 723
Front Suspension Oiling 723
Front Suspension Nitrogen Charging 725
REAR SUSPENSION 726
Rear Suspension Oiling 727
Rear Suspension Nitrogen Charging 729
OIL AND NITROGEN SPECIFICATIONS CHARTS 730
SECTION J BRAKE CIRCUIT 731
SECTION J2 BRAKE CIRCUIT 733
BRAKE CIRCUIT 735
SERVICE BRAKE CIRCUIT 735
PARKING BRAKE CIRCUIT 737
BRAKE LOCK CIRCUIT 737
SECONDARY BRAKING AND AUTOMATIC APPLY 738
WARNING CIRCUIT 738
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 741
BRAKE CIRCUIT COMPONENT SERVICE 743
BRAKE VALVE 743
Rebuild Criteria 743
Removal 744
Installation 744
Disassembly 745
Cleaning and Inspection 748
Assembly 748
Regulator Sleeve O-Ring Installation 749
BRAKE VALVE BENCH TEST AND ADJUSTMENT 751
Test Setup Procedure 752
Brake Valve Output Pressure Adjustment 752
Final Test and Adjustment 753
Installing Brake Pedal Actuator Assembly to Brake Valve 753
Installing Retard Pedal To Brake Pedal 753
DUAL RELAY VALVE 754
Removal 754
Installation 754
Disassembly 754
Cleaning and Inspection 755
Assembly 756
DUAL RELAY VALVE BENCH TEST AND ADJUSTMENT 757
Test Setup Procedure 758
Relay Valve Output Pressure Adjustment 758
BRAKE MANIFOLD 759
Removal 759
Installation 759
Disassembly 759
Cleaning and Inspection 760
Assembly 760
BRAKE ACCUMULATORS 760
Brake Accumulator Bleeddown Procedure 760
Removal 761
Installation 761
Disassembly 762
Cleaning and Inspection 763
Assembly 763
Accumulator Charging Procedure 765
Precharge Maintenance 767
Accumulator Storage Procedures 768
Bladder Storage Procedures 768
Installing A Bladder Accumulator From Storage 768
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 769
Removal 769
Installation 769
Disassembly 769
Lever Adjustments 769
Potentiometer Check 770
Assembly 770
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE 773
BRAKE CIRCUIT CHECK-OUT PROCEDURE 775
REQUIRED EQUIPMENT 776
INITIAL SYSTEM SETUP 777
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 778
PARKING BRAKE CHECK-OUT 779
SERVICE BRAKE CHECK-OUT 780
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 781
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 782
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDURE DATA SHEET 784
SECTION J5 WET DISC BRAKE ASSEMBLY 787
WET DISC BRAKE ASSEMBLY 789
OPERATION 789
BRAKE DISC WEAR INSPECTION 790
BRAKE REBUILD 791
Disassembly 791
Cleaning and Inspection 795
Assembly 796
Floating Ring Seal Assembly & Installation 801
WET DISC BRAKE BLEEDING PROCEDURE 805
SECTION J7 PARKING BRAKE 807
PARKING BRAKE 809
OPERATION 809
MAINTENANCE 810
Inspection 810
Removal 810
Installation 811
Disassembly 811
Cleaning and Inspection 811
Assembly 813
Cleaning and Inspecting New Discs 814
PARKING BRAKE BLEEDING PROCEDURE 815
SECTION L HYDRAULIC SYSTEM 817
SECTION L2 HYDRAULIC SYSTEM 819
HYDRAULIC SYSTEM 821
HYDRAULIC PUMP MODULE 821
HOIST CIRCUIT OPERATION 822
STEERING CIRCUIT OPERATION 824
DISC BRAKE COOLING SYSTEM 826
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 829
HYDRAULIC SYSTEM COMPONENT REPAIR 831
HOIST PUMP 831
Removal 831
Installation 833
Inspection 838
Assembly 838
HYDRAULIC TANK 844
Removal 844
Installation 845
HYDRAULIC TANK BREATHERS 845
HYDRAULIC TANK STRAINERS 846
Removal 846
Inspect and Clean 846
Installation 846
SECTION L4 STEERING CIRCUIT 847
STEERING CIRCUIT 849
STEERING CIRCUIT OPERATION 849
COMPONENT DESCRIPTION 850
Steering Control Unit 850
Bleeddown Manifold 851
Steering Accumulator Bleed Down Solenoid 851
Relief Valves 853
Hoist Up Limit Solenoid 853
Steering Accumulators 853
Low Precharge Warning Switch 853
High Pressure Filter 853
Quick Disconnect Ports 853
Flow Amplifier 855
FLOW AMPLIFIER SYSTEM OPERATION 856
No Steer 856
Steering Left 858
Steering Right 860
No Steer, External Shock Load 862
STEERING PUMP 864
Normal Operation 864
PRINCIPLE OF OPERATION 866
Full Pump Volume 866
Half Pump Volume 866
Neutral Position 866
Steering Pump 867
SECTION L5 STEERING CONTROL UNIT 869
STEERING CONTROL UNIT 871
REMOVAL 871
SPLINE INSPECTION 871
INSTALLATION 872
DISASSEMBLY 872
CLEANING AND INSPECTION 873
ASSEMBLY 875
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR 879
STEERING CIRCUIT COMPONENT REPAIR 881
BLEEDDOWN MANIFOLD VALVE 881
Removal 881
Installation 882
FLOW AMPLIFIER 883
Removal 883
Installation 883
Disassembly 883
Assembly 885
STEERING CYLINDERS 886
Disassembly 887
Piston Seal & Bearing Installation 887
Assembly 887
Testing 887
STEERING AND BRAKE PUMP 888
Removal 888
Installation 889
Disassembly 890
Inspection 893
Assembly 896
Driveshaft Group 897
Rotating Group 897
Valve Plate Group 898
STEERING ACCUMULATORS 900
Removal 900
Installation 900
Disassembly 901
Cleaning and Inspection 901
Assembly 902
Leak Testing 904
Charging Procedure 905
Precharge Maintenance 907
Accumulator Storage Procedures 908
Bladder Storage Procedures 908
Installing A Bladder Accumulator From Storage 908
TROUBLESHOOTING CHART 909
SECTION L7 HOIST CIRCUIT 913
HOIST CIRCUIT 915
BASIC OPERATION 915
COMPONENT DESCRIPTION 916
Hydraulic Tank 916
Hydraulic Pump 916
High Pressure Filters 916
Hoist Valve 916
Inlet Sections 916
Work Ports (Rear) Spool Section 917
Tank Ports (Front) Spool Section 917
Hoist Pilot Valve 917
Bleeddown Manifold 918
Hoist Up Limit Solenoid 918
Pilot Operated Check Valve 918
Overcenter Manifold 918
HOIST CIRCUIT OPERATION 919
Float Position Of Pilot Valve With Truck Body On Frame 920
Power Up Operation 922
Hold Operation 924
Power Down Operation 926
Float Operation 928
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 931
HOIST CIRCUIT COMPONENT REPAIR 933
HOIST VALVE 933
Removal 933
Installation 934
O-Ring Replacement 934
INLET SECTION 935
Cleaning and Inspection 936
Assembly 936
REAR SPOOL SECTION (Work Ports) 937
Disassembly 937
Cleaning and Inspection 937
Assembly 939
FRONT SPOOL SECTION (Tank Ports) 940
Disassembly 940
Cleaning and Inspection 940
Assembly 940
HOIST PILOT VALVE 942
Removal 942
Installation 942
Disassembly 943
Cleaning and Inspection 944
Assembly 944
HOIST CYLINDERS 945
Removal 945
Installation 946
Disassembly 948
Cleaning and Inspection 949
Assembly – Quill 950
Assembly – Cylinder 952
Testing 952
OVERCENTER VALVE MANIFOLD 953
SECTION L9 HYDRAULIC SYSTEM FILTERS 955
HYDRAULIC SYSTEM FILTERS 957
HOIST CIRCUIT FILTER 957
Filter Element Replacement 957
Removal – Hoist Circuit Filter 958
Installation – Hoist Circuit Filter 958
Indicator Switch – Hoist Circuit Filter 958
STEERING CIRCUIT FILTER 959
Filter Element Replacement 959
Removal – Steering Circuit Filter 960
Installation – Steering Circuit Filter 960
Indicator Switch – Steering Circuit Filter 960
INDICATOR SWITCH 960
Test Procedure 960
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 963
HYDRAULIC CHECKOUT PROCEDURE 965
GENERAL INFORMATION 965
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 972
Equipment Requirements 973
Pump Pressure Control Adjustments 973
Steering Control Valve and Flow Amplifier Leakage Test 974
Bleeddown Manifold Leakage Test 975
STEERING/BRAKE PUMP STROKE ADJUSTMENT 976
SHOCK AND SUCTION VALVES 976
Equipment Requirements 976
Pressure Tests 976
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 978
Equipment Requirements 978
Pressure Gauge Locations 978
Brake Cooling Circuit Test 978
Power Up Relief Pressure Test 979
Power Down Relief Pressure Test 980
Counterbalance Valve Pressure Check 981
Counterbalance Valve Adjustment 982
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 983
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEM DATA SHEET 984
SECTION M OPTIONS AND SPECIAL TOOLS 985
SECTION M7 HOT START SYSTEM 987
HOT START SYSTEM 989
SYSTEM OPERATION 989
HEATER INFORMATION 990
TROUBLESHOOTING GUIDELINES 991
SECTION M8 SPECIAL TOOLS 993
HIGH VOLTAGE TOOLS 998
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 998
SECTION M19 RADIATOR SHUTTERS 1001
RADIATOR SHUTTERS 1003
OPERATION 1003
Hydraulic Circuit 1003
Electrical Circuit 1004
MAINTENANCE AND REPAIR 1004
TROUBLESHOOTING 1005
SECTION M20 PAYLOAD METER III ™ 1009
OPERATION SECTION 1013
Introduction 1013
Data Summary 1013
Data Gathering 1013
COMPONENT DESCRIPTION 1014
System Diagram 1014
Suspension Pressure Sensors 1014
Inclinometer 1014
Operator Display 1014
Operator Switch 1015
Speed Input 1015
Body-Up Switch 1015
Brake Lock Switch 1015
Payload Meter 1015
Communications Ports 1015
Key Switch Input 1016
Payload Meter Power 1016
Load Lights 1016
Wiring and Termination 1017
TCI Outputs 1017
OPERATOR’S DISPLAY AND SWITCH 1018
Reading the Speedometer 1018
Reading the Load Display 1018
Using the Operator ID 1018
Using the Load and Ton Counter 1018
Total Ton Counter 1018
Total Load Counter 1019
Clearing the Counters 1019
Viewing Live Sensor Data 1019
Other Display Messages 1019
PAYLOAD OPERATION & CALCULATION 1020
Description of Haul Cycle States 1020
Haul Cycle Description 1020
Load Calculation 1021
Carry Back 1021
Measurement Accuracy 1021
SOURCES FOR PAYLOAD ERROR 1021
Payload Error 1021
Loading Conditions 1022
Pressure Sensors 1022
Swingloads 1022
Speed and Distance 1022
HAUL CYCLE DATA 1022
Haul Cycle Warning Flags 1024
Frame Torque Data 1025
Sprung Weight Data 1025
Maximum Speed Data 1025
Alarm Records 1025
Fault Code Data 1026
PC SOFTWARE OVERVIEW 1027
System Configuration 1027
Installing the PLMIII Software 1027
DOWNLOADING DATA 1028
PLM III SYSTEM CONFIGURATION 1029
Starting Communications 1029
Displayed Payload Units 1029
Time Units 1029
Connection Menu 1029
Connecting to the Payload Meter 1030
Configure the Payload Meter 1030
Setting the Date and Time 1030
Setting the Truck Type 1031
Setting the Gauge Display Units 1031
Setting the Frame Serial Number 1031
Setting the Truck Number 1031
Setting the Komatsu Distributor 1031
Setting the Komatsu Customer 1031
Clean Truck Tare Calibration 1032
Inclinometer Calibration 1032
DATA ANALYSIS 1033
Creating a Query 1033
Sorting on Truck Unit Number 1033
Sorting on Truck Type 1033
Sorting on Date Range 1034
Sorting on Time Range 1034
Payload Detail Screen 1035
Creating Reports 1035
Summary – one page report 1036
Detailed – multi-page report 1036
Creating Graphs 1037
Exporting Data 1037
CSV Export 1037
Compressed 1038
Importing Data 1039
Deleting Haul Cycle Records 1039
Viewing Alarms 1040
Deleting Alarm Records 1040
TROUBLESHOOTING SECTION 1041
TROUBLESHOOTING 1041
Viewing Active Alarms 1041
Real-Time Data Display 1041
Testing the Payload Lights 1041
Creating Log Files of Inputs 1042
Daily Inspections 1042
Periodic Maintenance 1042
Abnormal Displays at Power-Up 1043
No Payload Display When Key Switch is Turned ON 1044
No Display on Speedometer 1045
No Display on Operator Display 1045
No Communications With PC 1046
Load Lights Don’t Light During Loading 1047
Load Lights Remain ON 1048
Load Lights Remain ON During Dumping 1048
Display Doesn’t Clear When The Load Is Dumped 1048
Calibration Problems 1049
Alarm 1 – Left Front Pressure High 1050
Alarm 2 – Left Front Pressure Low 1050
Troubleshoot Wiring to Left Front Suspension 1050
Alarm 3 – Right Front Pressure High 1051
Alarm 4 – Right Front Pressure Low 1051
Troubleshoot Wiring to Right Front Suspension 1051
Alarm 5 -Left Rear Pressure High 1052
Alarm 6 – Left Rear Pressure Low 1052
Troubleshoot Wiring to Left Rear Suspension 1052
Alarm 7 – Right Rear Pressure High 1053
Alarm 8 – Right Rear Pressure Low 1053
Troubleshoot Wiring to Right Rear Suspension 1053
Alarm 9 – Inclinometer High 1054
Alarm 10 – Inclinometer Low 1054
Troubleshoot Inclinometer Wiring 1054
Alarm 13 – Body Up Input Failure 1055
Alarm 16 – Memory Write Failure 1056
Alarm 17 – Memory Read Failure 1056
Alarm 18 1057
Alarm 19 1057
Alarm 22 1057
Operator Switch Doesn’t Work 1058
Alarm 26 – User Switch Fault – SELECT 1058
Alarm 27 – User Switch Fault – SET 1058
Connector Map 1059
Connectors 1060
PLMIII CHECK OUT PROCEDURE 1061
General Description 1061
Tools Required 1061
Checkout Procedure 1061
PLMIII CHECKOUT PROCEDURE CONFIRMATION 1065
Flashburn Programming 1065
Confirmation Checklist 1067
SECTION M31 RESERVE ENGINE OIL SYSTEM 1069
RESERVE ENGINE OIL SYSTEM 1071
Operation 1072
LED Monitor Light 1072
Tank Fill Control (Optional) 1073
Filling Procedure (Remote Fill Feature) 1073
SERVICE 1074
Every 10 Hours, or once each shift: 1074
Every 500 Hours 1074
Changing Oil 1074
TROUBLESHOOTING 1075
Circuit Fuse 1075
SYSTEM ELECTRICAL SCHEMATICS 1076
SECTION N OPERATOR CAB INDEX 1077
SECTION N2 TRUCK CAB AND COMPONENTS 1079
TRUCK CAB AND COMPONENTS 1081
TRUCK CAB 1081
Description 1081
Removal 1082
Installation 1083
CAB DOOR 1084
Removal 1084
Installation 1084
Door Jamb Bolt Adjustment 1085
Door Handle Plunger Adjustment 1086
Replacing the Door Glass 1087
Replacing the Door Handle or Latch Assembly 1091
Replacing the Door Window Regulator 1092
Replacing the Door and Door Hinge Seal 1093
Replacing the Door Opening Seal 1093
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1094
Recommended Tools and Supplies 1094
Replacement Procedure 1094
WINDSHIELD AND REAR GLASS 1095
Removal 1095
Installation 1096
SECTION N3 CAB COMPONENTS 1097
CAB COMPONENTS 1099
WINDSHIELD WIPERS 1099
WIPER MOTOR 1099
Removal 1099
Installation 1099
WIPER ARM 1099
Removal 1099
Installation 1100
WIPER LINKAGE 1100
Removal 1100
Installation 1100
WINDSHIELD WASHER 1101
Operation 1101
Service 1101
OPERATOR SEAT 1102
Seat Belts 1102
Adjustment 1102
Inspection 1103
Removal 1103
Installation 1103
PASSENGER SEAT 1104
Inspection 1104
Removal 1104
Installation 1104
SECTION N4 HEATER / AIR CONDITIONER 1105
HEATER/AIR CONDITIONER 1107
OPERATION 1107
Fan Control Knob 1107
Temperature Control Knob 1107
Directional Control Knob 1107
Heater Vents 1107
COMPONENTS 1108
Fuse and Circuit Breaker 1108
Relays 1108
Heater Core 1108
Fan Motor And Speed Control 1109
Actuators 1109
Cab Air Filter 1109
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1112
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1112
PRINCIPLES OF REFRIGERATION 1112
Air Conditioning 1112
Refrigeration – The Act Of Cooling 1113
The Refrigeration Cycle 1113
AIR CONDITIONER SYSTEM COMPONENTS 1114
Compressor (Refrigerant Pump) 1114
Service Valves 1114
Condenser 1114
Receiver-Drier 1114
Expansion Block Valve 1115
Accumulator 1115
Evaporator 1115
ELECTRICAL CIRCUIT 1116
Thermostat 1116
Compressor Clutch 1116
Trinary™ Switch 1117
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1118
SERVICE TOOLS AND EQUIPMENT 1119
Recovery/Recycle Station 1119
Leak Detector 1119
Manifold Gauge Set 1120
Installing Manifold Gauge Set 1121
Purging Air From Service Hoses 1121
Service Valves 1122
Vacuum Pump 1122
SYSTEM PERFORMANCE TEST 1123
SYSTEM OIL 1124
Handling and Reusing PAG Oil 1124
Oil Quantity 1124
Checking System Oil 1124
REFRIGERANT 1125
Recycled Refrigerant 1125
Reclaimed Refrigerant 1125
Refrigerant Quantity 1126
R-134a Refrigerant Containers 1126
SYSTEM LEAK TESTING 1126
Electronic Leak Detector 1127
Tracer Dyes 1127
Soap and Water 1127
RECOVERING AND RECYCLING THE REFRIGERANT 1127
Draining Oil from the Previous Recovery Cycle 1127
Performing the Recovery Cycle 1127
Performing the Recycling Procedure 1128
Evacuating and Charging the A/C System 1128
SYSTEM REPAIR 1128
System Flushing 1128
A/C DRIVE BELT CHECKOUT PROCEDURE 1129
Pulley Alignment 1129
Belt Tension Check 1129
COMPONENT REPLACEMENT 1131
Hoses and Fittings 1131
Lines 1131
Expansion Valve 1131
Receiver-Drier 1131
Thermostat 1131
Compressor 1132
Accumulator 1132
Clutch 1132
Servicing the Compressor Clutch 1133
Pulley Removal 1135
Clutch Coil Check 1135
Pulley Installation 1135
Clutch Assembly Installation 1136
EVACUATING THE SYSTEM 1137
CHARGING THE A/C SYSTEM 1138
TROUBLESHOOTING 1139
Preliminary Checks 1139
Diagnosis Of Gauge Readings And System Performance 1139
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1140
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1146
SECTION N5 OPERATOR CAB CONTROLS 1147
OPERATOR CAB CONTROLS 1150
STEERING COLUMN 1151
Removal 1151
Inspection 1151
Installation 1152
STEERING WHEEL 1152
Removal 1152
Installation 1152
STEERING WHEEL AND CONTROLS 1154
Horn Button 1154
Tilt / Telescope Lever 1154
Multi-Function Turn Signal Switch 1154
DYNAMIC RETARDING 1155
Retarder Lever 1155
Brake/Retarder Pedal 1155
Throttle/Accelerator Pedal 1155
GRADE/SPEED CHART 1156
OVERHEAD PANEL AND DISPLAYS 1157
Speakers 1157
Warning Alarm Buzzer 1157
Radio/CD Player 1157
Warning Indicator Light Dimmer Control 1157
Status/Warning Indicator Light Panel 1157
Air Cleaner Restriction Gauges 1157
CENTER CONSOLE 1158
Directional Control Lever 1158
Override/Fault Reset Switch 1159
Engine Shutdown Switch 1159
Window Control Switches 1159
Hoist Control Lever 1159
Retarder Speed Control (RSC) Adjustment Dial 1160
Retarder Speed Control (RSC) Switch 1160
Data Store Button 1161
KOMTRAX Plus Snapshot In Progress Light 1161
Link Energized Light 1161
Service Engine Light 1161
12V Auxiliary Power Outlets 1161
DIAGNOSTIC PORTS 1161
KOMTRAX Plus Diagnostic Port 1161
Interface Module (IM) Diagnostic Port 1161
Payload Meter Diagnostic Port 1161
Truck Control Interface (TCI) Diagnostic Port 1161
Propulsion System Controller (PSC) Diagnostic Port 1161
Engine Diagnostic Port (CENSE) 1161
Engine Diagnostic Port (QUANTUM) 1161
INSTRUMENT PANEL 1162
Control Symbols 1162
Key Switch 1164
Air Conditioner Compressor Switch 1164
Rotating Beacon Switch (optional) 1164
Heated Mirrors Switch (optional) 1164
AC Drive System Rest Switch 1165
Wheel Brake Lock Switch 1165
Hazard Warning Lights 1165
Heater/Air Conditioner Vents 1165
Engine Oil Pressure Gauge 1166
Right Turn Signal Indicator 1166
Digital Tachometer 1166
High Beam Indicator 1166
Speedometer/Payload Meter Display 1166
Left Turn Signal Indicator 1166
Coolant Temperature Gauge 1166
Lamp Check Switch 1166
Light Switch (3-Way) 1166
Ladder Light Switch 1167
Backup Light Switch 1167
Fog Light Switch 1167
Payload Meter Switch 1167
Panel Illumination Light Dimmer Switch 1167
Hydraulic Oil Temperature Gauge 1167
Engine Hourmeter 1167
Fuel Gauge 1167
OVERHEAD STATUS / WARNING INDICATORS 1168
A1 High Hydraulic Oil Temperature 1169
B1 Low Steering Pressure 1169
C1 Low Accumulator Precharge Pressure 1170
D1 Not used 1170
E1 Low Brake Pressure 1170
A2 Low Hydraulic Tank Level 1170
B2 Low Automatic Lubrication System Pressure 1170
C2 Circuit Breaker Tripped 1170
D2 Hydraulic Oil Filter Monitor 1171
E2 Low Fuel 1171
A3 Parking Brake 1171
B3 Service Brake 1171
C3 Body Up 1171
D3 Dynamic Retarding 1171
E3 Stop Engine 1171
A4 Cranking Motor Failure 1172
B4 Backup Lights 1172
C4 Engine Shutdown Timer 1172
D4 Retard Speed Control (RSC) Indicator 1172
E4 Check Engine 1172
A5 No Power 1172
B5 Propulsion System Warning 1172
C5 Propulsion System Temperature 1172
D5 System/Component Failure 1173
E5 Battery Charging System Failure 1173
A6 No Propel 1173
B6 Propel System At Rest 1173
C6 Propel System Not Ready 1173
D6 Reduced Propulsion 1173
E6 Retard At Continuous Level 1173
REAR AXLE LIGHT BAR 1174
Backup Lights 1174
Retard Lights 1174
Brake Light 1174
Backup Alarm 1174
KOMTRAX PLUS 1175
Operation 1175
Interface Module 1177
Basic Precautions 1177
KOMATSU WIRELESS BRIDGE (Optional) 1178
General Information 1178
Communication Setup 1178
Switching to the KWB_SETUP Network 1178
Setting the Computer Subnet Mask and IP Address 1179
Properties 1179
Setting Up the KWB 1180
Adding Encryption 1180
Final Computer Settings 1180
Data Downloading 1181
Resetting the KWB 1181
KWB Lights 1181
SECTION P LUBRICATION AND SERVICE 1183
SECTION P2 LUBRICATION AND SERVICE 1185
LUBRICATION AND SERVICE 1187
GENERAL 1187
SERVICE CAPACITIES 1187
HYDRAULIC TANK SERVICE 1187
Adding Oil 1187
COOLING SYSTEM SERVICE 1188
Radiator Filling Procedure 1188
Coolant Specifications 1188
Unacceptable Practices 1188
WHEEL MOTOR SERVICE 1188
RESERVE OIL TANK SERVICE 1189
Filling the Reserve Oil Tank (Remote Fill) 1189
Inline Screen 1189
QUICK FILL SERVICE CENTER 1190
LUBRICATION CHART 1191
10 HOUR (DAILY) INSPECTIONS 1192
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1194
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1194
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1194
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1197
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1199
5000 HOUR MAINTENANCE CHECKS 1199
SECTION P3 AUTOMATIC LUBRICATION SYSTEM 1201
AUTOMATIC LUBRICATION SYSTEM 1203
GENERAL DESCRIPTION 1203
SYSTEM COMPONENTS 1205
Filter 1205
Hydraulic Motor and Pump 1205
Grease Reservoir 1205
Pressure Reducing Valve 1205
Flow Control Valve 1205
Solenoid Valve 1205
Vent Valve 1205
Lubrication Cycle Timer 1205
Over Pressure Cut Off Switch 1205
Grease Pressure Failure Switch 1205
Injectors 1205
Relief Valve (unloader valve) 1205
SYSTEM OPERATION 1206
Normal Operation 1206
Lubricant Required For System 1207
System Priming 1207
Filter Assembly 1207
LUBRICANT PUMP 1208
Pump Housing Oil Level 1208
Pump Pressure Control 1208
INJECTORS (SL-1 Series “H”) 1209
Injector Specifications 1209
Injector Adjustment 1209
INJECTOR OPERATION 1210
PREVENTIVE MAINTENANCE PROCEDURES 1211
Daily Lubrication System Inspection 1211
250 Hour Inspection 1211
1000 Hour Inspection 1211
SYSTEM CHECKOUT 1212
Lubrication Controller Check 1212
Lubrication Controller Components 1212
Lubrication Controller Adjustment 1212
SYSTEM TROUBLESHOOTING CHART 1214
SECTION Q ALPHABETICAL INDEX 1217
SECTION R SYSTEM SCHEMATICS 1221
HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC 1223
HYDRAULIC BRAKE SYSTEM SCHEMATIC 1224
ELECTRICAL SCHEMATICS 1225
DESCRIPTION:
Komatsu 930E-4SE Dump Truck Shop Manual CEBM020003 – PDF DOWNLOAD
SN A30587-A30677
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.
S.V 12/12/24
