Komatsu 930E-4SE Dump Truck Shop Manual CEBM029801 PDF

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Komatsu 930E-4SE Dump Truck Shop Manual CEBM029801 –  PDF DOWNLOAD

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Komatsu 930E-4SE Dump Truck Shop Manual CEBM029801 –  PDF DOWNLOAD

Language : English
Pages : 1391
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 930E-4SE Dump Truck Shop Manual CEBM029801 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31828 – A31874

SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTIONS 3
SECTION A2 COMPONENTS & SPECIFICATIONS 11
Truck And Engine 11
Main Alternator 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SECTION A2 SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
BATTERY ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 14
SERVICE BRAKES 14
STEERING 14
TIRES 14
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS 14
WEIGHT DISTRIBUTION 15
SECTION A3 SAFETY 17
GENERAL 17
PRECAUTIONS BEFORE OPERATION 20
OPERATING THE TRUCK 22
WORKING NEAR BATTERIES 25
BEFORE PERFORMING MAINTENANCE 27
WHILE PERFORMING MAINTENANCE 29
TIRES 31
WHEN REPAIRS ARE NECESSARY 32
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 33
CAPACITOR DISCHARGE SYSTEM 35
SECTION A3 OPERATING INSTRUCTIONS 43
PREPARING FOR OPERATION 43
WALK AROUND INSPECTION 43
RETRACTABLE LADDER SYSTEM (Optional) 47
IN-CAB CONTROL PANEL 48
USING THE IN-CAB CONTROL PANEL 49
USING THE GROUND LEVEL CONTROL BOX 51
EMERGENCY OPERATION 51
ENGINE START-UP 52
AFTER ENGINE HAS STARTED 53
PRE-SHIFT BRAKE CHECK 53
OPERATION 54
PERFORMING THE BRAKE TESTS 55
EMERGENCY STEERING SYSTEM 57
MACHINE OPERATION SAFETY PRECAUTIONS 58
OPERATING ON THE HAUL ROAD 59
STARTING ON A GRADE WITH A LOADED TRUCK 60
PASSING 60
LOADING 60
DUMPING 61
TOWING 63
SUDDEN LOSS OF ENGINE POWER 66
FUEL DEPLETION 66
SAFE PARKING PROCEDURES 65
NORMAL ENGINE SHUTDOWN PROCEDURE 65
DISABLED TRUCK DUMPING PROCEDURE 67
SECTION A4 WARNINGS AND CAUTIONS 69
GRADE/SPEED CHART 69
KEY SWITCH 69
ROPS/FOPS 69
BATTERIES 70
CAPACITORS 70
CRUSHING HAZARD 71
CYLINDER PRESSURE 71
FILLING THE HYDRAULIC TANK 72
HYDRAULIC OIL PRESSURE 72
HOT OIL SPRAY 73
WHEEL MOTOR OIL LEVEL 73
HOT EXHAUST 73
RADIATOR 73
EMERGENCY LADDER 73
ACCUMULATOR DRAIN VALVES 73
EMERGENCY DUMP PROCEDURE 74
EMERGENCY TOWING PROCEDURE 74
WELDING 74
EMERGENCY SHUTDOWN 74
INFORMATION DISPLAY 75
WIRELESS SIGNALS 75
HIGH VOLTAGE 75
LIFTING INSTRUCTIONS 76
PRODUCT IDENTIFICATION PLATE 77
LUBRICATION CHART 78
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 79
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 80
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 80
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 81
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 82
SECTION A7 STORAGE PROCEDURES AND IDLE MACHINE PREPARATION 89
SHORT TERM IDLE PERIODS 89
PREPARATION FOR STORAGE 90
REMOVAL FROM STORAGE 91
RECONDITIONING AN IDLE VEHICLE 92
ENGINE OPERATION 94
ENGINE STORAGE 96
RESTORING AN ENGINE AFTER EXTENDED STORAGE 97
ELECTRIC DRIVE TRUCKS 98
SECTION B STRUCTURES INDEX 101
SECTION B2 STRUCTURAL COMPONENTS INDEX 103
STRUCTURAL COMPONENTS 105
PREPARATION 105
DIAGONAL LADDER, GRILLE AND HOOD ASSEMBLY 106
RH DECK AND RETARDING GRID 107
LH DECK 108
CENTER DECK 109
SECTION B3 DUMP BODY INDEX 111
DUMP BODY 113
BODY PADS 115
BODY GUIDE 117
HOIST LIMIT SWITCH 117
BODY-UP SWITCH 117
BODY RETENTION SLING 117
ROCK EJECTORS 118
SECTION B4 FUEL TANK INDEX 119
FUEL TANK 121
FUEL TANK VENT ASSEMBLY 123
FUEL GAUGE SENDER 124
QUICK FILL FUEL RECEIVERS 124
SECTION C ENGINE INDEX 125
SECTION C2 POWER MODULE INDEX 127
POWER MODULE 129
PREPARATION FOR REMOVAL 129
REMOVAL 134
INSTALLATION 136
HOOKUP 137
EXHAUST TUBE INSTALLATION 138
EXHAUST BLANKET INSTALLATION 138
SECTION C3 COOLING SYSTEM INDEX 139
COOLING SYSTEM 141
RADIATOR 141
REPAIRING THE RADIATOR 144
COOLANT SYSTEM TROUBLESHOOTING 147
SECTION C4 POWER TRAIN INDEX 149
POWER TRAIN 151
ALTERNATOR REMOVAL 151
ALTERNATOR INSTALLATION 153
ENGINE 156
SECTION C5 AIR CLEANERS INDEX 157
AIR CLEANERS 159
OPERATION 159
SERVICING THE AIR CLEANERS 159
AIR CLEANER ASSEMBLY CLEANING 161
AIR INTAKE TROUBLESHOOTING 164
SECTION C7 FAN CLUTCH INDEX 165
FAN CLUTCH 167
REMOVAL & INSTALLATION TOOLING 167
DISASSEMBLY 170
CLEANING AND INSPECTION 180
ASSEMBLY 184
TEST PROCEDURE 199
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 201
SECTION D2 24VDC ELECTRICAL SUPPLY SYSTEM INDEX 203
24VDC ELECTRIC SUPPLY SYSTEM 205
CRANKING MOTORS 212
CRANKING MOTOR TROUBLESHOOTING 213
MAGNETIC SWITCH 215
24VDC ELECTRIC START SYSTEM 212
ELECTRICAL SYSTEM DESCRIPTION 205
BATTERIES 205
BATTERY SUPPLY SYSTEM 207
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 208
MAINTENANCE 209
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 210
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 217
24 VDC ELECTRICAL SYSTEM COMPONENTS 219
BRAKE WARNING BUZZER 219
AUXILIARY CONTROL CABINET COMPONENTS 219
RELAY BOARDS 225
BODY-UP SWITCH 230
HOIST LIMIT SWITCH 231
FUSE BLOCKS AND CIRCUIT BREAKERS 232
SECTION D11 KOMTRAX PLUS INDEX 235
KOMTRAX PLUS 237
KOMTRAX PLUS BASIC FEATURES 237
USING KOMTRAX PLUS 239
KOMTRAX PLUS DATA ITEMS 241
KOMTRAX PLUS DIAGNOSTIC FEATURES 248
KOMTRAX PLUS CONTROLLER 248
KOMTRAX PLUS SOFTWARE 250
KOMTRAX PLUS INITIALIZATION PROCEDURE 251
CONTROLLER SETUP PROCEDURE 251
SNAPSHOT PROCEDURE 254
DOWNLOAD PROCEDURE 255
FTP UPLOAD PROCEDURE 256
INITIALIZATION FORMS 257
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 258
KOMTRAX PLUS CONTROLLER CHECKOUT 263
ORBCOMM CONTROLLER (if equipped) 266
SECTION D12 INTERFACE MODULE INDEX 267
INTERFACE MODULE 269
INTERFACE MODULE 269
SENSORS 270
INTERFACE MODULE SOFTWARE 271
INTERFACE MODULE CHECKOUT 273
SECTION D13 INTERFACE MODULE AND KOMTRAX PLUS TROUBLESHOOTING INDEX 281
KOMTRAX Plus AND INTERFACE MODULE ERROR CODESAND TROUBLESHOOTING 283
GENERAL 283
TROUBLESHOOTING 284
FAULT CODES 284
FAULT TREE ANALYSIS 296
SECTION D14 KOMTRAX PLUS FORMS INDEX 301
KOMTRAX PLUS FORMS 303
KOMTRAX PLUS INITIALIZATION CHECK LIST 303
KOMTRAX PLUS DATA DOWNLOAD 304
KOMTRAX PLUS INITIALIZATION CHECK LIST 305
KOMTRAX PLUS INITIALIZATION FORM 307
SECTION E ELECTRIC PROPULSION SYSTEM INDEX 309
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 311
ELECTRICAL PROPULSION SYSTEM COMPONENTS 313
GENERAL SYSTEM DESCRIPTION 313
SYSTEM COMPONENTS 315
PSC SOFTWARE FUNCTIONS 336
ALTERNATOR FIELD CONTROL 340
EVENT DETECTION AND PROCESSING 342
EVENT RESTRICTIONS 343
EVENT LOGGING AND STORAGE 343
SERIAL DATA COMMUNICATIONS 345
OUTPUT PROCESSING 346
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 346
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 348
ELECTRONIC ACCELERATOR AND RETARD PEDALS 356
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 357
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 359
AC DRIVE SYSTEM MAINTENANCE 359
NORMAL TRUCK SHUTDOWN PROCEDURE 360
SHUTDOWN AFTER SYSTEM FAILURE 360
SYSTEM CHECKOUT 361
MEMORY BACKUP BATTERY REPLACEMENT 366
TCI PROGRAMMING 366
PSC PROGRAMMING 367
INVERTER PROGRAMMING 367
CPU RESET 367
PSC CHECKOUT 368
TCI CHECKOUT 373
CALIBRATIONS 381
ERASING EVENTS 381
GATE DRIVER POWER CONVERTER TEST 382
LOAD TESTING 383
TROUBLESHOOTING 390
PHASE MODULE REPLACEMENT 391
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A146) INDEX 393
Fault Code A001: Left front suspension pressure sensor signal is high 396
Fault Code A002: Left front suspension pressure sensor signal is low 397
Fault Code A003: Right front suspension pressure sensor signal is high 398
Fault Code A004: Right front suspension pressure sensor signal is low 399
Fault Code A005: Left rear suspension pressure sensor signal is high 400
Fault Code A006: Left rear suspension pressure sensor signal is low 401
Fault Code A007: Right rear suspension pressure sensor signal is high 402
Fault Code A008: Right rear suspension pressure sensor signal is low 403
Fault Code A009: Incline sensor signal is high 404
Fault Code A010: Incline sensor signal is low 405
Fault Code A011: Payload meter speed sensor signal has failed 406
Fault Code A013: Body up switch has failed 407
Fault Code A014: Payload meter checksum computation has failed 408
Fault Code A016: Payload meter write to flash memory has failed 409
Fault Code A017: Payload meter flash memory read has failed 410
Fault Code A018: Right rear flat suspension cylinder warning 412
Fault Code A019: Left rear flat suspension cylinder warning 414
Fault Code A022: Carryback load is excessive 416
Related circuit diagram 417
Fault Code A026: Payload meter user select switch has failed 418
Fault Code A027: Payload meter user clear switch has failed 419
Fault Code A101: High pressure detected across a hydraulic pump filter 420
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 424
Fault Code A109: GE has generated a propel system reduced level signal 426
Fault Code A111: Low steering pressure warning 428
Fault Code A115: Low steering precharge pressure is detected 430
Fault Code A117: Low brake accumulator pressure warning 432
Fault Code A118: Brake pressure is low while brake lock is activated 433
Fault Code A123: GE has generated a reduced retarding caution 434
Fault Code A124: GE has generated a no propel / no retard warning 436
Fault Code A125: GE has generated a no propel warning 438
Fault Code A126: Oil level in the hydraulic tank is low 440
Fault Code A127: IM furnished +5 volt output for sensors is low 442
Fault Code A128: IM furnished +5 volt output for sensors is high 444
Fault Code A139, A310: Low fuel level warning 446
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 450
Fault Code A146: Hydraulic temperature sensors cause posting of this fault 454
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A216) INDEX 457
Fault Code A152: Starter failure 458
Fault Code A153: Battery voltage is low with truck in operation 460
Fault Code A154: Battery charging voltage is excessive 464
Fault Code A155: Battery charging voltage is low 466
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 468
Fault Code A166: Left rear hydraulic oil temperature sensor is low 470
Fault Code A167: Right rear hydraulic oil temperature sensor is low 472
Fault Code A168: Left front hydraulic oil temperature sensor is low 474
Fault Code A169: Right front hydraulic oil temperature sensor is low 476
Fault Code A170: Left rear hydraulic oil temperature sensor is high 478
Fault Code A171: Right rear hydraulic oil temperature sensor is high 479
Fault Code A172: Left front hydraulic oil temperature sensor is high 480
Fault Code A173: Right front hydraulic oil temperature sensor is high 481
Fault Code A184: J1939 data link is not connected 482
Fault Code A190: Auto lube control has detected an incomplete lube cycle 484
Fault Code A194: Left front hydraulic oil temperature is high 486
Fault Code A195: Right front hydraulic oil temperature is high 488
Fault Code A196: Left rear hydraulic oil temperature is high 490
Fault Code A197: Right rear hydraulic oil temperature is high 492
Fault Code A198: Hoist pressure 1 sensor is high 494
Fault Code A199: Hoist pressure 2 sensor is high 495
Fault Code A200: Steering pressure sensor is high 496
Fault Code A201: Brake pressure sensor is high 497
Fault Code A202: Hoist pressure 1 sensor is low 498
Fault Code A203: Hoist pressure 2 sensor is low 500
Fault Code A204: Steering pressure sensor is low 502
Fault Code A205: Brake pressure sensor is low 504
Fault Code A206: Ambient temperature sensor is high 506
Fault Code A207: Ambient temperature sensor is low 507
Fault Code A212: Bad truck speed signal 508
Fault Code A213: Parking brake should have applied but is detected as not having applied 510
Fault Code A214: Parking brake should have released but is detected as not having released 514
Fault Code A215: Brake auto apply relay circuit is defective 518
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 522
SECTION E5 TROUBLESHOOTING FAULT CODES (A223-A292) INDEX 527
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 530
Fault Code A230: Parking brake has been requested while truck still moving 534
Fault Code A231: Dump body is up while traveling or intending to travel 536
Fault Code A233: Drive system CAN/RPC Control Link not connected 538
Fault Code A235: Steering accumulator is in the process of being bled down 539
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 540
Fault Code A237: The CAN/RPC connection to the display is open 542
Fault Code A240: The keyswitch input to the interface module is open 543
Fault Code A246: Payload meter reports truck overload 545
Fault Code A247: Low steering pressure warning 546
Fault Code A248: The status indicator module within the display panel is defective 547
Fault Code A249: Red warning lamp output used to drive the steering bleed fault lamp is shorted 548
Fault Code A250: Battery voltage is low with the truck parked 550
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 553
Fault Code A252: Start enable output circuit is either open or shorted to ground 554
Fault Code A253: Steering bleed circuit is not open while running 556
Fault Code A256: Red warning lamp output used to drive the steering bleed fault lamp is open 558
Fault Code A257: Payload CAN/RPC is not connected 561
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 562
Fault Code A260: Parking brake failure 564
Fault Code A261: Low brake accumulator pressure warning 567
Fault Code A262: Steering bleed valve circuit open during shutdown 568
Fault Code A263: Steering bleed circuit is shorted to ground 572
Fault Code A264: Parking brake relay circuit is defective 574
Fault Code A265: Service brake failure 576
Fault Code A266: Selector lever was not in park while attempting to crank engine 579
Fault Code A267: Parking brake was not set while attempting to crank engine 580
Fault Code A268: Secondary engine shutdown while cranking 581
Fault Code A270: Brake lock switch power supply is not on when required 582
Fault Code A271: Shifter not in gear 585
Fault Code A272: Brake lock switch power supply is not off when required 586
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 590
Fault Code A274: A brake setting fault has been detected 592
Fault Code A275: A starter has been detected as engaged without a cranking attempt 594
Fault Code A277: Parking brake applied while loading 597
Fault Code A278: Service brake applied while loading 598
Fault Code A279: Low steering pressure switch is defective 599
Fault Code A280: Steering accumulator Bleed Down switch is defective 600
Fault Code A281: Brake lock degradation switch is defective 601
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 602
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 606
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 608
Fault Code A285: The parking brake was not set when the key switch was turned off 610
Fault Code A286: A fault was detected in the shutdown delay relay circuit 612
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 614
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 619
Fault Code A303: Shifter is defective 620
Fault Code A304: Auto lube grease level is low 622
Fault Code A306: Red warning lamp output used to drive the steering bleed fault lamp is not open when it should be 624
Fault Code A307: Both GE inverters are disabled 626
Fault Code A309: No brakes applied when expected 627
Fault Code A311: Brake lock switch is on when it should not be 630
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 632
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 633
Fault Code A315: DC-DC converter 12 volt circuit is low 634
Fault Code A316: Starter engagement has been attempted with engine running 636
Fault Code A317: Operation of brake auto apply valve without a detected response 638
Fault Code A318: Unexpected power loss to interface module 641
Fault Code A328: Drive system not powered up 642
Fault Code A332: Seat belt not buckled 644
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 646
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 647
Fault Code A350: Overload on output 1B 648
Fault Code A351: Overload on output 1E 650
Fault Code A352: Overload on output 1H 652
Fault Code A353: Overload on output 1J 654
Fault Code A354: Overload on output 1K 656
Fault Code A355: Overload on output 1L 658
Fault Code A356: Overload on output 1M 660
Fault Code A357: Overload on output 1N 662
Fault Code A358: Overload on output 1P 664
Fault Code A359: Overload on output 1R 666
Fault Code A360: Overload on output 1S 668
Fault Code A361: Overload on output 1T 670
Fault Code A362: Overload on output 1U 672
Fault Code A363: Overload on output 1X 674
Fault Code A364: Overload on output 1Y 676
Fault Code A365: Overload on output 1Z 678
SECTION G REAR AXLE, SPINDLES AND WHEELS INDEX 681
SECTION G2 TIRES AND RIMS INDEX 683
TIRES AND RIMS 685
GENERAL PRECAUTIONS 685
RIM COMPONENTS 686
WHEEL STUD MAINTENANCE 687
FRONT TIRES AND RIMS 688
REAR TIRES AND RIMS 689
RIM AND TIRE SERVICE 692
SECTION G3 FRONT WHEEL HUB AND SPINDLE INDEX 709
FRONT WHEEL HUB AND SPINDLE 711
WHEEL HUB AND SPINDLE ASSEMBLY 711
WHEEL SPEED SENSOR TESTING 723
STEERING CYLINDERS 724
TIE ROD 727
TIE ROD INSPECTION AND TORQUE PROCEDURE 730
SECTION G4 REAR AXLE MOUNTING INDEX 733
REAR AXLE MOUNTING 735
PIVOT PIN 735
PIVOT EYE BEARING 736
PIVOT EYE REPAIR 737
ANTI-SWAY BAR 738
SECTION G5 REAR AXLE AND WHEEL MOTOR INDEX 741
REAR AXLE AND WHEEL MOTOR 743
REAR AXLE HOUSING 743
BLOWER PRESSURE SWITCH ADJUSTMENT 745
WHEEL MOTOR 746
WHEEL MOTOR GEAR OIL 754
ELEMENT SPECIFICATION CHARTS 757
SECTION H HYDRAIR® II SUSPENSIONS INDEX 761
SECTION H2 FRONT SUSPENSIONS INDEX 763
FRONT SUSPENSION 765
LOWER BEARING & SEALS 772
MAJOR SUSPENSION REBUILD 773
SUSPENSION PRESSURE TEST 775
SECTION H3 REAR SUSPENSIONS INDEX 777
REAR SUSPENSIONS 779
SUSPENSION CYLINDER 780
SUSPENSION PRESSURE TEST 784
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES INDEX 785
SUSPENSION OILING AND CHARGING PROCEDURES 787
CHECKING FOR IMPROPER SUSPENSION CHARGE 787
GENERAL 788
REQUIRED EQUIPMENT 788
HYDRAIR® CHARGING KIT 789
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 790
FRONT SUSPENSION 793
REAR SUSPENSION 795
OIL AND NITROGEN SPECIFICATIONS CHARTS 798
SECTION J BRAKE CIRCUIT INDEX 799
SECTION J2 BRAKE CIRCUIT INDEX 801
BRAKE CIRCUIT 803
SERVICE BRAKE CIRCUIT 803
PARKING BRAKE CIRCUIT 805
BRAKE LOCK CIRCUIT 805
SECONDARY BRAKING AND AUTOMATIC APPLY 806
WARNING CIRCUIT 806
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 809
BRAKE CIRCUIT COMPONENT SERVICE 811
BRAKE VALVE 811
BRAKE VALVE/PEDAL ASSEMBLY 813
DUAL RELAY VALVE 816
BRAKE MANIFOLD 817
BRAKE ACCUMULATORS 819
BLADDER BRAKE ACCUMULATORS 820
PISTON BRAKE ACCUMULATORS 825
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 832
FRONT BRAKE COOLING HOSE INSTALLATION 836
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 839
BRAKE CIRCUIT CHECK-OUT PROCEDURE 841
REQUIRED EQUIPMENT 842
INITIAL SYSTEM SETUP 843
BRAKE LOCK / SECONDARY BRAKE CHECK-OUT 844
PARKING BRAKE CHECK-OUT 845
SERVICE BRAKE CHECK-OUT 846
LOW ACCUMULATOR PRESSURE AND AUTO APPLY CHECK-OUT 847
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING CHART 848
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDUREDATA SHEET 850
HYDRAULIC BRAKE SYSTEM CHECK-OUT PROCEDUREDATA SHEET 851
SECTION J5 WET DISC BRAKE ASSEMBLY INDEX 853
WET DISC BRAKE ASSEMBLY 855
OPERATION 855
BRAKE DISC WEAR INSPECTION 856
BRAKE REBUILD 857
WET DISC BRAKE BLEEDING PROCEDURE 871
SECTION J7 PARKING BRAKE INDEX 873
PARKING BRAKE 875
OPERATION 875
MAINTENANCE 876
PARKING BRAKE BLEEDING PROCEDURE 881
SECTION L HYDRAULIC SYSTEM INDEX 883
SECTION L2 HYDRAULIC SYSTEM INDEX 885
HYDRAULIC SYSTEM 887
HYDRAULIC PUMP MODULE 887
HOIST CIRCUIT OPERATION 888
STEERING CIRCUIT OPERATION 890
DISC BRAKE COOLING SYSTEM 892
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 895
HYDRAULIC SYSTEM COMPONENT REPAIR 897
HOIST PUMP 897
HOIST PUMP TROUBLESHOOTING GUIDE 909
HYDRAULIC TANK 910
HYDRAULIC TANK BREATHERS 911
HYDRAULIC TANK STRAINERS 912
SECTION L4 STEERING CIRCUIT INDEX 913
STEERING CIRCUIT 915
STEERING CIRCUIT OPERATION 915
COMPONENT DESCRIPTION 916
FLOW AMPLIFIER SYSTEM OPERATION 922
STEERING PUMP 930
PRINCIPLE OF OPERATION 932
SECTION L5 STEERING CONTROL UNIT INDEX 935
STEERING CONTROL UNIT 937
REMOVAL 937
SPLINE INSPECTION 938
INSTALLATION 938
DISASSEMBLY 939
CLEANING AND INSPECTION 940
ASSEMBLY 942
SECTION L6 STEERING CIRCUIT COMPONENT REPAIR INDEX 947
STEERING CIRCUIT COMPONENT REPAIR 949
BLEEDDOWN MANIFOLD VALVE 949
FLOW AMPLIFIER 951
STEERING CYLINDERS 954
STEERING AND BRAKE PUMP 956
BLADDER STEERING ACCUMULATORS 968
PISTON STEERING ACCUMULATORS 977
TROUBLESHOOTING 981
STEERING CIRCUIT 981
STEERING PUMP 983
SECTION L7 HOIST CIRCUIT INDEX 997
HOIST CIRCUIT 999
BASIC OPERATION 999
COMPONENT DESCRIPTION 1000
HOIST CIRCUIT OPERATION 1003
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 1015
HOIST CIRCUIT COMPONENT REPAIR 1017
HOIST VALVE 1017
INLET SECTION 1019
REAR SPOOL SECTION (Work Ports) 1021
FRONT SPOOL SECTION (Tank Ports) 1024
HOIST PILOT VALVE 1026
HOIST CYLINDERS 1029
OVERCENTER VALVE MANIFOLD 1037
SECTION L9 HYDRAULIC SYSTEM FILTERS INDEX 1039
HYDRAULIC SYSTEM FILTERS 1041
HOIST CIRCUIT FILTER 1041
STEERING CIRCUIT FILTER 1043
INDICATOR SWITCH 1044
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1047
HYDRAULIC CHECKOUT PROCEDURE 1049
GENERAL INFORMATION 1049
HYDRAULIC SYSTEM FLUSHINGPROCEDURE 1049
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1056
STEERING/BRAKE PUMP STROKE ADJUSTMENT 1060
SHOCK AND SUCTION VALVES 1060
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES 1062
930E CHECK-OUT PROCEDURE – STEERING SYSTEM DATA SHEET 1067
930E CHECK-OUT PROCEDURE – BRAKE COOLING & HOIST SYSTEMDATA SHEET 1068
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 1069
SECTION M7 HOT START SYSTEM INDEX 1071
HOT START SYSTEM 1073
SYSTEM OPERATION 1073
HEATER INFORMATION 1074
TROUBLESHOOTING GUIDELINES 1075
SECTION M8 SPECIAL TOOLS 1077
SPECIAL TOOLS 1077
HIGH VOLTAGE TOOLS 1081
KOMVISION CALIBRATION TOOLS 1083
SECTION M19 RADIATOR SHUTTERS INDEX 1085
RADIATOR SHUTTERS 1087
OPERATION 1087
MAINTENANCE AND REPAIR 1088
TROUBLESHOOTING 1089
SECTION M20 PAYLOAD METER IV ™ INDEX 1093
PAYLOAD METER IV ™ 1095
INTRODUCTION 1095
COMPONENT DESCRIPTION 1096
PAYLOAD METER IV SOFTWARE AND TOOLS 1097
PAYLOAD METER IV SYSTEM CONFIGURATION 1097
PAYLOAD METER IV SOFTWARE INSTALLATION 1099
PLM IV SYSTEM CHECKOUT DATA SHEET 1105
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1106
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1109
RESERVE ENGINE OIL SYSTEM 1111
GENERAL 1111
OPERATION 1112
SERVICE 1115
TROUBLESHOOTING 1116
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1117
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1119
RETRACTABLE LADDER SYSTEM 0
LADDER SYSTEM OPERATION 1124
IN-CAB CONTROL PANEL 1126
IN-CAB CONTROL PANEL FEATURES 1127
IN-CAB CONTROL PANEL FUNCTIONS 1128
USING THE IN-CAB CONTROL PANEL 1129
USING THE GROUND LEVEL CONTROL BOX 1131
POWER PACK OPERATION 1132
MAINTENANCE 1135
PREVENTIVE MAINTENANCE PROCEDURES 1137
SERVICING 1138
RLS DIAGNOSTICS 1139
SECURITY ACCESS LEVELS 1143
USER ID – PASSWORD 1145
USER ID – NEW USER SETUP 1146
SYSTEM FAULTS 1146
DATA MANAGEMENT 1156
MENU DIAGRAMS 1163
SECTION M33 CAMERA SYSTEM INDEX 1171
CAMERA SYSTEM 1173
CAMERA SYSTEM 1173
CAMERA MONITOR 1175
CAMERA CONTROLLER 1176
CAMERA SWITCHER 1177
SETUP AND CHECKOUT PROCEDURE 1178
SECTION N OPERATOR CAB INDEX 1187
SECTION N2 TRUCK CAB AND COMPONENTS INDEX 1189
TRUCK CAB AND COMPONENTS 1191
TRUCK CAB 1191
CAB DOOR 1194
GLASS REPLACEMENT (Adhesive-Bonded Windows) 1204
WINDSHIELD AND REAR GLASS 1205
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1207
OPERATOR AND PASSENGER SEATS 1208
OPERATOR SEAT (STANDARD SEAT) 1208
PASSENGER SEAT (STANDARD SEAT) 1215
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1216
SEAT BELT REPLACEMENT (STANDARD SEATS) 1218
OPERATOR SEAT (OPTIONAL SEAT) 1220
PASSENGER SEAT (OPTIONAL SEAT) 1221
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1222
SECTION N4 HEATER / AIR CONDITIONER (PC2600) INDEX 1227
HEATER/AIR CONDITIONER 1229
OPERATION 1229
COMPONENTS 1230
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1234
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1234
PRINCIPLES OF REFRIGERATION 1234
AIR CONDITIONER SYSTEM COMPONENTS 1236
ELECTRICAL CIRCUIT 1238
AIR CONDITIONING SYSTEM SERVICING WARNINGS 1240
SERVICE TOOLS AND EQUIPMENT 1241
SYSTEM PERFORMANCE TEST 1245
SYSTEM OIL 1246
REFRIGERANT 1247
SYSTEM LEAK TESTING 1248
RECOVERING AND RECYCLING THE REFRIGERANT 1249
SYSTEM REPAIR 1250
COMPONENT REPLACEMENT 1251
EVACUATING THE SYSTEM 1253
CHARGING THE A/C SYSTEM 1254
TROUBLESHOOTING 1255
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1262
SECTION N5 OPERATOR CAB AND CONTROLS INDEX 1263
OPERATOR CAB AND CONTROLS 1266
STEERING COLUMN 1267
STEERING WHEEL 1268
STEERING WHEEL AND CONTROLS 1270
DYNAMIC RETARDING 1271
GRADE/SPEED CHART 1272
OVERHEAD PANEL AND DISPLAYS 1273
CENTER CONSOLE 1274
DIAGNOSTIC PORTS 1277
INSTRUMENT PANEL 1278
OVERHEAD STATUS / WARNING INDICATORS 1284
REAR AXLE LIGHT BAR 1291
KOMTRAX PLUS 1292
KOMATSU WIRELESS BRIDGE (Optional) 1295
SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX 1299
SECTION P2 PERIODIC MAINTENANCE INDEX 1301
PERIODIC MAINTENANCE 1303
GENERAL 1303
SERVICE CAPACITIES 1303
HYDRAULIC TANK SERVICE 1303
COOLING SYSTEM SERVICE 1304
WHEEL MOTOR SERVICE 1304
RESERVE OIL TANK SERVICE 1305
QUICK FILL SERVICE CENTER 1306
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1308
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1308
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1309
INITIAL 500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1311
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1315
4000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1317
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1317
10000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1318
18000 HOUR LUBRICATION AND MAINTENANCE CHECKS 1318
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1319
AUTOMATIC LUBRICATION SYSTEM 1321
GENERAL DESCRIPTION 1321
SYSTEM COMPONENTS 1323
SYSTEM OPERATION 1324
LUBRICANT PUMP 1326
INJECTORS (SL-1 Series “H”) 1327
PREVENTIVE MAINTENANCE PROCEDURES 1329
SYSTEM CHECKOUT 1330
SECTION R SYSTEM SCHEMATICS INDEX 1335
HYDRAULIC SUPPLY, BRAKE COOLING, STEERING & HOIST SCHEMATIC – EM1371 1336
HYDRAULIC BRAKE SYSTEM SCHEMATIC – 58F-60-40170 1337
ELECTRICAL SCHEMATICS – 58F-06-02006 1338
ELECTRICAL SUB-SYSTEMS – 58F-06-10551 1358

DESCRIPTION:

Komatsu 930E-4SE Dump Truck Shop Manual CEBM029801 –  PDF DOWNLOAD

• SERIAL NUMBERS 930E-4SE A31828 – A31874

• FOREWORD:
  This Shop Manual is written for use by the service technician and is designed to help the technician become fully
  knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel
  should read and understand the materials in this manual before performing maintenance and/or operational
  checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing
  repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general
  information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable
  area is dealt with individually. For example: The disassembly, service and reassembly of the radiator
  group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire
  mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed
  repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict
  a specific model.
• This manual shows dimensioning of metric (SI) and U.S. standard units throughout and all references to “Right”,
  “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated
  otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques
  are provided in the text in bold face type, such as 135 N·m (100 ft lbs) torque. All torque specifications have ±10%
  tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates
  the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W.
  (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers
  represent the basic truck model. The letter “E” designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service
  parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
  The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight
  (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
  includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the
  GVW rating. The result is the allowable payload.
• Exceeding the allowable payload will reduce expected life of truck components.

G.B 20/12/24