Komatsu 930E-2 Dump Truck Operation & Maintenance Manual A30292 – PDF DOWNLOAD

Description

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

FILE DETAILS:

Language : English
Pages : 165
Downloadable : Yes
File Type : PDF
Size: 2.33 MB
Book Code: CEAM011700

KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL A30292 – PDF DOWNLOAD:

DESCRIPTION:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

FOREWORD:

• This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
• All operators and maintenance personnel should read and understand the materials 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 or accomplishing repairs on the truck.
• A product identification plate is located on the frame in front of the right side front wheel and 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. 930E). The three numbers represent the basic truck model.

• The letter “M”, when present, designates a Mechanical drive system;
• The letter “E”, when present, designates an Electrical wheel motor drive system.

The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.

TABLE OF CONTENTS:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

MAIN MENU.....................................................................................  0
COVER.........................................................................................  1
SECTION 10 - INTRODUCTION.....................................................................  7
	FOREWORD..................................................................................  7
		ALERTS PAGE...........................................................................  8
	TABLE OF CONTENTS.........................................................................  9
		TRUCK MODEL ILLUSTRATION.............................................................. 16
	ABOUT THIS MANUAL......................................................................... 17
SECTION 12 - STANDARD CHARTS AND TABLES....................................................... 19
SECTION 20 - SAFETY........................................................................... 25
	Safety Rules.............................................................................. 25
	Safety Features........................................................................... 25
	Clothing And Personal Items............................................................... 25
	Unauthorized Modification................................................................. 25
	Leaving The Operator’s Seat............................................................... 26
	Mounting And Dismounting.................................................................. 26
	Fire Prevention For Fuel And Oil.......................................................... 26
	Precautions With High Temperature Fluids.................................................. 27
	Asbestos Dust Hazard Prevention........................................................... 27
	Prevention Of Injury By Work Equipment.................................................... 27
	Fire Extinguisher And First Aid Kit....................................................... 27
	Precautions When Using ROPS............................................................... 28
	Precautions For Attachments............................................................... 28
	PRECAUTIONS DURING OPERATION.............................................................. 29
		Safety Is Thinking Ahead.............................................................. 29
		Safety At The Worksite................................................................ 29
		Fire Prevention....................................................................... 29
		Preparing For Operation............................................................... 29
		Ventilation In Enclosed Areas......................................................... 29
		In Operator’s Cab - Before Starting The Engine........................................ 30
		Mirrors, Windows, And Lights.......................................................... 30
		OPERATING THE MACHINE................................................................. 30
			When Starting The Engine.......................................................... 30
			Truck Operation - General......................................................... 30
			Check When Traveling In Reverse................................................... 31
			Traveling......................................................................... 31
			Traveling On Slopes............................................................... 32
			Ensure Good Visibility............................................................ 32
			Operate Carefully On Snow......................................................... 32
			Avoid Damage To Dump Body......................................................... 32
			Driving Near High Voltage Cables.................................................. 32
			When Dumping...................................................................... 33
			Working On Loose Ground........................................................... 33
			When Loading...................................................................... 33
			Parking The Machine............................................................... 33
		TOWING................................................................................ 33
		WORKING NEAR BATTERIES................................................................ 34
			Battery Hazard Prevention......................................................... 34
			Starting With Booster Cables...................................................... 34
	PRECAUTIONS FOR MAINTENANCE............................................................... 35
		BEFORE PERFORMING MAINTENANCE......................................................... 35
			Warning Tag....................................................................... 35
			Proper Tools...................................................................... 35
			Stopping The Engine Before Service................................................ 35
			Securing The Dump Body............................................................ 35
		DURING MAINTENANCE.................................................................... 36
			Personnel......................................................................... 36
			Attachments....................................................................... 36
			Working Under The Machine......................................................... 36
			Keep The Machine Clean............................................................ 36
			Rules To Follow When Adding Fuel Or Oil........................................... 36
			Radiator Water Level.............................................................. 37
			Use Of Lighting................................................................... 37
			Precautions With The Battery...................................................... 37
			Handling High Pressure Hoses...................................................... 37
			Precautions With High Pressure Oil................................................ 37
			Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 38
			Rotating Fan And Belts............................................................ 38
			Waste Materials................................................................... 38
		TIRES................................................................................. 39
			Handling Tires.................................................................... 39
			Storing Tires After Removal....................................................... 39
	ADDITIONAL JOB SITE RULES................................................................. 40
	WHEN REPAIRS ARE NECESSARY................................................................ 41
	SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................................... 42
		Preliminary Procedures Before Welding or Performing Maintenance....................... 42
		Normal Engine Shutdown Procedure...................................................... 42
		Engine Shutdown Procedure Before Welding or Performing Maintenance.................... 43
SECTION 22 - WARNINGS AND CAUTIONS............................................................ 45
SECTION 30 - OPERATING INSTRUCTIONS........................................................... 55
	PREPARING FOR OPERATION................................................................... 55
		Safety Is Thinking Ahead.............................................................. 55
		At The Truck - Ground Level Walk Around Inspection.................................... 55
	ENGINE START-UP SAFETY PRACTICES.......................................................... 58
		Cold Weather Starting................................................................. 59
	AFTER ENGINE HAS STARTED.................................................................. 59
	MACHINE OPERATION SAFETY PRECAUTIONS...................................................... 60
	MACHINE OPERATION ON THE HAUL ROAD........................................................ 60
	STARTING ON A GRADE WITH A LOADED TRUCK................................................... 61
	PASSING................................................................................... 61
	LOADING................................................................................... 61
	DUMPING................................................................................... 62
		Raising The Dump Body................................................................. 62
		Lowering The Dump Body................................................................ 62
	TOWING.................................................................................... 64
	SAFE PARKING PROCEDURES................................................................... 64
	NORMAL ENGINE SHUTDOWN PROCEDURE.......................................................... 64
	DELAYED ENGINE SHUTDOWN PROCEDURE......................................................... 65
	SUDDEN LOSS OF ENGINE POWER............................................................... 66
	RESERVE ENGINE OIL SYSTEM (Optional)...................................................... 67
SECTION 32 - OPERATOR CAB AND CONTROLS........................................................ 69
	STEERING WHEEL AND CONTROLS............................................................... 70
		Horn Button........................................................................... 70
		Telescope Lock Ring................................................................... 70
		Tilt Wheel Lever...................................................................... 70
		Turn Signal/Headlight Dimmer.......................................................... 70
	DYNAMIC RETARDING......................................................................... 70
		Retarder Control Lever................................................................ 71
		Dynamic Retarder/Service Brake Pedal.................................................. 71
		Accelerator (Throttle) Pedal.......................................................... 71
		Starting on a Grade With a Loaded Truck............................................... 71
	GRADE/SPEED RETARD CHART.................................................................. 72
	INSTRUMENT PANEL.......................................................................... 73
	OVERHEAD PANEL AND DISPLAYS............................................................... 73
	CENTER CONSOLE............................................................................ 74
		F-N-R Selector Switch................................................................. 74
		Hoist Control Lever................................................................... 75
		Raising The Dump Body................................................................. 75
		Lowering The Dump Body:............................................................... 75
		Ash Tray.............................................................................. 75
		Lighter............................................................................... 75
		L.H. Window Control Switch............................................................ 75
		R.H. Window Control Switch............................................................ 75
		Engine Shutdown Switch................................................................ 75
		Override/Fault Reset Switch........................................................... 76
		Retard Speed Control (RSC) Switch..................................................... 76
		Retard Speed Control (RSC) Adjust Dial................................................ 76
		PSC Download Port..................................................................... 77
		Engine Diagnostics Download Port...................................................... 77
		TCI Download Port..................................................................... 77
		Passenger Seat........................................................................ 77
		Engine Control System................................................................. 77
		Modular Mining System................................................................. 77
		Payload Meter And Download Connector.................................................. 77
	OPERATOR COMFORT.......................................................................... 78
		OPERATOR SEAT......................................................................... 78
			Adjustment........................................................................ 78
		HEATER / AIR CONDITIONER COMPART MENT AND CONTROLS.................................... 79
			Defroster Vent Control Switch..................................................... 79
			Outside/Inside Air Control Switch................................................. 79
			Heater Control Switch............................................................. 79
			Temperature Control Knob.......................................................... 79
			Fan Control Knob.................................................................. 79
			Heater/Air Conditioner Selector Switch............................................ 79
			Heater/Air Conditioner Vents...................................................... 79
	INSTRUMENT PANEL AND INDICATOR LIGHTS..................................................... 81
		CONTROL SYMBOLS....................................................................... 81
		INSTRUMENT PANEL...................................................................... 81
	PANEL GAUGES, INDICATORS, AND CONTROLS.................................................... 83
		Key Switch............................................................................ 83
		Starting.............................................................................. 83
		Engine Shutdown Switch with 5 Minute Idle Timer Delay................................. 83
		Fog Lights (Optional)................................................................. 84
		Ladder Light Switch................................................................... 84
		Manual Backup Switch.................................................................. 84
		Panel Illumination Lights............................................................. 84
		Cab/Air Conditioner Vents............................................................. 84
		Rotating Beacon Light Switch (Optional)............................................... 84
		Heated Mirror Switch (Optional)....................................................... 84
		Wheel Brake Lock Control.............................................................. 85
		Parking Brake Control................................................................. 85
		Tachometer............................................................................ 85
		Right Turn Signal Indicator........................................................... 86
		High Beam Indicator................................................................... 86
		Left Turn Signal Indicator............................................................ 86
		Speedometer/Payload Meter Display..................................................... 86
		Voltmeter............................................................................. 86
		Engine Oil Pressure Gauge............................................................. 86
		Water Temperature Gauge............................................................... 86
		Fuel Gauge............................................................................ 86
		AC Drive System Temperature Gauge..................................................... 87
		Hourmeter............................................................................. 87
		Hydraulic Oil Temperature Gauge....................................................... 87
		Rest Switch........................................................................... 87
		Light Switch.......................................................................... 88
		Windshield Wiper and Washer........................................................... 88
		Panel Light Dimmer.................................................................... 88
		Payload Meter Switch.................................................................. 88
		OVERHEAD STATUS / WARNING INDICATORS.................................................. 89
		STATUS / WARNING INDICATOR LIGHT SYMBOLS.............................................. 90
			Hazard Warning Lights............................................................. 96
			Lamp Test Switch.................................................................. 96
			Link-On Warning Light............................................................. 96
SECTION 40 - LUBRICATION AND SERVICE.......................................................... 97
	930E SERVICE CAPACITIES................................................................... 97
	HYDRAULIC TANK SERVICE.................................................................... 97
		Adding Oil............................................................................ 97
	WHEEL MOTOR SERVICE....................................................................... 97
	COOLANT LEVEL CHECK....................................................................... 98
	RADIATOR FILLING PROCEDURE................................................................ 98
	RESERVE ENGINE OIL SYSTEM (Optional)...................................................... 98
		Reserve Oil Tank Filling Procedure (Remote fill)...................................... 98
	LUBRICATION CHART......................................................................... 99
	10 HOUR (DAILY) INSPECTION................................................................100
	50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................103
	100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................104
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................105
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................108
	1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................109
	2500 HOUR MAINTENANCE CHECKS..............................................................110
	5000 HOUR MAINTENANCE CHECKS..............................................................110
SECTION 42 - AUTOMATIC LUBRICATION SYSTEM.....................................................111
	GENERAL DESCRIPTION.......................................................................111
	SYSTEM COMPONENTS.........................................................................113
	SYSTEM OPERATION..........................................................................114
		Normal Operation......................................................................114
		Pressure Failure Detection Circuits...................................................115
	GENERAL INSTRUCTIONS......................................................................116
		Required Lubricant For System.........................................................116
		System Priming........................................................................116
		Filter Assembly.......................................................................116
	LUBRICANT PUMP............................................................................117
		Pump Housing Oil Level................................................................117
		Pump Pressure Control.................................................................117
		Pressure Control Valve Adjustment.....................................................117
	INJECTOR OPERATION........................................................................118
	INJECTORS (SL-1 Series “H”))..............................................................119
		Injector Specifications...............................................................119
		Injector Adjustment...................................................................119
	SYSTEM CHECKOUT...........................................................................120
		Lubrication Cycle Timer Check.........................................................120
		Lubrication Cycle Timer Adjustment....................................................120
	SYSTEM TROUBLESHOOTING CHART..............................................................121
	PREVENTATIVE MAINTENANCE PROCEDURES.......................................................124
		Daily Lubrication System Inspection...................................................124
		250 Hour Inspection...................................................................124
		1000 Hour Inspection..................................................................124
SECTION 50 - MAJOR COMPONENT DESCRIPTION......................................................125
SECTION 60 - PAYLOAD METER III™ - INDEX.......................................................129
	OPERATION SECTION.........................................................................131
		Introduction..........................................................................131
		Data Summary..........................................................................131
		Data Gathering........................................................................131
	COMPONENT DESCRIPTION.....................................................................132
		System Diagram........................................................................132
		Suspension Pressure Sensors...........................................................132
		Inclinometer..........................................................................132
		Operator Display......................................................................132
		Operator Switch.......................................................................133
		Speed Input...........................................................................133
		Body-Up Switch........................................................................133
		Brake Lock Switch.....................................................................133
		Payload Meter.........................................................................133
		Communications Ports..................................................................133
		Keyswitch Input.......................................................................134
		Payload Meter Power...................................................................134
		Load Lights...........................................................................134
		Wiring and Termination................................................................135
		TCI Outputs...........................................................................135
	OPERATOR’S DISPLAY AND SWITCH.............................................................136
		Reading the Speedometer...............................................................136
		Reading the Load Display..............................................................136
		Using the Operator ID.................................................................136
		Using the Load and Ton Counter........................................................136
		Total Ton Counter.....................................................................136
		Total Load Counter....................................................................137
		Clearing the Counters.................................................................137
		Viewing Live Sensor Data..............................................................137
		Other Display Messages................................................................137
	PAYLOAD OPERATION & CALCULATION...........................................................138
		Description of Haul Cycle States......................................................138
		Haul Cycle Description................................................................138
		Load Calculation......................................................................139
		Carry Back............................................................................139
		Measurement Accuracy..................................................................139
	SOURCES FOR PAYLOAD ERROR.................................................................139
		Payload Error.........................................................................139
		Loading Conditions....................................................................140
		Pressure Sensors......................................................................140
		Swingloads............................................................................140
		Speed and Distance....................................................................140
	HAUL CYCLE DATA...........................................................................140
		Haul Cycle Data.......................................................................141
		Haul Cycle Warning Flags..............................................................142
		A: Continuous Loading.................................................................142
		B: Loading to Dumping Transition......................................................142
		C: No Final Load......................................................................142
		D: Maneuvering to Dumping Transition..................................................142
		E: Average Load or Tare Used..........................................................142
		F: Final Zone to Dumping Transition...................................................142
		H: False Body Up......................................................................142
		I: Body Up Signal Failed..............................................................142
		J: Speed Sensor Failed................................................................142
		K: New Tare Not Calculated............................................................142
		L: Incomplete Haul Cycle..............................................................142
		M: Haul Cycle Too Long................................................................143
		N: Sensor Input Error.................................................................143
		Alarm Records.........................................................................143
		Frame Torque Data.....................................................................143
		Sprung Weight Data....................................................................144
		Maximum Speed Data....................................................................144
	PC SOFTWARE OVERVIEW......................................................................144
		PC Overview...........................................................................144
		System Configuration..................................................................144
		Installing the PLMIII Software........................................................144
	DOWNLOADING DATA..........................................................................145
	PLMIII SYSTEM CONFIGURATION...............................................................146
		Starting Communications...............................................................146
		Displayed Payload Units...............................................................146
		Time Units............................................................................146
		Connection Menu.......................................................................146
		Connecting to the Payload Meter.......................................................147
		Configure the Payload Meter...........................................................147
		Setting the Date and Time.............................................................147
		Setting the Truck Type................................................................148
		Setting the Gauge Display Units.......................................................148
		Setting the Frame Serial Number.......................................................148
		Setting the Truck Number..............................................................148
		Setting the Komatsu Distributor.......................................................148
		Setting the Komatsu Customer..........................................................148
		Clean Truck Tare......................................................................149
		Inclinometer Calibration..............................................................149
	DATA ANALYSIS.............................................................................150
		Sorting on Truck Unit Number..........................................................150
		Creating a Query......................................................................150
		Sorting on Truck Type.................................................................150
		Sorting on Date Range.................................................................151
		Sorting on Time Range.................................................................151
		Payload Detail Screen.................................................................152
		Creating Reports......................................................................152
		Summary - one page report.............................................................153
		Detailed - multi-page report..........................................................153
		Creating Graphs.......................................................................154
		Exporting Data........................................................................154
		CSV Export............................................................................154
		Compressed............................................................................155
		To export data in ZIP format:.........................................................156
		Importing Data........................................................................156
		Deleting Haul Cycle Records...........................................................156
		Viewing Alarms........................................................................157
		Deleting Alarm Records................................................................157
SECTION 70 - RADIO, AM / FM STEREO CASSETTE...................................................159
	SETTING THE TIME..........................................................................159
	GENERAL RECEIVER FUNCTIONS................................................................159
		Turning The Power On And Off..........................................................159
		Display...............................................................................159
		Setting The Default Display...........................................................160
		Adjusting Display Brightness..........................................................160
	OPERATING THE RADIO.......................................................................160
		BAND..................................................................................160
		TUNE/SEEK.............................................................................160
		Manual Tuning.........................................................................160
		SEEK Mode.............................................................................160
		SCAN..................................................................................160
		AUTO..................................................................................160
	PROGRAMMING PRESET STATIONS...............................................................161
	OPERATION OF THE WEATHERBAND (U.S.).......................................................161
	ADJUSTING THE RECEIVER SETTINGS...........................................................161
	PROGRAMMABLE EJECT DEFAULT................................................................162
	CASSETTE PLAYER...........................................................................162
		Playing A Cassette....................................................................162
		Cassette Functions....................................................................162
		Bad Tape Detect.......................................................................163
	CASSETTE PLAYER CLEANING..................................................................163

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