Komatsu 930E-2 Manuals

Manuals and User Guides for Komatsu 930E-2. We have 1 Komatsu 930E-2 manual available for free PDF download: Shop Manual

Komatsu 930E-2 Shop Manual (740 pages)

Dump Truck w/ Cummins QSK60 Engine

Brand: Komatsu | Category: Trucks | Size: 14.84 MB

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
- 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
- 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
- PVM Optimum Load Curve Handshaking Troubleshooting
  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
- 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
- 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

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