Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual CEBM036503 – PDF

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Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual CEBM036503 – PDF DOWNLOAD

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Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual CEBM036503 – PDF DOWNLOAD

Language : English
Pages :1412
Downloadable : Yes
File Type : PDF

TABLE OF CONTENT:

Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual CEBM036503 – PDF DOWNLOAD

SERIAL NUMBERS 930E-5
A40216 – A40329

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 25
Foreword 28
How to read the shop manual 29
Composition of shop manual 29
Revision and distribution 29
Symbols 30
General safety 31
Safety rules 31
Safety features 31
Fire extinguisher and first aid kit 31
Clothing and personal items 31
Leaving the operator seat 32
Mounting and dismounting 32
Fire prevention for fuel and oil 32
Precautions with high temperature fluids 33
Asbestos dust hazard prevention 33
Prevention of injury by work equipment 33
Unauthorized modification 33
Precautions when using ROPS 33
Precautions for attachments 34
Precautions for starting the truck 34
Precautions before operating the truck 34
Safety at the worksite 34
Fire prevention 35
Ventilation in enclosed areas 35
Preparing for operation 35
Mirrors, windows and lights 35
In operator cab (before starting the engine) 35
Seat Belts 35
Precautions while operating the truck 36
When starting the engine 36
General truck operation 36
Ensuring good visibility 36
Traveling 37
Traveling in reverse 37
Traveling on slopes 37
Operating on snow or ice 37
Avoid damage to dump body 37
Driving near high voltage cables 38
When dumping 38
When loading 38
Working on loose ground 38
Parking the truck 39
Towing 39
Working near batteries 40
Battery hazard prevention 40
Starting with jumper cables 41
Jump starting with receptacles 41
Precautions before performing service 42
Warning tag 42
Stopping the engine 42
Proper tools 42
Use of tie-off anchor during maintenance and repair 43
Tie-off anchor installation 43
Securing the dump body 44
Jack point locations 45
Precautions while performing service 46
Keep the truck clean 46
Attachments 46
Working under the truck 46
Rotating fan and belts 46
Adding fuel or oil 46
Use of lighting 46
Radiator coolant level 47
Precautions with the battery 47
Precautions with high pressure oil 47
Handling high pressure hoses 47
Precautions when performing maintenance near high temperature or high pressure 47
Waste materials 47
Tires 48
Inspection 48
Maintenance 48
Storage 49
Handling 50
Precautions for performing repairs 51
Engine shutdown procedure after AC drive system failure 51
Precautions for welding on the truck 52
Control cabinet capacitor discharge system 53
Handling electrical equipment and hydraulic components 55
Points to remember when handling electrical equipment 55
Points to remember when handling hydraulic equipment 61
Actions taken to meet exhaust gas regulations 63
About DEF 63
Precautions for diesel exhaust fluid (DEF) 64
About DEF 64
Precautions for handling DEF 64
Precautions for storing DEF 64
Precautions for disposing of DEF 65
Crystallization management 65
Precautions for cold weather operation 65
Standard tightening torques 66
Effect of special lubricants on fasteners and standard torque values 66
Suggested sources for rust preventive grease 66
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 67
SAE grade 9 capscrews 68
Class 109 capscrews and class 10 nuts 68
Standard tightening torques for fittings 69
Standard tightening torques for clamps 71
Conversion tables 72
Common conversion multipliers 72
01 Specification 77
Specification and technical data 77
Specification drawing 79
Specifications 80
Weight table 82
Fuel, coolant and lubricants 83
Suspension cylinder oil and nitrogen specifications 84
Wheel motor oil specifications 84
10 Structure and functions 87
Steering circuit 87
Steering circuit operation 88
Steering circuit components 93
Steering control unit 93
High pressure filter 93
Steering accumulators 93
Bleeddown manifold 94
Steering accumulator bleeddown solenoid 94
Quick disconnect ports 94
Flow amplifier 94
Steering/brake pump operation 95
High altitude operation 95
Neutral position 96
Full pump volume 97
Half pump volume 97
Flow amplifier operation 98
No steer 98
Steering left 100
Steering right 102
No steer, external shock load 104
Hoist circuit 107
Hoist circuit operation 108
Hoist circuit components 108
Hydraulic tank 108
Hoist pump 108
High pressure filters 108
Hoist valve 111
Inlet sections 111
Tank ports (front) spool section 111
Work ports (rear) spool section 112
Hoist pilot valve 112
Hoist limit solenoid 113
Pilot operated check valve 113
Overcenter manifold 113
Hoist pilot valve operation 114
Float position with body down 114
Power up operation 116
Hold operation 118
Power down operation 120
Float operation with body up 122
Brake circuits 125
General information 127
Service brake circuit operation 130
Secondary braking and auto apply 131
Parking brake circuit operation 132
Normal operation (key start switch ON, engine on) 132
Wheel brake lock circuit operation 133
Brake warning circuit operation 133
Electrical system, 24 volt 135
Battery supply system 137
Batteries 137
24VDC auxiliary battery receptacles 137
Isolation box 138
Ground level shutdown switch 138
Battery disconnect switches 138
Propel lockout lever 138
System busy light 138
LED lights 138
Engine starting system with prelube 139
Prelube operation 139
Cranking operation 140
Auxiliary control cabinet components 141
VEC blocks 142
24VDC to 12VDC converter 142
Circuit breakers 142
Engine service light timer 142
Ground terminals 142
24VDC power terminals 142
Relays 143
Body-up switch 144
Hoist limit switch 145
Heating/air conditioning (HVAC) system 147
Basic air conditioning system operation 149
HVAC components 151
Control panel 151
Water valve 151
Expansion valve 151
Actuators 151
Blower 151
Heater core 151
Evaporator core 151
Cab air temperature sensor 151
ECU module 151
Air filters 153
Compressor (refrigerant pump) 153
Compressor clutch 153
Trinary™ switch 154
Receiver-drier 154
Condenser 154
Accumulator 154
Automatic lubrication (auto lube) system 157
General information 159
System operation 160
Engine emissions aftertreatment system 163
About emissions aftertreatment 166
DEF injection system 166
DEF heating system 166
Sensors 166
Exhaust system cleaning 167
Propel lockout precaution 167
Inducement strategy 167
20 Standard value table 169
Standard value table 169
Standard value table for truck 171
30 Testing and adjusting 177
Steering, hoist, brake cooling and auxiliary hydraulic systems 177
Hydraulic system bleeddown procedure 179
Hydraulic system vacuum procedure 181
General information on system checkout 182
Hydraulic system checkout procedures 182
Required equipment 182
Preliminary steps 183
Hydraulic system flushing procedure 183
Flow amplifier adjustment 187
Steering pump unloader valve adjustment 188
Auxiliary accumulator pressure verification 188
System diagnostics 189
Hoist pilot relief valve adjustment 191
Hoist counterbalance valve adjustment 192
Final steps 193
Oil cleanliness check 193
Hydraulic system checkout data sheet 194
Toe-in adjustment 197
Hoist cylinder leakage test 198
Steering cylinder leakage test 198
Brake system 201
General information on system checkout 203
Brake system checkout procedures 203
Required equipment 203
Bleeddown procedure 203
Preliminary steps 206
Service brake checkout (front and rear) 207
Brake lock system checkout 208
Low brake pressure and auto apply checkout 208
Service brake checkout (left and right) 210
Parking brake checkout 211
Parking brake control logic checkout 211
Brake lock control logic checkout 213
Brake system checkout data sheet 216
Brake piston leakage test 225
Brake seal pressure test 225
Oil separator seal pressure test 225
Method 1 225
Method 2 226
Wet disc brake bleeding procedure 226
Parking brake bleeding procedure 227
Service brake disc wear inspection 228
Parking brake disc wear inspection 229
Accumulators and suspensions 231
Accumulator charging and storage 233
Temperature during precharge 233
Bladder accumulator charging procedure 234
Precharge maintenance 236
Bladder accumulator storage procedure 236
Bladder storage 236
Installing a bladder accumulator from storage 237
Bladder accumulator leak testing 237
Piston accumulator charging procedure 238
Piston accumulator storage 241
Piston accumulator leak testing 242
Checking for improper suspension charge on operating trucks 243
Suspension oil change recommendations 244
Suspension oiling and charging procedures 245
Required equipment 245
Installing the charging kit 246
Removing the charging kit 246
Support blocks for oiling and charging dimensions 247
Front suspensions 250
TOP FILL METHOD 251
PRESSURE FILL METHOD 251
Rear suspensions 253
TOP FILL METHOD 255
PRESSURE FILL METHOD 255
Suspension pressure test 258
Electrical systems 259
General information on system checkout 261
Loadbox test information 261
Truck shutdown procedure 262
Required software and tools 262
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 268
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 362
Checkout data sheet 371
Calibration sheets 376
Layout and assemblage 376
Unfolding a calibration sheet 379
Folding a calibration sheet 380
Placement of calibration sheets 381
Camera calibration procedures 383
Automatic 6 camera calibration 383
Manual 6 camera calibration 387
1 camera calibration 390
Radar setting procedure 393
Tire monitoring system 397
Tire monitoring system software and tools 399
Tire monitoring system configuration 399
Connecting to the tire monitoring system web server 399
Configuring a static IP address 399
Tire monitoring system software installation 401
Tire monitoring system checkout procedure 402
Field Troubleshooting 402
Ethernet troubleshooting 402
Tire monitoring system configuration 403
CAN RPC Troubleshooting 403
Resetting the tire monitoring system 403
Tire monitoring system checkout data sheet 404
40 Troubleshooting 407
Fuse, diode and relay locations 407
Vehicle Electrical Center (VEC-89) 409
Vehicle Electrical Center (VEC-90) 411
Vehicle Electrical Center (VEC-91) 413
Vehicle Electrical Center (VEC-92) 415
Rear Terminal Mini-fuse and Relay (RTMR3) 416
Rear Terminal Mini-fuse and Relay (RTMR4) 417
Circuit breakers 418
Troubleshooting by fault code, Part 1 421
Fault Code A001 424
Fault Code A002 425
Fault Code A003 426
Fault Code A004 427
Fault Code A005 428
Fault Code A006 429
Fault Code A007 430
Fault Code A008 431
Fault Code A009 432
Related circuit diagram 432
Fault Code A010 433
Related circuit diagram 433
Fault Code A011 434
Fault Code A013 435
Fault Code A014 436
Fault Code A016 437
Fault Code A017 438
Fault Code A018 439
Fault Code A019 440
Fault Code A022 441
Fault Code A100 442
Related circuit diagram 442
Fault Code A101 443
Fault Code A103 444
Fault Code A104 445
Fault Code A105 446
Fault Code A109 447
Fault Code A111 448
Fault Code A115 449
Fault Code A117 450
Fault Code A118 451
Fault Code A123 452
Fault Code A124 453
Fault Code A125 454
Fault Code A126 455
Fault Code A127 456
Fault Code A128 457
Fault Code A139 458
Troubleshooting by fault code, Part 2 461
Fault Code A145 464
Fault Code A146 465
Fault Code A152 466
Fault Code A153 467
Fault Code A154 468
Fault Code A155 469
Fault Code A158 470
Fault Code A166 471
Fault Code A167 472
Fault Code A168 473
Fault Code A169 474
Fault Code A170 475
Fault Code A171 476
Fault Code A172 477
Fault Code A173 478
Fault Code A184 479
Fault Code A190 480
Fault Code A193 481
Fault Code A194 482
Fault Code A195 483
Fault Code A196 484
Fault Code A197 485
Fault Code A198 486
Fault Code A199 487
Fault Code A200 488
Fault Code A201 489
Fault Code A202 490
Fault Code A203 491
Fault Code A204 492
Fault Code A205 493
Fault Code A206 494
Fault Code A207 495
Fault Code A213 496
Fault Code A214 497
Fault Code A215 498
Fault Code A216 499
Fault Code A223 500
Fault Code A230 501
Fault Code A231 502
Fault Code A233 503
Fault Code A235 504
Fault Code A236 505
Fault Code A237 506
Fault Code A238 507
Fault Code A239 509
Related circuit diagram 510
Fault Code A240 511
Fault Code A242 512
Fault Code A243 513
Fault Code A244 514
Fault Code A245 515
Fault Code A246 516
Troubleshooting by fault code, Part 3 519
Fault Code A247 521
Fault Code A248 522
Fault Code A249 523
Fault Code A250 524
Fault Code A251 525
Fault Code A252 526
Fault Code A253 527
Fault Code A256 528
Fault Code A257 529
Fault Code A258 530
Fault Code A260 531
Fault Code A261 532
Fault Code A262 533
Fault Code A264 534
Fault Code A265 535
Fault Code A266 536
Fault Code A267 537
Fault Code A268 538
Fault Code A270 539
Fault Code A271 540
Related circuit diagram 541
Fault Code A272 542
Fault Code A273 543
Fault Code A274 544
Fault Code A275 545
Fault Code A277 546
Fault Code A278 547
Fault Code A279 548
Fault Code A280 549
Fault Code A281 550
Fault Code A282 551
Fault Code A283 552
Fault Code A284 553
Fault Code A285 554
Fault Code A286 555
Fault Code A292 556
Troubleshooting by fault code, Part 4 559
Fault Code A303 562
Fault Code A304 563
Fault Code A305 564
Fault Code A307 565
Fault Code A309 566
Fault Code A310 567
Fault Code A311 568
Fault Code A312 569
Fault Code A313 570
Fault Code A315 571
Fault Code A316 572
Fault Code A317 573
Fault Code A318 574
Fault Code A328 575
Fault Code A332 576
Fault Code A333 577
Fault Code A334 578
Fault Code A335 579
Fault Code A337 580
Fault Code A338 581
Fault Code A339 582
Fault Code A340 583
Fault Code A341 584
Fault Code A342 585
Fault Code A343 586
Fault Code A344 587
Fault Code A345 588
Fault Code A346 589
Fault Code A347 590
Fault Code A348 591
Fault Code A349 592
Fault Code A350 593
Fault Code A351 594
Fault Code A352 595
Fault Code A353 596
Fault Code A354 597
Fault Code A355 598
Fault Code A356 599
Fault Code A357 600
Fault Code A358 601
Fault Code A359 602
Fault Code A360 603
Fault Code A361 604
Fault Code A362 605
Fault Code A363 606
Fault Code A364 607
Fault Code A365 608
Fault Code A366 609
Troubleshooting by fault code, Part 5 611
Fault Code A400 614
Fault Code A401 615
Fault Code A402 616
Fault Code A403 617
Fault Code A404 618
Fault Code A405 619
Fault Code A406 620
Fault Code A407 621
Fault Code A408 622
Fault Code A409 623
Fault Code A410 624
Fault Code A411 625
Fault Code A412 626
Fault Code A413 627
Fault Code A414 628
Fault Code A415 629
Fault Code A416 630
Fault Code A417 631
Fault Code A418 632
Fault Code A419 633
Fault Code A420 634
Fault Code A421 635
Fault Code A422 636
Fault Code A423 637
Fault Code A424 638
Fault Code A425 639
Fault Code A426 640
Fault Code A427 641
Fault Code A428 642
Fault Code A429 643
Fault Code A430 644
Fault Code A431 645
Fault Code A432 646
Fault Code A433 647
Fault Code A434 648
Fault Code A435 649
Fault Code A436 650
Fault Code A437 651
Fault Code A438 652
Fault Code A439 653
Fault Code A440 654
Fault Code A441 655
Fault Code A442 656
Fault Code A443 657
Fault Code A444 658
Fault Code A445 659
Fault Code A446 660
Fault Code A447 661
Aftertreatment system fault codes 663
Fault Code CA256 667
Fault Code CA1677 669
Fault Code CA1678 671
Fault Code CA1682 674
Fault Code CA1683 681
Fault Code CA1684 683
Fault Code CA1685 685
Fault Code CA1686 687
Fault Code CA1712 689
Fault Code CA1713 691
Fault Code CA1714 693
Fault Code CA1715 694
Fault Code CA1887 696
Fault Code CA2771 697
Fault Code CA3142 701
Fault Code CA3143 703
Fault Code CA3146 705
Fault Code CA3147 707
Fault Code CA3232 709
Fault Code CA3497 712
Fault Code CA3498 713
Fault Code CA3547 714
Fault Code CA3558 715
Fault Code CA3559 717
Fault Code CA3562 719
Fault Code CA3563 721
Fault Code CA3567 723
Fault Code CA3571 725
Fault Code CA3572 727
Fault Code CA3573 730
Fault Code CA3574 732
Fault Code CA3575 734
Fault Code CA3712 736
Fault Code CA3713 737
Fault Code CA3714 740
Fault Code CA3867 741
Fault Code CA3868 743
Fault Code CA3878 746
Fault Code CA3988 747
Fault Code CA3995 751
Fault Code CA4113 753
Fault Code CA4114 755
Fault Code CA4119 757
Fault Code CA4121 759
Fault Code CA4152 761
Fault Code CA4164 765
Fault Code CA4165 767
Fault Code CA4166 770
Fault Code CA4168 772
Fault Code CA4169 774
Fault Code CA4174 776
Fault Code CA4175 778
Fault Code CA4233 781
Fault Code CA4234 782
Fault Code CA4243 783
Fault Code CA4277 784
Fault Code CA4457 786
Fault Code CA4458 788
Fault Code CA4459 791
Fault Code CA4461 793
Fault Code CA4462 795
Fault Code CA4464 797
Fault Code CA4465 799
Fault Code CA4466 802
Fault Code CA4467 809
Fault Code CA4474 811
Fault Code CA4475 813
Fault Code CA4572 816
Fault Code CA4677 820
Fault Code CA4679 824
Fault Code CA4682 825
Fault Code CA4731 826
Fault Code CA4732 827
Fault Code CA4736 828
Fault Code CA4737 829
Fault Code CA4738 830
Fault Code CA4739 831
Fault Code CA4745 832
Fault Code CA4768 833
Fault Code CA4769 835
Fault Code CA4842 837
Fault Code CA4863 838
Fault Code CA4947 839
Fault Code CA5115 840
Fault Code CA5116 843
Fault Code CA5117 846
Fault Code CA5247 849
Fault Code CA5653 851
Fault Code CA5654 854
Fault Code CA5725 856
Fault Code CA5727 861
Fault Code CA5728 864
Fault Code CA5729 867
Fault Code CA5748 869
Fault Code CA5749 871
Fault Code CA5751 873
Fault Code CA5753 875
Fault Code CA5755 878
Fault Code CA5756 883
Fault Code CA5758 885
Fault Code CA5768 887
Fault Code CA5769 889
Fault Code CA5771 892
Fault Code CA5772 894
Fault Code CA5773 897
Fault Code CA5774 900
Fault Code CA5775 902
Fault Code CA5776 907
Fault Code CA5778 909
Fault Code CA5779 911
Fault Code CA5887 913
Fault Code CA5888 914
Fault Code CA5889 915
Fault Code CA5891 916
Fault Code CA5892 917
Fault Code CA5893 918
Fault Code CA6692 919
Fault Code CA6693 921
Fault Code CA6694 923
Fault Code CA6695 925
Fault Code CA6696 927
Fault Code CA6697 929
Fault Code CA6855 931
Fault Code CA6856 934
Steering system 937
Steering circuit troubleshooting chart 939
Steering circuit troubleshooting guidelines 941
Basic hydraulic system checks 942
System leakage check 943
Steering pump troubleshooting guide 945
Pump pressure control checks 948
Pump fails to unload 949
Pump fails to develop pressure 949
Pump slow in developing pressure 950
Pump control valve inspection and troubleshooting 951
Pump case drain check 953
Setting pump pressure controls 953
KomVision 957
KomVision fault codes 959
Automatic lubrication (auto lube) system 969
Autolube troubleshooting chart 971
Heating/air conditioning (HVAC) system 975
Control panel configurations 977
Diagnostics mode 978
Error codes 978
Advanced diagnostics 978
Firmware version 979
Additional HVAC troubleshooting chart 979
Voltage levels 981
Electronic fan clutch 983
Electronic fan clutch troubleshooting 985
Electronic fan clutch fault codes 987
50 Disassembly and assembly 989
Service tools 989
Special tool group 991
Additional service tools 992
KomVision calibration tools 993
Locally made tools 993
Wheels, spindles and rear axle 995
General precautions for tires and rims 997
Wheel stud maintenance 998
Rear outer wheel stud installation 999
Removal and installation of front wheel1000
Removal1000
Installation1001
Removal and installation of rear wheel1002
Removal1002
Installation1003
Rim components1005
Smart Rim Component Layout1005
Rim and tire service1006
Lubricants1006
Tire inflation1006
Lock ring retainer installation1006
Removing the lock ring1007
Installing the lock ring1008
Removing the tire from the front rim (5-piece rim)1009
Removing the tire from the rear outer dual rim (7-piece Smart rim)1012
Removing the tire from the rear inner dual rim (5-piece rim)1014
Preparation before assembly1015
Installing the tire on the front rim (5-piece rim)1016
Installing the tire on the rear inner dual rim (5-piece rim)1018
Installing the tire on the rear outer dual rim (7-piece Smart rim)1019
Removal and installation of front wheel hub and spindle1020
Removal1020
Spindle removal (off the truck)1026
Installation1028
Disassembly and assembly of front wheel hub and spindle1029
Cross Section View1029
Disassembly1030
Cleaning and inspection1037
Assembly1038
Wheel bearing adjustment1040
Seal assembly gap adjustment1041
Brake seal installation1042
Oil separation seal installation1043
Brake installation1044
Speed sensor installation and adjustment1048
Floating ring seal assembly and installation1050
Removal and installation of rear axle1059
Removal1059
Cleaning and inspection1061
Installation1061
Removal and installation of anti-sway bar1062
Removal1062
Installation1064
Removal and installation of pivot pin1065
Removal1065
Installation1066
Removal and installation of pivot bearing1067
Replacement criteria1067
Removal1069
Inspection1069
Installation1069
Removal and installation of pivot eye1070
Removal1070
Inspection1070
Installation1070
Removal of wheel motor1071
Preparation1071
Installation of wheel motor1073
Cleaning and inspection1073
Installation1074
Removal and installation of rear brake assembly1077
Brake system1079
Removal and installation of brake valve1081
Removal1081
Installation1082
Disassembly and assembly of brake valve/pedal assembly1083
Disassembly1083
Assembly1084
Removal and installation of dual relay valve1087
Removal1087
Installation1088
Removal and installation of brake manifold1089
Removal1089
Installation1089
Disassembly and assembly of brake manifold1090
Disassembly1090
Assembly1090
Removal and installation of piston brake accumulator1091
Removal1091
Installation1093
Disassembly and assembly of piston brake accumulator1095
Disassembly1095
Cleaning and inspection1097
Piston seal replacement1097
Assembly1098
Disassembly and assembly of front wheel brake1099
Disassembly1099
Cleaning and inspection1102
Assembly1103
Disassembly and assembly of rear wheel brake1105
Disassembly1105
Cleaning and inspection1109
Assembly1110
Brake floating ring seal assembly and installation1114
Rear hub floating ring seal assembly and installation1123
Removal and installation of parking brake1129
Removal1129
Installation1131
Disassembly and assembly of parking brake1132
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1132
Disassembly1132
Cleaning and inspection1134
Cleaning and inspecting new discs1136
Assembly1137
Steering system1139
Removal and installation of steering control unit1141
Removal1141
Installation1143
Disassembly and assembly of steering control unit1144
Disassembly1144
Assembly1146
Removal and installation of steering column1149
Removal1149
Installation1150
Removal and installation of steering wheel1151
Removal1151
Installation1151
Removal and installation of bleeddown manifold1152
Removal1152
Installation1153
Removal and installation of flow amplifier1154
Removal1154
Installation1154
Removal and installation of steering cylinders and tie rod1155
Removal1155
Installation1155
Disassembly and assembly of steering cylinders1157
Disassembly1157
Cleaning and inspection1159
Assembly1159
Removal and installation of steering/brake pump1160
Removal1160
Installation1162
Removal and installation of piston steering accumulator1163
Removal1163
Installation1165
Disassembly and assembly of piston steering accumulator1167
Disassembly1167
Cleaning and inspection1169
Piston seal replacement1169
Assembly1170
Suspensions1173
General information1175
Removal and installation of front suspension1175
Preparation1175
Removal1175
Cleaning and Inspection1177
Installation1178
Disassembly and assembly of front suspension1183
Disassembly1183
Cleaning and inspection1186
Assembly1186
Removal and installation of rear suspension1188
Removal1188
Installation1191
Disassembly and assembly of rear suspension1194
Disassembly1194
Cleaning and inspection1196
Assembly1197
Hoist circuit1199
Removal and installation of hoist pump1201
Removal1201
Installation1205
Disassembly and assembly of hoist pump1206
Disassembly1206
Inspection1211
Assembly1212
Removal and installation of hoist valve1215
Removal1215
Installation1217
Disassembly and assembly of hoist valve1217
O-ring replacement1217
Disassembly of inlet section1219
Assembly of inlet section1220
Disassembly of rear spool section1221
Assembly of rear spool section1223
Disassembly of front spool section1224
Assembly of front spool section1225
Overcenter manifold service1225
Removal and installation of hoist pilot valve1226
Removal1226
Installation1226
Disassembly and assembly of hoist pilot valve1228
Disassembly1228
Cleaning and inspection1229
Assembly1229
Removal and installation of hoist cylinders1230
Removal1230
Installation1233
Disassembly and assembly of hoist cylinders1236
Disassembly1236
Cleaning and inspection1240
Installation of the quill1241
Assembly1243
Body and structures1249
Removal and installation of dump body1251
Removal1251
Inspection1252
Installation1253
Removal and installation of body pads1254
Removal1254
Installation1254
Body pad shimming procedure1255
Removal and installation of diagonal ladder/ hood and grille assembly1256
Removal1256
Installation1256
Removal and installation of RH deck1258
Removal1258
Installation1258
Removal and installation of LH deck1260
Removal1260
Installation1260
Removal and installation of fuel tank1262
Removal1262
Cleaning and inspection1262
Installation1264
Removal and installation of fuel gauge sender1264
Removal1264
Installation1264
Removal and installation of hydraulic tank1265
Removal1265
Installation1266
Removal and installation of hydraulic tank strainers1267
Removal1267
Cleaning and inspection1268
Installation1268
Operator cab1271
Removal and installation of operator cab1273
Removal1273
Installation1276
Removal and installation of cab door1276
Removal1276
Installation1277
Disassembly and assembly of cab door1278
Removing the window regulator1278
Installing the window regulator1279
Removing the door glass1280
Installing the door glass1281
Replacing the inner door seal1282
Replacing the outer door seal1282
Removing the interior door handle and door latch (earlier models)1283
Installation and removal of interior door handle and door latch (later models)1286
Adjustment of cab door1288
Door jamb bolt adjustment1288
Exterior door handle release button adjustment1290
Removal and installation of side window glass1291
Recommended tools and supplies1291
Removal1291
Installation1292
Removal and installation of windshield and rear window glass1293
Removal1293
Installation1293
Removal and installation of windshield wiper components1294
Removing the windshield wiper motor1294
Installing the windshield wiper motor1294
Removing the windshield wiper arm and linkage1295
Installing the windshield wiper arm and linkage1296
Removal and installation of cab seats1296
Removal1296
Servicing the seat1297
Installation1297
Removal and installation of seat belts1298
Removal1298
Installation1299
Power module1301
Removal and installation of power module1303
General1303
Removal1304
Installation1312
Exhaust tube installation1315
Exhaust blanket installation1315
Removal and installation of alternator1316
Removal1316
Installation1319
Engine/alternator attachment checkout data sheet1329
Removal and installation of radiator1335
Removal1335
Installation1339
Repairing the radiator1340
Internal inspection1340
External cleaning1340
Disassembly1341
Cleaning and inspection1342
Assembly1342
Pressure testing1343
Removal and installation of engine1344
Removal1344
Service1344
Installation1345
Removal and installation of electronic fan clutch1346
Removal1346
Installation1347
Removal and installation of electronic fan clutch speed sensor1347
Removal1347
Installation1347
90 Diagrams and drawings1349
Hydraulic circuit diagrams1349
Electrical circuit diagrams1356

TABLE OF CONTENTS:

Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual CEBM036503 – PDF DOWNLOAD

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 25
Foreword 28
How to read the shop manual 29
Composition of shop manual 29
Revision and distribution 29
Symbols 30
General safety 31
Safety rules 31
Safety features 31
Fire extinguisher and first aid kit 31
Clothing and personal items 31
Leaving the operator seat 32
Mounting and dismounting 32
Fire prevention for fuel and oil 32
Precautions with high temperature fluids 33
Asbestos dust hazard prevention 33
Prevention of injury by work equipment 33
Unauthorized modification 33
Precautions when using ROPS 33
Precautions for attachments 34
Precautions for starting the truck 34
Precautions before operating the truck 34
Safety at the worksite 34
Fire prevention 35
Ventilation in enclosed areas 35
Preparing for operation 35
Mirrors, windows and lights 35
In operator cab (before starting the engine) 35
Seat Belts 35
Precautions while operating the truck 36
When starting the engine 36
General truck operation 36
Ensuring good visibility 36
Traveling 37
Traveling in reverse 37
Traveling on slopes 37
Operating on snow or ice 37
Avoid damage to dump body 37
Driving near high voltage cables 38
When dumping 38
When loading 38
Working on loose ground 38
Parking the truck 39
Towing 39
Working near batteries 40
Battery hazard prevention 40
Starting with jumper cables 41
Jump starting with receptacles 41
Precautions before performing service 42
Warning tag 42
Stopping the engine 42
Proper tools 42
Use of tie-off anchor during maintenance and repair 43
Tie-off anchor installation 43
Securing the dump body 44
Jack point locations 45
Precautions while performing service 46
Keep the truck clean 46
Attachments 46
Working under the truck 46
Rotating fan and belts 46
Adding fuel or oil 46
Use of lighting 46
Radiator coolant level 47
Precautions with the battery 47
Precautions with high pressure oil 47
Handling high pressure hoses 47
Precautions when performing maintenance near high temperature or high pressure 47
Waste materials 47
Tires 48
Inspection 48
Maintenance 48
Storage 49
Handling 50
Precautions for performing repairs 51
Engine shutdown procedure after AC drive system failure 51
Precautions for welding on the truck 52
Control cabinet capacitor discharge system 53
Handling electrical equipment and hydraulic components 55
Points to remember when handling electrical equipment 55
Points to remember when handling hydraulic equipment 61
Actions taken to meet exhaust gas regulations 63
About DEF 63
Precautions for diesel exhaust fluid (DEF) 64
About DEF 64
Precautions for handling DEF 64
Precautions for storing DEF 64
Precautions for disposing of DEF 65
Crystallization management 65
Precautions for cold weather operation 65
Standard tightening torques 66
Effect of special lubricants on fasteners and standard torque values 66
Suggested sources for rust preventive grease 66
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 67
SAE grade 9 capscrews 68
Class 109 capscrews and class 10 nuts 68
Standard tightening torques for fittings 69
Standard tightening torques for clamps 71
Conversion tables 72
Common conversion multipliers 72
01 Specification 77
Specification and technical data 77
Specification drawing 79
Specifications 80
Weight table 82
Fuel, coolant and lubricants 83
Suspension cylinder oil and nitrogen specifications 84
Wheel motor oil specifications 84
10 Structure and functions 87
Steering circuit 87
Steering circuit operation 88
Steering circuit components 93
Steering control unit 93
High pressure filter 93
Steering accumulators 93
Bleeddown manifold 94
Steering accumulator bleeddown solenoid 94
Quick disconnect ports 94
Flow amplifier 94
Steering/brake pump operation 95
High altitude operation 95
Neutral position 96
Full pump volume 97
Half pump volume 97
Flow amplifier operation 98
No steer 98
Steering left 100
Steering right 102
No steer, external shock load 104
Hoist circuit 107
Hoist circuit operation 108
Hoist circuit components 108
Hydraulic tank 108
Hoist pump 108
High pressure filters 108
Hoist valve 111
Inlet sections 111
Tank ports (front) spool section 111
Work ports (rear) spool section 112
Hoist pilot valve 112
Hoist limit solenoid 113
Pilot operated check valve 113
Overcenter manifold 113
Hoist pilot valve operation 114
Float position with body down 114
Power up operation 116
Hold operation 118
Power down operation 120
Float operation with body up 122
Brake circuits 125
General information 127
Service brake circuit operation 130
Secondary braking and auto apply 131
Parking brake circuit operation 132
Normal operation (key start switch ON, engine on) 132
Wheel brake lock circuit operation 133
Brake warning circuit operation 133
Electrical system, 24 volt 135
Battery supply system 137
Batteries 137
24VDC auxiliary battery receptacles 137
Isolation box 138
Ground level shutdown switch 138
Battery disconnect switches 138
Propel lockout lever 138
System busy light 138
LED lights 138
Engine starting system with prelube 139
Prelube operation 139
Cranking operation 140
Auxiliary control cabinet components 141
VEC blocks 142
24VDC to 12VDC converter 142
Circuit breakers 142
Engine service light timer 142
Ground terminals 142
24VDC power terminals 142
Relays 143
Body-up switch 144
Hoist limit switch 145
Heating/air conditioning (HVAC) system 147
Basic air conditioning system operation 149
HVAC components 151
Control panel 151
Water valve 151
Expansion valve 151
Actuators 151
Blower 151
Heater core 151
Evaporator core 151
Cab air temperature sensor 151
ECU module 151
Air filters 153
Compressor (refrigerant pump) 153
Compressor clutch 153
Trinary™ switch 154
Receiver-drier 154
Condenser 154
Accumulator 154
Automatic lubrication (auto lube) system 157
General information 159
System operation 160
Engine emissions aftertreatment system 163
About emissions aftertreatment 166
DEF injection system 166
DEF heating system 166
Sensors 166
Exhaust system cleaning 167
Propel lockout precaution 167
Inducement strategy 167
20 Standard value table 169
Standard value table 169
Standard value table for truck 171
30 Testing and adjusting 177
Steering, hoist, brake cooling and auxiliary hydraulic systems 177
Hydraulic system bleeddown procedure 179
Hydraulic system vacuum procedure 181
General information on system checkout 182
Hydraulic system checkout procedures 182
Required equipment 182
Preliminary steps 183
Hydraulic system flushing procedure 183
Flow amplifier adjustment 187
Steering pump unloader valve adjustment 188
Auxiliary accumulator pressure verification 188
System diagnostics 189
Hoist pilot relief valve adjustment 191
Hoist counterbalance valve adjustment 192
Final steps 193
Oil cleanliness check 193
Hydraulic system checkout data sheet 194
Toe-in adjustment 197
Hoist cylinder leakage test 198
Steering cylinder leakage test 198
Brake system 201
General information on system checkout 203
Brake system checkout procedures 203
Required equipment 203
Bleeddown procedure 203
Preliminary steps 206
Service brake checkout (front and rear) 207
Brake lock system checkout 208
Low brake pressure and auto apply checkout 208
Service brake checkout (left and right) 210
Parking brake checkout 211
Parking brake control logic checkout 211
Brake lock control logic checkout 213
Brake system checkout data sheet 216
Brake piston leakage test 225
Brake seal pressure test 225
Oil separator seal pressure test 225
Method 1 225
Method 2 226
Wet disc brake bleeding procedure 226
Parking brake bleeding procedure 227
Service brake disc wear inspection 228
Parking brake disc wear inspection 229
Accumulators and suspensions 231
Accumulator charging and storage 233
Temperature during precharge 233
Bladder accumulator charging procedure 234
Precharge maintenance 236
Bladder accumulator storage procedure 236
Bladder storage 236
Installing a bladder accumulator from storage 237
Bladder accumulator leak testing 237
Piston accumulator charging procedure 238
Piston accumulator storage 241
Piston accumulator leak testing 242
Checking for improper suspension charge on operating trucks 243
Suspension oil change recommendations 244
Suspension oiling and charging procedures 245
Required equipment 245
Installing the charging kit 246
Removing the charging kit 246
Support blocks for oiling and charging dimensions 247
Front suspensions 250
TOP FILL METHOD 251
PRESSURE FILL METHOD 251
Rear suspensions 253
TOP FILL METHOD 255
PRESSURE FILL METHOD 255
Suspension pressure test 258
Electrical systems 259
General information on system checkout 261
Loadbox test information 261
Truck shutdown procedure 262
Required software and tools 262
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 268
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 362
Checkout data sheet 371
Calibration sheets 376
Layout and assemblage 376
Unfolding a calibration sheet 379
Folding a calibration sheet 380
Placement of calibration sheets 381
Camera calibration procedures 383
Automatic 6 camera calibration 383
Manual 6 camera calibration 387
1 camera calibration 390
Radar setting procedure 393
Tire monitoring system 397
Tire monitoring system software and tools 399
Tire monitoring system configuration 399
Connecting to the tire monitoring system web server 399
Configuring a static IP address 399
Tire monitoring system software installation 401
Tire monitoring system checkout procedure 402
Field Troubleshooting 402
Ethernet troubleshooting 402
Tire monitoring system configuration 403
CAN RPC Troubleshooting 403
Resetting the tire monitoring system 403
Tire monitoring system checkout data sheet 404
40 Troubleshooting 407
Fuse, diode and relay locations 407
Vehicle Electrical Center (VEC-89) 409
Vehicle Electrical Center (VEC-90) 411
Vehicle Electrical Center (VEC-91) 413
Vehicle Electrical Center (VEC-92) 415
Rear Terminal Mini-fuse and Relay (RTMR3) 416
Rear Terminal Mini-fuse and Relay (RTMR4) 417
Circuit breakers 418
Troubleshooting by fault code, Part 1 421
Fault Code A001 424
Fault Code A002 425
Fault Code A003 426
Fault Code A004 427
Fault Code A005 428
Fault Code A006 429
Fault Code A007 430
Fault Code A008 431
Fault Code A009 432
Related circuit diagram 432
Fault Code A010 433
Related circuit diagram 433
Fault Code A011 434
Fault Code A013 435
Fault Code A014 436
Fault Code A016 437
Fault Code A017 438
Fault Code A018 439
Fault Code A019 440
Fault Code A022 441
Fault Code A100 442
Related circuit diagram 442
Fault Code A101 443
Fault Code A103 444
Fault Code A104 445
Fault Code A105 446
Fault Code A109 447
Fault Code A111 448
Fault Code A115 449
Fault Code A117 450
Fault Code A118 451
Fault Code A123 452
Fault Code A124 453
Fault Code A125 454
Fault Code A126 455
Fault Code A127 456
Fault Code A128 457
Fault Code A139 458
Troubleshooting by fault code, Part 2 461
Fault Code A145 464
Fault Code A146 465
Fault Code A152 466
Fault Code A153 467
Fault Code A154 468
Fault Code A155 469
Fault Code A158 470
Fault Code A166 471
Fault Code A167 472
Fault Code A168 473
Fault Code A169 474
Fault Code A170 475
Fault Code A171 476
Fault Code A172 477
Fault Code A173 478
Fault Code A184 479
Fault Code A190 480
Fault Code A193 481
Fault Code A194 482
Fault Code A195 483
Fault Code A196 484
Fault Code A197 485
Fault Code A198 486
Fault Code A199 487
Fault Code A200 488
Fault Code A201 489
Fault Code A202 490
Fault Code A203 491
Fault Code A204 492
Fault Code A205 493
Fault Code A206 494
Fault Code A207 495
Fault Code A213 496
Fault Code A214 497
Fault Code A215 498
Fault Code A216 499
Fault Code A223 500
Fault Code A230 501
Fault Code A231 502
Fault Code A233 503
Fault Code A235 504
Fault Code A236 505
Fault Code A237 506
Fault Code A238 507
Fault Code A239 509
Related circuit diagram 510
Fault Code A240 511
Fault Code A242 512
Fault Code A243 513
Fault Code A244 514
Fault Code A245 515
Fault Code A246 516
Troubleshooting by fault code, Part 3 519
Fault Code A247 521
Fault Code A248 522
Fault Code A249 523
Fault Code A250 524
Fault Code A251 525
Fault Code A252 526
Fault Code A253 527
Fault Code A256 528
Fault Code A257 529
Fault Code A258 530
Fault Code A260 531
Fault Code A261 532
Fault Code A262 533
Fault Code A264 534
Fault Code A265 535
Fault Code A266 536
Fault Code A267 537
Fault Code A268 538
Fault Code A270 539
Fault Code A271 540
Related circuit diagram 541
Fault Code A272 542
Fault Code A273 543
Fault Code A274 544
Fault Code A275 545
Fault Code A277 546
Fault Code A278 547
Fault Code A279 548
Fault Code A280 549
Fault Code A281 550
Fault Code A282 551
Fault Code A283 552
Fault Code A284 553
Fault Code A285 554
Fault Code A286 555
Fault Code A292 556
Troubleshooting by fault code, Part 4 559
Fault Code A303 562
Fault Code A304 563
Fault Code A305 564
Fault Code A307 565
Fault Code A309 566
Fault Code A310 567
Fault Code A311 568
Fault Code A312 569
Fault Code A313 570
Fault Code A315 571
Fault Code A316 572
Fault Code A317 573
Fault Code A318 574
Fault Code A328 575
Fault Code A332 576
Fault Code A333 577
Fault Code A334 578
Fault Code A335 579
Fault Code A337 580
Fault Code A338 581
Fault Code A339 582
Fault Code A340 583
Fault Code A341 584
Fault Code A342 585
Fault Code A343 586
Fault Code A344 587
Fault Code A345 588
Fault Code A346 589
Fault Code A347 590
Fault Code A348 591
Fault Code A349 592
Fault Code A350 593
Fault Code A351 594
Fault Code A352 595
Fault Code A353 596
Fault Code A354 597
Fault Code A355 598
Fault Code A356 599
Fault Code A357 600
Fault Code A358 601
Fault Code A359 602
Fault Code A360 603
Fault Code A361 604
Fault Code A362 605
Fault Code A363 606
Fault Code A364 607
Fault Code A365 608
Fault Code A366 609
Troubleshooting by fault code, Part 5 611
Fault Code A400 614
Fault Code A401 615
Fault Code A402 616
Fault Code A403 617
Fault Code A404 618
Fault Code A405 619
Fault Code A406 620
Fault Code A407 621
Fault Code A408 622
Fault Code A409 623
Fault Code A410 624
Fault Code A411 625
Fault Code A412 626
Fault Code A413 627
Fault Code A414 628
Fault Code A415 629
Fault Code A416 630
Fault Code A417 631
Fault Code A418 632
Fault Code A419 633
Fault Code A420 634
Fault Code A421 635
Fault Code A422 636
Fault Code A423 637
Fault Code A424 638
Fault Code A425 639
Fault Code A426 640
Fault Code A427 641
Fault Code A428 642
Fault Code A429 643
Fault Code A430 644
Fault Code A431 645
Fault Code A432 646
Fault Code A433 647
Fault Code A434 648
Fault Code A435 649
Fault Code A436 650
Fault Code A437 651
Fault Code A438 652
Fault Code A439 653
Fault Code A440 654
Fault Code A441 655
Fault Code A442 656
Fault Code A443 657
Fault Code A444 658
Fault Code A445 659
Fault Code A446 660
Fault Code A447 661
Aftertreatment system fault codes 663
Fault Code CA256 667
Fault Code CA1677 669
Fault Code CA1678 671
Fault Code CA1682 674
Fault Code CA1683 681
Fault Code CA1684 683
Fault Code CA1685 685
Fault Code CA1686 687
Fault Code CA1712 689
Fault Code CA1713 691
Fault Code CA1714 693
Fault Code CA1715 694
Fault Code CA1887 696
Fault Code CA2771 697
Fault Code CA3142 701
Fault Code CA3143 703
Fault Code CA3146 705
Fault Code CA3147 707
Fault Code CA3232 709
Fault Code CA3497 712
Fault Code CA3498 713
Fault Code CA3547 714
Fault Code CA3558 715
Fault Code CA3559 717
Fault Code CA3562 719
Fault Code CA3563 721
Fault Code CA3567 723
Fault Code CA3571 725
Fault Code CA3572 727
Fault Code CA3573 730
Fault Code CA3574 732
Fault Code CA3575 734
Fault Code CA3712 736
Fault Code CA3713 737
Fault Code CA3714 740
Fault Code CA3867 741
Fault Code CA3868 743
Fault Code CA3878 746
Fault Code CA3988 747
Fault Code CA3995 751
Fault Code CA4113 753
Fault Code CA4114 755
Fault Code CA4119 757
Fault Code CA4121 759
Fault Code CA4152 761
Fault Code CA4164 765
Fault Code CA4165 767
Fault Code CA4166 770
Fault Code CA4168 772
Fault Code CA4169 774
Fault Code CA4174 776
Fault Code CA4175 778
Fault Code CA4233 781
Fault Code CA4234 782
Fault Code CA4243 783
Fault Code CA4277 784
Fault Code CA4457 786
Fault Code CA4458 788
Fault Code CA4459 791
Fault Code CA4461 793
Fault Code CA4462 795
Fault Code CA4464 797
Fault Code CA4465 799
Fault Code CA4466 802
Fault Code CA4467 809
Fault Code CA4474 811
Fault Code CA4475 813
Fault Code CA4572 816
Fault Code CA4677 820
Fault Code CA4679 824
Fault Code CA4682 825
Fault Code CA4731 826
Fault Code CA4732 827
Fault Code CA4736 828
Fault Code CA4737 829
Fault Code CA4738 830
Fault Code CA4739 831
Fault Code CA4745 832
Fault Code CA4768 833
Fault Code CA4769 835
Fault Code CA4842 837
Fault Code CA4863 838
Fault Code CA4947 839
Fault Code CA5115 840
Fault Code CA5116 843
Fault Code CA5117 846
Fault Code CA5247 849
Fault Code CA5653 851
Fault Code CA5654 854
Fault Code CA5725 856
Fault Code CA5727 861
Fault Code CA5728 864
Fault Code CA5729 867
Fault Code CA5748 869
Fault Code CA5749 871
Fault Code CA5751 873
Fault Code CA5753 875
Fault Code CA5755 878
Fault Code CA5756 883
Fault Code CA5758 885
Fault Code CA5768 887
Fault Code CA5769 889
Fault Code CA5771 892
Fault Code CA5772 894
Fault Code CA5773 897
Fault Code CA5774 900
Fault Code CA5775 902
Fault Code CA5776 907
Fault Code CA5778 909
Fault Code CA5779 911
Fault Code CA5887 913
Fault Code CA5888 914
Fault Code CA5889 915
Fault Code CA5891 916
Fault Code CA5892 917
Fault Code CA5893 918
Fault Code CA6692 919
Fault Code CA6693 921
Fault Code CA6694 923
Fault Code CA6695 925
Fault Code CA6696 927
Fault Code CA6697 929
Fault Code CA6855 931
Fault Code CA6856 934
Steering system 937
Steering circuit troubleshooting chart 939
Steering circuit troubleshooting guidelines 941
Basic hydraulic system checks 942
System leakage check 943
Steering pump troubleshooting guide 945
Pump pressure control checks 948
Pump fails to unload 949
Pump fails to develop pressure 949
Pump slow in developing pressure 950
Pump control valve inspection and troubleshooting 951
Pump case drain check 953
Setting pump pressure controls 953
KomVision 957
KomVision fault codes 959
Automatic lubrication (auto lube) system 969
Autolube troubleshooting chart 971
Heating/air conditioning (HVAC) system 975
Control panel configurations 977
Diagnostics mode 978
Error codes 978
Advanced diagnostics 978
Firmware version 979
Additional HVAC troubleshooting chart 979
Voltage levels 981
Electronic fan clutch 983
Electronic fan clutch troubleshooting 985
Electronic fan clutch fault codes 987
50 Disassembly and assembly 989
Service tools 989
Special tool group 991
Additional service tools 992
KomVision calibration tools 993
Locally made tools 993
Wheels, spindles and rear axle 995
General precautions for tires and rims 997
Wheel stud maintenance 998
Rear outer wheel stud installation 999
Removal and installation of front wheel1000
Removal1000
Installation1001
Removal and installation of rear wheel1002
Removal1002
Installation1003
Rim components1005
Smart Rim Component Layout1005
Rim and tire service1006
Lubricants1006
Tire inflation1006
Lock ring retainer installation1006
Removing the lock ring1007
Installing the lock ring1008
Removing the tire from the front rim (5-piece rim)1009
Removing the tire from the rear outer dual rim (7-piece Smart rim)1012
Removing the tire from the rear inner dual rim (5-piece rim)1014
Preparation before assembly1015
Installing the tire on the front rim (5-piece rim)1016
Installing the tire on the rear inner dual rim (5-piece rim)1018
Installing the tire on the rear outer dual rim (7-piece Smart rim)1019
Removal and installation of front wheel hub and spindle1020
Removal1020
Spindle removal (off the truck)1026
Installation1028
Disassembly and assembly of front wheel hub and spindle1029
Cross Section View1029
Disassembly1030
Cleaning and inspection1037
Assembly1038
Wheel bearing adjustment1040
Seal assembly gap adjustment1041
Brake seal installation1042
Oil separation seal installation1043
Brake installation1044
Speed sensor installation and adjustment1048
Floating ring seal assembly and installation1050
Removal and installation of rear axle1059
Removal1059
Cleaning and inspection1061
Installation1061
Removal and installation of anti-sway bar1062
Removal1062
Installation1064
Removal and installation of pivot pin1065
Removal1065
Installation1066
Removal and installation of pivot bearing1067
Replacement criteria1067
Removal1069
Inspection1069
Installation1069
Removal and installation of pivot eye1070
Removal1070
Inspection1070
Installation1070
Removal of wheel motor1071
Preparation1071
Installation of wheel motor1073
Cleaning and inspection1073
Installation1074
Removal and installation of rear brake assembly1077
Brake system1079
Removal and installation of brake valve1081
Removal1081
Installation1082
Disassembly and assembly of brake valve/pedal assembly1083
Disassembly1083
Assembly1084
Removal and installation of dual relay valve1087
Removal1087
Installation1088
Removal and installation of brake manifold1089
Removal1089
Installation1089
Disassembly and assembly of brake manifold1090
Disassembly1090
Assembly1090
Removal and installation of piston brake accumulator1091
Removal1091
Installation1093
Disassembly and assembly of piston brake accumulator1095
Disassembly1095
Cleaning and inspection1097
Piston seal replacement1097
Assembly1098
Disassembly and assembly of front wheel brake1099
Disassembly1099
Cleaning and inspection1102
Assembly1103
Disassembly and assembly of rear wheel brake1105
Disassembly1105
Cleaning and inspection1109
Assembly1110
Brake floating ring seal assembly and installation1114
Rear hub floating ring seal assembly and installation1123
Removal and installation of parking brake1129
Removal1129
Installation1131
Disassembly and assembly of parking brake1132
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1132
Disassembly1132
Cleaning and inspection1134
Cleaning and inspecting new discs1136
Assembly1137
Steering system1139
Removal and installation of steering control unit1141
Removal1141
Installation1143
Disassembly and assembly of steering control unit1144
Disassembly1144
Assembly1146
Removal and installation of steering column1149
Removal1149
Installation1150
Removal and installation of steering wheel1151
Removal1151
Installation1151
Removal and installation of bleeddown manifold1152
Removal1152
Installation1153
Removal and installation of flow amplifier1154
Removal1154
Installation1154
Removal and installation of steering cylinders and tie rod1155
Removal1155
Installation1155
Disassembly and assembly of steering cylinders1157
Disassembly1157
Cleaning and inspection1159
Assembly1159
Removal and installation of steering/brake pump1160
Removal1160
Installation1162
Removal and installation of piston steering accumulator1163
Removal1163
Installation1165
Disassembly and assembly of piston steering accumulator1167
Disassembly1167
Cleaning and inspection1169
Piston seal replacement1169
Assembly1170
Suspensions1173
General information1175
Removal and installation of front suspension1175
Preparation1175
Removal1175
Cleaning and Inspection1177
Installation1178
Disassembly and assembly of front suspension1183
Disassembly1183
Cleaning and inspection1186
Assembly1186
Removal and installation of rear suspension1188
Removal1188
Installation1191
Disassembly and assembly of rear suspension1194
Disassembly1194
Cleaning and inspection1196
Assembly1197
Hoist circuit1199
Removal and installation of hoist pump1201
Removal1201
Installation1205
Disassembly and assembly of hoist pump1206
Disassembly1206
Inspection1211
Assembly1212
Removal and installation of hoist valve1215
Removal1215
Installation1217
Disassembly and assembly of hoist valve1217
O-ring replacement1217
Disassembly of inlet section1219
Assembly of inlet section1220
Disassembly of rear spool section1221
Assembly of rear spool section1223
Disassembly of front spool section1224
Assembly of front spool section1225
Overcenter manifold service1225
Removal and installation of hoist pilot valve1226
Removal1226
Installation1226
Disassembly and assembly of hoist pilot valve1228
Disassembly1228
Cleaning and inspection1229
Assembly1229
Removal and installation of hoist cylinders1230
Removal1230
Installation1233
Disassembly and assembly of hoist cylinders1236
Disassembly1236
Cleaning and inspection1240
Installation of the quill1241
Assembly1243
Body and structures1249
Removal and installation of dump body1251
Removal1251
Inspection1252
Installation1253
Removal and installation of body pads1254
Removal1254
Installation1254
Body pad shimming procedure1255
Removal and installation of diagonal ladder/ hood and grille assembly1256
Removal1256
Installation1256
Removal and installation of RH deck1258
Removal1258
Installation1258
Removal and installation of LH deck1260
Removal1260
Installation1260
Removal and installation of fuel tank1262
Removal1262
Cleaning and inspection1262
Installation1264
Removal and installation of fuel gauge sender1264
Removal1264
Installation1264
Removal and installation of hydraulic tank1265
Removal1265
Installation1266
Removal and installation of hydraulic tank strainers1267
Removal1267
Cleaning and inspection1268
Installation1268
Operator cab1271
Removal and installation of operator cab1273
Removal1273
Installation1276
Removal and installation of cab door1276
Removal1276
Installation1277
Disassembly and assembly of cab door1278
Removing the window regulator1278
Installing the window regulator1279
Removing the door glass1280
Installing the door glass1281
Replacing the inner door seal1282
Replacing the outer door seal1282
Removing the interior door handle and door latch (earlier models)1283
Installation and removal of interior door handle and door latch (later models)1286
Adjustment of cab door1288
Door jamb bolt adjustment1288
Exterior door handle release button adjustment1290
Removal and installation of side window glass1291
Recommended tools and supplies1291
Removal1291
Installation1292
Removal and installation of windshield and rear window glass1293
Removal1293
Installation1293
Removal and installation of windshield wiper components1294
Removing the windshield wiper motor1294
Installing the windshield wiper motor1294
Removing the windshield wiper arm and linkage1295
Installing the windshield wiper arm and linkage1296
Removal and installation of cab seats1296
Removal1296
Servicing the seat1297
Installation1297
Removal and installation of seat belts1298
Removal1298
Installation1299
Power module1301
Removal and installation of power module1303
General1303
Removal1304
Installation1312
Exhaust tube installation1315
Exhaust blanket installation1315
Removal and installation of alternator1316
Removal1316
Installation1319
Engine/alternator attachment checkout data sheet1329
Removal and installation of radiator1335
Removal1335
Installation1339
Repairing the radiator1340
Internal inspection1340
External cleaning1340
Disassembly1341
Cleaning and inspection1342
Assembly1342
Pressure testing1343
Removal and installation of engine1344
Removal1344
Service1344
Installation1345
Removal and installation of electronic fan clutch1346
Removal1346
Installation1347
Removal and installation of electronic fan clutch speed sensor1347
Removal1347
Installation1347
90 Diagrams and drawings1349
Hydraulic circuit diagrams1349
Electrical circuit diagrams1356

DESCRIPTION:

SERIAL NUMBERS 930E-5
A40216 – A40329

Komatsu Dump Truck 930E-5 A40216-A40329 Shop Manual  CEBM036503 – PDF DOWNLOAD

Foreword

This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing 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 typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section.
• Specific torques, when provided in the text, are in bold face type, such as 135 Nm (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 960E). The three numbers represent the basic truck model.
• The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. 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 maximum GVW. GVW is total weight empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW.
• The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.
• IMAGES PREVIEW OF THE MANUAL:

S.M 24/12/24