Komatsu 930E-2 - Special Tools

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SPECIAL TOOLS

PART NO. DESCRIPTION USE

TG1106 Eye Bolt, 0.75–10 UNC

Misc. lifting

requirements

WA4826 Eye Bolt, 1.25–7 UNC

PART NO. DESCRIPTION USE

EB1759

NItrogen Charging

Kit

Suspension &

Accumulator

Nitrogen Charging

PART NO. DESCRIPTION USE

EF4875 Roll-Out Assembly

Power Module

Removal &

Installation

M08012 9/99 Special Tools M8-1

Main Page

A00017 03/01 Introduction a5
Table of Contents7
KOMATSU MODEL 930E Dump Truck8
General Information9
Major Component Description11
Truck and Engine11
Alternator (GE-GTA34)11
Operator’s Cab11
Grade11
930E Major Components12
Specifications13
Grade13
Overall Truck Dimensions14
Clothing and Personal Protective Items15
Safety Features15
Safety Rules15
General Safety15
Leaving the Operator’s Seat16
Mounting and Dismounting16
Fire Prevention for Fuel and Oil16
Precautions When Handling at High Temperatures17
Prevention of Injury by Work Equipment17
Fire Extinguisher and First Aid Kit17
Precautions When Using Rops18
Precautions for Attachments18
Precautions During Operation19
Safety at Worksite19
Fire Prevention19
Preparing for Operation19
Truck Operation - General20
When Starting Engine20
Operating the Machine20
In Operator’s Cab - before Starting Engine20
Check When Traveling in Reverse21
Traveling21
Traveling on Slopes22
Operate Carefully on Snow22
When Dumping23
Working on Loose Ground23
When Loading23
Parking the Machine23
Battery24
Battery Hazard Prevention24
Starting with Booster Cables24
Warning Tag25
Stopping the Engine before Service25
Before Carrying out Maintenance25
Precautions for Maintenance25
During Maintenance26
Personnel26
Attachments26
Work under the Machine26
Handling High-Pressure Hoses27
Precautions with Battery27
Use of Lighting27
Radiator Water Level27
Precautions When Carrying out Maintenance at High Temperature28
Rotating Fan and Belt28
Waste Materials28
Tires29
Handling Tires29
Storing Tires after Removal29
When Repairs Are Necessary31
Normal Engine Shutdown Procedure32
Preliminary Procedures before Welding or Performing Maintenance32
Special Precautions for Working on a 930E Truck32
Truck Operation34
Walk Around Inspection35
Engine Start-Up Safety Practices37
After Engine Has Started38
Cold Weather Starting38
Machine Operation Safety Precautions39
Machine Operation on the Haul Road39
Dynamic Retarding Operation40
Dynamic Retarder Control Lever40
Dynamic Retarder/Service Brake Pedal40
Starting on a Grade with a Loaded Truck41
Passing41
Loading41
Dumping41
To Raise Dump Body42
To Lower Body42
Towing43
Safe Parking Procedures44
Delayed Engine Shutdown Procedure44
Warnings and Cautions47
Standard Charts and Tables55
Index of Tables55
Effect of Special Lubricants55
Standard Assembly Torques for 12-Point, Grade 9, Capscrews (SAE)56
Temperature Conversions59
Common Conversion Multipliers60
Storage and Idle Machine Preparation61
Short Term Idle Periods61
Preparation for Storage62
Removal from Storage63
Reconditioning an Idle Vehicle65
Engine Operation68
Engine Storage70
Preparing Engine for Storage70
Temporary Storage (30 Days or Less)70
Extended Storage (more than 30 Days)70
Electric Drive Trucks73
Storage Instructions and Procedures73
Placing Equipment into Storage73
When Storing a Truck that Is Operational73
When Storing a Truck that Is Not Operational74
When Storing a Major Component74
Periodic Inspections75
Placing Equipment into Service after Storage75
When a Truck Is Operational75
When a Truck Is Not Operational75
Table of Contents77
Structures77
Index78
- Deck Components79
- Preparation79
- Structural Components79
- Grille, Hood and Ladder80
- Hood and Grille Removal80
- Right Deck and Components81
- Typical Deck Structure Mounting81
- Center Deck82
- Left Deck82
- Dump Body83
  - Dump Body Removal83
  - Hoist Cylinder Mount (Upper)83
  - Dump Body Pivot Pin84
- Installation84
- Body Pad Installation85
- Body Pads85
- Body Guide86
- Body up Switch86
- Body-Up Retention Cable86
- Hoist Limit Switch86
  - Rock Ejector Installation87
  - Rock Ejector Mounting Bracket87
- Rock Ejectors87
- Fuel Tank89
- Fuel Tank Installation89
- Cleaning90
- Installation90
- Removal90
- Repair90
- Fuel Gauge Sender91
- Installation91
- Removal91
- Vent91
- Engine93
- Power Module95
- Preparation95
  - Hydraulic Pump Drive Shaft96
  - Main Alternator Blower Duct96
  - Engine Air Inlet Piping97
  - Engine Exhaust Piping98
- Removal98
  - Power Module Removal & Installation99
  - Power Module Lift Points100
  - Subframe Rollers100
  - Power Module Hookup101
  - Power Module Installation101
  - Air Inlet Piping Connections102
- Specifications102
- Air Conditioner Condenser103
- Cooling System103
  - Radiator103
  - Radiator Installation103
  - Fan Guard104
  - Radiator Piping104
- Installation105
  - Radiator Mount105
  - Coolant System Troubleshooting106
  - Radiator Filling Procedure106
- Alternator Removal Procedure107
  - Cradle Structure107
  - Engine and Alternator107
- Power Train107
- Alternator to Engine Mounting108
- Engine/Alternator Mating109
  - Measuring Procedure109
  - SERVICE DATA - Eccentricity & Runout Limits109
  - Alternator End-Play110
  - Alternator-To-Flywheel Housing Adapter110
  - Rotor-To-Drive Ring110
- Joining Alternator and Engine111
- Engine Mounting112
- Installation112
- Removal112
- Air Cleaners113
- Air Filtration System113
  - Engine Air Cleaners113
  - General Service Information113
  - Air Cleaner Assembly114
- Filter Element Replacement114
- Inspecting Filter Element115
- Main Filter Element Cleaning115
- Cleaning Filter Element with Compressed Air116
- Cleaning Precleaner Tubes116
- Precleaner Section116
- Removing Dust from Precleaner Tubes116
- Air Intake Troubleshooting117
  - Washing and Soaking Precleaner Section117
  - Electrical System (24 VDC Non–Propulsion)119
  - Truck Shutdown Procedure120
  - 24Vdc Electric Supply System121
- Batteries121
- Electrical System Description121
  - Maintenance and Service121
  - 24Vdc Battery Charging Alternator123
- Battery Box123
- Battery Control Box123
- Battery Supply System123
- Battery Control Box124
- Battery Disconnect Switches124
- VDC Auxiliary Battery Connectors124
- Battery Equalizer125
- 24 VDC Electrical System Components127
- 5 Minute Idle Timer Components127
- Passenger Seat Base Compartment127
  - Tail Light Resistor Diode Assemblies127
  - 5 Minute Idle Relay129
  - 5 Minute Idle Timer129
- Alarm Indicating Device (Aid) System129
  - Brake Warning Buzzer (Bwb)129
  - Aid System Card Enclosure130
  - Hot Switch Inverter130
  - Temperature and Latch130
  - Diode Matrix (Without Sound)131
  - Hot Switch Inverter Card (Slot 4) (Not Used)131
  - Oil Level131
  - Temperature131
  - Barometric Pressure Transducer132
- Electrical Interface Cabinet132
  - Lubrication System Timer132
  - Truck Control Interface Panel132
- Truck Control Interface Panel (Tci)133
  - Circuit Breaker Panel134
  - Diode Board - Db1134
- Diode Testing134
- Relay Boards135
- Service135
  - To Replace a Circuit Breaker135
  - To Replace a Relay135
  - Relay Board Identification136
  - To Replace a Circuit Panel Card136
  - Typical Relay Board136
  - Relay Board 1 (RB1)137
  - Relay Board 2 (RB2)137
  - Relay Board 3 (RB3)137
  - Relay Board Functions137
  - Installing Additional Circuits138
  - Relay Board 6 (RB6)138
  - Body-Up Switch Adjustment139
  - Body Limit Switch Adjustment140
- Hoist Limit Switch140
  - Circuit Breakers141
  - Electrical Propulsion System143
  - Electrical Propulsion System Components145
- General System Description145
  - Propulsion System Diagram146
  - Auxiliary Blower System147
  - Propulsion System Controller (Psc)147
- System Components147
  - Truck Control Interface Panel (Tci)148
  - Diagnostic Information Display149
- DID Panel Fault Codes149
- Input Processing174
- Psc Software Functions174
  - Startup/Shutdown State174
  - State Management174
  - Retard State175
  - Transition to Startup/Shutdown State (Shutdown)175
  - Transition to Startup/Shutdown State (Startup)175
  - Transitions between States175
  - Transition from Propel State to Ready State176
  - Transition from Propel State to Retard State176
  - Transition from Ready State to Retard State176
  - Transition from Rest State to Test State176
  - DC Link State177
  - De-Powering the Link177
  - Engine Control177
  - Powering the Link177
  - Alternator Field Control178
  - Desired DC Link Voltage178
  - Desired Three-Phase Voltage178
  - Self-Load178
  - Motor Torque Limits179
  - Propel Torque Control179
  - Retard Torque Control179
  - Speed Override179
  - Auxiliary Blower Control180
  - Chopper Voltage Control180
  - Event Processing180
  - Resistor Grid Control180
  - Event Restrictions181
  - Initiated Tests181
  - No Power181
  - Periodic Tests181
  - Data Packs182
  - Event History Buffer182
  - Event Logging and Storage182
  - Event Reset183
  - Output Processing183
  - PSC - PTU Communications Processing183
  - Serial Data Communications183
  - Abnormal Conditions/Overriding Functions184
  - Engine Shutdown/Engine Not Running184
  - Fast Start184
  - Limp Home Mode184
- Propulsion System Component Abbreviations185
  - Propulsion System Components Description185
  - Electrical Cabinet, Front View191
  - Electrical Cabinet, Top View192
  - Electrical Cabinet, Rear & Floor View193
  - Information Display Panel194
  - Retarding Grids194
- Electronic Accelerator and Retard Pedals195
- Typical Electronic Pedal195
- Ac Drive System Electrical Checkout Procedure197
- Ac Drive System Maintenance197
- Truck Shutdown Procedures197
  - Normal Truck Shutdown Procedure198
  - Blower Control Devices199
- Shutdown after a System Failure199
  - Battery and Control Checks of System with Battery Power off200
  - Battery Circuit Voltage Check200
  - Resistance Checks, Low Voltage Circuits200
- SYSTEM CHECKOUT (Release 17 Software)200
  - Circuit Resistance Checks201
  - Chopper Modules (CM1, CM2)202
  - DC Link Checks202
  - Gate Driver Power Supply (GDPS)202
  - Resistance Checks, Propulsion System Circuits202
  - AFSE P1 Adjustment203
  - Battery and Control Circuit Checks of System with Battery Power on203
  - GRR Wiring203
  - A3PV Panel (17FM458A2)204
  - Checks with Key Switch off204
  - Checks with Key Switch on204
  - Sensor Power Supply (SPS)204
  - CPU Battery Checks205
  - Input Voltage205
  - Positive Output Voltage205
  - TCI Card Checks205
- Memory Backup Battery Replacement206
- Tci Programming206
  - To Program the 17FB144 CPU Card206
  - To Replace the Battery on Either Card206
- Inverter Programming207
- Psc Programming207
  - To Program the 17FB147 CPU Card207
  - To Program the Inverters207
  - Check Comm Status208
  - Log on to the TCI Panel208
  - Tci Checkout208
  - View/Set the Date and Time in the PSC Panel208
  - TCI Analog Input Checks209
  - TCI Digital Output Tests210
  - AUX ERROR CODE Check211
  - Figure 3-4. Status/Warning Lights211
  - Trucks with Prelube System211
  - Trucks Without Prelube System211
  - DID Display212
  - TCI Digital Input Tests212
  - PSC Checkout Procedure214
  - PSC Digital Output Tests214
  - PSC Digital Input Checks216
  - 17FM458 Panel Checks:217
  - A3PV Panel217
  - LINKV Panel217
  - Thermistor Checks217
  - Meter Calibration Procedure218
  - Pedal Percentages and Meter Calibration218
  - Retard Lever218
  - Retard Pedal218
  - Accelerator Pedal219
  - Pot Reference219
  - Retard Speed Pot Setting219
  - Truck Speed219
  - Reprogram with Serial Numbers and Pedal Percentages220
  - Check Pedal Percentages221
  - Program TCI221
  - Alternator Speed Sensor Check222
  - Battery Boost Check222
- Load Testing222
  - Preload Checks222
  - Psc Real Time Data Screen223
  - Tci Real Time Data Screen223
  - Additional Truck Checks224
  - Aux Blower Rotation Check224
  - Brake System Pressure Switch Checks224
  - Hoist & Steering Circuit Switch Checks224
  - Final Checks225
  - Inverter Link Voltage Check225
- On-Board Load Testing226
  - Psc Real Time Data Screen Sample226
  - Initiate Loadbox Test227
  - Self Load Test Screen, Rp1 Picked up227
  - Tci Real Time Data Screen Sample227
  - Self Load Test Screen, Rp1 & Rp2/3 Picked up228
  - Manual Offset HP Output Adjustment229
  - Self Load Test, Rp1, 2 & 3 Picked up229
  - Trucks with DDEC Engine229
  - Trucks with Komatsu SSDA16V160 Engine229
  - Total Parasitic Loss at Full Power230
- PVM Optimum Load Curve Handshaking Troubleshooting231
  - Trucks Equipped with DDEC Engine231
  - Trucks Equipped with Komatsu Engine231
  - Trucks with Either Engine231
- Miscellaneous Component Repair232
- Phase Module Removal and Snubber Resistor Replacement232
- Troubleshooting Phase Modules and Chopper Modules232
  - Phase Module Installation233
  - Snubber Resistor Installation233
  - To Remove the Snubber Resistors233
- Auxiliary Blower Control System Troubleshooting234
- Auxiliary Blower Control Components235
- Auxiliary Inverter (Controller) Troubleshooting237
- Measurement Points237
- Auxiliary Snubber Panel Troubleshooting238
  - Auxiliary Snubber Schematic238
  - Igbt Check Test Points239
- IGBT Troubleshooting239
- Rear Axle, Spindles and Wheels241
- Tires and Rims243
- Typical Tire Handler243
- Front Tires and Rims244
- Front Wheel Hub and Rim Assembly244
- Removal244
- Installation245
  - Rear Axle Jack Location245
  - Rear Tire Removal245
- Rear Tires and Rims245
- Installation246
- Rear Wheel Assembly246
- Rim248
- Tire Removal248
- Tire Installation249
- Front Wheel & Spindle Installation251
- Front Wheel Hub and Spindle251
  - Wheel Hub and Spindle Assembly251
  - Spindle and Wheel Hub Removal252
  - Wheel Hub and Spindle Removal252
  - Spindle Removal Tool253
  - Spindle Removal Tool Installation253
- Cleaning and Inspection255
- Disassembly255
- Front Wheel Spindle, Hub & Brake Assembly256
- Assembly257
- Wheel Bearing Adjustment257
  - Brake Installation258
  - Measuring Seal Gap259
- Seal Assembly Gap Check259
- Steering Cylinders and Tie Rod259
- Removal260
- Steering Cylinder and Tie Rod Installation260
- Bearing Replacement261
  - Typical Bearing Installation261
  - Measuring Toe-In262
- Toe-In Adjustment262
- Pivot Pin263
- Pivot Pin Assembly263
- Rear Axle Housing Mounting Attachment263
  - Pivot Eye Bearing264
  - Pivot Eye Bearing Installation264
  - Pivot Eye Attachment265
  - Pivot Eye Repair265
- Anti-Sway Bar266
- Anti-Sway Bar Assembly266
- Rear Axle Housing267
  - Rear Axle Housing and Wheel Motors268
  - Wheel Motor270
  - Wheel Motor Alignment271
  - Mastic Sealant272
  - Hydrair II Suspensions273
  - Charging Valve Installation275
  - Front Suspension275
  - Suspension Charging Valve275
  - Suspension Installation276
  - Installation of Hardened Flat Washer277
  - Reference Marks for 120 Degree Advance278
  - Reference Marks for 60 Degree Advance278
  - “TURN-OF-THE-NUT” Tightening Procedure278
  - Bearing Retainer Installation279
  - Bearing Retainer Removal279
  - Minor Repair Only279
  - Piston Rod Removal279
  - Major Suspension Rebuild280
  - Back-Up Ring Placement281
  - Charging Valve283
  - Rear Suspension Installation283
  - Rear Suspensions283
  - Suspension Mounting Pin284
  - Rear Suspension Assembly287
  - Equipment List289
  - Hydrair Charging Kit289
  - Oiling and Charging Procedure289
  - Front Suspension Oiling290
  - Removal of Charging Kit290
  - Support Blocks for Oiling and Charging Dimensions290
  - Front Suspension Nitrogen Charging291
  - Rear Suspension Oiling292
  - Rear Suspension Dimensions (Empty)293
  - Rear Suspension Nitrogen Charging293
  - Oil and Nitrogen Specifications Charts294
  - Brake System295
- Brake Circuit297
- Service Brake Circuit297
- Hydraulic Components Cabinet298
- Parking Brake Circuit299
- Secondary Braking and Automatic Apply299
- Brake Lock Circuit300
  - Pressure Sensor, Low Brake Pressure300
  - Pressure Sensor, System Supply Pressure300
- Warning Circuit300
  - Brake Valve301
  - Rear Axle Brake Lines302
  - Rear Brake Hoses302
  - Brake Accumulator Bleed down303
- Brake Circuit Component Service303
- Rebuild Criteria303
- Installation304
- Removal304
- Brake Valve/Retard Pedal Assembly305
- Disassembly305
  - Actuator Cap & Boot306
  - Actuator Base Threaded Inserts308
- Assembly308
- Boot and Cap308
- Cleaning and Inspection308
  - Valve Body Seal Installation308
  - Actuator Plunger O-Ring Installation309
  - Assembly of Valve309
  - Regulator Sleeve O-Ring Installation309
  - Sleeve Seal Placement309
- Differential Pressure Switch311
- Test Bench Set up312
- Valve Bench Test and Adjustment312
- Brake Valve Output Pressure Adjustment313
- Differential Pressure Switch Adjustment313
  - Test Set up Procedure313
  - Final Test and Adjustment314
- Installation of Brake Pedal Actuator Assembly to Brake Valve315
  - Installation of Retard Pedal to Brake Pedal315
  - Brake Valve and Pedal Assembly316
- Dual Relay Valve317
  - Front Brake Circuit317
  - Rear Brake Circuit317
  - Dual Relay Valve & Differential Pressure Sw318
- Assembly319
- Cleaning and Inspection319
- Disassembly319
- Differential Pressure Switch320
- Dual Relay Valve Bench Test Setup321
- Valve Test and Adjustment321
- Differential Pressure Switch Adjustment323
  - Accumulators - Hydraulic Components Cabinet324
  - Brake Accumulator Bleed down Procedure324
- Disassembly324
- Hydraulic Brake Accumulators324
- Installation324
- Removal324
  - Anti-Extrusion Ring Removal325
  - Bladder Removal325
- Cleaning and Inspection325
  - Locknut Removal325
  - Spacer Removal325
  - Bladder Installation326
  - Plug Assembly326
  - Valve Stem Installation326
  - Washer Installation326
- Charging Procedure327
  - Installation/Removal of "Dyna-Seal"327
  - Locknut Installation327
  - Accumulators - Frame Mounted328
  - Brake Accumulator Installation328
  - Charging Valves328
- Removal328
- Accumulator Assembly329
- Cleaning and Inspection329
- Disassembly329
- Gland Removal Tool329
- Assembly330
  - Testing330
  - Accumulator Charging Procedure331
  - Column-Mounted Retarder Control Lever332
  - Lever Assembly Installation332
  - Lever Assembly Removal332
  - Retarder Control Lever (Steering Column-Mounted)332
- Assembly333
  - Potentiometer Check333
  - Brake Circuit Check-Out Procedure335
  - Brake Manifold336
  - Brake Circuit Abbreviations337
- Equipment Required337
  - Brake Cabinet Port Identification338
  - Initial System Set-Up338
- Brake System Checkout339
- Failure Modes Check-Out340
  - Bottom View341
  - Rear View341
  - Both Brake Circuits Are Dragging343
- Brake Circuit and Brake Valve Troubleshooting343
  - One Brake Circuit Is Dragging343
  - The Brakes Are Locked, Service And/Or Parking343
  - A Low Brake Pressure Warning Occurs When Brakes Are Applied344
  - The Differential Pressure Warning Circuit Is Not Operating344
  - A Brake Accumulator Bleeds off Quickly When Supply Pressure Is Cut off345
  - Low Pressure Warning Comes on and Pressure Is Low345
  - Low Pressure Warning Is on Even Though System Pressure Is Proper345
  - The Low Pressure Warning Circuit Not Operating Properly345
  - Oil Is Leaking Around the Pedal Base346
  - Check-Out Procedure347
  - Hydraulic Brake System Data Sheet347
- Operation349
- WET DISC BRAKE ASSEMBLY (Front and Rear)349
- Brake Disc Wear Indicator350
- Maintenance350
  - Brake Wear Indicator Installation351
  - Both Front and Rear Wheel Brakes352
  - Brake Assembly352
- Brake Rebuild352
- Disassembly352
  - Rear Wheel Brake Only352
  - Initial Disassembly353
  - Piston Removal353
  - Piston/Housing Assembly Removal353
- Cleaning and Inspection355
- Seal Wear Progression355
- Assembly356
  - Piston Pressure Test356
  - Disc Pack Installation357
  - Inner Gear Installation357
  - Rear Brake, Hub Installation358
  - Seal Gap Adjustment358
- Floating Ring Seal Assembly/Installation359
  - Seal Terminology359
  - Alternate Procedure360
  - Front Wheel Brakes362
  - Rear Wheel Brakes362
  - Results of Incorrect Assembly362
- Wet Disc Brake Bleeding Procedure362
- Operation363
- Parking Brake363
- Parking Brake Installation363
- Inspection364
- Maintenance364
- Removal364
  - Gear Installation365
  - Gear Removal365
  - Park Brake Installation365
- Assembly366
- Cleaning and Inspection366
- Disassembly366
  - Parking Brake Assembly367
  - Pressure Test367
- Parking Brake Bleeding Procedure368
- Hydraulic System369
- Hydraulic System Components and Piping371
- Hoist Circuit Operation372
- HOIST PUMP PIPING (Top View)373
- Steering Circuit Operation374
- Hydraulic Pump Module374
- STEERING SYSTEM COMPONENTS (Bottom View)375
- Disc Brake Cooling System376
- Brake/Hoist Return Oil Manifold376
- Hydraulic System Component Repair379
- Hoist Pump379
- Hoist and Steering Pump Piping379
- Hydraulic Pumps380
- Steering/Brake Pump Removal380
- HOIST PUMP DISASSEMBLY (Rear Section)383
- HOIST PUMP DISASSEMBLY (Front Section)384
- Preparation for Seal Removal385
- Shaft Seal Removal385
- Inspection of Parts386
- Gear Bore Inspection386
- Shaft Seal Installation386
- Pump Reassembly387
- Pressure Plate Installation388
- Hoist Pump Reassembly388
- Pump Gear Timing390
- Pump Rotation Check390
- Troubleshooting Guide391
- Filling Instructions392
- Hydraulic Tank392
- Hydraulic Tank Strainers393
- Strainer Removal393
- Hydraulic Tank Breathers394
- Steering Circuit395
- TEERING SYSTEM COMPONENTS (Bottom View)395
- Component Description396
- Steering Control Unit396
- Bleeddown Manifold Valve397
- Bleeddown Solenoid397
- Bleeddown Manifold397
- Bleeddown Manifold Schematic398
- Relief Valves399
- Hoist Limit Solenoid399
- Accumulators399
- High Pressure Filter399
- Flow Amplifier400
- Flow Amplifier Valve401
- Flow Amplifier System Operation402
- No Steer402
- Flow Amplifier - no Steer403
- Steering Left404
- Flow Amplifier - Left Steer405
- Steering Right406
- Flow Amplifier - Right Steer407
- No Steer, External Shock Load408
- No Steer - External Shock Load409
- Steering Pump410
- High Altitude Operation410
- Principle of Operation412
- Full Pump Volume412
- Half Pump Volume412
- Neutral Position412
- Steering Pump Assembly413
- Steering Pump Pressure Control Schematic413
- Steering Control Unit Installation415
- Steering Control Unit Rebuild416
- Marking Valve Components416
- End Cover Removal417
- Dust Seal Removal417
- Steering Control Valve418
- Spool and Sleeve Assembly419
- Neutral Position Spring Installation419
- Bearing Installation420
- Spool Installation420
- Check Ball Installation421
- Steering Circuit Component Repair423
- Accumulator Installation424
- Steering Accumulator Charging Procedure427
- Flow Amplifier Rebuild428
- Shock and & Suction Valve Assembly430
- Amplifier Spool Assembly430
- Steering Cylinders432
- Steering Cylinder Mounting432
- Steering Cylinder Assembly433
- Piston Seal & Bearing Installation433
- Cylinder Assembly433
- Steering and Brake Pump434
- Steering Pump Removal434
- Control Piston Group436
- Pump, Front Housing437
- Pump, Rotating Group438
- Rotating Group439
- Driveshaft Group439
- Valve Plate Group439
- Pump, Rear Housing440
- Swashblock Group441
- Unloader & Compensator Controls441
- Compensator Block and Unloader Module442
- Stroke Adjuster Assembly442
- O-Ring Location on Piston Sleeve444
- Troubleshooting Chart445
- Slow Steering, Hard Steering or Loss of Power Assist445
- Drift - Truck Veers Slowly in One Direction445
- Wander - Truck will Not Stay in Straight Line445
- Erratic Steering446
- Free Wheeling446
- Excessive Free Play at Steered Wheels446
- Binding or Poor Centering of Steered Wheels446
- Low Pump Output447
- No Pump Output447
- Steering Wheel Oscillates or Turns by Itself447
- Loss of Pressure448
- Excessive or High Peak Pressure448
- Noise or Squeal448
- Erratic Pump (Load/Unload) Cycle448
- Resistance When Initially Turning Steering Whee449
- Inability to Steer (no Pressure Build-Up)449
- Free Wheeling (no End Stop)449
- Slow or Hard Steer449
- Float Position of Pilot Valve with Truck Body on Frame456
- Float Position457
- Power up Operation458
- Hold Operation460
- Hold Position461
- Power down Operation462
- Power down Position463
- Float Operation464
- Hoist Circuit Component Repair467
- Hoist Valve467
- Hoist Valve and Piping467
- O-Ring Replacement468
- Hoist Valve Assembly468
- Tie Rod Installation468
- Tightening Sequence468
- Inlet Section Disassembly469
- Restrictor Poppet Removal469
- Rear Spool Section470
- Poppet and Ball470
- Work Ports Spool Section Assembly471
- Poppet Identification472
- Front Spool Section473
- Tank Ports Spool Section Assembly474
- Hoist Pilot Valve475
- Hoist Pilot Valve & Piping475
- Relief Valve476
- Hoist Pilot Valve Reassembly477
- Tie Rod Nut Torque477
- Hoist Cylinders478
- Hoist Cylinder Lower Mount479
- Quill Installation482
- Assembly of Quill and Cylinder483
- Installation of Check Balls and Plugs in Quill484
- Assembly of Cylinder485
- Rd STAGE PISTON485
- Disabled Truck Dumping Procedure486
- Pump Module, Hose Hookup486
- Dumping Procedure486
- Lowering the Body486
- Hoist Circuit Filter487
- Hydraulic System Filters487
- Indicator Switch488
- Steering Circuit Filter489
- Indicator Switch Pressure Test Block491
- Hydraulic Check-Out Procedure493
- Steering Circuit Check-Out & Adjustment Procedure493
Warnings and Cautions493
- Equipment Requirements494
- Pump Pressure Control Adjustments494
- Pump Pressure Controls494
- Bleeddown Manifold Leakage Test495
- Steering Control Unit and Flow Amplifier Leakage Test495
- Steering Relief Valve Adjustment496
- Steering/Brake Pump Stroke Adjustment496
- Shock and Suction Valves497
- Brake Cooling Circuit Test498
- Hoist System Relief Valve and Brake Cooling Circuit Pressures498
- Pump Pressure Taps498
- Inlet Section499
- Power up Relief Pressure Test499
- Power down Relief Pressure Test500
- Power down Relief Valve500
- Counterbalance Valve Adjustment501
- Counterbalance Valve Pressure Check Only501
- Hoist Counterbalance Valve Adjustment501
- Hydraulic System Flushing Procedure502
- 930E Check-Out Procedure505
- Checkfire Electric Detection and Actuation System - Series 1509
- Manual/Automatic Actuator510
- Power Wire510
- Squib510
- Test Kit510
- Do Not Connect Squib511
- Power Check511
- Securing the Detection Wire511
- The Power Wire511
- Install Jumper512
- Install Test Module Assembly512
- Remove Indicator Light Assy512
- Remove Jumper Assembly512
- Install Actuator Cartridge513
- Installation Procedure for Squib513
- Daily514
- Normal Maintenance Based on Actual Operating Hours514
- Remove Cartridge and Disconnect Squib514
- Attach Indicator Light Assy515
- In Case of Fire515
- Remove Test Module515
- Actuator Assembly516
- Recharging the Electric Detection and Actuation System516
- What to Do after the Fire Is out516
- What to Expect516
- Blown Fuse in Battery Connector Assembly517
- Test Module Light will Not Go out517
- Test Module Light will Not Illuminate517
- Troubleshooting the Electric Detection System517
- Fire Control System519
- Fire Control System (Manual)519
- Inspection and Maintenance519
- Nozzle and Blow-Off Cap519
- Operation519
- Nozzles and Blow-Off Cap520
- Recharging Procedures520
- Fuel Receiver521
- Fuel Tank Breather & Receiver Installation521
- Wiggins Quick Fill Fuel System521
- Tank Breather Valve522
- Left Side Fill523
  - Special Tools525
  - Front Hydrair/Spindle Removal529
  - Front Spindle Removal Using Pusher Structure529
  - Installing Pusher Structure529
  - Piston/Spindle/Steering Arm529
  - Pusher Structure Hardware530
  - 930E Piston/Spindle Pusher Structure531
  - Air Conditioning System533
  - Basic Air Conditioning System (Typical)533
- Environmental Impact533
  - Air Conditioning534
  - Operator Cab Air Conditioning534
- Principles of Refrigeration534
  - Refrigeration - the Act of Cooling535
  - The Refrigeration Cycle535
  - Air Conditioner System Components536
  - COMPRESSOR (Refrigerant Pump)536
  - Receiver-Drier536
  - Thermostatic Expansion Valve536
  - Evaporator537
  - Compressor Clutch538
  - Electrical Circuit538
  - Safety Switches538
  - Thermostat538
  - R-134A Refrigerant Containers539
- System Servicing539
  - Leak Detector540
  - Recovery/Recycle Station540
  - Service Tools and Equipment540
  - Service Valves541
  - Vacuum Pump541
  - High Side Gauge542
  - Low Side Gauge542
  - Manifold Gauge Set542
  - Installing Manifold Gauge Set543
  - Service Hose Hook-Up543
  - Adding Refrigerant to the System544
  - Purging Air from Service Hoses544
  - Purging System544
  - Adding Refrigerant and Stabilizing the System545
  - Draining the Oil from the Previous Recovery Cycle545
  - Performing the Recovery Cycle545
  - Stabilizing the AC System545
  - Charging the AC System546
  - Evacuating and Charging the AC System546
  - Evacuating the System546
  - Performing the Recycling Procedure546
  - Electronic Leak Detector547
  - System Leak Testing547
  - System Performance Test547
  - Hoses and Fittings548
  - Soap and Water548
  - System Repair548
  - Tracer Dyes548
  - Checking Compressor Oil Level549
- Evacuating the System550
  - Vacuum Pump Hookup550
  - Insufficient Cooling553
  - Little or no Cooling553
  - Troubleshooting by Manifold Gauge Set Readings553
  - Air And/Or Moisture in the System554
  - Extremely Low Refrigerant Charge in the System554
  - Excessive Air And/Or Moisture in the System555
  - Expansion Valve Stuck or Plugged555
  - Expansion Valve Stuck Open556
  - System High Pressure Side Restriction556
  - Compressor Malfunction557
  - Condenser Malfunction or System Overcharge557
  - Thermostatic Switch Malfunction558
  - Preventive Maintenance Schedule for A/C System559
- Electrical System Description561
- Battery Charging System (Niehoff 240 Amp. Alternator)563
- General Description563
- Troubleshooting Procedures (on Truck)563
  - Regulator Bypass Test565
  - Test Meter Hookup565
  - Parts Illustration566
  - High Voltage Output567
  - Low Voltage Output567
  - On Vehicle Troubleshooting Guide Self Energized Alternator567
  - Charge Volt and Amp Values568
  - Definitions568
  - High-Cycle Maintenance Free Types568
  - Maintenance Free Types568
  - No Alternator Output569
  - Go to Regulator570
  - Go to ’R’ Terminal on Alternator570
  - Vehicle Charging Circuit Test Is Now Complete570
  - Alternator Dimensions572
  - Alternator Specifications573
  - Service Parts574
  - Alternator Parts575
- On Vehicle Test576
  - Preliminary Checks576
  - Test Set-Up576
  - Bypass Test577
- Bench Test578
  - Full Load Test578
  - No-Load Test578
  - Check for Open Field Coil579
  - Check Function of Clamping Diode579
  - Field Coil Tests579
- Static Tests579
  - Check Continuity of Terminal Strip Connections580
  - Check for Grounded Field Coil580
  - Control Box Tests580
  - Diode Heat Sink Tests580
  - Check Front & Rear Stator581
  - Check Negative Diodes581
  - Check Positive Diodes581
  - Stator Tests581
- Alternator Disassembly582
  - Fan Removal582
  - Pulley Removal582
  - Regulator Removal582
  - End Housing Removal583
  - Rear Bearing Removal583
  - Rear Rotor Removal583
  - Front Housing Removal584
  - Control Unit Assembly Removal585
  - Typical Control Unit585
  - Alternate Method586
  - Field Coil Removal586
  - Front Bearing Removal586
  - Front Rotor Removal586
- Alternator Assembly587
- Field Coil Assembly587
- Service Tool Instructions587
  - Front Bearing Assembly588
  - Front Housing – Rotor, Shaft & Core Assembly589
  - Front Rotor Assembly589
  - Front Housing – Stator, Field Coil & Shell Assembly590
  - Control Unit Assembly591
  - Control Unit Assembly Replacement591
  - End Housing Assembly592
  - Rear Rotor Assembly592
  - Ring Seal Conversion592
  - Install New Shaft/Core Assembly593
  - Shaft/Core Replacement593
  - Loose Fit Rear Bearings594
  - Press Fit Rear Bearings594
  - Rear Bearing Assembly594
  - Regulator Assembly594
  - Fan Assembly595
  - Pulley Assembly595
  - Bf4822 Stator Service Tool Instructions596
  - Stator Removal and Replacement596
  - Shell Assembly Preparation597
  - Stator Installation597
  - Pressure Plate Set up598
  - On Board Weighing System (Obws)599
- General Information601
- On Board Weighing System (Obws)601
- Payload Meter II601
- Display Panel602
- LIGHTS, SWITCHES, and COMPONENTS602
  - Memory Card Access Lamp (CARD Busy)602
  - Reception Pilot Lamp (Rx Busy)602
  - Transmission Pilot Lamp (Tx Busy)602
- External Display Lights603
- Tips for Operation603
- Basic Description604
- Linkage Factor604
- Theory of Operation604
- Brake Lock605
- Sources of Error605
- Suspensions605
- Typical Data from Service Check Mode605
- Calculation of the Calibration Load606
- Example Calculation of Payload606
- In Order to Adjust this Gain606
- Cycle Data607
- Number 1 - 65535607
- Types of Data Stored607
- Unit Range607
- Day608
- Engine ON/OFF Data608
- Engine Operation608
- Fault Codes and Warning Data608
- Hour 24 Hour Clock608
- Metric Tons Short Tons608
- Minute608
- Month608
- Unit Range608
- Year608
  - Other Data609
  - Total Payload and Total Number of Cycles609
- Clearing the Operator Load Counter610
- Description610
- Dimming the Lights on the Display610
- Operator Functions610
- Using the Operator Load Counter610
- Viewing the Operator Load Counter610
- Checking the Operator Check Mode611
- Initial Setup of Payload Meter611
- Switch Settings611
- Checking the G T Setting612
- Checking the Inclinometer Settings612
- Checking the Service Check Mode612
- Calibrating a Truck613
- To Calibrate the Payload Meter613
- Displays at Start-Up614
  - Normal Operation614
  - Power on614
- Setting the Option Code615
- Setting the Speed Limit615
- Setup and Maintenance615
  - Speed Limit615
  - Data All Clear616
- Day616
- Download of Information616
- Month616
- Setting the Operator I.D. Code616
- Setting the Time and Date616
- Display of Fault Codes617
- Monitoring Input Signals620
  - Service Check Mode620
  - Description of up Factor621
  - Load Calculation Timing621
- PL Mode - Load Calculation Timing621
- UP Factor - Payload Calculation Gain621
- Final Gear Ratio Selection622
- Access to Battery623
- Battery Replacement Procedure623
- Error Code, F-09, Displayed623
- Replacing the Battery623
- After Replacing the Battery624
  - Battery Connection624
  - Pressure Sensor624
- Removal624
- Suspension Pressure Sensor624
- Inclinometer625
- Inclinometer Side Connector View625
- Installation625
- Removal625
- Sensor Side Connector View625
- Description626
- Making Connections626
- Scoreboard626
- Normal Operation of the Scoreboard628
- Payload Meter Back Panel628
  - CN1 - AMP MIC-MKII 13 Pins White Connector629
  - CN2 - AMP 040 12 Pins Black Connector629
- Connections (AMP Pin Identification)629
- Payload Circuit Numbers630
- Payload Meter II Re-Initialization Procedure631
- Cab Assembly635
- Description635
- Truck Cab635
- Removal636
- Cab Hydraulic and Electrical Connections637
- Cab Door638
- Installation638
- Removal638
- Door Adjustment639
  - Door Jam Bolt Adjustment639
  - Door Handle Plunger Adjustment640
  - Latch Assembly640
  - Measuring Travel Distance of Plunger640
- Replace Door Glass641
  - Replace Door Handle or Latch Assembly645
  - Replace Door Window Regulator645
  - Door and Door Hinge Seal Replacement646
  - Door Opening Seal Removal646
  - Adhesive-Bonded Windows647
- Glass Replacement647
  - Recommended Tools/Supplies647
  - Windshield & Rear Glass648
- Cab Components649
  - Motor Installation649
  - Motor Removal649
- Windshield Wiper649
- Windshield Washer650
- Windshield Washer Fluid Reservoir and Pump650
- Circuit Breakers651
- Heater Components651
- Heater/Air Conditioner651
- Actuators652
- Air Conditioner Components652
- Fan Motor and Speed Control652
- Filter652
- Heater Coil652
  - Heater/Air Conditioner Assembly653
  - Operator Comfort655
  - Operator Seat655
  - Heater/Air Conditioner Controls656
  - Cab Heater Components657
  - Heater Control Components657
- Operator Cab Controls661
- Removal661
- Steering Column661
  - Steering Column Installation661
  - Cab Interior - Operator View662
- Dynamic Retarding663
- Horn Button663
- Steering Wheel and Controls663
  - Telescope Lock Ring663
  - Turn Signal / Headlight Dimmer663
  - Accelerator (Throttle) Pedal664
  - Retarder Control Lever664
  - Grade/Speed Chart665
  - Heater / Air Conditioner Vents665
  - Instrument Panel665
  - Cab Radio (Optional)666
- Payload Meter666
  - Radio Speakers666
  - Warning Alarm Buzzer666
  - Windshield Wipers666
- Center Console667
  - F-N-R Selector Switch667
  - Ash Tray668
  - Hoist Control Lever668
  - L.h. Window Control Switch668
  - Lighter668
  - Override /Fault Reset Switch669
  - Retard Speed Control (Rsc) Adjust Dial669
  - Retard Speed Control (Rsc) “Off/On” Switch669
  - Engine Control System670
  - Engine Diagnostics Download Port670
  - Psc Download Port670
  - Tci Download Port670
  - Control Symbols671
- Instrument Panel and Indicator Lights671
- Wire Numbers672
- Panel Gauges, Indicators and Controls673
- Panel Gauges, Indicators, and Controls672
- Key Switch673
- Normal Engine Shutdown673
- Starting673
- Engine Shutdown Switch674
- Manual Backup Switch674
- Ladder Light Switch674
- Fog Lights (Optional)674
- Panel Illumination Lights675
- Cab Air Conditioner / Heater Vents675
- Rotating Beacon Light Switch (Optional)675
- Wheel Brake Lock Control675
- High Beam Indicator676
- Left Turn Signal Indicator676
- Right Turn Signal Indicator676
- Tachometer676
- Ac Drive System Temperature Gauge677
- Hourmeter677
- Temperature Gauge677
- Rest Switch677
- Light Switch678
- WINDSHIELD WIPER and WASHER678
- Panel Light Dimmer678
- Overhead Status / Warning Indicator Lights679
- Status / Warning Indicator Light Symbols680
- Low Steering Pressure680
- Low Brake Pressure680
- Low Accumulator Precharge Pressure680
- Body up681
- Hydraulic Oil Filter Monitor681
- Circuit Breaker Tripped681
- Low Hydraulic Tank Level681
- Manual Backup Lights682
- Engine Shutdown Timer - 5 Minute Idle682
- Retard Speed Control Indicator682
- Check Engine682
- High Hydraulic Oil Temperature683
- Propulsion System Temperature683
- Propulsion System Warning683
- No Propel684
- Propel System @ Rest684
- Propel System Not Ready684
- Reduced Propulsion684
- Hazard Warning Lights685
- Lamp Test Switch685
- Link-On Warning Light685
- Lubrication and Service687
- 930E Service Capacities689
- Adding Oil689
- Hydraulic Tank Service689
- Coolant Level Check690
- Anti - Freeze Recommendations690
- 10 Hour (Daily) Inspection692
- 10 Hour Lubrication and Maintenance Checks692
- Fan Drive and Turbochargers692
- Fuel Filters692
- Cab Air Filter693
- Automatic Lube System693
- Cooling Air Ductwork693
- Wheels and Tires693
- 50 Hour Lubrication and Maintenance Checks694
- Motorized Wheels694
- 100 Hour Lubrication and Maintenance Checks695
- 250 Hour Lubrication and Maintenance Checks696
- Steering Linkage697
- Hydraulic Pump Driveshaft & U-Joints697
- Magnetic Plug697
- Rear Wheel Mounting697
- 500 Hour Lubrication and Maintenance Checks698
- Final Drive Case Breathers698
- Throttle and Brake Pedal698
- Hoist Actuator Linkage698
- 1000 Hours Lubrication and Maintenance Checks699
- Auxiliary Blower699
- 2500 Hour Maintenance Checks700
- 5000 Hour Maintenance Checks700
- Automatic Lubrication System701
- General Description701
- Pump and Reservoir Components701
- Auto Lube System Installation702
- Delay Timer703
- Vent Valve703
- Lubrication Cycle Timer703
- Hydraulic Motor and Pump703
- Hydraulic Schematic704
- Pressure Failure Detection Circuits705
- Electrical Schematic705
- Injector Operation706
- General Instructions707
- Lubricant Required for System707
- System Priming707
- Pump Pressure Control707
- Injector Specifications708
- Injector Adjustment708
- Type Sl-1 Injector708
- Lubrication Cycle Timer Adjustment709
- Timer (Top Cover Removed)709
- Filter Assembly709
- Lubrication Cycle Timer Check709
- Pump Rebuild710
- Lube Pump Assembly711
- System Troubleshooting Chart713
- Pump Does Not Operate713
- Pump will Not Prime713
- Pump will Not Build Pressure713
- Timer Stays Timed out714
- Pump Pressure Builds very Slowly or Not at All714
- Lube Cycle Timer Not Operating714
- Pressure Gauge Does Not Register Pressure714
- Preventative Maintenance Procedures716
- Daily Lubrication System Inspection716
- 250 Hour Inspection716
- 1000 Hour Inspection716
- Alphabetical Index717
- System Schematics721

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Komatsu 930E-2 - Special Tools

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