PDF Shop Manual Komatsu 930E-4 Dump Truck - 6 MB
This factory shop manual is the definitive technical guide for the Komatsu 930E-4 Dump Truck.
It provides the in-depth information that professional technicians require for major overhauls and complex repairs.
Inside, you'll find detailed specifications, testing and adjusting procedures, and disassembly/assembly instructions.
This is the ultimate resource for keeping your mining haul truck in peak operational condition.
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--- Page 1 ---
CEBM036500
Shop
Manual
930E-5
DUMP TRUCK
SERIAL NUMBERS 930E-5 A40216 and up
ENGINE 16V160
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright January 2022
Printed in U.S.A.
Komatsu America Corp.
--- Page 3 ---
CEN00067-00 00 Index and foreword
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
12
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00 Index and foreword CEN00038-06
General safety Fire extinguisher and first aid kit
Safety records from most organizations will show that • Make sure that fire extinguishers are accessible
the greatest percentage of accidents are caused by and proper usage techniques are known.
unsafe acts performed by people. The remainder are • Provide a first aid kit at the storage point.
caused by unsafe mechanical or physical conditions.
Report all unsafe conditions to the proper authority. • Know what to do in the event of a fire.
The following safety rules are provided as a guide for • Keep the phone numbers of persons you should
the operator. However, local conditions and regulations contact in case of an emergency on hand.
may add many more to this list.
Read and follow all safety precautions. Failure to
do so may result in serious injury or death.
Safety rules Clothing and personal items
• Only trained and authorized personnel may • Avoid loose clothing, jewelry, and loose long hair.
operate and maintain the truck. They can catch on controls or in moving parts and
• Follow the local safety statutes and laws when cause serious injury or death. Also, never wear oily
working with electrical components. clothes as they are flammable.
• Follow all safety rules, precautions and instructions • Wear a hard hat, safety glasses, safety shoes,
when operating or performing maintenance on the mask and gloves when operating or maintaining a
truck. truck. Always wear safety goggles, hard hat and
heavy gloves if your job involves scattering metal
• When working with another operator or a person chips or minute materials, particularly when driving
on work site traffic duty, make sure that all pins with a hammer or when cleaning air cleaner
personnel understand all hand signals that are to elements with compressed air. Also, ensure that
be used. the work area is free from other personnel during
such tasks.
Safety features
• Make sure that all guards and covers are in their
proper position. Have any damaged guards and
covers repaired.
• Learn the proper use of safety features such as
safety locks, safety pins, and seat belts. Use these
safety features properly.
• Never remove any safety features. Always keep
them in good operating condition.
• Improper use of safety features could result in
serious bodily injury or death.
• Check the seat belt fabric, buckle and hardware for
damage or wear. Replace any worn or damaged
parts immediately.
• The seat belts must be replaced 5 years after seat
belt manufacture, or after every 3 years of use,
whichever comes first.
7
--- Page 5 ---
CEN00038-06 00 Index and foreword
Precautions while performing service Working under the truck
NOTE: Only authorized personnel should service and • Always lower all movable work equipment to the
repair the truck. ground or to their lowest position before
performing service or repairs under the truck.
Keep the truck clean
• Always block the tires of the truck securely.
• Spilled oil, grease, scattered tools, etc, can cause • Never work under the truck if the truck is poorly
you to slip or trip. Always keep your truck clean supported.
and tidy.
• If water gets into the electrical system, there is
danger that the truck may move unexpectedly and/
or damage to components may occur. Do not use
water or steam to clean any sensors, connectors
or the inside of the operator's compartment.
• Use extreme care when washing the electrical
control cabinet. Do not allow water to enter the
control cabinet around the doors or vents. Do not Rotating fan and belts
allow any water to enter the cooling air inlet duct Stay away from all rotating parts such as the radiator
above the electrical control cabinet. If water enters fan and fan belts. Serious bodily injury may result from
the control cabinet through any opening or crevice,
direct or indirect contact with rotating parts and flying
major damage to the electrical components is
possible. objects.
• Never spray water into the rear wheel electric
motor covers. Damage to the wheel motor
armatures may occur.
• Do not spray water into the retarding grids. Excess
water in the retarding grids can cause a ground
fault, which will prevent propulsion.
Adding fuel or oil
• Spilled fuel and oil may cause slipping. Always
clean up spills immediately.
• Always add fuel and oil in a well-ventilated area.
• When refueling, stop the engine and do not smoke.
• Tighten the cap of the fuel and oil fillers securely.
• Never use fuel to wash parts.
Attachments
Use of lighting
Place attachments that have been removed from the
truck in a safe place and manner to prevent them from When checking fuel, oil, coolant or battery electrolyte,
falling. always use lighting with anti-explosion specifications. If
such lighting equipment is not used, there is danger of
an explosion.
20
--- Page 6 ---
00 Index and foreword CEN00038-06
• Heavy duty wire connector (DT 8-pole, 12-pole)
a. For disconnection, press both sides of locks
(a) and (b) while pulling out female connector
(2).
b. For connection, push in female connector (2)
horizontally until the lock clicks.
Since locks (a) and (b) may not be set com-
pletely, push in female connector (2) while mov-
ing it up and down until the locks are set normally.
• Right half of figure: Lock (a) is pulled down
(not set completely) and lock (b) is set
completely.
1. Male connector a. Lock
2. Female connector b. Lock
• Drying wiring harness
If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high pressure water
or steam directly on the wiring harness. If water
gets directly on the connector, perform the follow-
ing procedure.
a. Disconnect the connector and wipe off the
water with a dry cloth. If the connector is
blown dry with compressed air, there is the
risk that oil in the air may cause defective con-
tact, so remove all oil and water from the com-
pressed air before blowing with air.
b. If water gets inside the connector, use a dryer
to dry the inside of the connector. Hot air from
the dryer can be used, but regulate the time
that the hot air is used in order not to make the
connector or related parts too hot, as this will
cause deformation or damage to the connec-
tor.
c. After drying, leave the wiring harness discon-
nected and carry out a continuity test to check
for any short circuits between pins caused by
water.
d. After completely drying the connector, blow it
with contact restorer and reassemble.
33
--- Page 7 ---
CEN00038-06 00 Index and foreword
Conversion tables
Common conversion multipliers
Table 13: English to metric Table 14: Metric to English
Multiply Multiply
From To From To
by by
inch (in.) millimeter (mm) 25.40 millimeter (mm) inch (in.) 0.0394
inch (in.) centimeter (cm) 2.54 centimeter (cm) inch (in.) 0.3937
foot (ft) meter (m) 0.3048 meter (m) foot (ft) 3.2808
yard (yd) meter (m) 0.914 meter (m) yard (yd) 1.0936
mile (mi) kilometer (km) 1.61 kilometer (km) mile (mi) 0.6210
square centimeter square centimeter
square inch (in.2) 6.45 square inch (in.2) 0.1550
(cm2) (cm2)
square centimeter square centimeter
square foot (ft2) 929 square foot (ft2) 0.001
(cm2) (cm2)
cubic centimeter cubic centimeter
cubic inch (in.3) 16.39 cubic inch (in.3) 0.061
(cm3) (cm3)
cubic inch (in.3) liter (l) 0.016 liter (l) cubic inch (in.3) 61.02
cubic foot (ft3) cubic meter (m3) 0.028 cubic meter (m3) cubic foot (ft3) 35.314
3
cubic foot (ft ) liter (l) 28.317 liter (l) cubic foot (ft3) 0.0353
ounce (oz) gram (g) 28.350 gram (g) ounce (oz) 0.0353
fluid ounce (fl oz) milliliter (ml) 29.573 milliliter (ml) fluid ounce (fl oz) 0.0338
pound (lb) - mass kilogram (kg) 0.454 kilogram (kg) pound (lb) - mass 2.2046
pound (lb) - force Newton (N) 4.448 Newton (N) pound (lb) - force 0.2248
inch pound (in lb) Newton meter (N·m) 0.113 Newton meter (N·m) inch pound (in lb) 8.85
foot pound (ft lb) Newton meter (N·m) 1.356 Newton meter (N·m) foot pound (ft lb) 0.7376
foot pound (ft lb) kilogram meter (kgm) 0.138 kilogram meter (kgm) foot pound (ft lb) 7.2329
pounds/square inch pounds/square inch
kilopascal (kPa) 6.895 kilopascal (kPa) 0.1450
(psi) (psi)
pounds/square inch pounds/square inch
megapascal (MPa) 0.007 megapascal (MPa) 145.038
(psi) (psi)
pounds/square inch kilograms/square kilograms/square pounds/square inch
0.0704 14.2231
(psi) centimeter (kg/cm2) centimeter (kg/cm2) (psi)
short ton kilogram (kg) 907.2 kilogram (kg) short ton 0.0011
short ton metric ton 0.0907 metric ton short ton 1.1023
quart (qt) liter (l) 0.946 liter (l) quart (qt) 1.0567
U.S gallon (gal) liter (l) 3.785 liter (l) U.S gallon (gal) 0.2642
horsepower (HP) kilowatt (kw) 0.745 kilowatt (kw) horsepower (HP) 1.3410
46
--- Page 8 ---
01 Specification CEN01018-03
NOTES
9
--- Page 9 ---
CEN10077-00 10 Structure and functions
Flow amplifier operation
No steer
Refer to Figure 10-11.
High pressure oil from the steering pump and steering
accumulators is available through the bleeddown
manifold to the “HP” port on the flow amplifier.
Upon entering the priority valve, the oil goes past the
spool to the closed amplifier valve and also out port “P”
through a hose to port “P” on the steering control unit.
In the steering control unit, the oil goes to a closed
area in the control.
As pressure builds up in these two areas, oil passes
through orifices in the end of the priority valve and
builds pressure on the end of the valve and port "PP".
When pressure reaches approximately 1 600 kPa (232
psi), the spool moves, compressing its spring and
closing off oil supply through area “A”, resulting in high
pressure at “PP” but only 1 600 kPa (232 psi) at the
amplifier spool and steering control unit.
12
--- Page 10 ---
10 Structure and functions CEN10078-00
Hoist valve Inlet sections
Hoist valve (1, Figure 10-2) is mounted on a modular Each of the front and rear inlet sections of the hoist
assembly containing the hoist valve, overcenter valve contains of the following components:
manifold, and both hydraulic pumps. This assembly is • Flow control valve and main relief valve
bolted to brackets attached to the frame rails behind
the main alternator. The hoist valve is a split spool • Secondary low pressure relief valve
design. The term “split spool” describes the spool • Anti-void check valve
section of the valve.
• Load check valve
The hoist valve precisely follows the differential The flow control portion of the flow control and main
pressure input signals generated by the hoist pilot relief valves allow pump flow to be diverted to the
valve when the operator moves the hoist control lever service brake cooling circuit unless the body is being
while raising and lowering the dump body. raised or lowered. The relief portion of this valve is
direct-acting and has the capacity to limit the
maximum working pressure at full pump flow.
The secondary low pressure relief valve is located
between the low pressure core and the outlet to the
brake cooling circuit. It provides pressure relief if
pressure spikes occur in the low pressure passage
area.
The load check allows free flow from the inlet to the
high pressure core and prevents flow from the high
pressure core to the inlet.
The anti-void check valve allows free flow from the low
pressure core to the high pressure core and prevents
flow from the high pressure core to the low pressure
core.
Tank ports (front) spool section
The primary low pressure valves are located in the
front spool section of the hoist valve. These valves
maintain back pressure on the low pressure passage
FIGURE 10-3. HOIST VALVE and direct the hoist cylinder return oil back to the
hydraulic tank.
1. Inlet Section 4. Inlet Section
2. Work Ports Spool 5. Inlet Port
Section 6. Outlet Port
3. Tank Ports Spool 7. Spool Section Cover
Section 8. Separator Plate
5
--- Page 11 ---
CEN10078-00 10 Structure and functions
930E Dump truck
Form No. CEN10078-00
18
--- Page 12 ---
10 Structure and functions CEN10109-00
Battery supply system 24VDC auxiliary battery receptacles
Batteries Two auxiliary battery receptacles (5, Figure 10-1) are
provided to attach battery charger leads for charging
The truck uses a 24VDC electrical system to supply the batteries. These receptacles can also be used for
power for the engine starting circuits and most non- connecting external batteries to aid engine starting
propulsion related electrical components. The 24VDC during cold weather.
electrical circuit is supplied by four heavy duty, type
8D, 12-volt storage batteries (1, Figure 10-1) located in When external batteries are used, they should be of
the battery box on the platform in front of the radiator. the same type (8D) as the batteries that are installed
The batteries are of the lead-acid type, each on the truck. Two pairs of batteries should be used.
containing six 2-volt cells. Each pair should be connected in series to provide
24VDC, with one pair connected to each receptacle.
While the engine is off, power is supplied by the
batteries. During engine cranking, power is supplied
by the batteries. When the engine is running, however,
power is supplied by a high capacity alternator that is
driven by the engine.
During operation, the batteries function as an
electrochemical device that converts chemical energy
into the electrical energy that is required for operating
the accessories when the engine is off.
1 1 1 1 2
3
5
4
89079
FIGURE 10-1. BATTERY BOX COMPONENTS
1. Batteries 4. Fuses (battery charging alternator and
2. 24VDC Bus Bar auxiliary control cabinet)
3. Negative Bus Bar 5. Auxiliary Battery Receptacles
3
--- Page 13 ---
CEN10088-01 10 Structure and functions
FIGURE 10-1. BASIC AIR CONDITIONING SYSTEM
1. Blower Switch 7. Evaporator Core 13. Magnetic Clutch
2. Thermostatic Switch 8. Expansion Valve 14. Compressor Drive Pulley
3. Battery Supply 9. Suction Line 15. Receiver-Drier
4. Circuit Breaker 10. Test Gauges & Manifold 16. Discharge Line
5. Blower 11. Compressor 17. Condenser
6. Temperature Sensor 12. Refrigerant Container 18. Accumulator
4
--- Page 14 ---
CEN10083-02
DUMP TRUCK 1SHOP MANUAL
730E
830E
930E
980E
Machine model Serial number
730E-10 A50002 and up
830E-5 A50005 - A500153
830E-5AT A50005 and up
930E-5 A40004 and up
930E-5AT A40004 and up
980E-5 A50005 and up
980E-5AT A50005 and up
10 Structure and functions
Engine emissions aftertreatment system
About emissions aftertreatment ............................................................................................................................ 4
DEF injection system ............................................................................................................................................ 4
DEF heating system.............................................................................................................................................. 4
Sensors................................................................................................................................................................. 4
Exhaust system cleaning ...................................................................................................................................... 5
Inducement strategy ............................................................................................................................................. 5
1
--- Page 15 ---
CEN20007-00 20 Standard value table
930E Dump truck
Form No. CEN20007-00
8
--- Page 16 ---
30 Testing and adjusting CEN30087-02
f. With the bleed valve on the auxiliary hydraulic NOTE: The following step is for troubleshooting and
manifold open, verify that the pressures at test may be skipped if no excessive leakage in the steering
ports TP2 and TP3 remain above 16 550 kPa system is suspected.
(2,400 psi) for at least five minutes after the
39. To check for leakage in the steering system:
auxiliary accumulator is bled down below 100
kPa (15 psi). a. Disconnect the flow amplifier return hose at
the steering bleeddown manifold and plug the
* Record on Data Sheet
fitting on the manifold. Disconnect the steering
g. If either of the steering accumulator pressures control unit return hose at the flow amplifier
at test port TP2 or TP3 falls or the pressure at (port T) and plug the port.
auxiliary hydraulic manifold test port GA rises,
b. Start the engine. Allow the steering
correct the problem and return to step 33b.
accumulators to fully charge and the steering
h. Close the bleed valve on the auxiliary pump to unload. Do not turn the steering
hydraulic manifold. wheel while the return hoses are
disconnected.
c. Measure the leakage from the flow amplifier
System diagnostics and the steering control unit.
34. Turn the key switch OFF and wait two minutes for • Leakage from the flow amplifier should not
the steering accumulators to bleed down. exceed 820 mL (50 in.3) per minute. If
Connect the Realtime monitor and observe the leakage is excessive, replace the flow
state of low steering pressure status bit IM2S. amplifier.
Status bit IM2S should be 1.
• Leakage from the steering control unit should
35. Start the engine and observe the pressure gauge not exceed 164 mL (10 in.3) per minute. If
at test port TP2. Allow the steering accumulators leakage is excessive, replace the steering