Komatsu 930E-5 DUMP TRUCK Shop Manual CEBM032209 – PDF DOWNLOAD

Description

Komatsu 930E-5 DUMP TRUCK Shop Manual CEBM032209 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 930E-5 DUMP TRUCK Shop Manual CEBM032209 – PDF DOWNLOAD

Language : English
Pages :1122
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 930E-5 DUMP TRUCK Shop Manual CEBM032209 – PDF DOWNLOAD

SERIAL NUMBERS 950E-5 A40004-A40066

FOREWORD
HOW TO READ THE SHOP MANUAL
REMARK
Some attachments and options given in this shop manual may not be available in some areas. If they are required, speak to your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Komatsu shop manuals are available for the “machine part”. For detailed information on the “engine part “drive system part”, see the shop manual from the original equipment manufacturer (OEM).
Actual machine may differ from the images which are given in this manual. A typical model is shown in th illustrations of this shop manual.
Composition of the shop manual
This manual supports quality repair through education of the product, correct repair procedures, and assista with repair decisions.
Understand the content of this manual and use it at every opportunity.
This shop manual contains technical information necessary to perform services in the workshops. It is organ into chapters for ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine such as dimensions, performance, component weig and lubricant charts.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful to understand the structure of each component and to do the troubleshooting procedure.
20 STANDARD VALUE TABLE
This section describes the standard values for a new machine and failure criteria for testing, adjusting, and troubleshooting. Use the “STANDARD VALUE TABLE” to check the standard values for testing and adjusting troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measurement tools and methods to test and adjust each part. The standard valu and repair limit for TESTING AND ADJUSTING are given in the “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes how to troubleshoot and repair failures in the machine.
Troubleshooting steps are sorted by failure mode.
Troubleshooting steps correlate “Problems” to “Causes” in this section.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard sho the criteria and remedies for disassembly and assembly.

TABLE OF CONTENTS:

Komatsu 930E-5 DUMP TRUCK Shop Manual CEBM032209 – PDF DOWNLOAD

SERIAL NUMBERS 950E-5 A40004-A40066

00 CONTENTS AND FOREWORD 3
Foreword 19
How to Read the Shop Manual 19
Safety Alert Symbol and Signal Words 20
General Precautions Common to Operation and Maintenance 21
Preparations for Safe Operation 21
Fire and Explosion Prevention 23
Precautions When Getting On or Off the Machine 24
Precautions for Cab and Working Around Machine 27
Precautions for Diesel Exhaust Fluid (DEF) 28
Operation Precautions 31
Precautions at Jobsite 31
Precautions in Starting Engine 32
Precautions During Operation 34
Maintenance Precautions 36
Precautions Before Inspection and Maintenance 36
Precautions During Inspection and Maintenance 41
Precautions for Electrical Equipment 48
Primary Causes of Wiring Harness Failure 49
Control Cabinet Capacitor Discharge 51
Hydraulic Equipment Precautions 52
01 SPECIFICATIONS 55
Specifications 56
Specifications: 930E-5 56
Weight Table: 930E-5 57
Recommended Fuel, Coolant, and Lubricant 59
Suspension Cylinder Oil and Nitrogen Specifications 59
Wheel Motor Oil Specifications 61
10 STRUCTURE AND FUNCTION 63
Steering System 64
Steering System Layout 64
Steering System Operation 64
Steering Bleeddown Manifold 66
Steering Control Unit 67
Steering Accumulators (Piston Type) 68
Steering/Brake Pump Operation 68
Flow Amplifier Operation 70
Hoist System 78
Hoist System Layout 78
Hoist System Operation 79
Hoist Control Valve 80
Hoist Pilot Valve 82
Brake System 83
Service Brake System Layout 83
Hydraulic Brake Cabinet Layout 84
Service Brake Operation 84
Parking Brake Operation 85
Brake Lock Operation 85
Secondary Braking and Auto Apply 86
Electrical System, 24V 87
Battery Power Supply 87
Battery Disconnect Switches 88
Engine Starting System 89
Auxiliary Control Cabinet Components 90
Body-Up Switch 92
Hoist Limit Switch 93
Automatic Lubrication (Auto Lube) System 94
Automatic Lubrication (Auto Lube) Grease Pump and Reservoir 94
Automatic Lubrication (Auto Lube) System Operation 95
Suspensions 97
Engine Emissions After-Treatment System Operations 98
20 STANDARD VALUE TABLE 101
Standard Value Table 102
30 TEST AND ADJUST 107
Hydraulic Systems 108
Hydraulic System Checkout Procedures 108
Hydraulic System Checkout Sheet 120
Steering System Leakage Check 123
Toe-In Adjustment 124
Hoist Cylinder Leakage Test 125
Steering Cylinder Leakage Test 125
Checking the Steering/Brake Pump Control Pressures 126
Adjusting the Steering/Brake Pump Control Pressures 127
High Altitude Steering/Brake Pump Adjustment 129
Brake System 130
Brake System Checkout Procedures 130
Brake System Checkout Sheet 140
Brake System Leakage Check 147
Brake Piston Leakage Test 148
Parking Brake Piston Leakage Test 149
Brake Floating Seal Pressure Test 149
Oil Separation Seal Pressure Test (Air Pressure Method) 150
Oil Separation Seal Pressure Test (Oil Pressure Method) 150
Wet Disc Brake Bleeding Procedure 151
Parking Brake Bleeding Procedure 151
Wet Disc Brake Wear Inspection 152
Parking Brake Wear Inspection 154
Accumulators and Suspensions 155
Bladder Accumulator Charging Procedure 155
Bladder Accumulator Leakage Test 156
Bladder Accumulator Storage 157
Piston Accumulator Charging Procedure 158
Piston Accumulator Leakage Test 159
Piston Accumulator Storage 160
Check for Improper Suspension Charge 161
Suspension Oiling and Charging Procedures 162
Oiling and Charging Tools and Support Blocks 163
Nitrogen Charging Kit Installation 167
Nitrogen Charging Kit Removal 167
Front Suspension Oiling and Charging 168
Rear Suspension Oiling and Charging 171
Suspension Pressure Test 174
Automatic Lubrication (Auto Lube) System 175
Prime the Auto Lube Pump 175
Prime the Auto Lube Grease Lines 175
Auto Lube System Checkout 176
Adjust the Auto Lube Cycle Timing (original IM only) 177
Adjust the Auto Lube Cycle Timing (IM2 only) 178
Cab Air Conditioning 179
Refrigerant Leak Detection 180
A/C System Performance Test 180
Check the A/C System Oil 181
A/C System Flushing Procedure 182
Manifold Gauge Set Installation 183
Refrigerant: Recycled vs Reclaimed 184
Refrigerant Recovery Procedure 184
Evacuate the A/C System 184
Charge the A/C System 185
Electrical Systems 187
Shutdown Procedure for Drive System Service 187
Electrical System Checkout Procedures 188
Visual Checks 188
Resistance Checks 188
Voltage Checks 188
Truck Function Checks 191
Interface Module (IM) Checks 192
KOMTRAX Plus II Checks 192
Payload Meter (PLM) Checks 192
Drive System Checks 192
Engine Delayed Shutdown Smart Timer Check 193
Hoist Limit Switch Check 193
Electrical System Checkout Sheet 194
Interface Module (IM) 196
Interface Module Software and Tools 196
Interface Module Checkout Procedures 196
Setup for IM Realtime Monitor Software 196
Checking Digital Inputs to the IM 197
Checking Analog Inputs to the IM 198
Checking Serial Communication to the IM 199
Checking Outputs from the IM 199
Interface Module Checkout Sheet 200
Interface Module 2 (IM2) 203
Interface Module 2 Software and Tools 203
Program the IM2 Controller 203
Interface Module 2 Checkout Procedures 205
Check for IM Fault Codes 205
Checking Digital Inputs to the IM2 206
Checking Analog Inputs to the IM2 207
Checking Serial Communication to the IM 208
Checking Outputs from the IM2 208
Interface Module 2 Checkout Sheet 209
Payload Meter IV 212
Payload Meter IV Software and Tools 212
Payload Meter IV System Configuration 212
Configuring a Static IP Address 212
Payload Meter IV Software Installation 215
Payload Meter IV Data Downloading 215
Payload Meter IV Checkout Procedure 216
Payload Meter IV Checkout Sheet 222
KOMTRAX Plus II 223
KOMTRAX Plus II Software and Tools 223
Komtrax Plus II Controller Ethernet Connection 223
KOMTRAX Plus II Configuration 224
GPS Connection Test 227
Satellite Connection Test 229
Komtrax Plus II System Initialization 232
KomVision 234
KomVision Setup and Calibration Requirements 234
KomVision Initial Setup and Checkout Procedure 234
KomVision Checkout Sheet 240
KomVision Calibration Sheets 242
Calibration Sheet Layout 242
Unfold and Fold Calibration Sheet 245
Calibration Sheet Placement 247
KomVision Camera Calibration Procedures 248
Automatic 6 Camera Calibration 248
Manual 6 Camera Calibration 251
1 Camera Calibration 253
KomVision Radar Setting Procedure 256
Komatsu Wireless Bridge (KWB) 259
Komatsu Wireless Bridge Software and Tools 259
Bullet Wireless Radio Configuration 259
Bullet Wireless Radio Installation 262
NanoStation Access Point Configuration 263
NanoStation Access Point Connection Test 265
Tire Monitoring System 267
Tire Monitoring System Software and Tools 267
Tire Monitoring System Software Installation 267
Tire Monitoring System Configuration 267
Connecting to the Tire Monitoring System Web Server 267
Configuring a Static IP Address 268
Tire Monitoring System Reset 270
Tire Monitoring System Checkout Procedure 270
Tire Monitoring System Checkout Sheet 272
40 TROUBLESHOOTING 273
Fuses, Diodes and Relays 274
Standard Truck Fault Codes 283
KomVision Fault Codes 630
Troubleshoot the Steering System 641
Steering System Troubleshooting Guide 641
Basic Hydraulic System Checks 642
Steering/Brake Pump Troubleshooting Guide 643
Steering/Brake Pump Troubleshooting Checks 646
Steering/Brake Pump Fails to Unload 646
Steering/Brake Pump Fails to Develop Pressure 646
Steering/Brake Pump Slow to Develop Pressure 647
Steering/Brake Pump Control Valve Inspection 648
Steering/Brake Pump Case Drain Check 649
Troubleshoot the Auto Lube System 650
Troubleshoot the HVAC System 654
Control Panel Configurations 654
Diagnostics Mode 655
Error Codes 655
Advanced Diagnostics 655
Firmware Version 656
Additional HVAC Troubleshooting Chart 656
Voltage Levels 658
50 DISASSEMBLY AND ASSEMBLY 661
Special Tools List 662
Wheels, Spindles and Rear Axle 664
General Precautions for Tires and Rims 664
Lubricants for Tire and Rim Service 664
Tire Inflation 665
Rim Components 665
Wheel Stud Maintenance 666
Rear Outer Wheel Stud Installation 667
Front Wheel Removal 668
Front Wheel Installation 669
Rear Wheel Removal 670
Rear Wheel Installation 671
Lock Ring Retainer Installation 673
Lock Ring Removal 673
Lock Ring Installation 674
Tire Removal (Front 5-Piece Rim) 675
Tire Removal (Rear Outer 7-Piece Rim) 678
Tire Removal (Rear Inner 5-Piece Rim) 680
Tire and Rim Preparation 681
Tire Installation (Front 5-Piece Rim) 682
Tire Installation (Rear Inner 5-Piece Rim) 683
Tire Installation (Rear Outer 7-Piece Rim) 684
Front Wheel Hub and Spindle Removal 685
Spindle Removal While Off the Truck 689
Front Wheel Hub and Spindle Installation 691
Spindle, Hub and Brake Assembly Cross-Section View 694
Front Wheel Hub and Spindle Disassembly 695
Front Wheel Hub and Spindle Cleaning and Inspection 703
Front Wheel Hub and Spindle Assembly 704
Hub Floating Seal Installation 715
Brake Floating Seal Installation 719
Rear Axle Removal 724
Rear Axle Cleaning and Inspection 725
Rear Axle Installation 726
Anti-Sway Bar Removal 727
Anti-Sway Bar Installation 729
Pivot Pin Removal 731
Pivot Pin Installation 733
Pivot Eye Bearing Wear Inspection 735
Pivot Eye Bearing Replacement 736
Pivot Eye Removal 737
Pivot Eye Installation 737
Wheel Motor Removal 737
Wheel Motor Cleaning and Inspection 740
Wheel Motor Installation 740
Rear Wheel Brake Removal 744
Rear Wheel Brake Installation 745
Steering System 748
Steering Control Unit Removal 748
Steering Control Unit Installation 748
Steering Control Unit Disassembly 750
Steering Control Unit Assembly 752
Steering Column Removal 755
Steering Column Installation 757
Steering Wheel Removal 759
Steering Wheel Installation 759
Bleeddown Manifold Removal 760
Bleeddown Manifold Installation 761
Flow Amplifier Removal 762
Flow Amplifier Installation 763
Steering Pin Joint Wear Inspection 764
Tie Rod Removal 766
Tie Rod Installation 767
Steering Cylinder Removal 768
Steering Cylinder Installation 769
Steering Cylinder Disassembly 770
Steering Cylinder Cleaning and Inspection 772
Steering Cylinder Assembly 773
Steering/Brake Pump Removal 775
Steering/Brake Pump Installation 776
Piston Steering Accumulator Removal 777
Piston Steering Accumulator Installation 779
Piston Steering Accumulator Disassembly 781
Piston Accumulator Cleaning and Inspection 783
Piston Seal Replacement 783
Piston Steering Accumulator Assembly 784
Brake System 786
Brake Valve Removal 786
Brake Valve Installation 787
Brake Valve/Pedal Disassembly 789
Brake Valve/Pedal Assembly 790
Front Brake Dual Relay Valve Removal 793
Front Brake Dual Relay Valve Installation 794
Rear Brake Dual Relay Valve Removal 795
Rear Brake Dual Relay Valve Installation 795
Brake Manifold Removal 797
Brake Manifold Installation 798
Brake Manifold Component Replacement 799
Piston Brake Accumulator Removal 800
Piston Brake Accumulator Installation 801
Piston Brake Accumulator Disassembly 803
Piston Accumulator Cleaning and Inspection 804
Piston Seal Replacement 805
Piston Brake Accumulator Assembly 805
Front Wheel Brake Disassembly 806
Wheel Brake Cleaning and Inspection 810
Front Wheel Brake Assembly 811
Rear Wheel Brake Disassembly 814
Wheel Brake Cleaning and Inspection 818
Rear Wheel Brake Assembly 819
Brake Floating Seal Installation 823
Parking Brake Removal 828
Parking Brake Installation 830
Parking Brake Disassembly 831
Parking Brake Cleaning and Inspection 834
New Parking Brake Disc Cleaning and Inspection 835
Parking Brake Assembly 836
Hoist System 839
Hoist Pump Removal 839
Hoist Pump Installation 843
Hoist Pump Disassembly 846
Hoist Pump Inspection 851
Hoist Pump Assembly 851
Hoist Valve Removal 856
Hoist Valve Installation 859
Hoist Valve Service 860
Hoist Valve O-Ring Replacement 860
Inlet Section Disassembly 861
Inlet Section Assembly 862
Rear Spool Section Disassembly 864
Rear Spool Section Assembly 866
Front Spool Section Disassembly 868
Front Spool Section Assembly 870
Overcenter Manifold Service 871
Hoist Pilot Valve Removal 872
Hoist Pilot Valve Installation 873
Hoist Pilot Valve Disassembly 873
Hoist Pilot Valve Cleaning and Inspection 875
Hoist Pilot Valve Assembly 875
Hoist Cylinder Removal 877
Hoist Cylinder Installation 879
Hoist Cylinder Disassembly 882
Hoist Cylinder Cleaning and Inspection 890
Quill Installation 891
Quill Check Ball and Plug Installation 893
Hoist Cylinder Assembly 894
Suspensions 906
Front Suspension Removal 906
Front Suspension Cleaning and Inspection 907
Front Suspension Installation 908
Front Suspension Bolted Joint Inspection 913
Front Suspension Charging Valve Replacement 913
Front Suspension Disassembly 913
Front Suspension Assembly 918
Rear Suspension Removal 923
Rear Suspension Installation 926
Rear Suspension Charging Valve Replacement 930
Rear Suspension Disassembly 931
Rear Suspension Cleaning and Inspection 934
Rear Suspension Assembly 935
Dump Body and Structures 938
Dump Body Removal 938
Dump Body Inspection 939
Dump Body Installation 940
Body Pads Removal 941
Body Pads Installation 942
Body Pad Shimming Procedure 942
Diagonal Ladder Removal 943
Diagonal Ladder Installation 944
RH Deck Removal 946
RH Deck Installation 947
LH Deck Removal 949
LH Deck Installation 950
Fuel Tank Removal 952
Fuel Tank Cleaning and Inspection 954
Fuel Tank Installation 955
Fuel Gauge Sender Removal 956
Fuel Gauge Sender Installation 956
Hydraulic Tank Removal 957
Hydraulic Tank Installation 958
Hydraulic Tank Strainers Removal 959
Hydraulic Tank Strainers Cleaning and Inspection 960
Hydraulic Tank Strainers Installation 961
Operator Cab 962
Operator Cab Removal 962
Operator Cab Installation 965
Cab Door Removal 968
Cab Door Installation 969
Window Regulator Removal 970
Window Regulator Installation 971
Door Glass Removal 973
Door Glass Installation 975
Inner Door Seal Replacement 977
Outer Door Seal Replacement 978
Interior Door Handle and Door Latch Removal 979
Interior Door Handle and Door Latch Installation 982
Door Jamb Bolt Adjustment 984
Poor Seal When Door Is Closed 984
Door Springs Back Open 985
Exterior Door Handle Release Button Adjustment 985
Side Window Glass Removal 986
Side Window Glass Installation 986
Windshield and Rear Window Glass Removal 988
Windshield and Rear Window Glass Installation 988
Windshield Wiper Motor Removal 989
Windshield Wiper Motor Installation 991
Windshield Wiper Arm and Linkage Removal 992
Windshield Wiper Arm and Linkage Installation 993
Cab Seat Removal 993
Cab Seat Servicing 994
Cab Seat Installation 994
Seat Belt Removal 995
Seat Belt Installation 996
Power Module 998
Power Module General Information 998
Power Module Removal 998
Power Module Installation1005
Exhaust Tube Installation1013
Exhaust Blanket Installation1014
Alternator Removal1014
Alternator Installation1018
Engine Flywheel Adapter Face Runout1018
Engine Crankshaft Endplay1019
Engine Flywheel to Flywheel Housing Adapter – Measurement “C”1020
Alternator Housing to Rotor – Measurement “A”1021
Measurements After Joining the Alternator and Engine1025
Flywheel Housing Face Runout1026
Flywheel Housing Radial Runout1026
Flywheel/Flexplate Face Runout1027
Flywheel/Flexplate Radial Runout1027
Rotor Shaft Radial Runout (Assembled)1027
Radiator Removal1028
Radiator Installation1032
Radiator Internal Inspection1036
Radiator External Cleaning1036
Radiator Disassembly1037
Radiator Cleaning and Inspection1038
Radiator Assembly1038
Engine Removal1039
Engine Service1040
Engine Installation1040
60 MAINTENANCE STANDARD1043
Rules for Maintenance1044
Torque Specifications1045
Hydraulic System Bleeddown Procedure1052
Hydraulic System Vacuum Procedure1055
Hydraulic Pumps1056
Steering/Brake Pump1056
Hoist Pump1057
Wet Disc Brakes1058
Service Brake1058
Parking Brake1059
Tie Rod1061
Tail Lights, Clearance Lights and Turn Signals1062
90 CIRCUIT DIAGRAMS1063
CONTENTS: 930E-51064

IMAGES PREVIEW OF THE MANUAL:

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