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Komatsu 930E-2 User Manual
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FIGURE 3-13. TOTAL PARASITIC LOSS AT FUL
L POWER
Komatsu SSDA16V160 - 2700
GHP, ECS 8 Blade, 78" dia. 5.3" PW @ 798 RPM
FIGURE 3-14. TOTAL PARASITIC LOSS AT FUL
L POWER
DDEC 4000 - 2700 GHP, ECS 8 Blade, 78"
dia. 5.3" PW @ 836 RPM
E3-34
AC Drive System Electrical Checkout Procedure
3/01 E03015
(Release 17 Software)
229
231
Table of Contents
A00017 03/01 Introduction a
5
Table of Contents
7
KOMATSU MODEL 930E Dump Truck
8
General Information
9
Major Component Description
11
Truck and Engine
11
Alternator (GE-GTA34)
11
Operator’s Cab
11
Grade
11
930E Major Components
12
Specifications
13
Grade
13
Overall Truck Dimensions
14
Clothing and Personal Protective Items
15
Safety Features
15
Safety Rules
15
General Safety
15
Leaving the Operator’s Seat
16
Mounting and Dismounting
16
Fire Prevention for Fuel and Oil
16
Precautions When Handling at High Temperatures
17
Prevention of Injury by Work Equipment
17
Fire Extinguisher and First Aid Kit
17
Precautions When Using Rops
18
Precautions for Attachments
18
Precautions During Operation
19
Safety at Worksite
19
Fire Prevention
19
Preparing for Operation
19
Truck Operation - General
20
When Starting Engine
20
Operating the Machine
20
In Operator’s Cab - before Starting Engine
20
Check When Traveling in Reverse
21
Traveling
21
Traveling on Slopes
22
Operate Carefully on Snow
22
When Dumping
23
Working on Loose Ground
23
When Loading
23
Parking the Machine
23
Battery
24
Battery Hazard Prevention
24
Starting with Booster Cables
24
Warning Tag
25
Stopping the Engine before Service
25
Before Carrying out Maintenance
25
Precautions for Maintenance
25
During Maintenance
26
Personnel
26
Attachments
26
Work under the Machine
26
Handling High-Pressure Hoses
27
Precautions with Battery
27
Use of Lighting
27
Radiator Water Level
27
Precautions When Carrying out Maintenance at High Temperature
28
Rotating Fan and Belt
28
Waste Materials
28
Tires
29
Handling Tires
29
Storing Tires after Removal
29
When Repairs Are Necessary
31
Normal Engine Shutdown Procedure
32
Preliminary Procedures before Welding or Performing Maintenance
32
Special Precautions for Working on a 930E Truck
32
Truck Operation
34
Walk Around Inspection
35
Engine Start-Up Safety Practices
37
After Engine Has Started
38
Cold Weather Starting
38
Machine Operation Safety Precautions
39
Machine Operation on the Haul Road
39
Dynamic Retarding Operation
40
Dynamic Retarder Control Lever
40
Dynamic Retarder/Service Brake Pedal
40
Starting on a Grade with a Loaded Truck
41
Passing
41
Loading
41
Dumping
41
To Raise Dump Body
42
To Lower Body
42
Towing
43
Safe Parking Procedures
44
Delayed Engine Shutdown Procedure
44
Warnings and Cautions
47
Standard Charts and Tables
55
Index of Tables
55
Effect of Special Lubricants
55
Standard Assembly Torques for 12-Point, Grade 9, Capscrews (SAE)
56
Temperature Conversions
59
Common Conversion Multipliers
60
Storage and Idle Machine Preparation
61
Short Term Idle Periods
61
Preparation for Storage
62
Removal from Storage
63
Reconditioning an Idle Vehicle
65
Engine Operation
68
Engine Storage
70
Preparing Engine for Storage
70
Temporary Storage (30 Days or Less)
70
Extended Storage (more than 30 Days)
70
Electric Drive Trucks
73
Storage Instructions and Procedures
73
Placing Equipment into Storage
73
When Storing a Truck that Is Operational
73
When Storing a Truck that Is Not Operational
74
When Storing a Major Component
74
Periodic Inspections
75
Placing Equipment into Service after Storage
75
When a Truck Is Operational
75
When a Truck Is Not Operational
75
Table of Contents
77
Structures
77
Index
78
Deck Components
79
Preparation
79
Structural Components
79
Grille, Hood and Ladder
80
Hood and Grille Removal
80
Right Deck and Components
81
Typical Deck Structure Mounting
81
Center Deck
82
Left Deck
82
Dump Body
83
Dump Body Removal
83
Hoist Cylinder Mount (Upper)
83
Dump Body Pivot Pin
84
Installation
84
Body Pad Installation
85
Body Pads
85
Body Guide
86
Body up Switch
86
Body-Up Retention Cable
86
Hoist Limit Switch
86
Rock Ejector Installation
87
Rock Ejector Mounting Bracket
87
Rock Ejectors
87
Fuel Tank
89
Fuel Tank Installation
89
Cleaning
90
Installation
90
Removal
90
Repair
90
Fuel Gauge Sender
91
Installation
91
Removal
91
Vent
91
Engine
93
Power Module
95
Preparation
95
Hydraulic Pump Drive Shaft
96
Main Alternator Blower Duct
96
Engine Air Inlet Piping
97
Engine Exhaust Piping
98
Removal
98
Power Module Removal & Installation
99
Power Module Lift Points
100
Subframe Rollers
100
Power Module Hookup
101
Power Module Installation
101
Air Inlet Piping Connections
102
Specifications
102
Air Conditioner Condenser
103
Cooling System
103
Radiator
103
Radiator Installation
103
Fan Guard
104
Radiator Piping
104
Installation
105
Radiator Mount
105
Coolant System Troubleshooting
106
Radiator Filling Procedure
106
Alternator Removal Procedure
107
Cradle Structure
107
Engine and Alternator
107
Power Train
107
Alternator to Engine Mounting
108
Engine/Alternator Mating
109
Measuring Procedure
109
SERVICE DATA - Eccentricity & Runout Limits
109
Alternator End-Play
110
Alternator-To-Flywheel Housing Adapter
110
Rotor-To-Drive Ring
110
Joining Alternator and Engine
111
Engine Mounting
112
Installation
112
Removal
112
Air Cleaners
113
Air Filtration System
113
Engine Air Cleaners
113
General Service Information
113
Air Cleaner Assembly
114
Filter Element Replacement
114
Inspecting Filter Element
115
Main Filter Element Cleaning
115
Cleaning Filter Element with Compressed Air
116
Cleaning Precleaner Tubes
116
Precleaner Section
116
Removing Dust from Precleaner Tubes
116
Air Intake Troubleshooting
117
Washing and Soaking Precleaner Section
117
Electrical System (24 VDC Non–Propulsion)
119
Truck Shutdown Procedure
120
24Vdc Electric Supply System
121
Batteries
121
Electrical System Description
121
Maintenance and Service
121
24Vdc Battery Charging Alternator
123
Battery Box
123
Battery Control Box
123
Battery Supply System
123
Battery Control Box
124
Battery Disconnect Switches
124
VDC Auxiliary Battery Connectors
124
Battery Equalizer
125
24 VDC Electrical System Components
127
5 Minute Idle Timer Components
127
Passenger Seat Base Compartment
127
Tail Light Resistor Diode Assemblies
127
5 Minute Idle Relay
129
5 Minute Idle Timer
129
Alarm Indicating Device (Aid) System
129
Brake Warning Buzzer (Bwb)
129
Aid System Card Enclosure
130
Hot Switch Inverter
130
Temperature and Latch
130
Diode Matrix (Without Sound)
131
Hot Switch Inverter Card (Slot 4) (Not Used)
131
Oil Level
131
Temperature
131
Barometric Pressure Transducer
132
Electrical Interface Cabinet
132
Lubrication System Timer
132
Truck Control Interface Panel
132
Truck Control Interface Panel (Tci)
133
Circuit Breaker Panel
134
Diode Board - Db1
134
Diode Testing
134
Relay Boards
135
Service
135
To Replace a Circuit Breaker
135
To Replace a Relay
135
Relay Board Identification
136
To Replace a Circuit Panel Card
136
Typical Relay Board
136
Relay Board 1 (RB1)
137
Relay Board 2 (RB2)
137
Relay Board 3 (RB3)
137
Relay Board Functions
137
Installing Additional Circuits
138
Relay Board 6 (RB6)
138
Body-Up Switch Adjustment
139
Body Limit Switch Adjustment
140
Hoist Limit Switch
140
Circuit Breakers
141
Electrical Propulsion System
143
Electrical Propulsion System Components
145
General System Description
145
Propulsion System Diagram
146
Auxiliary Blower System
147
Propulsion System Controller (Psc)
147
System Components
147
Truck Control Interface Panel (Tci)
148
Diagnostic Information Display
149
DID Panel Fault Codes
149
Input Processing
174
Psc Software Functions
174
Startup/Shutdown State
174
State Management
174
Retard State
175
Transition to Startup/Shutdown State (Shutdown)
175
Transition to Startup/Shutdown State (Startup)
175
Transitions between States
175
Transition from Propel State to Ready State
176
Transition from Propel State to Retard State
176
Transition from Ready State to Retard State
176
Transition from Rest State to Test State
176
DC Link State
177
De-Powering the Link
177
Engine Control
177
Powering the Link
177
Alternator Field Control
178
Desired DC Link Voltage
178
Desired Three-Phase Voltage
178
Self-Load
178
Motor Torque Limits
179
Propel Torque Control
179
Retard Torque Control
179
Speed Override
179
Auxiliary Blower Control
180
Chopper Voltage Control
180
Event Processing
180
Resistor Grid Control
180
Event Restrictions
181
Initiated Tests
181
No Power
181
Periodic Tests
181
Data Packs
182
Event History Buffer
182
Event Logging and Storage
182
Event Reset
183
Output Processing
183
PSC - PTU Communications Processing
183
Serial Data Communications
183
Abnormal Conditions/Overriding Functions
184
Engine Shutdown/Engine Not Running
184
Fast Start
184
Limp Home Mode
184
Propulsion System Component Abbreviations
185
Propulsion System Components Description
185
Electrical Cabinet, Front View
191
Electrical Cabinet, Top View
192
Electrical Cabinet, Rear & Floor View
193
Information Display Panel
194
Retarding Grids
194
Electronic Accelerator and Retard Pedals
195
Typical Electronic Pedal
195
Ac Drive System Electrical Checkout Procedure
197
Ac Drive System Maintenance
197
Truck Shutdown Procedures
197
Normal Truck Shutdown Procedure
198
Blower Control Devices
199
Shutdown after a System Failure
199
Battery and Control Checks of System with Battery Power off
200
Battery Circuit Voltage Check
200
Resistance Checks, Low Voltage Circuits
200
SYSTEM CHECKOUT (Release 17 Software)
200
Circuit Resistance Checks
201
Chopper Modules (CM1, CM2)
202
DC Link Checks
202
Gate Driver Power Supply (GDPS)
202
Resistance Checks, Propulsion System Circuits
202
AFSE P1 Adjustment
203
Battery and Control Circuit Checks of System with Battery Power on
203
GRR Wiring
203
A3PV Panel (17FM458A2)
204
Checks with Key Switch off
204
Checks with Key Switch on
204
Sensor Power Supply (SPS)
204
CPU Battery Checks
205
Input Voltage
205
Positive Output Voltage
205
TCI Card Checks
205
Memory Backup Battery Replacement
206
Tci Programming
206
To Program the 17FB144 CPU Card
206
To Replace the Battery on Either Card
206
Inverter Programming
207
Psc Programming
207
To Program the 17FB147 CPU Card
207
To Program the Inverters
207
Check Comm Status
208
Log on to the TCI Panel
208
Tci Checkout
208
View/Set the Date and Time in the PSC Panel
208
TCI Analog Input Checks
209
TCI Digital Output Tests
210
AUX ERROR CODE Check
211
Figure 3-4. Status/Warning Lights
211
Trucks with Prelube System
211
Trucks Without Prelube System
211
DID Display
212
TCI Digital Input Tests
212
PSC Checkout Procedure
214
PSC Digital Output Tests
214
PSC Digital Input Checks
216
17FM458 Panel Checks:
217
A3PV Panel
217
LINKV Panel
217
Thermistor Checks
217
Meter Calibration Procedure
218
Pedal Percentages and Meter Calibration
218
Retard Lever
218
Retard Pedal
218
Accelerator Pedal
219
Pot Reference
219
Retard Speed Pot Setting
219
Truck Speed
219
Reprogram with Serial Numbers and Pedal Percentages
220
Check Pedal Percentages
221
Program TCI
221
Alternator Speed Sensor Check
222
Battery Boost Check
222
Load Testing
222
Preload Checks
222
Psc Real Time Data Screen
223
Tci Real Time Data Screen
223
Additional Truck Checks
224
Aux Blower Rotation Check
224
Brake System Pressure Switch Checks
224
Hoist & Steering Circuit Switch Checks
224
Final Checks
225
Inverter Link Voltage Check
225
On-Board Load Testing
226
Psc Real Time Data Screen Sample
226
Initiate Loadbox Test
227
Self Load Test Screen, Rp1 Picked up
227
Tci Real Time Data Screen Sample
227
Self Load Test Screen, Rp1 & Rp2/3 Picked up
228
Manual Offset HP Output Adjustment
229
Self Load Test, Rp1, 2 & 3 Picked up
229
Trucks with DDEC Engine
229
Trucks with Komatsu SSDA16V160 Engine
229
Total Parasitic Loss at Full Power
230
PVM Optimum Load Curve Handshaking Troubleshooting
231
Trucks Equipped with DDEC Engine
231
Trucks Equipped with Komatsu Engine
231
Trucks with Either Engine
231
Miscellaneous Component Repair
232
Phase Module Removal and Snubber Resistor Replacement
232
Troubleshooting Phase Modules and Chopper Modules
232
Phase Module Installation
233
Snubber Resistor Installation
233
To Remove the Snubber Resistors
233
Auxiliary Blower Control System Troubleshooting
234
Auxiliary Blower Control Components
235
Auxiliary Inverter (Controller) Troubleshooting
237
Measurement Points
237
Auxiliary Snubber Panel Troubleshooting
238
Auxiliary Snubber Schematic
238
Igbt Check Test Points
239
IGBT Troubleshooting
239
Rear Axle, Spindles and Wheels
241
Tires and Rims
243
Typical Tire Handler
243
Front Tires and Rims
244
Front Wheel Hub and Rim Assembly
244
Removal
244
Installation
245
Rear Axle Jack Location
245
Rear Tire Removal
245
Rear Tires and Rims
245
Installation
246
Rear Wheel Assembly
246
Rim
248
Tire Removal
248
Tire Installation
249
Front Wheel & Spindle Installation
251
Front Wheel Hub and Spindle
251
Wheel Hub and Spindle Assembly
251
Spindle and Wheel Hub Removal
252
Wheel Hub and Spindle Removal
252
Spindle Removal Tool
253
Spindle Removal Tool Installation
253
Cleaning and Inspection
255
Disassembly
255
Front Wheel Spindle, Hub & Brake Assembly
256
Assembly
257
Wheel Bearing Adjustment
257
Brake Installation
258
Measuring Seal Gap
259
Seal Assembly Gap Check
259
Steering Cylinders and Tie Rod
259
Removal
260
Steering Cylinder and Tie Rod Installation
260
Bearing Replacement
261
Typical Bearing Installation
261
Measuring Toe-In
262
Toe-In Adjustment
262
Pivot Pin
263
Pivot Pin Assembly
263
Rear Axle Housing Mounting Attachment
263
Pivot Eye Bearing
264
Pivot Eye Bearing Installation
264
Pivot Eye Attachment
265
Pivot Eye Repair
265
Anti-Sway Bar
266
Anti-Sway Bar Assembly
266
Rear Axle Housing
267
Rear Axle Housing and Wheel Motors
268
Wheel Motor
270
Wheel Motor Alignment
271
Mastic Sealant
272
Hydrair II Suspensions
273
Charging Valve Installation
275
Front Suspension
275
Suspension Charging Valve
275
Suspension Installation
276
Installation of Hardened Flat Washer
277
Reference Marks for 120 Degree Advance
278
Reference Marks for 60 Degree Advance
278
“TURN-OF-THE-NUT” Tightening Procedure
278
Bearing Retainer Installation
279
Bearing Retainer Removal
279
Minor Repair Only
279
Piston Rod Removal
279
Major Suspension Rebuild
280
Back-Up Ring Placement
281
Charging Valve
283
Rear Suspension Installation
283
Rear Suspensions
283
Suspension Mounting Pin
284
Rear Suspension Assembly
287
Equipment List
289
Hydrair Charging Kit
289
Oiling and Charging Procedure
289
Front Suspension Oiling
290
Removal of Charging Kit
290
Support Blocks for Oiling and Charging Dimensions
290
Front Suspension Nitrogen Charging
291
Rear Suspension Oiling
292
Rear Suspension Dimensions (Empty)
293
Rear Suspension Nitrogen Charging
293
Oil and Nitrogen Specifications Charts
294
Brake System
295
Brake Circuit
297
Service Brake Circuit
297
Hydraulic Components Cabinet
298
Parking Brake Circuit
299
Secondary Braking and Automatic Apply
299
Brake Lock Circuit
300
Pressure Sensor, Low Brake Pressure
300
Pressure Sensor, System Supply Pressure
300
Warning Circuit
300
Brake Valve
301
Rear Axle Brake Lines
302
Rear Brake Hoses
302
Brake Accumulator Bleed down
303
Brake Circuit Component Service
303
Rebuild Criteria
303
Installation
304
Removal
304
Brake Valve/Retard Pedal Assembly
305
Disassembly
305
Actuator Cap & Boot
306
Actuator Base Threaded Inserts
308
Assembly
308
Boot and Cap
308
Cleaning and Inspection
308
Valve Body Seal Installation
308
Actuator Plunger O-Ring Installation
309
Assembly of Valve
309
Regulator Sleeve O-Ring Installation
309
Sleeve Seal Placement
309
Differential Pressure Switch
311
Test Bench Set up
312
Valve Bench Test and Adjustment
312
Brake Valve Output Pressure Adjustment
313
Differential Pressure Switch Adjustment
313
Test Set up Procedure
313
Final Test and Adjustment
314
Installation of Brake Pedal Actuator Assembly to Brake Valve
315
Installation of Retard Pedal to Brake Pedal
315
Brake Valve and Pedal Assembly
316
Dual Relay Valve
317
Front Brake Circuit
317
Rear Brake Circuit
317
Dual Relay Valve & Differential Pressure Sw
318
Assembly
319
Cleaning and Inspection
319
Disassembly
319
Differential Pressure Switch
320
Dual Relay Valve Bench Test Setup
321
Valve Test and Adjustment
321
Differential Pressure Switch Adjustment
323
Accumulators - Hydraulic Components Cabinet
324
Brake Accumulator Bleed down Procedure
324
Disassembly
324
Hydraulic Brake Accumulators
324
Installation
324
Removal
324
Anti-Extrusion Ring Removal
325
Bladder Removal
325
Cleaning and Inspection
325
Locknut Removal
325
Spacer Removal
325
Bladder Installation
326
Plug Assembly
326
Valve Stem Installation
326
Washer Installation
326
Charging Procedure
327
Installation/Removal of "Dyna-Seal"
327
Locknut Installation
327
Accumulators - Frame Mounted
328
Brake Accumulator Installation
328
Charging Valves
328
Removal
328
Accumulator Assembly
329
Cleaning and Inspection
329
Disassembly
329
Gland Removal Tool
329
Assembly
330
Testing
330
Accumulator Charging Procedure
331
Column-Mounted Retarder Control Lever
332
Lever Assembly Installation
332
Lever Assembly Removal
332
Retarder Control Lever (Steering Column-Mounted)
332
Assembly
333
Potentiometer Check
333
Brake Circuit Check-Out Procedure
335
Brake Manifold
336
Brake Circuit Abbreviations
337
Equipment Required
337
Brake Cabinet Port Identification
338
Initial System Set-Up
338
Brake System Checkout
339
Failure Modes Check-Out
340
Bottom View
341
Rear View
341
Both Brake Circuits Are Dragging
343
Brake Circuit and Brake Valve Troubleshooting
343
One Brake Circuit Is Dragging
343
The Brakes Are Locked, Service And/Or Parking
343
A Low Brake Pressure Warning Occurs When Brakes Are Applied
344
The Differential Pressure Warning Circuit Is Not Operating
344
A Brake Accumulator Bleeds off Quickly When Supply Pressure Is Cut off
345
Low Pressure Warning Comes on and Pressure Is Low
345
Low Pressure Warning Is on Even Though System Pressure Is Proper
345
The Low Pressure Warning Circuit Not Operating Properly
345
Oil Is Leaking Around the Pedal Base
346
Check-Out Procedure
347
Hydraulic Brake System Data Sheet
347
Operation
349
WET DISC BRAKE ASSEMBLY (Front and Rear)
349
Brake Disc Wear Indicator
350
Maintenance
350
Brake Wear Indicator Installation
351
Both Front and Rear Wheel Brakes
352
Brake Assembly
352
Brake Rebuild
352
Disassembly
352
Rear Wheel Brake Only
352
Initial Disassembly
353
Piston Removal
353
Piston/Housing Assembly Removal
353
Cleaning and Inspection
355
Seal Wear Progression
355
Assembly
356
Piston Pressure Test
356
Disc Pack Installation
357
Inner Gear Installation
357
Rear Brake, Hub Installation
358
Seal Gap Adjustment
358
Floating Ring Seal Assembly/Installation
359
Seal Terminology
359
Alternate Procedure
360
Front Wheel Brakes
362
Rear Wheel Brakes
362
Results of Incorrect Assembly
362
Wet Disc Brake Bleeding Procedure
362
Operation
363
Parking Brake
363
Parking Brake Installation
363
Inspection
364
Maintenance
364
Removal
364
Gear Installation
365
Gear Removal
365
Park Brake Installation
365
Assembly
366
Cleaning and Inspection
366
Disassembly
366
Parking Brake Assembly
367
Pressure Test
367
Parking Brake Bleeding Procedure
368
Hydraulic System
369
Hydraulic System Components and Piping
371
Hoist Circuit Operation
372
HOIST PUMP PIPING (Top View)
373
Steering Circuit Operation
374
Hydraulic Pump Module
374
STEERING SYSTEM COMPONENTS (Bottom View)
375
Disc Brake Cooling System
376
Brake/Hoist Return Oil Manifold
376
Hydraulic System Component Repair
379
Hoist Pump
379
Hoist and Steering Pump Piping
379
Hydraulic Pumps
380
Steering/Brake Pump Removal
380
HOIST PUMP DISASSEMBLY (Rear Section)
383
HOIST PUMP DISASSEMBLY (Front Section)
384
Preparation for Seal Removal
385
Shaft Seal Removal
385
Inspection of Parts
386
Gear Bore Inspection
386
Shaft Seal Installation
386
Pump Reassembly
387
Pressure Plate Installation
388
Hoist Pump Reassembly
388
Pump Gear Timing
390
Pump Rotation Check
390
Troubleshooting Guide
391
Filling Instructions
392
Hydraulic Tank
392
Hydraulic Tank Strainers
393
Strainer Removal
393
Hydraulic Tank Breathers
394
Steering Circuit
395
TEERING SYSTEM COMPONENTS (Bottom View)
395
Component Description
396
Steering Control Unit
396
Bleeddown Manifold Valve
397
Bleeddown Solenoid
397
Bleeddown Manifold
397
Bleeddown Manifold Schematic
398
Relief Valves
399
Hoist Limit Solenoid
399
Accumulators
399
High Pressure Filter
399
Flow Amplifier
400
Flow Amplifier Valve
401
Flow Amplifier System Operation
402
No Steer
402
Flow Amplifier - no Steer
403
Steering Left
404
Flow Amplifier - Left Steer
405
Steering Right
406
Flow Amplifier - Right Steer
407
No Steer, External Shock Load
408
No Steer - External Shock Load
409
Steering Pump
410
High Altitude Operation
410
Principle of Operation
412
Full Pump Volume
412
Half Pump Volume
412
Neutral Position
412
Steering Pump Assembly
413
Steering Pump Pressure Control Schematic
413
Steering Control Unit Installation
415
Steering Control Unit Rebuild
416
Marking Valve Components
416
End Cover Removal
417
Dust Seal Removal
417
Steering Control Valve
418
Spool and Sleeve Assembly
419
Neutral Position Spring Installation
419
Bearing Installation
420
Spool Installation
420
Check Ball Installation
421
Steering Circuit Component Repair
423
Accumulator Installation
424
Steering Accumulator Charging Procedure
427
Flow Amplifier Rebuild
428
Shock and & Suction Valve Assembly
430
Amplifier Spool Assembly
430
Steering Cylinders
432
Steering Cylinder Mounting
432
Steering Cylinder Assembly
433
Piston Seal & Bearing Installation
433
Cylinder Assembly
433
Steering and Brake Pump
434
Steering Pump Removal
434
Control Piston Group
436
Pump, Front Housing
437
Pump, Rotating Group
438
Rotating Group
439
Driveshaft Group
439
Valve Plate Group
439
Pump, Rear Housing
440
Swashblock Group
441
Unloader & Compensator Controls
441
Compensator Block and Unloader Module
442
Stroke Adjuster Assembly
442
O-Ring Location on Piston Sleeve
444
Troubleshooting Chart
445
Slow Steering, Hard Steering or Loss of Power Assist
445
Drift - Truck Veers Slowly in One Direction
445
Wander - Truck will Not Stay in Straight Line
445
Erratic Steering
446
Free Wheeling
446
Excessive Free Play at Steered Wheels
446
Binding or Poor Centering of Steered Wheels
446
Low Pump Output
447
No Pump Output
447
Steering Wheel Oscillates or Turns by Itself
447
Loss of Pressure
448
Excessive or High Peak Pressure
448
Noise or Squeal
448
Erratic Pump (Load/Unload) Cycle
448
Resistance When Initially Turning Steering Whee
449
Inability to Steer (no Pressure Build-Up)
449
Free Wheeling (no End Stop)
449
Slow or Hard Steer
449
Float Position of Pilot Valve with Truck Body on Frame
456
Float Position
457
Power up Operation
458
Hold Operation
460
Hold Position
461
Power down Operation
462
Power down Position
463
Float Operation
464
Hoist Circuit Component Repair
467
Hoist Valve
467
Hoist Valve and Piping
467
O-Ring Replacement
468
Hoist Valve Assembly
468
Tie Rod Installation
468
Tightening Sequence
468
Inlet Section Disassembly
469
Restrictor Poppet Removal
469
Rear Spool Section
470
Poppet and Ball
470
Work Ports Spool Section Assembly
471
Poppet Identification
472
Front Spool Section
473
Tank Ports Spool Section Assembly
474
Hoist Pilot Valve
475
Hoist Pilot Valve & Piping
475
Relief Valve
476
Hoist Pilot Valve Reassembly
477
Tie Rod Nut Torque
477
Hoist Cylinders
478
Hoist Cylinder Lower Mount
479
Quill Installation
482
Assembly of Quill and Cylinder
483
Installation of Check Balls and Plugs in Quill
484
Assembly of Cylinder
485
Rd STAGE PISTON
485
Disabled Truck Dumping Procedure
486
Pump Module, Hose Hookup
486
Dumping Procedure
486
Lowering the Body
486
Hoist Circuit Filter
487
Hydraulic System Filters
487
Indicator Switch
488
Steering Circuit Filter
489
Indicator Switch Pressure Test Block
491
Hydraulic Check-Out Procedure
493
Steering Circuit Check-Out & Adjustment Procedure
493
Warnings and Cautions
493
Equipment Requirements
494
Pump Pressure Control Adjustments
494
Pump Pressure Controls
494
Bleeddown Manifold Leakage Test
495
Steering Control Unit and Flow Amplifier Leakage Test
495
Steering Relief Valve Adjustment
496
Steering/Brake Pump Stroke Adjustment
496
Shock and Suction Valves
497
Brake Cooling Circuit Test
498
Hoist System Relief Valve and Brake Cooling Circuit Pressures
498
Pump Pressure Taps
498
Inlet Section
499
Power up Relief Pressure Test
499
Power down Relief Pressure Test
500
Power down Relief Valve
500
Counterbalance Valve Adjustment
501
Counterbalance Valve Pressure Check Only
501
Hoist Counterbalance Valve Adjustment
501
Hydraulic System Flushing Procedure
502
930E Check-Out Procedure
505
Checkfire Electric Detection and Actuation System - Series 1
509
Manual/Automatic Actuator
510
Power Wire
510
Squib
510
Test Kit
510
Do Not Connect Squib
511
Power Check
511
Securing the Detection Wire
511
The Power Wire
511
Install Jumper
512
Install Test Module Assembly
512
Remove Indicator Light Assy
512
Remove Jumper Assembly
512
Install Actuator Cartridge
513
Installation Procedure for Squib
513
Daily
514
Normal Maintenance Based on Actual Operating Hours
514
Remove Cartridge and Disconnect Squib
514
Attach Indicator Light Assy
515
In Case of Fire
515
Remove Test Module
515
Actuator Assembly
516
Recharging the Electric Detection and Actuation System
516
What to Do after the Fire Is out
516
What to Expect
516
Blown Fuse in Battery Connector Assembly
517
Test Module Light will Not Go out
517
Test Module Light will Not Illuminate
517
Troubleshooting the Electric Detection System
517
Fire Control System
519
Fire Control System (Manual)
519
Inspection and Maintenance
519
Nozzle and Blow-Off Cap
519
Operation
519
Nozzles and Blow-Off Cap
520
Recharging Procedures
520
Fuel Receiver
521
Fuel Tank Breather & Receiver Installation
521
Wiggins Quick Fill Fuel System
521
Tank Breather Valve
522
Left Side Fill
523
Special Tools
525
Front Hydrair/Spindle Removal
529
Front Spindle Removal Using Pusher Structure
529
Installing Pusher Structure
529
Piston/Spindle/Steering Arm
529
Pusher Structure Hardware
530
930E Piston/Spindle Pusher Structure
531
Air Conditioning System
533
Basic Air Conditioning System (Typical)
533
Environmental Impact
533
Air Conditioning
534
Operator Cab Air Conditioning
534
Principles of Refrigeration
534
Refrigeration - the Act of Cooling
535
The Refrigeration Cycle
535
Air Conditioner System Components
536
COMPRESSOR (Refrigerant Pump)
536
Receiver-Drier
536
Thermostatic Expansion Valve
536
Evaporator
537
Compressor Clutch
538
Electrical Circuit
538
Safety Switches
538
Thermostat
538
R-134A Refrigerant Containers
539
System Servicing
539
Leak Detector
540
Recovery/Recycle Station
540
Service Tools and Equipment
540
Service Valves
541
Vacuum Pump
541
High Side Gauge
542
Low Side Gauge
542
Manifold Gauge Set
542
Installing Manifold Gauge Set
543
Service Hose Hook-Up
543
Adding Refrigerant to the System
544
Purging Air from Service Hoses
544
Purging System
544
Adding Refrigerant and Stabilizing the System
545
Draining the Oil from the Previous Recovery Cycle
545
Performing the Recovery Cycle
545
Stabilizing the AC System
545
Charging the AC System
546
Evacuating and Charging the AC System
546
Evacuating the System
546
Performing the Recycling Procedure
546
Electronic Leak Detector
547
System Leak Testing
547
System Performance Test
547
Hoses and Fittings
548
Soap and Water
548
System Repair
548
Tracer Dyes
548
Checking Compressor Oil Level
549
Evacuating the System
550
Vacuum Pump Hookup
550
Insufficient Cooling
553
Little or no Cooling
553
Troubleshooting by Manifold Gauge Set Readings
553
Air And/Or Moisture in the System
554
Extremely Low Refrigerant Charge in the System
554
Excessive Air And/Or Moisture in the System
555
Expansion Valve Stuck or Plugged
555
Expansion Valve Stuck Open
556
System High Pressure Side Restriction
556
Compressor Malfunction
557
Condenser Malfunction or System Overcharge
557
Thermostatic Switch Malfunction
558
Preventive Maintenance Schedule for A/C System
559
Electrical System Description
561
Battery Charging System (Niehoff 240 Amp. Alternator)
563
General Description
563
Troubleshooting Procedures (on Truck)
563
Regulator Bypass Test
565
Test Meter Hookup
565
Parts Illustration
566
High Voltage Output
567
Low Voltage Output
567
On Vehicle Troubleshooting Guide Self Energized Alternator
567
Charge Volt and Amp Values
568
Definitions
568
High-Cycle Maintenance Free Types
568
Maintenance Free Types
568
No Alternator Output
569
Go to Regulator
570
Go to ’R’ Terminal on Alternator
570
Vehicle Charging Circuit Test Is Now Complete
570
Alternator Dimensions
572
Alternator Specifications
573
Service Parts
574
Alternator Parts
575
On Vehicle Test
576
Preliminary Checks
576
Test Set-Up
576
Bypass Test
577
Bench Test
578
Full Load Test
578
No-Load Test
578
Check for Open Field Coil
579
Check Function of Clamping Diode
579
Field Coil Tests
579
Static Tests
579
Check Continuity of Terminal Strip Connections
580
Check for Grounded Field Coil
580
Control Box Tests
580
Diode Heat Sink Tests
580
Check Front & Rear Stator
581
Check Negative Diodes
581
Check Positive Diodes
581
Stator Tests
581
Alternator Disassembly
582
Fan Removal
582
Pulley Removal
582
Regulator Removal
582
End Housing Removal
583
Rear Bearing Removal
583
Rear Rotor Removal
583
Front Housing Removal
584
Control Unit Assembly Removal
585
Typical Control Unit
585
Alternate Method
586
Field Coil Removal
586
Front Bearing Removal
586
Front Rotor Removal
586
Alternator Assembly
587
Field Coil Assembly
587
Service Tool Instructions
587
Front Bearing Assembly
588
Front Housing – Rotor, Shaft & Core Assembly
589
Front Rotor Assembly
589
Front Housing – Stator, Field Coil & Shell Assembly
590
Control Unit Assembly
591
Control Unit Assembly Replacement
591
End Housing Assembly
592
Rear Rotor Assembly
592
Ring Seal Conversion
592
Install New Shaft/Core Assembly
593
Shaft/Core Replacement
593
Loose Fit Rear Bearings
594
Press Fit Rear Bearings
594
Rear Bearing Assembly
594
Regulator Assembly
594
Fan Assembly
595
Pulley Assembly
595
Bf4822 Stator Service Tool Instructions
596
Stator Removal and Replacement
596
Shell Assembly Preparation
597
Stator Installation
597
Pressure Plate Set up
598
On Board Weighing System (Obws)
599
General Information
601
On Board Weighing System (Obws)
601
Payload Meter II
601
Display Panel
602
LIGHTS, SWITCHES, and COMPONENTS
602
Memory Card Access Lamp (CARD Busy)
602
Reception Pilot Lamp (Rx Busy)
602
Transmission Pilot Lamp (Tx Busy)
602
External Display Lights
603
Tips for Operation
603
Basic Description
604
Linkage Factor
604
Theory of Operation
604
Brake Lock
605
Sources of Error
605
Suspensions
605
Typical Data from Service Check Mode
605
Calculation of the Calibration Load
606
Example Calculation of Payload
606
In Order to Adjust this Gain
606
Cycle Data
607
Number 1 - 65535
607
Types of Data Stored
607
Unit Range
607
Day
608
Engine ON/OFF Data
608
Engine Operation
608
Fault Codes and Warning Data
608
Hour 24 Hour Clock
608
Metric Tons Short Tons
608
Minute
608
Month
608
Unit Range
608
Year
608
Other Data
609
Total Payload and Total Number of Cycles
609
Clearing the Operator Load Counter
610
Description
610
Dimming the Lights on the Display
610
Operator Functions
610
Using the Operator Load Counter
610
Viewing the Operator Load Counter
610
Checking the Operator Check Mode
611
Initial Setup of Payload Meter
611
Switch Settings
611
Checking the G T Setting
612
Checking the Inclinometer Settings
612
Checking the Service Check Mode
612
Calibrating a Truck
613
To Calibrate the Payload Meter
613
Displays at Start-Up
614
Normal Operation
614
Power on
614
Setting the Option Code
615
Setting the Speed Limit
615
Setup and Maintenance
615
Speed Limit
615
Data All Clear
616
Day
616
Download of Information
616
Month
616
Setting the Operator I.D. Code
616
Setting the Time and Date
616
Display of Fault Codes
617
Monitoring Input Signals
620
Service Check Mode
620
Description of up Factor
621
Load Calculation Timing
621
PL Mode - Load Calculation Timing
621
UP Factor - Payload Calculation Gain
621
Final Gear Ratio Selection
622
Access to Battery
623
Battery Replacement Procedure
623
Error Code, F-09, Displayed
623
Replacing the Battery
623
After Replacing the Battery
624
Battery Connection
624
Pressure Sensor
624
Removal
624
Suspension Pressure Sensor
624
Inclinometer
625
Inclinometer Side Connector View
625
Installation
625
Removal
625
Sensor Side Connector View
625
Description
626
Making Connections
626
Scoreboard
626
Normal Operation of the Scoreboard
628
Payload Meter Back Panel
628
CN1 - AMP MIC-MKII 13 Pins White Connector
629
CN2 - AMP 040 12 Pins Black Connector
629
Connections (AMP Pin Identification)
629
Payload Circuit Numbers
630
Payload Meter II Re-Initialization Procedure
631
Cab Assembly
635
Description
635
Truck Cab
635
Removal
636
Cab Hydraulic and Electrical Connections
637
Cab Door
638
Installation
638
Removal
638
Door Adjustment
639
Door Jam Bolt Adjustment
639
Door Handle Plunger Adjustment
640
Latch Assembly
640
Measuring Travel Distance of Plunger
640
Replace Door Glass
641
Replace Door Handle or Latch Assembly
645
Replace Door Window Regulator
645
Door and Door Hinge Seal Replacement
646
Door Opening Seal Removal
646
Adhesive-Bonded Windows
647
Glass Replacement
647
Recommended Tools/Supplies
647
Windshield & Rear Glass
648
Cab Components
649
Motor Installation
649
Motor Removal
649
Windshield Wiper
649
Windshield Washer
650
Windshield Washer Fluid Reservoir and Pump
650
Circuit Breakers
651
Heater Components
651
Heater/Air Conditioner
651
Actuators
652
Air Conditioner Components
652
Fan Motor and Speed Control
652
Filter
652
Heater Coil
652
Heater/Air Conditioner Assembly
653
Operator Comfort
655
Operator Seat
655
Heater/Air Conditioner Controls
656
Cab Heater Components
657
Heater Control Components
657
Operator Cab Controls
661
Removal
661
Steering Column
661
Steering Column Installation
661
Cab Interior - Operator View
662
Dynamic Retarding
663
Horn Button
663
Steering Wheel and Controls
663
Telescope Lock Ring
663
Turn Signal / Headlight Dimmer
663
Accelerator (Throttle) Pedal
664
Retarder Control Lever
664
Grade/Speed Chart
665
Heater / Air Conditioner Vents
665
Instrument Panel
665
Cab Radio (Optional)
666
Payload Meter
666
Radio Speakers
666
Warning Alarm Buzzer
666
Windshield Wipers
666
Center Console
667
F-N-R Selector Switch
667
Ash Tray
668
Hoist Control Lever
668
L.h. Window Control Switch
668
Lighter
668
Override /Fault Reset Switch
669
Retard Speed Control (Rsc) Adjust Dial
669
Retard Speed Control (Rsc) “Off/On” Switch
669
Engine Control System
670
Engine Diagnostics Download Port
670
Psc Download Port
670
Tci Download Port
670
Control Symbols
671
Instrument Panel and Indicator Lights
671
Wire Numbers
672
Panel Gauges, Indicators and Controls
673
Panel Gauges, Indicators, and Controls
672
Key Switch
673
Normal Engine Shutdown
673
Starting
673
Engine Shutdown Switch
674
Manual Backup Switch
674
Ladder Light Switch
674
Fog Lights (Optional)
674
Panel Illumination Lights
675
Cab Air Conditioner / Heater Vents
675
Rotating Beacon Light Switch (Optional)
675
Wheel Brake Lock Control
675
High Beam Indicator
676
Left Turn Signal Indicator
676
Right Turn Signal Indicator
676
Tachometer
676
Ac Drive System Temperature Gauge
677
Hourmeter
677
Temperature Gauge
677
Rest Switch
677
Light Switch
678
WINDSHIELD WIPER and WASHER
678
Panel Light Dimmer
678
Overhead Status / Warning Indicator Lights
679
Status / Warning Indicator Light Symbols
680
Low Steering Pressure
680
Low Brake Pressure
680
Low Accumulator Precharge Pressure
680
Body up
681
Hydraulic Oil Filter Monitor
681
Circuit Breaker Tripped
681
Low Hydraulic Tank Level
681
Manual Backup Lights
682
Engine Shutdown Timer - 5 Minute Idle
682
Retard Speed Control Indicator
682
Check Engine
682
High Hydraulic Oil Temperature
683
Propulsion System Temperature
683
Propulsion System Warning
683
No Propel
684
Propel System @ Rest
684
Propel System Not Ready
684
Reduced Propulsion
684
Hazard Warning Lights
685
Lamp Test Switch
685
Link-On Warning Light
685
Lubrication and Service
687
930E Service Capacities
689
Adding Oil
689
Hydraulic Tank Service
689
Coolant Level Check
690
Anti - Freeze Recommendations
690
10 Hour (Daily) Inspection
692
10 Hour Lubrication and Maintenance Checks
692
Fan Drive and Turbochargers
692
Fuel Filters
692
Cab Air Filter
693
Automatic Lube System
693
Cooling Air Ductwork
693
Wheels and Tires
693
50 Hour Lubrication and Maintenance Checks
694
Motorized Wheels
694
100 Hour Lubrication and Maintenance Checks
695
250 Hour Lubrication and Maintenance Checks
696
Steering Linkage
697
Hydraulic Pump Driveshaft & U-Joints
697
Magnetic Plug
697
Rear Wheel Mounting
697
500 Hour Lubrication and Maintenance Checks
698
Final Drive Case Breathers
698
Throttle and Brake Pedal
698
Hoist Actuator Linkage
698
1000 Hours Lubrication and Maintenance Checks
699
Auxiliary Blower
699
2500 Hour Maintenance Checks
700
5000 Hour Maintenance Checks
700
Automatic Lubrication System
701
General Description
701
Pump and Reservoir Components
701
Auto Lube System Installation
702
Delay Timer
703
Vent Valve
703
Lubrication Cycle Timer
703
Hydraulic Motor and Pump
703
Hydraulic Schematic
704
Pressure Failure Detection Circuits
705
Electrical Schematic
705
Injector Operation
706
General Instructions
707
Lubricant Required for System
707
System Priming
707
Pump Pressure Control
707
Injector Specifications
708
Injector Adjustment
708
Type Sl-1 Injector
708
Lubrication Cycle Timer Adjustment
709
Timer (Top Cover Removed)
709
Filter Assembly
709
Lubrication Cycle Timer Check
709
Pump Rebuild
710
Lube Pump Assembly
711
System Troubleshooting Chart
713
Pump Does Not Operate
713
Pump will Not Prime
713
Pump will Not Build Pressure
713
Timer Stays Timed out
714
Pump Pressure Builds very Slowly or Not at All
714
Lube Cycle Timer Not Operating
714
Pressure Gauge Does Not Register Pressure
714
Preventative Maintenance Procedures
716
Daily Lubrication System Inspection
716
250 Hour Inspection
716
1000 Hour Inspection
716
Alphabetical Index
717
System Schematics
721
5
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Komatsu 930E-2 Specifications
General
Brand
Komatsu
Model
930E-2
Category
Trucks
Language
English
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