Komatsu 930E-5 Dump Truck Shop Manual CEBM036500 – PDF DOWNLOAD

Description

Komatsu 930E-5 Dump Truck Shop Manual CEBM036500 – PDF DOWNLOAD

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TABLE OF CONTENTS:

Komatsu 930E-5 Dump Truck Shop Manual CEBM036500 – PDF DOWNLOAD

Shop Manual, contents binder, binder label and tabs CEBM036500
00 Index and foreword
Index CEN00067-00
Foreword, safety and general information CEN00038-06
01 Specification
Specification and technical data CEN01018-03
10 Structure and functions
Steering circuit CEN10077-00
Hoist circuit CEN10078-00
Brake circuits CEN10079-01
Electrical system, 24 volt CEN10109-00
Cab air conditioning CEN10088-01
Automatic lubrication (auto lube) system CEN10080-00
Engine emissions after-treatment system CEN10083-02
20 Standard value table
Standard value table CEN20007-00
30 Testing and adjusting
Steering, brake cooling and hoist hydraulic system CEN30087-02
Brake system CEN30088-02
Accumulators and suspensions CEN30098-12
Electrical systems CEN30102-02
Interface module 2 (IM2) CEN30125-01
Payload meter IV CEN30070-03
KOMTRAX Plus II CEN30091-01
Komatsu Wireless Bridge (KWB) CEN30101-00
00 Index and foreword CEN00067-00
3
Cab air conditioning CEN30029-01
Automatic lubrication (auto lube) system CEN30089-00
KomVision CEN30105-02
Tire monitoring system CEN30114-00
40 Troubleshooting
Fuse, diode and relay locations CEN40186-00
Troubleshooting by failure code, Part 1 CEN40178-02
Troubleshooting by failure code, Part 2 CEN40179-02
Troubleshooting by failure code, Part 3 CEN40180-03
Troubleshooting by failure code, Part 4 CEN40181-04
Troubleshooting by failure code, Part 5 CEN40182-01
Aftertreatment system fault codes CEN40222-02
Steering system CEN40190-01
KomVision CEN40200-01
Automatic lubrication (auto lube) system CEN40202-00
Heating/air conditioning (HVAC) system CEN40226-00
50 Disassembly and assembly
Service tools CEN50139-00
Wheels, spindles and rear axle CEN50140-00
Brake system CEN50066-01
Steering system CEN50067-00
Suspensions CEN50068-00
Hoist circuit CEN50069-01
Body and structures CEN50070-00
Operator cab CEN50079-02
Power module CEN50073-03
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90023-00
Electrical circuit diagrams CEN90051-00
CEN00067-00 00 Index and foreword
4
Table of contents
00 Index and foreword
Index CEN00067-00
Composition of shop manual 2
Table of contents 4
Foreword, safety and general information CEN00038-06
Foreword 4
How to read the shop manual 5
General safety 7
Precautions before operating the truck 10
Precautions while operating the truck 12
Working near batteries 15
Precautions before performing service 17
Precautions while performing service 20
Tires 22
Precautions for performing repairs 25
Precautions for welding on the truck 26
Control cabinet capacitor discharge system 27
Handling electrical equipment and hydraulic components 29
Actions taken to meet exhaust gas regulations 37
Precautions for diesel exhaust fluid (DEF) 38
Standard tightening torques 40
Conversion tables 46
01 Specification
Specification and technical data CEN01018-03
Specification drawing 3
Specifications 4
Weight table 6
Fuel, coolant and lubricants 7
10 Structure and functions
Steering circuit CEN10077-00
Steering circuit operation 2
Steering circuit components 7
Steering/brake pump operation 9
Flow amplifier operation 12
Hoist circuit CEN10078-00
Hoist circuit operation 2
Hoist circuit components 2
Hoist pilot valve operation 8
Brake circuits CEN10079-01
General information 3
Service brake circuit operation 6
00 Index and foreword CEN00067-00
5
Secondary braking and auto apply 7
Parking brake circuit operation 8
Wheel brake lock circuit operation 9
Brake warning circuit operation 9
Electrical system, 24 volt CEN10109-00
Battery supply system 3
Isolation box 4
Engine starting system with prelube 5
Auxiliary control cabinet components 6
Body-up switch 9
Hoist limit switch 10
Heating/air conditioning (HVAC) system CEN10088-01
Basic air conditioning system operation 3
HVAC components 5
Automatic lubrication (auto lube) system CEN10080-00
General information 3
System operation 4
Engine emissions aftertreatment system CEN10083-02
About emissions aftertreatment 4
DEF injection system 4
DEF heating system 4
Sensors 4
Exhaust system cleaning 5
Inducement strategy 5
20 Standard value table
Standard value table CEN20007-00
Standard value table for truck 3
30 Testing and adjusting
Steering, hoist, brake cooling and auxiliaryhydraulic systems CEN30087-02
Hydraulic system bleeddown procedure 3
Hydraulic system vacuum procedure 5
General information on system checkout 6
Hydraulic system checkout procedures 6
Hydraulic system checkout data sheet 18
Toe-in adjustment 21
Hoist cylinder leakage test 22
Steering cylinder leakage test 22
Brake system CEN30088-02
General information on system checkout 3
Brake system checkout procedures 3
Brake system checkout data sheet 16
Brake piston leakage test 25
Brake seal pressure test 25
Oil separator seal pressure test 25
CEN00067-00 00 Index and foreword
6
Wet disc brake bleeding procedure 26
Parking brake bleeding procedure 27
Service brake disc wear inspection 28
Parking brake disc wear inspection 29
Accumulators and suspensions CEN30098-12
Accumulator charging and storage 3
Bladder accumulator charging procedure 4
Piston accumulator charging procedure 8
Piston accumulator storage 11
Piston accumulator leak testing 12
Checking for improper suspension charge 13
Suspension oiling and charging procedures 14
Suspension pressure test 23
Electrical systems CEN30102-02
General information on system checkout 3
Truck shutdown procedure 4
AC drive system 5
Electrical system checkout procedures 6
Electrical checkout sheet 12
Interface module 2 (IM2) CEN30125-01
Required tools 3
Programming the IM2 3
Interface module checkout procedures 5
IM checkout sheet 11
Payload meter IV CEN30070-03
Payload meter IV software and tools 3
Payload meter IV system configuration 3
Payload meter IV software installation 5
Payload meter IV checkout procedure 6
PLM IV system checkout data sheet 12
Downloading PLM IV data and possible errors 13
KOMTRAX Plus II CEN30091-01
Required software and tools 3
Ethernet connection to KOMTRAX Plus II controller 3
KOMTRAX Plus II configuration 5
GPS connection test 7
Iridium satellite system opening 9
Data download over ethernet connection for KOMTRAX Plus II initialization 12
Komatsu wireless bridge (KWB) CEN30101-00
General information 3
Required software and tools 3
Configuring the Bullet wireless radio 4
Installing the Bullet wireless radio 7
Configuring the NanoStation access point 8
Testing the connection 11
Changing a service computer’s IP address 12
00 Index and foreword CEN00067-00
7
Cab air conditioning CEN30029-01
General information 3
Service tools and equipment 4
Detecting leaks 7
System performance test 8
Checking system oil 9
System flushing 10
Installing the manifold gauge set 11
Recovering and recycling refrigerant 12
Evacuating the air conditioning system 14
Charging the air conditioning system 15
Automatic lubrication (auto lube) system CEN30089-00
Priming the system 3
Checkout procedure 5
Adjusting the lubrication cycle timing 5
KomVision CEN30105-02
Requirements 3
Initial setup 3
Checkout data sheet 10
Calibration sheets 15
Camera calibration procedures 22
Radar setting procedure 32
Tire monitoring system CEN30114-00
Tire monitoring system software and tools 3
Tire monitoring system configuration 3
Tire monitoring system software installation 5
Tire monitoring system checkout procedure 6
Resetting the tire monitoring system 7
Tire monitoring system checkout data sheet 8
40 Troubleshooting
Fuse, diode and relay locations CEN40186-00
Vehicle Electrical Center (VEC-89) 3
Vehicle Electrical Center (VEC-90) 5
Vehicle Electrical Center (VEC-91) 7
Vehicle Electrical Center (VEC-92) 9
Rear Terminal Mini-fuse and Relay (RTMR3) 10
Rear Terminal Mini-fuse and Relay (RTMR4) 11
Circuit breakers 11
Troubleshooting by fault code, Part 1 CEN40178-02
Fault Code A001 3
Fault Code A002 4
Fault Code A003 5
Fault Code A004 6
Fault Code A005 7
Fault Code A006 8
CEN00067-00 00 Index and foreword
8
Fault Code A007 9
Fault Code A008 10
Fault Code A011 11
Fault Code A013 12
Fault Code A014 13
Fault Code A016 14
Fault Code A017 15
Fault Code A018 16
Fault Code A019 17
Fault Code A022 18
Fault Code A101 19
Fault Code A103 20
Fault Code A104 21
Fault Code A105 22
Fault Code A109 23
Fault Code A111 24
Fault Code A115 25
Fault Code A117 26
Fault Code A118 27
Fault Code A123 28
Fault Code A124 29
Fault Code A125 30
Fault Code A126 31
Fault Code A127 32
Fault Code A128 33
Fault Code A139 34
Troubleshooting by fault code, Part 2 CEN40179-02
Fault Code A145 3
Fault Code A146 4
Fault Code A152 5
Fault Code A153 6
Fault Code A154 7
Fault Code A155 8
Fault Code A158 9
Fault Code A166 10
Fault Code A167 11
Fault Code A168 12
Fault Code A169 13
Fault Code A170 14
Fault Code A171 15
Fault Code A172 16
Fault Code A173 17
Fault Code A184 18
Fault Code A190 19
Fault Code A193 20
Fault Code A194 21
00 Index and foreword CEN00067-00
9
Fault Code A195 22
Fault Code A196 23
Fault Code A197 24
Fault Code A198 25
Fault Code A199 26
Fault Code A200 27
Fault Code A201 28
Fault Code A202 29
Fault Code A203 30
Fault Code A204 31
Fault Code A205 32
Fault Code A206 33
Fault Code A207 34
Fault Code A213 35
Fault Code A214 36
Fault Code A215 37
Fault Code A216 38
Fault Code A223 39
Fault Code A230 40
Fault Code A231 41
Fault Code A233 42
Fault Code A235 43
Fault Code A236 44
Fault Code A237 45
Fault Code A240 46
Fault Code A242 47
Fault Code A243 48
Fault Code A244 49
Fault Code A245 50
Fault Code A246 51
Troubleshooting by fault code, Part 3 CEN40180-03
Fault Code A247 3
Fault Code A248 4
Fault Code A249 5
Fault Code A250 6
Fault Code A251 7
Fault Code A252 8
Fault Code A253 9
Fault Code A256 10
Fault Code A257 11
Fault Code A258 12
Fault Code A260 13
Fault Code A261 14
Fault Code A262 15
Fault Code A264 16
Fault Code A265 17
CEN00067-00 00 Index and foreword
10
Fault Code A266 18
Fault Code A267 19
Fault Code A268 20
Fault Code A270 21
Fault Code A272 22
Fault Code A273 23
Fault Code A274 24
Fault Code A275 25
Fault Code A277 26
Fault Code A278 27
Fault Code A279 28
Fault Code A280 29
Fault Code A281 30
Fault Code A282 31
Fault Code A283 32
Fault Code A284 33
Fault Code A285 34
Fault Code A286 35
Fault Code A292 36
Troubleshooting by fault code, Part 4 CEN40181-04
Fault Code A303 4
Fault Code A304 5
Fault Code A305 6
Fault Code A307 7
Fault Code A309 8
Fault Code A310 9
Fault Code A311 10
Fault Code A312 11
Fault Code A313 12
Fault Code A315 13
Fault Code A316 14
Fault Code A317 15
Fault Code A318 16
Fault Code A328 17
Fault Code A332 18
Fault Code A333 19
Fault Code A334 20
Fault Code A335 21
Fault Code A337 22
Fault Code A338 23
Fault Code A339 24
Fault Code A340 25
Fault Code A341 26
Fault Code A342 27
Fault Code A343 28
Fault Code A344 29
00 Index and foreword CEN00067-00
11
Fault Code A345 30
Fault Code A346 31
Fault Code A347 32
Fault Code A348 33
Fault Code A349 34
Fault Code A350 35
Fault Code A351 36
Fault Code A352 37
Fault Code A353 38
Fault Code A354 39
Fault Code A355 40
Fault Code A356 41
Fault Code A357 42
Fault Code A358 43
Fault Code A359 44
Fault Code A360 45
Fault Code A361 46
Fault Code A362 47
Fault Code A363 48
Fault Code A364 49
Fault Code A365 50
Fault Code A366 51
Troubleshooting by fault code, Part 5 CEN40182-01
Fault Code A400 4
Fault Code A401 5
Fault Code A402 6
Fault Code A403 7
Fault Code A404 8
Fault Code A405 9
Fault Code A406 10
Fault Code A407 11
Fault Code A408 12
Fault Code A409 13
Fault Code A410 14
Fault Code A411 15
Fault Code A412 16
Fault Code A413 17
Fault Code A414 18
Fault Code A415 19
Fault Code A416 20
Fault Code A417 21
Fault Code A418 22
Fault Code A419 23
Fault Code A420 24
Fault Code A421 25
Fault Code A422 26
CEN00067-00 00 Index and foreword
12
Fault Code A423 27
Fault Code A424 28
Fault Code A425 29
Fault Code A426 30
Fault Code A427 31
Fault Code A428 32
Fault Code A429 33
Fault Code A430 34
Fault Code A431 35
Fault Code A432 36
Fault Code A433 37
Fault Code A434 38
Fault Code A435 39
Fault Code A436 40
Fault Code A437 41
Fault Code A438 42
Fault Code A439 43
Fault Code A440 44
Fault Code A441 45
Fault Code A442 46
Fault Code A443 47
Fault Code A444 48
Fault Code A445 49
Fault Code A446 50
Fault Code A447 51
Aftertreatment system fault codes CEN40222-02
Fault Code CA256 5
Fault Code CA1677 7
Fault Code CA1678 9
Fault Code CA1682 12
Fault Code CA1683 19
Fault Code CA1684 21
Fault Code CA1685 23
Fault Code CA1686 25
Fault Code CA1712 27
Fault Code CA1713 29
Fault Code CA1714 31
Fault Code CA1715 32
Fault Code CA1887 34
Fault Code CA2771 35
Fault Code CA3142 39
Fault Code CA3143 41
Fault Code CA3146 43
Fault Code CA3147 45
Fault Code CA3232 47
Fault Code CA3497 50
00 Index and foreword CEN00067-00
13
Fault Code CA3498 51
Fault Code CA3547 52
Fault Code CA3558 53
Fault Code CA3559 55
Fault Code CA3562 57
Fault Code CA3563 59
Fault Code CA3567 61
Fault Code CA3571 63
Fault Code CA3572 65
Fault Code CA3573 68
Fault Code CA3574 70
Fault Code CA3575 72
Fault Code CA3712 74
Fault Code CA3713 75
Fault Code CA3714 78
Fault Code CA3867 79
Fault Code CA3868 81
Fault Code CA3878 84
Fault Code CA3988 85
Fault Code CA3995 89
Fault Code CA4113 91
Fault Code CA4114 93
Fault Code CA4119 95
Fault Code CA4121 97
Fault Code CA4152 99
Fault Code CA4164 103
Fault Code CA4165 105
Fault Code CA4166 108
Fault Code CA4168 110
Fault Code CA4169 112
Fault Code CA4174 114
Fault Code CA4175 116
Fault Code CA4233 119
Fault Code CA4234 120
Fault Code CA4243 121
Fault Code CA4277 122
Fault Code CA4457 124
Fault Code CA4458 126
Fault Code CA4459 129
Fault Code CA4461 131
Fault Code CA4462 133
Fault Code CA4464 135
Fault Code CA4465 137
Fault Code CA4466 140
Fault Code CA4467 147
Fault Code CA4474 149
CEN00067-00 00 Index and foreword
14
Fault Code CA4475 151
Fault Code CA4572 154
Fault Code CA4677 158
Fault Code CA4679 162
Fault Code CA4682 163
Fault Code CA4731 164
Fault Code CA4732 165
Fault Code CA4736 166
Fault Code CA4737 167
Fault Code CA4738 168
Fault Code CA4739 169
Fault Code CA4745 170
Fault Code CA4768 171
Fault Code CA4769 173
Fault Code CA4842 175
Fault Code CA4863 176
Fault Code CA4947 177
Fault Code CA5115 178
Fault Code CA5116 181
Fault Code CA5117 184
Fault Code CA5247 187
Fault Code CA5653 189
Fault Code CA5654 192
Fault Code CA5725 194
Fault Code CA5727 199
Fault Code CA5728 202
Fault Code CA5729 205
Fault Code CA5748 207
Fault Code CA5749 209
Fault Code CA5751 211
Fault Code CA5753 213
Fault Code CA5755 216
Fault Code CA5756 221
Fault Code CA5758 223
Fault Code CA5768 225
Fault Code CA5769 227
Fault Code CA5771 230
Fault Code CA5772 232
Fault Code CA5773 235
Fault Code CA5774 238
Fault Code CA5775 240
Fault Code CA5776 245
Fault Code CA5778 247
Fault Code CA5779 249
Fault Code CA5887 251
Fault Code CA5888 252
00 Index and foreword CEN00067-00
15
Fault Code CA5889 253
Fault Code CA5891 254
Fault Code CA5892 255
Fault Code CA5893 256
Fault Code CA6692 257
Fault Code CA6693 259
Fault Code CA6694 261
Fault Code CA6695 263
Fault Code CA6696 265
Fault Code CA6697 267
Fault Code CA6855 269
Fault Code CA6856 272
Steering system CEN40190-01
Steering circuit troubleshooting chart 3
Steering circuit troubleshooting guidelines 5
Basic hydraulic system checks 6
System leakage check 7
Steering pump troubleshooting guide 9
Pump pressure control checks 12
KomVision CEN40200-01
KomVision fault codes 3
Automatic lubrication (auto lube) system CEN40202-00
Autolube troubleshooting chart 3
Heating/air conditioning (HVAC) system CEN40226-00
Control panel configurations 3
Diagnostics mode 4
Additional HVAC troubleshooting chart 5
Voltage levels 7
Electronic fan clutch CEN40256-00
Electronic fan clutch troubleshooting 3
50 Disassembly and assembly
Service tools CEN50139-00
Special tool group 3
Additional service tools 4
KomVision calibration tools 5
Locally made tools 5
Wheels, spindles and rear axle CEN50140-00
General precautions for tires and rims 3
Rim components 4
Wheel stud maintenance 5
Wheel stud installation height 6
Removal and installation of front wheel 7
Removal and installation of rear wheel 9
Rim and tire service 12
Removal and installation of front wheel hub and spindle 26
CEN00067-00 00 Index and foreword
16
Disassembly and assembly of front wheel hub and spindle 34
Hub floating ring seal assembly and installation 55
Brake floating seal assembly and installation 61
Removal and installation of rear axle 68
Removal and installation of anti-sway bar 71
Removal and installation of pivot pin 74
Pivot eye and bearing service 76
Removal and installation of wheel motor 78
Removal and installation of rear brake assembly 85
Brake system CEN50066-01
Removal and installation of brake valve 3
Disassembly and assembly of brake valve/pedal assembly 5
Removal and installation of dual relay valve 9
Removal and installation of brake manifold 11
Disassembly and assembly of brake manifold 12
Removal and installation of piston brake accumulator 14
Disassembly and assembly of piston brake accumulator 16
Disassembly and assembly of front wheel brake 20
Disassembly and assembly of rear wheel brake 26
Brake floating ring seal assembly and installation 35
Removal and installation of parking brake 41
Disassembly and assembly of parking brake 43
Steering system CEN50067-00
Removal and installation of steering control unit 3
Disassembly and assembly of steering control unit 5
Removal and installation of steering column 10
Removal and installation of steering wheel 12
Removal and installation of bleeddown manifold 13
Removal and installation of flow amplifier 15
Removal and installation of steering cylinders and tie rod 16
Disassembly and assembly of steering cylinders 18
Removal and installation of steering/brake pump 21
Removal and installation of piston steering accumulator 23
Disassembly and assembly of piston steering accumulator 26
Suspensions CEN50068-00
Removal and installation of front suspension 3
Disassembly and assembly of front suspension 11
Removal and installation of rear suspension 16
Disassembly and assembly of rear suspension 20
Hoist circuit CEN50069-01
Removal and installation of hoist pump 3
Disassembly and assembly of hoist pump 8
Removal and installation of hoist valve 17
Disassembly and assembly of hoist valve 19
Overcenter manifold service 27
Removal and installation of hoist pilot valve 28
00 Index and foreword CEN00067-00
17
Disassembly and assembly of hoist pilot valve 30
Removal and installation of hoist cylinders 32
Disassembly and assembly of hoist cylinders 35
Body and structures CEN50070-00
Removal and installation of dump body 3
Removal and installation of body pads 6
Removal and installation of diagonal ladder/hood and grille assembly 8
Removal and installation of RH deck 10
Removal and installation of LH deck 12
Removal and installation of fuel tank 14
Removal and installation of fuel gauge sender 16
Removal and installation of hydraulic tank 17
Removal and installation of hydraulic tank strainers 19
Operator cab CEN50079-02
Removal and installation of operator cab 3
Removal and installation of cab door 6
Disassembly and assembly of cab door 8
Adjustment of cab door 17
Removal and installation of side window glass 20
Removal and installation of windshield and rear window glass 22
Removal and installation of windshield wiper components 23
Removal and installation of cab seats 25
Removal and installation of seat belts 27
Power module CEN50073-03
Removal and installation of power module 3
Exhaust tube installation 15
Exhaust blanket installation 15
Removal and installation of alternator 16
Removal and installation of radiator 33
Repairing the radiator 38
Removal and installation of engine 42
Removal and installation of electronic fan clutch 44
Removal and installation of electronic fan clutch speed sensor 45
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90023-00
Steering, hoist and brake cooling hydraulic circuit diagram 58F-60-00832
Brake hydraulic circuit diagram 58F-60-00841
Auxiliary system hydraulic circuit schematic 58E-60-01680
Electrical circuit diagrams CEN90051-00
Electrical circuit diagram 58F-06-02317
Electrical sub-system circuit diagram 58F-06-10562
HVAC electrical circuit diagram 58B-06-06830

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DESCRIPTION:

Komatsu 930E-5 Dump Truck Shop Manual CEBM036500 – PDF DOWNLOAD

SERIAL NUMBERS 930E-5 A40216 and up
ENGINE 16V160

Composition of shop manual:
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated next
to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.

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