Komatsu 930E-2 Dump Truck Operation & Maintenance Manual A30298, A30299 – PDF DOWNLOAD

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Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

FILE DETAILS:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

Language : English
Pages :165
Downloadable : Yes
File Type : PDF
Size:  2.41 MB
Book Code: CEAM011900

KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL A30298, A30299 – 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. 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 N·m (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.

TABLE OF CONTENTS:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

MAIN MENU.................................................................................  0
COVER.....................................................................................  1
FOREWARD..................................................................................  6
	ALERTS PAGE...........................................................................  7
TABLE OF CONTENTS.........................................................................  8
	TRUCK MODEL ILLUSTRATION.............................................................. 15
ABOUT THIS MANUAL......................................................................... 16
STANDARD CHARTS AND TABLES................................................................ 18
SAFETY.................................................................................... 24
	Safety Rules.......................................................................... 24
	Safety Features....................................................................... 24
	Clothing And Personal Items........................................................... 24
	Unauthorized Modification............................................................. 24
	Leaving The Operator's Seat........................................................... 25
	Mounting And Dismounting.............................................................. 25
	Fire Prevention For Fuel And Oil...................................................... 25
	Precautions With High Temperature Fluids.............................................. 26
	Asbestos Dust Hazard Prevention....................................................... 26
	Prevention Of Injury By Work Equipment................................................ 26
	Fire Extinguisher And First Aid Kit................................................... 26
	Precautions When Using ROPS........................................................... 27
	Precautions For Attachments........................................................... 27
	PRECAUTIONS DURING OPERATION.......................................................... 28
		Safety Is Thinking Ahead.......................................................... 28
		Safety At The Worksite............................................................ 28
		Fire Prevention................................................................... 28
		Preparing For Operation........................................................... 28
		Ventilation In Enclosed Areas..................................................... 28
		In Operator's Cab - Before Starting The Engine.................................... 29
		Mirrors, Windows, And Lights...................................................... 29
	OPERATING THE MACHINE................................................................. 29
		When Starting The Engine.......................................................... 29
		Truck Operation - General......................................................... 29
		Check When Traveling In Reverse................................................... 30
		Traveling......................................................................... 30
		Traveling On Slopes............................................................... 31
		Ensure Good Visibility............................................................ 31
		Operate Carefully On Snow......................................................... 31
		Avoide Damage To Dump Body........................................................ 31
		Driving Near High Voltage Cables.................................................. 31
		When Dumping...................................................................... 32
		Working On Loose Ground........................................................... 32
		When Loading...................................................................... 32
		Parking The Machine............................................................... 32
	TOWING................................................................................ 32
	WORKING NEAR BATTERIES................................................................ 33
		Battery Hazard Prevention......................................................... 33
		Starting With Booster Cables...................................................... 33
PRECAUTIONS FOR MAINTENANCE............................................................... 34
	BEFORE PERFORMING MAINTENANCE......................................................... 34
		Warning Tag....................................................................... 34
		Proper Tools...................................................................... 34
		Stopping The Engine Before Service................................................ 34
		Securing The Dump Body............................................................ 34
	DURING MAINTENANCE.................................................................... 35
		Personnel......................................................................... 35
		Attachments....................................................................... 35
		Working Under The Machine......................................................... 35
		Keep The Machine Clean............................................................ 35
		Rules To Follow When Adding Fuel Or Oil........................................... 35
		Radiator Water Level.............................................................. 36
		Use Of Lighting................................................................... 36
		Precautions With The Battery...................................................... 36
		Handling High Pressure Hoses...................................................... 36
		Precautions With High Pressure Oil  .............................................. 36
		Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 37
		Rotating Fan And Belts............................................................ 37
		Waste Materials................................................................... 37
	TIRES................................................................................. 38
		Handling Tires.................................................................... 38
		Storing Tires After Removal....................................................... 38
	ADDITIONAL JOB SITE RULES............................................................. 39
WHEN REPAIRS ARE NECESSARY................................................................ 40
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................................... 41
	Preliminary Procedures Before Welding Or Performing Maintenance....................... 41
	Normal Engine Shutdown Procedure...................................................... 41
	Engine Shutdown Procedure Before Welding Or Performing Maintenance.................... 42
WARNINGS AND CAUTIONS..................................................................... 44
OPERATING INSTRUCTIONS.................................................................... 54
	PREPARING FOR OPERATION............................................................... 54
		Safety Is Thinking Ahead.......................................................... 54
		At The Truck - Ground Level Walk Around Inspection................................ 54
	ENGINE START-UP SAFETY PRACTICES...................................................... 57
		Cold Weather Starting............................................................. 58
	AFTER ENGINE HAS STARTED.............................................................. 58
	MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 59
	MACHINE OPERATION ON THE HAUL ROAD.................................................... 59
	STARTING ON A GRADE WITH A LOADED TRUCK............................................... 60
	PASSING .............................................................................. 60
	LOADING .............................................................................. 60
	DUMPING............................................................................... 61
		Raising The Dump Body............................................................. 61
		Lowering The Dump Body............................................................ 61
	TOWING................................................................................ 63
	SAFE PARKING PROCEDURES............................................................... 63
	NORMAL ENGINE SHUTDOWN PROCEDURE...................................................... 63
	DELAYED ENGINE SHUTDOWN PROCEDURE..................................................... 64
	SUDDEN LOSS OF ENGINE POWER........................................................... 65
	RESERVE ENGINE OIL SYSTEM (OPTIONAL).................................................. 66
OPERATOR CAB AND CONTROLS................................................................. 68
	STEERING WHEEL AND CONTROLS........................................................... 69
		Horn Button....................................................................... 69
		Telescope Lock Ring............................................................... 69
		Tilt Wheel Lever.................................................................. 69
		Turn Signal/Headlight Dimmer...................................................... 69
	DYNAMIC RETARDING..................................................................... 69
		Retarder Control Lever............................................................ 70
		Dynamic Retarder/Service Brake Pedal.............................................. 70
		Accelerator (Throttle) Pedal...................................................... 70
		Starting On A Grade With A Loaded Truck........................................... 70
	GRADE/SPEED RETARD CHART.............................................................. 71
	INSTRUMENT PANEL...................................................................... 72
	OVERHEAD PANEL AND DISPLAYS........................................................... 72
	CENTER CONSOLE........................................................................ 73
		F-N-R Selector Switch............................................................. 73
		Hoist Control Lever............................................................... 74
		Raising The Dump Body............................................................. 74
		Lowering The Dump Body............................................................ 74
		Ash Tray.......................................................................... 74
		Lighter........................................................................... 74
		L.H. Window Control Switch........................................................ 74
		R.H. Window Control Switch........................................................ 74
		Engine Shutdown Switch............................................................ 74
		Override/Fault Reset Switch....................................................... 75
		Retard Speed Control (RSC) Switch................................................. 75
		Retard Speed Control (RSC) Adjust Dial............................................ 75
		PSC Download Port................................................................. 76
		Engine Diagnostics Download Port.................................................. 76
		TCI Download Port................................................................. 76
		Passenger Seat.................................................................... 76
		Engine Control System............................................................. 76
		Modular Mining System............................................................. 76
		Payload Meter And Download Connector.............................................. 76
OPERATOR COMFORT.......................................................................... 77
	OPERATOR SEAT......................................................................... 77
		Adjustment........................................................................ 77
		Seat Removal...................................................................... 77
		Seat Installation................................................................. 77
	HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 78
		Defroster Vent Control Switch..................................................... 78
		Outside/Inside Air Control Switch................................................. 78
		Heater Control Switch............................................................. 78
		Temperature Control Knob.......................................................... 78
		Fan Control Knob.................................................................. 78
		Heater/Air Conditioner Selector Switch............................................ 78
		Heater/Air Conditioner Selector Vents............................................. 78
INSTRUMENT PANEL AND INDICATOR LIGHTS..................................................... 80
	CONTROL SYMBOLS....................................................................... 80
	 INSTRUMENT PANEL..................................................................... 80
PANEL GAUGES, INDICATORS, AND CONTROLS.................................................... 82
	Key Switch............................................................................ 82
		Starting.......................................................................... 82
	Engine Shutdown Switch With 5 Minute Idle Timer Delay................................. 82
	Fog Lights (Optional)................................................................. 83
	Ladder Light Switch................................................................... 83
	Manual Backup Switch.................................................................. 83
	Panel Illumination Lights............................................................. 83
	Cab/Air Conditioner Vents............................................................. 83
	Rotating Beacon Light Switch (Optional)............................................... 83
	Heated Mirror Switch (Optional)....................................................... 83
	Wheel Brake Lock Control.............................................................. 84
	Parking Brake Control................................................................. 84
	Tachometer............................................................................ 84
	Right Turn Signal Indicator .......................................................... 85
	High Beam Indicator................................................................... 85
	Left Turn Signal Indicator............................................................ 85
	Speedometer/Payload Meter Display..................................................... 85
	Voltmeter............................................................................. 85
	Engine Oil Pressure Gauge............................................................. 85
	Water Temperature Gauge............................................................... 85
	Fuel Gauge............................................................................ 85
	AC Drive System Temperature Gauge..................................................... 86
	Hourmeter............................................................................. 86
	Hydraulic Oil Temperature Gauge....................................................... 86
	Rest Switch........................................................................... 86
	Light Switch.......................................................................... 87
	Windshield Wiper And Washer........................................................... 87
	Panel Light And DImmer................................................................ 87
	Payload Meter Switch.................................................................. 87
	OVERHEAD STATUS/WARNING INDICATORS.................................................... 88
	STATUS/WARNING INDICATOR LIGHT SYMBOLS................................................ 89
		Hazard Warning Lights............................................................. 95
		Lamp Test Switch.................................................................. 95
		Link-On Warning Light............................................................. 95
LUBRICATION AND SERVICE................................................................... 96
	930E SERVICE CAPACITIES............................................................... 96
	HYDRAULIC TANK SERVICE................................................................ 96
		Adding Oil........................................................................ 96
	WHEEL MOTOR SERVICE................................................................... 96
	COOLANT LEVEL CHECK................................................................... 97
	RADIATOR FILLING PROCEDURE............................................................ 97
	RESERVE ENGINE OIL SYSTEM (OPTIONAL).................................................. 97
		Reserve Oil Tank Filling Procedure (Remote Fill).................................. 97
	LUBRICATION CHART..................................................................... 98
	10 HOUR (DAILY) INSPECTION............................................................ 99
	50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................102
	100 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................103
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................104
	500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................107
	1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................108
	2500 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................109
	5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................109
AUTOMATIC LUBRICATION SYSTEM..............................................................110
	GENERAL DESCRIPTION...................................................................110
	SYSTEM COMPONENTS.....................................................................112
	SYSTEM OPERATION......................................................................113
		Normal Operation..................................................................113
		Pressure Failure Detection Circuits...............................................114
	GENERAL INSTRUCTIONS..................................................................115
		Required Lubricant For System.....................................................115
		System Priming....................................................................115
		Filter Assembly...................................................................115
	LUBRICANT PUMP........................................................................116
		Pump Housing Oil Level............................................................116
		Pump Pressure Control.............................................................116
		Pressure Control Valve Adjustment.................................................116
	INJECTOR OPERATION....................................................................117
		INJECTORS (SL-1 SERIES "H").......................................................118
		Injector Specifications...........................................................118
		Injector Adjustment...............................................................118
	SYSTEM CHECKOUT.......................................................................119
		Lubrication Cycle Timer Check.....................................................119
		Lubrication Cycle Timer Adjustment................................................119
	SYSTEM TROUBLESHOOTING CHART..........................................................120
	PREVENTATIVE MAINTENANCE PROCEDURES...................................................123
		Daily Lubrication System Inspection...............................................123
		250 Hour Inspection...............................................................123
		1000 Hour Inspection..............................................................123
MAJOR COMPONENT DESCRIPTION...............................................................124
PAYLOAD METER III TM......................................................................128
	INDEX.................................................................................128
	OPERATION SECTION.....................................................................130
		Introduction......................................................................130
		Data Summary......................................................................130
		Data Gathering....................................................................130
	COMPONENT DESCRIPTION.................................................................131
		System Diagram....................................................................131
		Suspension Pressure Sensors.......................................................131
		Inclinometer......................................................................131
		Operator Display..................................................................131
		Operator Switch...................................................................132
		Speed Input.......................................................................132
		Body-Up Switch....................................................................132
		Brake Lock Switch.................................................................132
		Payload Meter.....................................................................132
		Communications Ports..............................................................132
		Keyswitch Input...................................................................133
		Payload Meter Power...............................................................133
		Load Lights.......................................................................133
		Wiring and Termination............................................................134
		TCI Outputs.......................................................................134
	OPERATOR’S DISPLAY AND SWITCH.........................................................135
		Reading the Speedometer...........................................................135
		Reading the Load Display..........................................................135
		Using the Operator ID.............................................................135
		Using the Load and Ton Counter....................................................135
		Total Ton Counter.................................................................135
		Total Load Counter................................................................136
		Clearing the Counters.............................................................136
		Viewing Live Sensor Data..........................................................136
		Other Display Messages............................................................136
	PAYLOAD OPERATION & CALCULATION.......................................................137
		Description of Haul Cycle States..................................................137
		Haul Cycle Description............................................................137
		Load Calculation..................................................................138
		Carry Back........................................................................138
		Measurement Accuracy..............................................................138
	SOURCES FOR PAYLOAD ERROR.............................................................138
		Payload Error.....................................................................138
		Loading Conditions................................................................139
		Pressure Sensors..................................................................139
		Swingloads........................................................................139
		Speed and Distance................................................................139
	HAUL CYCLE DATA.......................................................................139
		Haul Cycle Data...................................................................140
		Haul Cycle Warning Flags..........................................................141
		A: Continuous Loading.............................................................141
		B: Loading to Dumping Transition..................................................141
		C: No Final Load..................................................................141
		D: Maneuvering to Dumping Transition..............................................141
		E: Average Load or Tare Used......................................................141
		F: Final Zone to Dumping Transition...............................................141
		H: False Body Up..................................................................141
		I: Body Up Signal Failed..........................................................141
		J: Speed Sensor Failed............................................................141
		K: New Tare Not Calculated........................................................141
		L: Incomplete Haul Cycle..........................................................141
		M: Haul Cycle Too Long............................................................142
		N: Sensor Input Error.............................................................142
		Alarm Records.....................................................................142
		Frame Torque Data.................................................................142
		Sprung Weight Data................................................................143
		Maximum Speed Data................................................................143
	PC SOFTWARE OVERVIEW..................................................................143
		PC Overview.......................................................................143
		System Configuration..............................................................143
		Installing the PLMIII Software....................................................143
	DOWNLOADING DATA......................................................................144
	PLMIII SYSTEM CONFIGURATION...........................................................145
		Starting Communications...........................................................145
		Displayed Payload Units...........................................................145
		Time Units........................................................................145
		Connection Menu...................................................................145
		Connecting to the Payload Meter...................................................146
		Configure the Payload Meter.......................................................146
		Setting the Date and Time.........................................................146
		Setting the Truck Type............................................................147
		Setting the Gauge Display Units...................................................147
		Setting the Frame Serial Number...................................................147
		Setting the Truck Number..........................................................147
		Setting the Komatsu Distributor...................................................147
		Setting the Komatsu Customer......................................................147
		Clean Truck Tare..................................................................148
		Inclinometer Calibration..........................................................148
	DATA ANALYSIS.........................................................................149
		Sorting on Truck Unit Number......................................................149
		Creating a Query..................................................................149
		Sorting on Truck Type.............................................................149
		Sorting on Date Range.............................................................150
		Sorting on Time Range.............................................................150
		Payload Detail Screen.............................................................151
		Creating Reports..................................................................151
		Summary - one page report.........................................................152
		Detailed - multi-page report......................................................152
		Creating Graphs...................................................................153
		Exporting Data....................................................................153
		CSV Export........................................................................153
		Compressed........................................................................154
		To export data in ZIP format:.....................................................155
		Importing Data....................................................................155
		Deleting Haul Cycle Records.......................................................155
		Viewing Alarms....................................................................156
		Deleting Alarm Records............................................................156
RADIO, AM / FM STEREO CASSETTE............................................................158
	SETTING THE TIME......................................................................158
	GENERAL RECEIVER FUNCTIONS............................................................158
		Turning The Power On And Off......................................................158
		Display...........................................................................158
		Setting The Default Display.......................................................159
		Adjusting Display Brightness......................................................159
	OPERATING THE RADIO...................................................................159
		BAND..............................................................................159
		TUNE/SEEK.........................................................................159
		Manual Tuning.....................................................................159
		SEEK Mode.........................................................................159
		SCAN..............................................................................159
		AUTO..............................................................................159
	ADJUSTING THE RECEIVER SETTINGS.......................................................160
	PROGRAMMING PRESET STATIONS...........................................................160
	OPERATION OF THE WEATHERBAND (U.S.)...................................................160
	SATELLITE RADIO.......................................................................161
		Operating Satellite Radio.........................................................161
		Program Type Search (PTY).........................................................161
	CASSETTE PLAYER.......................................................................162
		Playing A Cassette................................................................162
		Cassette Functions................................................................162
	PROGRAMMABLE EJECT DEFAULT............................................................162
		Bad Tape Detect...................................................................163
	CASSETTE PLAYER CLEANING..............................................................163

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