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Komatsu 930E-4SE Rigid Dump Truck Shop Manual (CEBM039002)

Format: PDF (Printable Document)

File Language: English

File Pages: 958

File Size: 37.45 MB (Speed Download Link)

Brand: Komatsu

Model: 930E-4SE Rigid Dump Truck

Book No: CEBM039002

Serial No: SN A32194-UP

Type of Document: Shop Manual

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Komatsu 930E-4SE Rigid Dump Truck Shop Manual (CEBM039002)

The Komatsu 930E-4SE Rigid Dump Truck is a big mine truck used for heavy haul in large pits and quarries, running long shifts with high loads and harsh conditions. The Komatsu 930E-4SE Rigid Dump Truck Shop Manual (CEBM039002) is what shop techs and field mechanics reach for when a truck is down and they need to get it earning again. People usually want this manual to chase electrical or hydraulic faults, plan heavy repairs, and avoid guessing on reassembly.

What this manual helps you do

  • Trace electrical faults using wiring information and step-by-step diagnostic routines that these manuals usually provide.
  • Check and service the engine, drivetrain, and braking systems to workshop standard, instead of relying on basic operator guides.
  • Follow disassembly and assembly sequences for major components so you don’t damage high‑value parts during overhaul.
  • Diagnose hydraulic and braking issues by following the kind of test and inspection procedures these shop manuals normally lay out.
  • Verify adjustments and post-repair checks so the truck returns to service safely and you don’t see the same fault twice.

Who this is for

This shop manual suits a mine site mechanic, dealership/independent shop tech, or fleet maintenance manager planning in-house repairs. If you only need basic operation or daily checks, you’re better off with the Operation & Maintenance manual instead of this shop manual.

FAQ

Q: Is this a PDF I can search and print?

A: Yes, it’s a digital PDF you can search on-screen and print selected pages for use in the shop.

Q: Is it deep enough for full overhauls or just light service?

A: The Komatsu 930E-4SE Rigid Dump Truck Shop Manual walks through diagnostic procedures, disassembly sequences, and workshop-level repair guidance.

Q: How do I know if it matches my exact truck variant?

A: Check your truck’s model designation and match it to 930E-4SE; for serial number details, compare your plate with the CEBM039002 reference before buying.

If you’re doing real repair work or managing uptime on 930E-4SE haul trucks, this is the right manual; if you only operate the machine, keep looking for the operator/maintenance book instead.

📘 Show Index

Table of Contents:

  • COVER
  • 00 CONTENTS AND FOREWORD
    • Foreword
      • How to Read the Shop Manual
      • Safety Alert Symbol and Signal Words
    • General Precautions Common to Operation and Maintenance
      • Preparations for Safe Operation
      • Fire and Explosion Prevention
      • Precautions When Getting On or Off the Machine
      • Precautions for Cab and Working Around Machine
    • Operation Precautions
      • Precautions at Jobsite
      • Precautions in Starting Engine
      • Precautions During Operation
    • Maintenance Precautions
      • Precautions Before Inspection and Maintenance
      • Precautions During Inspection and Maintenance
      • Precautions for Electrical Equipment
        • Primary Causes of Wiring Harness Failure
      • Capacitor Discharge System
        • Manual DC link capacitor discharge procedure
        • Failure of the discharge system
        • Manual discharge of capacitors
        • Short isolated capacitor terminals
      • Hydraulic Equipment Precautions
  • 01 SPECIFICATIONS
    • Specifications
      • Specifications: 930E-4SE
      • Recommended Fuel, Coolant, and Lubricant
        • Wheel Motor Oil Specifications
        • Suspension Cylinder Oil and Nitrogen Specifications
  • 10 STRUCTURE AND FUNCTION
    • Steering System
      • Steering System Layout
      • Steering System Operation
      • Steering Bleeddown Manifold
      • Steering Control Unit
      • Steering Accumulators (Piston Type)
      • Steering/Brake Pump Operation
      • Flow Amplifier Operation
    • Hoist System
      • Hoist System Layout
      • Hoist System Operation
      • Hoist Pilot Valve
    • Brake System
      • Service Brake System Layout
      • Hydraulic Brake Cabinet Layout
      • Service Brake Operation
      • Parking Brake Operation
      • Brake Lock Operation
      • Secondary Braking and Auto Apply
      • Warning Circuit
    • Electrical System, 24V
      • Battery Power Supply
        • Battery Disconnect Switches
      • Engine Starting System
      • Auxiliary Control Cabinet Components
      • Body-Up Switch
      • Hoist Limit Switch
    • Electrical System, AC Drive
      • General System Operation
      • AC Drive System Components
      • DSC Software Functions
      • Alternator Field Control
      • Event Detection and Processing
      • Event Restrictions
      • Event Logging and Storage
      • Abnormal Conditions/Overriding Functions
      • Electronic Accelerator and Retard Pedals
      • Propulsion System Component Abbreviations and Locations
    • Automatic Lubrication (Auto Lube) System
      • Automatic Lubrication (Auto Lube) Grease Pump and Reservoir
      • Automatic Lubrication (Auto Lube) System Operation
    • Suspensions
  • 20 STANDARD VALUE TABLE
    • Standard Value Table
  • 30 TEST AND ADJUST
    • Hydraulic Systems
      • Hydraulic System Checkout Procedures
        • Hydraulic System Checkout Sheet
      • Steering System Leakage Check
      • Toe-In Adjustment
      • Hoist Cylinder Leakage Test
      • Steering Cylinder Leakage Test
      • Checking the Steering/Brake Pump Control Pressures
      • Adjusting the Steering/Brake Pump Control Pressures
      • High Altitude Steering/Brake Pump Adjustment
    • Brake System
      • Test Port Locations for Brake Checkout
      • Brake System Checkout Procedures
        • Pre-checkout Items
        • Brake System Checkout Procedure
        • Brake System Checkout Sheet
      • Brake System Leakage Check
      • Brake Piston Leakage Test
      • Parking Brake Piston Leakage Test
      • Brake Floating Seal Pressure Test
      • Wet Disc Brake Bleeding Procedure
      • Parking Brake Bleeding Procedure
      • Wet Disc Brake Wear Inspection
      • Parking Brake Wear Inspection
    • Accumulators and Suspensions
      • Bladder Accumulator Charging Procedure
      • Bladder Accumulator Leakage Test
      • Bladder Accumulator Storage
      • Piston Accumulator Charging Procedure
      • Piston Accumulator Leakage Test
      • Piston Accumulator Storage
      • Check for Improper Suspension Charge
      • Suspension Oiling and Charging Procedures
        • Oiling and Charging Tools and Support Blocks
        • Nitrogen Charging Kit Installation
        • Nitrogen Charging Kit Removal
        • Front Suspension Oiling and Charging
        • Rear Suspension Oiling and Charging
      • Suspension Pressure Test
    • Automatic Lubrication (Auto Lube) System
      • Prime the Auto Lube Pump
      • Prime the Auto Lube Grease Lines
      • Auto Lube System Checkout
      • Adjust the Auto Lube Cycle Timing
    • Cab Air Conditioning
      • Refrigerant Leak Detection
      • A/C System Performance Test
      • Check the A/C System Oil
      • A/C System Flushing Procedure
      • Manifold Gauge Set Installation
      • Purging Air From The Service Hoses
      • Refrigerant: Recycled vs Reclaimed
      • Refrigerant Recovery Procedure
      • Evacuate the A/C System
      • Charge the A/C System
    • Interface Module 2 (IM2)
      • Interface Module 2 Software and Tools
      • Program the IM2 Controller
      • Interface Module 2 Checkout Procedures
        • Check for IM Fault Codes
        • Checking Digital Inputs to the IM2
        • Checking Analog Inputs to the IM2
        • Checking Serial Communication to the IM
        • Checking Outputs from the IM2
        • Interface Module 2 Checkout Sheet
    • Payload Meter IV
      • Payload Meter IV Software and Tools
      • Payload Meter IV System Configuration
        • Configuring a Static IP Address
      • Payload Meter IV Software Installation
      • Payload Meter IV Data Downloading
      • Payload Meter IV Checkout Procedure
        • Payload Meter IV Checkout Sheet
    • KOMTRAX Plus
      • KOMTRAX Plus Software and Tools
      • KOMTRAX Plus Controller Setup Procedure
        • Preliminary Steps
        • Setup Procedure
      • Precautions When Replacing the KOMTRAX Plus Controller
      • KOMTRAX Plus Controller Checkout Procedure
        • Preliminary steps
        • Checkout Procedure
    • KomVision
      • KomVision Setup and Calibration Requirements
      • KomVision Initial Setup and Checkout Procedure
        • KomVision Checkout Sheet
      • KomVision Calibration Sheets
        • Calibration Sheet Layout
        • Unfold and Fold Calibration Sheet
        • Calibration Sheet Placement
      • KomVision Camera Calibration Procedures
        • Automatic 6 Camera Calibration
        • Manual 6 Camera Calibration
        • 1 Camera Calibration
      • KomVision Radar Setting Procedure
    • Komatsu Wireless Bridge (KWB)
      • Komatsu Wireless Bridge Software and Tools
      • Bullet Wireless Radio Configuration
      • Bullet Wireless Radio Installation
      • NanoStation Access Point Configuration
      • NanoStation Access Point Connection Test
  • 40 TROUBLESHOOTING
    • Vehicle Electrical Centers (VEC)
    • AC Drive System Fault Codes (DSC)
      • Event Restrictions
      • DSC Event List
      • Inverter Event List
      • DID Panel Fault Codes
    • Standard Truck Fault Codes
      • A001
      • A002
      • A003
      • A004
      • A005
      • A006
      • A007
      • A008
      • A009
      • A010
      • A011
      • A013
      • A014
      • A016
      • A017
      • A018
      • A019
      • A022
      • A101
      • A105
      • A109
      • A111
      • A115
      • A117
      • A118
      • A123
      • A124
      • A125
      • A126
      • A127
      • A128
      • A139
      • A145
      • A146
      • A152
      • A153
      • A154
      • A155
      • A158
      • A166
      • A167
      • A168
      • A169
      • A170
      • A171
      • A172
      • A173
      • A184
      • A190
      • A198
      • A200
      • A201
      • A202
      • A203
      • A204
      • A205
      • A206
      • A207
      • A212
      • A213
      • A214
      • A215
      • A216
      • A223
      • A230
      • A231
      • A233
      • A235
      • A236
      • A237
      • A240
      • A242
      • A243
      • A244
      • A245
      • A246
      • A247
      • A248
      • A249
      • A250
      • A251
      • A252
      • A253
      • A255
      • A256
      • A257
      • A258
      • A260
      • A261
      • A262
      • A264
      • A265
      • A266
      • A267
      • A268
      • A270
      • A271
      • A272
      • A273
      • A274
      • A275
      • A277
      • A278
      • A279
      • A280
      • A281
      • A282
      • A283
      • A284
      • A285
      • A286
      • A292
      • A303
      • A304
      • A307
      • A309
      • A311
      • A312
      • A313
      • A315
      • A316
      • A317
      • A318
      • A328
      • A333
      • A334
      • A335
      • A350
      • A351
      • A352
      • A353
      • A354
      • A355
      • A356
      • A357
      • A358
      • A359
      • A360
      • A361
      • A362
      • A363
      • A364
      • A365
    • KomVision Fault Codes
    • Troubleshoot the Steering System
      • Steering System Troubleshooting Guide
      • Basic Hydraulic System Checks
      • Steering/Brake Pump Troubleshooting Guide
      • Steering/Brake Pump Troubleshooting Checks
        • Steering/Brake Pump Fails to Unload
        • Steering/Brake Pump Fails to Develop Pressure
        • Steering/Brake Pump Slow to Develop Pressure
        • Steering/Brake Pump Control Valve Inspection
        • Steering/Brake Pump Case Drain Check
    • Troubleshoot the Cab Air Conditioning
      • Preliminary Checks
      • Diagnosis of Gauge Readings and System
      • Troubleshooting by Manifold Gauge Set Readings
    • Troubleshoot the Auto Lube System
  • 50 DISASSEMBLY AND ASSEMBLY
    • Special Tools List
    • Wheels, Spindles and Rear Axle
      • General Precautions for Tires and Rims
      • Lubricants for Tire and Rim Service
      • Tire Inflation
      • Rim Components
      • Wheel Stud Maintenance
      • Rear Outer Wheel Stud Installation
      • Front Wheel Removal
      • Front Wheel Installation
      • Rear Wheel Removal
      • Rear Wheel Installation
      • Lock Ring Removal
      • Lock Ring Installation
      • Tire Removal (Front 5-Piece Rim)
      • Tire and Rim Preparation
      • Tire Installation (Front 5-Piece Rim)
      • Tire Installation (Rear Inner 5-Piece Rim)
      • Front Wheel Hub and Spindle Removal
      • Spindle Removal While Off the Truck
      • Front Wheel Hub and Spindle Installation
      • Spindle, Hub and Brake Assembly Cross-Section View
      • Front Wheel Hub and Spindle Disassembly
      • Front Wheel Hub and Spindle Cleaning and Inspection
      • Front Wheel Hub and Spindle Assembly
      • Rear Axle Removal
      • Rear Axle Cleaning and Inspection
      • Rear Axle Installation
      • Anti-Sway Bar Removal
      • Anti-Sway Bar Installation
      • Pivot Pin Removal
      • Pivot Pin Installation
      • Pivot Eye Bearing Wear Inspection
      • Pivot Eye Bearing Replacement
      • Pivot Eye Removal
      • Pivot Eye Installation
      • Wheel Motor Removal
      • Wheel Motor Cleaning and Inspection
      • Wheel Motor Installation
    • Steering System
      • Steering Control Unit Removal
      • Steering Control Unit Installation
      • Steering Control Unit Disassembly
      • Steering Control Unit Assembly
      • Steering Column Removal
      • Steering Column Installation
      • Steering Wheel Removal
      • Steering Wheel Installation
      • Bleeddown Manifold Removal
      • Bleeddown Manifold Installation
      • Flow Amplifier Removal
      • Flow Amplifier Installation
      • Steering Pin Joint Wear Inspection
      • Tie Rod Removal
      • Tie Rod Installation
      • Steering Cylinder Removal
      • Steering Cylinder Installation
      • Steering Cylinder Disassembly
      • Steering Cylinder Cleaning and Inspection
      • Steering Cylinder Assembly
      • Steering/Brake Pump Removal
      • Steering/Brake Pump Installation
      • Piston Steering Accumulator Removal
      • Piston Steering Accumulator Installation
      • Piston Steering Accumulator Disassembly
      • Piston Accumulator Cleaning and Inspection
      • Piston Seal Replacement
      • Piston Steering Accumulator Assembly
    • Brake System
      • Brake Treadle Valve Removal
      • Brake Treadle Valve Installation
      • Brake Valve/Pedal Disassembly
      • Brake Valve/Pedal Assembly
      • Front Brake Dual Relay Valve Removal
      • Front Brake Dual Relay Valve Installation
      • Rear Brake Dual Relay Valve Removal
      • Rear Brake Dual Relay Valve Installation
      • Brake Manifold Removal
      • Brake Manifold Installation
      • Brake Manifold Component Replacement
      • Piston Brake Accumulator Removal
      • Piston Brake Accumulator Installation
      • Piston Brake Accumulator Disassembly
      • Piston Accumulator Cleaning and Inspection
      • Piston Seal Replacement
      • Piston Brake Accumulator Assembly
      • Front Wheel Brake Disassembly
      • Front Wheel Brake Assembly
      • Rear Wheel Brake Removal
      • Rear Wheel Brake Installation
      • Rear Wheel Brake Disassembly
      • Rear Wheel Brake Assembly
      • Brake Floating Seal Assembly
      • Wheel Brake Cleaning and Inspection
      • Parking Brake Removal
      • Parking Brake Installation
      • Parking Brake Disassembly
      • Parking Brake Cleaning and Inspection
      • New Parking Brake Disc Cleaning and Inspection
      • Parking Brake Assembly
    • Hoist System
      • Hoist Pump Removal
      • Hoist Pump Installation
      • Hoist Pump Disassembly
      • Hoist Pump Inspection
      • Hoist Pump Assembly
      • Hoist Control Valve Removal
      • Hoist Control Valve Installation
      • Hoist Control Valve Service
        • Hoist Control Valve O-Ring Replacement
        • Inlet Section Disassembly
        • Inlet Section Assembly
        • Rear Spool Section Disassembly
        • Rear Spool Section Assembly
        • Front Spool Section Disassembly
        • Front Spool Section Assembly
        • Overcenter Manifold Service
      • Hoist Pilot Valve Removal
      • Hoist Pilot Valve Installation
      • Hoist Pilot Valve Disassembly
      • Hoist Pilot Valve Cleaning and Inspection
      • Hoist Pilot Valve Assembly
      • Hoist Cylinder Removal
      • Hoist Cylinder Installation
      • Hoist Cylinder Disassembly
      • Hoist Cylinder Cleaning and Inspection
      • Quill Installation
      • Quill Check Ball and Plug Installation
      • Hoist Cylinder Assembly
    • Suspensions
      • Front Suspension Removal
      • Front Suspension Cleaning and Inspection
      • Front Suspension Installation
      • Front Suspension Bolted Joint Inspection
      • Front Suspension Charging Valve Replacement
      • Front Suspension Disassembly
      • Front Suspension Assembly
      • Rear Suspension Removal
      • Rear Suspension Installation
      • Rear Suspension Charging Valve Replacement
      • Rear Suspension Disassembly
      • Rear Suspension Cleaning and Inspection
      • Rear Suspension Assembly
    • Dump Body and Structures
      • Dump Body Removal
      • Dump Body Inspection
      • Dump Body Installation
      • Body Pads Removal
      • Body Pads Installation
      • Body Pad Shimming Procedure
      • Diagonal Ladder Removal
      • Diagonal Ladder Installation
      • Grille and Hood Assembly Removal
      • Grille and Hood Assembly Installation
      • Egress Gate Adjustment
      • RH Deck Removal
      • RH Deck Installation
      • LH Deck Removal
      • LH Deck Installation
      • Center Deck Removal
      • Center Deck Installation
      • Fuel Tank Removal
      • Fuel Tank Cleaning and Inspection
      • Fuel Tank Installation
      • Fuel Tank Vent Disassembly
      • Fuel Tank Vent Assembly
      • Fuel Gauge Sender Removal
      • Fuel Gauge Sender Installation
      • Hydraulic Tank Removal
      • Hydraulic Tank Installation
      • Hydraulic Tank Strainers Removal
      • Hydraulic Tank Strainers Cleaning and Inspection
      • Hydraulic Tank Strainers Installation
    • Operator Cab
      • Operator Cab Removal
      • Operator Cab Installation
      • Cab Door Removal
      • Cab Door Installation
      • Door Panel Removal
      • Door Panel Installation
      • Window Regulator Removal
      • Window Regulator Installation
      • Door Glass Removal
      • Door Glass Installation
      • Door Seal Replacement
        • Replacing Door Assembly Seal and Door Hinge Seal
        • Replacing Door Opening Seal
      • Outer Door Seal Replacement
      • Interior Door Handle and Door Latch Removal
      • Interior Door Handle and Door Latch Installation
      • Door Jamb Bolt Adjustment
        • Poor Seal When Door Is Closed
        • Door Springs Back Open
      • Door Handle Plunger Adjustment
      • Side Window Glass Removal
      • Side Window Glass Installation
      • Windshield Glass Removal
      • Rear Window Glass Removal
      • Windshield Glass Installation
      • Rear Window Glass Installation
      • Windshield Wiper Motor Removal
      • Windshield Wiper Motor Installation
      • Windshield Wiper Arm Removal
      • Windshield Wiper Arm Installation
      • Windshield Wiper Linkage Removal
      • Windshield Wiper Linkage Installation
      • Cab Seat Servicing
      • Cab Seat Inspection
      • Operator Seat Removal
      • Operator Seat Installation
      • Seat Compressor Replacement
      • Passenger Seat Removal
      • Passenger Seat Installation
      • Seat Belt Removal (Standard Seat)
      • Seat Belt Installation (Standard Seat)
      • Seat Belt Service (Optional Seats)
        • Seat Belt Removal (Optional Seat)
        • Seat Belt Installation (Optional Seat)
    • Power Module
      • Power Module General Information
      • Power Module Preparation for Removal
      • Power Module Removal
      • Power Module Installation
      • Power Module Hookup
      • Exhaust Tube Installation
      • Exhaust Blanket Installation
      • Alternator Removal
      • Alternator Installation
        • Engine Flywheel Adapter Face Runout
        • Engine Crankshaft Endplay
        • Engine Flywheel to Flywheel Housing Adapter – Measurement “C”
        • Alternator Housing to Rotor – Measurement “A”
        • Measurements After Joining the Alternator and Engine
        • Flywheel Housing Face Runout
        • Flywheel Housing Radial Runout
        • Flywheel/Flexplate Face Runout
        • Flywheel/Flexplate Radial Runout
      • Radiator Removal
      • Radiator Installation
      • Radiator Internal Inspection
      • Radiator External Cleaning
      • Radiator Disassembly
      • Radiator Cleaning and Inspection
      • Radiator Assembly
      • Engine Removal
      • Engine Service
      • Engine Installation
    • Air Conditioning System Component Replacement
      • Hoses and Fittings
      • Line
      • Expansion Valve
      • Receiver-drier
      • Thermostat
      • Compressor
      • Accumulator
      • Clutch
  • 60 MAINTENANCE STANDARD
    • Rules for Maintenance
    • Torque Specifications
    • Wheel Motor Gear Oil
    • Shutting Down the Machine
    • Hydraulic System Bleeddown Procedure
    • Hydraulic System Vacuum Procedure
    • Long Term Storage of Electric Dump Truck
    • Hydraulic Pumps
      • Steering/Brake Pump
      • Hoist Pump
    • Wet Disc Brakes
      • Service Brake
      • Parking Brake
    • Tie Rod
    • Tail Lights, Clearance Lights and Turn Signals
  • 90 CIRCUIT DIAGRAMS
    • CONTENTS: 930E-4SE

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