Table Of Contents - Komatsu 930E-2 Shop Manual

Table of Contents

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
Overall Truck Dimensions14
General Safety15
Safety Rules15
Safety Features15
Clothing And Personal Protective Items15
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
In Operator's Cab - before Starting Engine20
Operating The Machine20
When Starting Engine20
Truck Operation - General20
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
Precautions For Maintenance25
Before Carrying Out Maintenance25
Warning Tag25
Stopping The Engine Before Service25
During Maintenance26
Personnel26
Attachments26
Work Under The Machine26
Radiator Water Level27
Use Of Lighting27
Precautions With Battery27
Handling High-Pressure Hoses27
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
Special Precautions For Working On A 930E Truck32
Preliminary Procedures Before Welding Or Performing Maintenance32
Normal Engine Shutdown Procedure32
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
Structures77
Index78
Structural Components79
Deck Components79
Preparation79
Grille, Hood And Ladder80
Hood And Grille Removal80
Right Deck And Components81
Typical Deck Structure Mounting81
Left Deck82
Center Deck82
Dump Body83
Dump Body Removal83
Hoist Cylinder Mount (Upper)83
Dump Body Pivot Pin84
Installation84
Body Pads85
Body Pad Installation85
Body Guide86
Hoist Limit Switch86
Body Up Switch86
Body-Up Retention Cable86
Rock Ejectors87
Rock Ejector Installation87
Rock Ejector Mounting Bracket87
Fuel Tank89
Fuel Tank Installation89
Removal90
Repair90
Cleaning90
Vent91
Fuel Gauge Sender91
Engine93
Power Module95
Hydraulic Pump Drive Shaft96
Main Alternator Blower Duct96
Engine Air Inlet Piping97
Engine Exhaust Piping98
Power Module Removal & Installation99
Subframe Rollers100
Power Module Lift Points100
Power Module Installation101
Power Module Hookup101
Air Inlet Piping Connections102
Cooling System103
Radiator103
Radiator Installation103
Air Conditioner Condenser103
Radiator Piping104
Fan Guard104
Radiator Mount105
Radiator Filling Procedure106
Coolant System Troubleshooting106
Power Train107
Alternator Removal Procedure107
Cradle Structure107
Engine And Alternator107
Alternator To Engine Mounting108
Engine/Alternator Mating109
Measuring Procedure109
Service Data - Eccentricity & Runout Limits109
Alternator End-Play110
Rotor-To-Drive Ring110
Alternator-To-Flywheel Housing Adapter110
Joining Alternator And Engine111
Engine Mounting112
Air Filtration System113
Air Cleaners113
Engine Air Cleaners113
General Service Information113
Filter Element Replacement114
Air Cleaner Assembly114
Main Filter Element Cleaning115
Inspecting Filter Element115
Precleaner Section116
Cleaning Precleaner Tubes116
Cleaning Filter Element With Compressed Air116
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
Electrical System Description121
Batteries121
Maintenance And Service121
Battery Supply System123
24Vdc Battery Charging Alternator123
Battery Box123
Battery Control Box123
Battery Disconnect Switches124
Vdc Auxiliary Battery Connectors124
Battery Equalizer125
24 Vdc Electrical System Components127
Passenger Seat Base Compartment127
Tail Light Resistor Diode Assemblies127
5 Minute Idle Timer Components127
Brake Warning Buzzer (Bwb)129
Alarm Indicating Device (Aid) System129
5 Minute Idle Timer129
5 Minute Idle Relay129
Temperature And Latch130
Hot Switch Inverter130
Aid System Card Enclosure130
Hot Switch Inverter Card (Slot 4) (Not Used)131
Oil Level131
Temperature131
Diode Matrix (Without Sound)131
Electrical Interface Cabinet132
Truck Control Interface Panel132
Lubrication System Timer132
Barometric Pressure Transducer132
Truck Control Interface Panel (Tci)133
Diode Board - Db1134
Diode Testing134
Circuit Breaker Panel134
Relay Boards135
To Replace A Relay135
To Replace A Circuit Breaker135
Service135
Relay Board Identification136
To Replace A Circuit Panel Card136
Typical Relay Board136
Relay Board Functions137
Relay Board 1 (Rb1)137
Relay Board 2 (Rb2)137
Relay Board 3 (Rb3)137
Relay Board 6 (Rb6)138
Installing Additional Circuits138
Body-Up Switch Adjustment139
Body Limit Switch Adjustment140
Circuit Breakers141
Electrical Propulsion System143
Electrical Propulsion System Components145
General System Description145
Propulsion System Diagram146
System Components147
Auxiliary Blower System147
Propulsion System Controller (Psc)147
Did Panel Fault Codes149
Diagnostic Information Display149
Psc Software Functions174
Input Processing174
State Management174
Startup/Shutdown State174
Retard State175
Transitions Between States175
Transition To Startup/Shutdown State (Startup)175
Transition To Startup/Shutdown State (Shutdown)175
Transition From Ready State To Retard State176
Transition From Propel State To Retard State176
Transition From Rest State To Test State176
Transition From Propel State To Ready State176
Dc Link State177
Powering The Link177
De-Powering The Link177
Engine Control177
Alternator Field Control178
Desired Three-Phase Voltage178
Desired Dc Link Voltage178
Self-Load178
Propel Torque Control179
Retard Torque Control179
Speed Override179
Motor Torque Limits179
Event Processing180
Resistor Grid Control180
Chopper Voltage Control180
Auxiliary Blower Control180
Event Restrictions181
Initiated Tests181
Periodic Tests181
No Power181
Event Logging And Storage182
Event History Buffer182
Data Packs182
Serial Data Communications183
Output Processing183
Event Reset183
Psc - Ptu Communications Processing183
Abnormal Conditions/Overriding Functions184
Fast Start184
Engine Shutdown/Engine Not Running184
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
Shutdown After A System Failure199
Blower Control Devices199
Battery Circuit Voltage Check200
Resistance Checks, Low Voltage Circuits200
Battery And Control Checks Of System With Battery Power Off200
System Checkout (Release 17 Software)200
Circuit Resistance Checks201
Resistance Checks, Propulsion System Circuits202
Dc Link Checks202
Chopper Modules (Cm1, Cm2)202
Gate Driver Power Supply (Gdps)202
Battery And Control Circuit Checks Of System With Battery Power On203
Afse P1 Adjustment203
Grr Wiring203
A3Pv Panel (17Fm458A2)204
Sensor Power Supply (Sps)204
Checks With Key Switch Off204
Checks With Key Switch On204
Cpu Battery Checks205
Tci Card Checks205
Input Voltage205
Positive Output Voltage205
Memory Backup Battery Replacement206
Tci Programming206
To Replace The Battery On Either Card206
To Program The 17Fb144 Cpu Card206
Psc Programming207
Inverter Programming207
To Program The 17Fb147 Cpu Card207
To Program The Inverters207
Tci Checkout208
Log On To The Tci Panel208
View/Set The Date And Time In The Psc Panel208
Check Comm Status208
Tci Analog Input Checks209
Tci Digital Output Tests210
Aux Error Code Check211
Figure 3-4. Status/Warning Lights211
Trucks Without Prelube System211
Trucks With Prelube System211
Tci Digital Input Tests212
Did Display212
Psc Checkout Procedure214
Psc Digital Output Tests214
Psc Digital Input Checks216
17Fm458 Panel Checks:217
A3Pv Panel217
Linkv Panel217
Thermistor Checks217
Pedal Percentages And Meter Calibration218
Meter Calibration Procedure218
Retard Pedal218
Retard Lever218
Truck Speed219
Accelerator Pedal219
Retard Speed Pot Setting219
Pot Reference219
Reprogram With Serial Numbers And Pedal Percentages220
Program Tci221
Check Pedal Percentages221
Load Testing222
Preload Checks222
Alternator Speed Sensor Check222
Battery Boost Check222
Psc Real Time Data Screen223
Tci Real Time Data Screen223
Additional Truck Checks224
Hoist & Steering Circuit Switch Checks224
Aux Blower Rotation Check224
Brake System Pressure Switch Checks224
Final Checks225
Inverter Link Voltage Check225
On-Board Load Testing226
Psc Real Time Data Screen Sample226
Initiate Loadbox Test227
Tci Real Time Data Screen Sample227
Self Load Test Screen, Rp1 Picked Up227
Self Load Test Screen, Rp1 & Rp2/3 Picked Up228
Trucks With Ddec Engine229
Trucks With Komatsu Ssda16V160 Engine229
Manual Offset Hp Output Adjustment229
Self Load Test, Rp1, 2 & 3 Picked Up229
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
Troubleshooting Phase Modules And Chopper Modules232
Phase Module Removal And Snubber Resistor Replacement232
To Remove The Snubber Resistors233
Snubber Resistor Installation233
Phase Module Installation233
Auxiliary Blower Control System Troubleshooting234
Auxiliary Blower Control Components235
Auxiliary Inverter (Controller) Troubleshooting237
Measurement Points237
Auxiliary Snubber Panel Troubleshooting238
Auxiliary Snubber Schematic238
Igbt Troubleshooting239
Igbt Check Test Points239
Rear Axle, Spindles And Wheels241
Tires And Rims243
Typical Tire Handler243
Front Tires And Rims244
Front Wheel Hub And Rim Assembly244
Rear Tires And Rims245
Rear Axle Jack Location245
Rear Tire Removal245
Rear Wheel Assembly246
Rim248
Tire Removal248
Tire Installation249
Front Wheel Hub And Spindle251
Wheel Hub And Spindle Assembly251
Front Wheel & Spindle Installation251
Spindle And Wheel Hub Removal252
Wheel Hub And Spindle Removal252
Spindle Removal Tool Installation253
Spindle Removal Tool253
Cleaning And Inspection255
Disassembly255
Front Wheel Spindle, Hub & Brake Assembly256
Wheel Bearing Adjustment257
Assembly257
Brake Installation258
Steering Cylinders And Tie Rod259
Seal Assembly Gap Check259
Measuring Seal Gap259
Steering Cylinder And Tie Rod Installation260
Bearing Replacement261
Typical Bearing Installation261
Toe-In Adjustment262
Measuring Toe-In262
Pivot Pin263
Pivot Pin Assembly263
Rear Axle Housing Mounting Attachment263
Pivot Eye Bearing264
Pivot Eye Bearing Installation264
Pivot Eye Repair265
Pivot Eye Attachment265
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
Front Suspension275
Suspension Charging Valve275
Charging Valve Installation275
Suspension Installation276
Installation Of Hardened Flat Washer277
"TURN-OF-THE-NUT" Tightening Procedure278
Reference Marks For 60 Degree Advance278
Reference Marks For 120 Degree Advance278
Minor Repair Only279
Bearing Retainer Removal279
Bearing Retainer Installation279
Piston Rod Removal279
Major Suspension Rebuild280
Back-Up Ring Placement281
Rear Suspensions283
Rear Suspension Installation283
Charging Valve283
Suspension Mounting Pin284
Rear Suspension Assembly287
Oiling And Charging Procedure289
Equipment List289
Hydrair Charging Kit289
Removal Of Charging Kit290
Front Suspension Oiling290
Support Blocks For Oiling And Charging Dimensions290
Front Suspension Nitrogen Charging291
Rear Suspension Oiling292
Rear Suspension Nitrogen Charging293
Rear Suspension Dimensions (Empty)293
Oil And Nitrogen Specifications Charts294
Brake System295
Brake Circuit297
Service Brake Circuit297
Hydraulic Components Cabinet298
Secondary Braking And Automatic Apply299
Parking Brake Circuit299
Brake Lock Circuit300
Warning Circuit300
Pressure Sensor, System Supply Pressure300
Pressure Sensor, Low Brake Pressure300
Brake Valve301
Rear Axle Brake Lines302
Rear Brake Hoses302
Brake Circuit Component Service303
Rebuild Criteria303
Brake Accumulator Bleed Down303
Brake Valve/Retard Pedal Assembly305
Actuator Cap & Boot306
Actuator Base Threaded Inserts308
Boot And Cap308
Valve Body Seal Installation308
Regulator Sleeve O-Ring Installation309
Actuator Plunger O-Ring Installation309
Assembly Of Valve309
Sleeve Seal Placement309
Differential Pressure Switch311
Valve Bench Test And Adjustment312
Test Bench Set Up312
Test Set Up Procedure313
Brake Valve Output Pressure Adjustment313
Differential Pressure Switch Adjustment313
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
Valve Test And Adjustment321
Dual Relay Valve Bench Test Setup321
Hydraulic Brake Accumulators324
Accumulators - Hydraulic Components Cabinet324
Brake Accumulator Bleed Down Procedure324
Locknut Removal325
Spacer Removal325
Anti-Extrusion Ring Removal325
Bladder Removal325
Bladder Installation326
Valve Stem Installation326
Plug Assembly326
Washer Installation326
Locknut Installation327
Installation/Removal Of "Dyna-Seal"327
Charging Procedure327
Accumulators - Frame Mounted328
Charging Valves328
Brake Accumulator Installation328
Accumulator Assembly329
Gland Removal Tool329
Testing330
Accumulator Charging Procedure331
Retarder Control Lever (Steering Column-Mounted)332
Lever Assembly Removal332
Lever Assembly Installation332
Column-Mounted Retarder Control Lever332
Potentiometer Check333
Brake Circuit Check-Out Procedure335
Brake Manifold336
Equipment Required337
Brake Circuit Abbreviations337
Initial System Set-Up338
Brake Cabinet Port Identification338
Brake System Checkout339
Failure Modes Check-Out340
Bottom View341
Rear View341
Brake Circuit And Brake Valve Troubleshooting343
The Brakes Are Locked, Service And/Or Parking343
Both Brake Circuits Are Dragging343
One Brake Circuit Is Dragging343
A Low Brake Pressure Warning Occurs When Brakes Are Applied344
The Differential Pressure Warning Circuit Is Not Operating344
The Low Pressure Warning Circuit Not Operating Properly345
Low Pressure Warning Is On Even Though System Pressure Is Proper345
Low Pressure Warning Comes On And Pressure Is Low345
A Brake Accumulator Bleeds Off Quickly When Supply Pressure Is Cut Off345
Oil Is Leaking Around The Pedal Base346
Check-Out Procedure347
Hydraulic Brake System Data Sheet347
Wet Disc Brake Assembly (Front And Rear)349
Operation349
Maintenance350
Brake Disc Wear Indicator350
Brake Wear Indicator Installation351
Brake Rebuild352
Rear Wheel Brake Only352
Both Front And Rear Wheel Brakes352
Brake Assembly352
Initial Disassembly353
Piston/Housing Assembly Removal353
Piston Removal353
Seal Wear Progression355
Piston Pressure Test356
Inner Gear Installation357
Disc Pack Installation357
Rear Brake, Hub Installation358
Seal Gap Adjustment358
Floating Ring Seal Assembly/Installation359
Seal Terminology359
Alternate Procedure360
Wet Disc Brake Bleeding Procedure362
Rear Wheel Brakes362
Front Wheel Brakes362
Results Of Incorrect Assembly362
Parking Brake363
Parking Brake Installation363
Inspection364
Gear Removal365
Gear Installation365
Park Brake Installation365
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
Hydraulic Tank392
Filling Instructions392
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
Steering Wheel Oscillates Or Turns By Itself447
No Pump Output447
Low Pump Output447
Loss Of Pressure448
Excessive Or High Peak Pressure448
Noise Or Squeal448
Erratic Pump (Load/Unload) Cycle448
Slow Or Hard Steer449
Free Wheeling (No End Stop)449
Inability To Steer (No Pressure Build-Up)449
Resistance When Initially Turning Steering Whee449
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
Hydraulic System Filters487
Hoist Circuit Filter487
Indicator Switch488
Steering Circuit Filter489
Indicator Switch Pressure Test Block491
Hydraulic Check-Out Procedure493
Steering Circuit Check-Out & Adjustment Procedure493
Equipment Requirements494
Pump Pressure Control Adjustments494
Pump Pressure Controls494
Steering Control Unit And Flow Amplifier Leakage Test495
Bleeddown Manifold Leakage Test495
Steering/Brake Pump Stroke Adjustment496
Steering Relief Valve Adjustment496
Shock And Suction Valves497
Hoist System Relief Valve And Brake Cooling Circuit Pressures498
Brake Cooling Circuit Test498
Pump Pressure Taps498
Power Up Relief Pressure Test499
Inlet Section499
Power Down Relief Pressure Test500
Power Down Relief Valve500
Hoist Counterbalance Valve Adjustment501
Counterbalance Valve Pressure Check Only501
Counterbalance Valve Adjustment501
Hydraulic System Flushing Procedure502
930E Check-Out Procedure505
Checkfire Electric Detection And Actuation System - Series 1509
Manual/Automatic Actuator510
Power Wire510
Test Kit510
Squib510
Securing The Detection Wire511
The Power Wire511
Power Check511
Do Not Connect Squib511
Install Jumper512
Remove Jumper Assembly512
Install Test Module Assembly512
Remove Indicator Light Assy512
Installation Procedure For Squib513
Install Actuator Cartridge513
Daily514
Normal Maintenance Based On Actual Operating Hours514
Remove Cartridge And Disconnect Squib514
In Case Of Fire515
Attach Indicator Light Assy515
Remove Test Module515
What To Expect516
What To Do After The Fire Is Out516
Recharging The Electric Detection And Actuation System516
Actuator Assembly516
Troubleshooting The Electric Detection System517
Blown Fuse In Battery Connector Assembly517
Test Module Light Will Not Illuminate517
Test Module Light Will Not Go Out517
Fire Control System (Manual)519
Fire Control System519
Nozzle And Blow-Off Cap519
Inspection And Maintenance519
Nozzles And Blow-Off Cap520
Recharging Procedures520
Wiggins Quick Fill Fuel System521
Fuel Receiver521
Fuel Tank Breather & Receiver Installation521
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
Environmental Impact533
Basic Air Conditioning System (Typical)533
Operator Cab Air Conditioning534
Principles Of Refrigeration534
Air Conditioning534
Refrigeration - The Act Of Cooling535
The Refrigeration Cycle535
Air Conditioner System Components536
Compressor (Refrigerant Pump)536
Receiver-Drier536
Thermostatic Expansion Valve536
Evaporator537
Electrical Circuit538
Compressor Clutch538
Thermostat538
Safety Switches538
System Servicing539
R-134A Refrigerant Containers539
Service Tools And Equipment540
Recovery/Recycle Station540
Leak Detector540
Service Valves541
Vacuum Pump541
Manifold Gauge Set542
Low Side Gauge542
High Side Gauge542
Installing Manifold Gauge Set543
Service Hose Hook-Up543
Purging Air From Service Hoses544
Adding Refrigerant To The System544
Purging System544
Stabilizing The Ac System545
Adding Refrigerant And Stabilizing The System545
Performing The Recovery Cycle545
Draining The Oil From The Previous Recovery Cycle545
Performing The Recycling Procedure546
Evacuating And Charging The Ac System546
Evacuating The System546
Charging The Ac System546
System Performance Test547
System Leak Testing547
Electronic Leak Detector547
System Repair548
Tracer Dyes548
Soap And Water548
Hoses And Fittings548
Checking Compressor Oil Level549
Vacuum Pump Hookup550
Troubleshooting By Manifold Gauge Set Readings553
Insufficient Cooling553
Little Or No Cooling553
Extremely Low Refrigerant Charge In The System554
Air And/Or Moisture 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
Battery Charging System (Niehoff 240 Amp. Alternator)563
Troubleshooting Procedures (On Truck)563
General Description563
Regulator Bypass Test565
Test Meter Hookup565
Parts Illustration566
On Vehicle Troubleshooting Guide Self Energized Alternator567
Low Voltage Output567
High Voltage Output567
Maintenance Free Types568
High-Cycle Maintenance Free Types568
Charge Volt And Amp Values568
Definitions568
No Alternator Output569
Go to 'R' Terminal on Alternator570
Go To Regulator570
Vehicle Charging Circuit Test Is Now Complete570
Alternator Dimensions572
Alternator Specifications573
Service Parts574
Alternator Parts575
Preliminary Checks576
Test Set-Up576
On Vehicle Test576
Bypass Test577
Bench Test578
Full Load Test578
No-Load Test578
Static Tests579
Field Coil Tests579
Check For Open Field Coil579
Check Function Of Clamping Diode579
Control Box Tests580
Check For Grounded Field Coil580
Check Continuity Of Terminal Strip Connections580
Diode Heat Sink Tests580
Stator Tests581
Check Positive Diodes581
Check Negative Diodes581
Check Front & Rear Stator581
Alternator Disassembly582
Fan Removal582
Regulator Removal582
Pulley Removal582
End Housing Removal583
Rear Rotor Removal583
Rear Bearing Removal583
Front Housing Removal584
Control Unit Assembly Removal585
Typical Control Unit585
Front Bearing Removal586
Front Rotor Removal586
Alternate Method586
Field Coil Removal586
Alternator Assembly587
Field Coil Assembly587
Service Tool Instructions587
Front Bearing Assembly588
Front Rotor Assembly589
Front Housing – Rotor, Shaft & Core Assembly589
Front Housing – Stator, Field Coil & Shell Assembly590
Control Unit Assembly Replacement591
Control Unit Assembly591
End Housing Assembly592
Rear Rotor Assembly592
Ring Seal Conversion592
Shaft/Core Replacement593
Install New Shaft/Core Assembly593
Rear Bearing Assembly594
Press Fit Rear Bearings594
Loose Fit Rear Bearings594
Regulator Assembly594
Fan Assembly595
Pulley Assembly595
Bf4822 Stator Service Tool Instructions596
Stator Removal And Replacement596
Stator Installation597
Shell Assembly Preparation597
Pressure Plate Set Up598
On Board Weighing System (Obws)599
Payload Meter Ii601
Display Panel602
Reception Pilot Lamp (Rx Busy)602
Transmission Pilot Lamp (Tx Busy)602
Memory Card Access Lamp (Card Busy)602
Lights, Switches, And Components602
Tips For Operation603
External Display Lights603
Theory Of Operation604
Basic Description604
Linkage Factor604
Typical Data From Service Check Mode605
Brake Lock605
Sources Of Error605
Suspensions605
Calculation Of The Calibration Load606
In Order To Adjust This Gain606
Example Calculation Of Payload606
Types Of Data Stored607
Cycle Data607
Unit Range607
Number 1 - 65535607
Engine On/Off Data608
Fault Codes And Warning Data608
Hour 24 Hour Clock608
Metric Tons Short Tons608
Year608
Month608
Day608
Minute608
Total Payload And Total Number Of Cycles609
Other Data609
Operator Functions610
Using The Operator Load Counter610
Viewing The Operator Load Counter610
Clearing The Operator Load Counter610
Description610
Dimming The Lights On The Display610
Initial Setup Of Payload Meter611
Switch Settings611
Checking The Operator Check Mode611
Checking The Service Check Mode612
Checking The G T Setting612
Checking The Inclinometer Settings612
Calibrating A Truck613
To Calibrate The Payload Meter613
Displays At Start-Up614
Power On614
Normal Operation614
Setup And Maintenance615
Speed Limit615
Setting The Speed Limit615
Setting The Option Code615
Download Of Information616
Setting The Operator I.d. Code616
Setting The Time And Date616
Data All Clear616
Display Of Fault Codes617
Monitoring Input Signals620
Service Check Mode620
Up Factor - Payload Calculation Gain621
Description Of Up Factor621
Pl Mode - Load Calculation Timing621
Load Calculation Timing621
Final Gear Ratio Selection622
Battery Replacement Procedure623
Error Code, F-09, Displayed623
Replacing The Battery623
Access To Battery623
Suspension Pressure Sensor624
Battery Connection624
After Replacing The Battery624
Pressure Sensor624
Inclinometer625
Sensor Side Connector View625
Inclinometer Side Connector View625
Scoreboard626
Making Connections626
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
Truck Cab635
Cab Assembly635
Cab Hydraulic And Electrical Connections637
Cab Door638
Door Adjustment639
Door Jam Bolt Adjustment639
Door Handle Plunger Adjustment640
Latch Assembly640
Measuring Travel Distance Of Plunger640
Replace Door Glass641
Replace Door Window Regulator645
Replace Door Handle Or Latch Assembly645
Door And Door Hinge Seal Replacement646
Door Opening Seal Removal646
Glass Replacement647
Adhesive-Bonded Windows647
Recommended Tools/Supplies647
Windshield & Rear Glass648
Cab Components649
Windshield Wiper649
Motor Removal649
Motor Installation649
Windshield Washer650
Windshield Washer Fluid Reservoir And Pump650
Heater/Air Conditioner651
Heater Components651
Heater Coil652
Fan Motor And Speed Control652
Actuators652
Air Conditioner Components652
Filter652
Heater/Air Conditioner Assembly653
Operator Comfort655
Operator Seat655
Heater/Air Conditioner Controls656
Heater Control Components657
Cab Heater Components657
Operator Cab Controls661
Steering Column661
Steering Column Installation661
Cab Interior - Operator View662
Steering Wheel And Controls663
Horn Button663
Telescope Lock Ring663
Turn Signal / Headlight Dimmer663
Dynamic Retarding663
Retarder Control Lever664
Accelerator (Throttle) Pedal664
Heater / Air Conditioner Vents665
Instrument Panel665
Grade/Speed Chart665
Radio Speakers666
Warning Alarm Buzzer666
Cab Radio (Optional)666
Windshield Wipers666
Payload Meter666
Center Console667
F-N-R Selector Switch667
Hoist Control Lever668
Ash Tray668
Lighter668
L.h. Window Control Switch668
Override /Fault Reset Switch669
Retard Speed Control (Rsc) "Off/On" Switch669
Retard Speed Control (Rsc) Adjust Dial669
Psc Download Port670
Engine Diagnostics Download Port670
Engine Control System670
Tci Download Port670
Instrument Panel And Indicator Lights671
Control Symbols671
Panel Gauges, Indicators, And Controls672
Wire Numbers672
Panel Gauges, Indicators And Controls673
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
Tachometer676
Right Turn Signal Indicator676
High Beam Indicator676
Left Turn Signal Indicator676
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
Low Hydraulic Tank Level681
Circuit Breaker Tripped681
Hydraulic Oil Filter Monitor681
Body Up681
Manual Backup Lights682
Engine Shutdown Timer - 5 Minute Idle682
Retard Speed Control Indicator682
Check Engine682
Propulsion System Warning683
Propulsion System Temperature683
High Hydraulic Oil Temperature683
No Propel684
Propel System @ Rest684
Propel System Not Ready684
Reduced Propulsion684
Hazard Warning Lights685
Lamp Test Switch685
Link-On Warning Light685
Lubrication And Service687
Hydraulic Tank Service689
Adding Oil689
930E Service Capacities689
Coolant Level Check690
Anti - Freeze Recommendations690
10 Hour (Daily) Inspection692
10 Hour Lubrication And Maintenance Checks692
Fan Drive And Turbochargers692
Fuel Filters692
Wheels And Tires693
Cab Air Filter693
Automatic Lube System693
Cooling Air Ductwork693
50 Hour Lubrication And Maintenance Checks694
Motorized Wheels694
100 Hour Lubrication And Maintenance Checks695
250 Hour Lubrication And Maintenance Checks696
Hydraulic Pump Driveshaft & U-Joints697
Rear Wheel Mounting697
Magnetic Plug697
Steering Linkage697
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
Pump And Reservoir Components701
Auto Lube System Installation702
Hydraulic Motor And Pump703
Vent Valve703
Lubrication Cycle Timer703
Delay Timer703
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 Check709
Filter Assembly709
Lubrication Cycle Timer Adjustment709
Timer (Top Cover Removed)709
Pump Rebuild710
Lube Pump Assembly711
System Troubleshooting Chart713
Pump Does Not Operate713
Pump Will Not Prime713
Pump Will Not Build Pressure713
Pressure Gauge Does Not Register Pressure714
Pump Pressure Builds Very Slowly Or Not At All714
Lube Cycle Timer Not Operating714
Timer Stays Timed Out714
Preventative Maintenance Procedures716
Daily Lubrication System Inspection716
250 Hour Inspection716
1000 Hour Inspection716
Alphabetical Index717
System Schematics721