980E-4 Hoist System Components, Operation, Adjustment

930/980E-4 Hoist System
Subject to 2018 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.
Hoist System
Components, Operation and Adjustment
Copyright © 2018 Technical Training ELTM0090618E0BK2

Jose L. Rodriguez
Training Instructor Tec.
EPSA Chile
joseluis.rodriguez@epsagroup. com
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Komatsu Shop Manual
● Use the correct manual as

supplied with the new Equipment
● The Material in this course is to

be considered as a supplement to
the KOMATSU Shop Manual
● The Shop Manual contains

precise details of all topics
discussed in this training course
which should be considered as
your Core reference document
Technical Training ELTM0090618E0BK2

Slide 2
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Course Objectives
After successful completion of this lesson, the student will…..

● Understand the Hoist system components of the Komatsu 930/980E-4
Rear Dump Truck.
● Learn about operational aspects
● Learn how to make use of the maintenance procedures in the Shop
Manual
● Identify the following components
Hydraulic Oil Reservoir Hydraulic
Pump assemblies Hoist Filters
Hoist Pilot Valve
Hoist Valve
Over Center Valve
Hoist Cylinders

Slide 3
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hydraulic Tank, Filling Procedure
Maintain Suction Strainers

and inspect return Diffuser
every 1000 operating hours

Slide 4
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hydraulic Pumps
Hoist & Cooling Pump

Gear-type with outputs of
270 gpm (1022 liters/min) at 1900 rpm
Steering and Brake Pump

Piston type with an output of
66 gpm (246 liters/min) at 1900 rpm
Bleed air from Pump Delivery and Drain Lines after replacement of Pump or Hoses

Slide 5
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Schematic 930E 2500 psi

980E 2750 psi

Slide 6
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
High-Pressure Filters
1. Two In-Line Hoist filters
2. Pall 6 micron Elements
3. Coreless design
4. By-pass valves
5. By-Pass indicators
58B-06-31000
Prone to closure
Ref P&SN AA09152C
with cold oil

Slide 7
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist, Relief and Over-center Valves
Relief Valves at each Input Cover

Slide 8
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Valve Assembly

Slide 9
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist System Components

● Hoist Valve
Assembly
● Over Center
Manifold
● Brake Cooling
Manifold
● Hydraulic Filters

Slide 10
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Control – Cable Adjustment

Slide 11
Jose L. Rodriguez
Instructor Tec.
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Cylinders
● 3-stage, dual-acting on all stages

● 24 second hoist time
● Quill soft stop

Slide 12
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Cylinder ● Double acting on all three stages

● Welded glands
● Snubber Quill
Check for
interference
Check lock plates

periodically

Slide 13
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Components and Duplications 930E 2500 psi

980E 2750 psi
Not a
feature

Slide 14
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Components and Duplications

The main Hoist valve is pilot operated by a cable actuated pilot valve situated in the Brake cabinet.
The Hoist valve can actually be considered as having two individual input sections supplying oil to the Head End Spool and
Rod End Spools, from the schematic and legend it will be noted that many of the devices are duplicated. This duplication is
identified by the blue shading. Since both input sections are working in parallel, the functionality of the assembly can be best
understood by analyzing just one or the other input section.
Each Main pump supplies one input section via port (11) both input sections contain a relief valve (1), a none adjustable Flow
control Valve (2) which will maintain a minimum of 414 kPa (60 psi) internal working pressure, and divert pump flow to Brake
Cooling circuit, item (3) is a none functional Secondary Low pressure Valve set at 1724 kPa (250 psi).
Hoist Pump #1 Oil flow will be diverted to the Rear Brake cooling circuit, and Hoist Pump #2 Oil flow will be diverted to the
Front Brake cooling circuit, whenever the Hoist pilot valve is in Hold or Float.
Rod End work port (5) and Spool (7) make up the Power Down and return circuit for “annulus oil”, the Head End port (9) and
Spool (8) make up the Hoist Up and return circuit for “barrel oil”. Port 10 is the return path to Tank for all Hoist Cylinder
“work” oil.
Item 13 is the Hoist Limit Solenoid, located on the Bleed Down Manifold which is controlled by the Dump Body UP limit
switch, item (14) Raise pilot signal from Hoist pilot valve and (15) Down pilot line from the same valve.
The Power Down Relief Valve (16) is mounted on the Hoist pilot Valve assembly, Anti Void Check Valve (17) will prevent air
pockets developing in the Head circuit by transferring annulus oil to the barrel circuit during moments of over center action
when the Hoist Pump might be at idle.
The load control valve (18) prevents supply circuit pressure spikes in the event that the engine dies during Hoisting.
The Pilot operated Check Valve is mounted on the Bleed Down manifold and provides a pilot path for power down when the
Body Limit solenoid is Energized. The Primary Low pressure valve (22) maintains 26 psi in the return circuit to balance the
work spools .
Item (3) Secondary Low pressure relief valve can be considered from a functional stand point as if it were a plugged port,
although it is indexed and shown as a relief valve, the control spring tension is rated at 1724 kPa (250 psi), the valve is
situated in a low pressure gallery alongside the Primary relief valve (22), and the spring tension on this valve is rated at 179
kPa (26 psi), thus item 22 is in control of the maximum pressure in this gallery.

Slide 15
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Description -- Float Body Down
HOLD
position
DOWN
dow n
up
UP

Slide 16
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Description -- Power Up
HOLD
position
DOWN
dow n
up
UP

Slide 17
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Description -- Hold
HOLD
position
DOWN
dow n
up
UP

Slide 18
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Description -- Power Down
HOLD
position
DOWN
1500 dow n
up
UP

Slide 19
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit – Float Body Descends

Annulus Area Filling
HOLD
position
DOWN
dow n
up
UP

Slide 20
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Circuit Description -- Float Body Down
HOLD
position
DOWN
dow n
up
UP

Slide 21
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist System Adjustments

● With engine stopped and steering accumulators bled down, connect two
0~34.4 mPa (0~5000 psi) gauges to test point on hoist filters
● Start engine, allow steering accumulators to charge; pull fuse F51 in VEC91
(to disable body-up limit), slowly hoist body to end of stroke, then accelerate
engine with power up and observe gauge.
▪ This pressure cannot be adjusted without dismantling the hoist valve (see note below)
▪ 930E-4 17.2 MPa, (2500 psi) ± 4%
▪ 980E-4 18.9 MPa (2750 psi) ± 4%
● Return body to frame and accelerate engine with power down and observe
10.3 mPa (1500 psi) +/- 4% on gauge, if incorrect make adjustments to relief on
hoist pilot valve
● Replace Fuse VEC 91- F51

Slide 22
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Cylinder Over-Center Manifold

● Return oil (down line) is blocked by 3 Check
Valves and a 20.6 MPa (3000psi) Relief Valve
● When Power Up pressure is present, the
Piloted Relief Valve (Counterbalance Valve) is
open and annulus oil returns freely to tank
● If the Dump Body goes over center, pilot
pressure is reduced, Counterbalance Valve
closes and annulus flow is blocked below the
relief setting, 20.6 MPa (3000psi)
● With annulus oil flow closed off, the Dump
Body may not run over center
● 3 check valves provide free flow for power
down flow direction

Slide 23
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Over Center Valve Verification and Adjustment

a) With Engine stopped, Dump Body down, connect one 0~34.5 MPa (0~5000 psi) gauge to
TR point (7), then remove plug from pilot vent (8) and install a drain hose.
b) Loosen locknut on needle valve (9) and turn valve fully in (this closes pilot supply to Relief
Valve)
c) Start Engine and hold at idle, hoist Dump Body to the start of second & third stages then
observe gauge which should rise but not exceed 20.7 MPa (3000 psi). Increase RPM
slightly in stages and repeat process up to hi-idle. The over-center valve is in-correctly set,
if gauge pressure is below or above 20.7 MPa (3000 psi) if so, follow step (d).
d) Loosen lock nut on CBV (4) and turn fully CW (this sets the lowest possible setting), then
proceed as above in step “c” by gradually turning out CCW CBV valve until 20.7 MPa
(3000 psi) is obtained at hi-idle as the second and third stages extend.
e) Lockup CBV valve, open NV (9) and remove gauge from TR port and replace plug (8)

Slide 27
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Over Center Valve Verification and Adjustment

The Counter Balance Valve adjustment and operation MUST be verified before trucks are
commissioned.
During normal operation its functionality cannot be readily observed, it is only when the
system does not operate as required, that we realize the consequences and damage
caused;
Adjustment too low……….Damaged Cylinders and Rod ends
Adjustment too high……….Leaking rod seals and or burst hoses.
A brief summary of set up is as follows, a) With engine stopped, body down, connect one 0-
34474 kPa (0-5000 psi) gauge to TR point (7), then remove plug from pilot vent (8) and
install a drain hose. B) Loosen locknut on needle valve (9) and turn valve fully in (this closes
pilot supply to relief valve). c) Start engine and hold at idle, hoist body to the start of second
& third stages then observe gauge which should rise but not exceed 20684 kPa (3000 psi).
Increase RPM slightly in stages and repeat process up to hi-idle & over-center valve is
correctly set, stop tests if gauge pressure exceeds 20684 kPa (3000 psi) and follow step d)
Loosen lock nut on CBV (4) and turn fully CW (this sets the lowest possible setting), then
proceed as above in step “c” by gradually turning out CCW CBV valve until 20684 kPa
(3000 psi) is obtained at hi-idle as the second and third stages extend.
After verification, lockup CBV valve, open NV (9) and remove gauge from TR port and
replace plug (8)
Refer to the Shop manual for a detailed check out procedure.

Slide 28
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Procedure to Hoist Disabled Truck

Slide 29
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Counterbalance Valve
X
Slide 32
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Schematic -- Hoist Up Limit Active
● Hoist to Limit
● Body UP limit Active
● Pilot pressure directed to

TANK Flow Control Valve
directs to TANK

Slide 33
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4Hoist
HoistSystem
System Components
Hoist Schematic – Power Down Limit Active
● Power Down Request
● Body UP limit Active
● Power Down command

mechanically Pilots the
Check Valve

Slide 34
Jose L. Rodriguez
EPSA Chile
930/980E-4
930/980E-4 Monitoring
MonitoringSystems
Systems
THE END
Jose L. Rodriguez
EPSA Chile

980E-4 Hoist System Components, Operation, Adjustment

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980E-4 Hoist System Components, Operation, Adjustment

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930/980E-4 Hoist System

Copyright © 2018 Technical Training ELTM0090618E0BK2

Komatsu Shop Manual

● Use the correct manual as

● The Material in this course is to

● The Shop Manual contains

Technical Training ELTM0090618E0BK2

After successful completion of this lesson, the student will…..

Technical Training ELTM0090618E0BK2

Hydraulic Tank, Filling Procedure

Maintain Suction Strainers

Technical Training ELTM0090618E0BK2

Hoist & Cooling Pump

Steering and Brake Pump

Technical Training ELTM0090618E0BK2

Hoist Schematic 930E 2500 psi

Technical Training ELTM0090618E0BK2

Technical Training ELTM0090618E0BK2

Hoist, Relief and Over-center Valves

Relief Valves at each Input Cover

Technical Training ELTM0090618E0BK2

Hoist Valve Assembly

Technical Training ELTM0090618E0BK2

Hoist System Components

Technical Training ELTM0090618E0BK2

Hoist Control – Cable Adjustment

Technical Training ELTM0090618E0BK2

● 3-stage, dual-acting on all stages

Technical Training ELTM0090618E0BK2

Hoist Cylinder ● Double acting on all three stages

Check lock plates

Technical Training ELTM0090618E0BK2

Hoist Circuit Components and Duplications 930E 2500 psi

Technical Training ELTM0090618E0BK2

Hoist Circuit Components and Duplications

Technical Training ELTM0090618E0BK2

Hoist Circuit Description -- Float Body Down

Technical Training ELTM0090618E0BK2

Hoist Circuit Description -- Power Up

Technical Training ELTM0090618E0BK2

Hoist Circuit Description -- Hold

Technical Training ELTM0090618E0BK2

Hoist Circuit Description -- Power Down

Technical Training ELTM0090618E0BK2

Hoist Circuit – Float Body Descends

Technical Training ELTM0090618E0BK2

Hoist Circuit Description -- Float Body Down

Technical Training ELTM0090618E0BK2

Hoist System Adjustments

Technical Training ELTM0090618E0BK2

Hoist Cylinder Over-Center Manifold

Technical Training ELTM0090618E0BK2

Over Center Valve Verification and Adjustment

Technical Training ELTM0090618E0BK2

Over Center Valve Verification and Adjustment

Technical Training ELTM0090618E0BK2

Procedure to Hoist Disabled Truck

Technical Training ELTM0090618E0BK2

Hoist Schematic -- Hoist Up Limit Active

● Body UP limit Active

● Pilot pressure directed to

Technical Training ELTM0090618E0BK2

Hoist Schematic – Power Down Limit Active