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

Description

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

Description:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

• 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.
• The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment.
• 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. 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 G.V.W. (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. 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 total maximum Gross Vehicle Weight (GVW) and this means the TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.

Table Of Contents:

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

MAIN MENU.............................................................................  0
COVER.................................................................................  1
INTRODUCTION..........................................................................  8
	FOREWARD..........................................................................  6
	ALERTS............................................................................  7
	CONTENTS..........................................................................  8
	TRUCK MODEL ILLUSTRATION.......................................................... 11
	ABOUT THIS MANUAL................................................................. 12
	STANDARD CHARTS AND TABLES........................................................ 14
SAFETY................................................................................ 20
	GENERAL SAFETY.................................................................... 20
	PRECAUTIONS DURING OPERATION...................................................... 24
		OPERATING MACHINE............................................................. 25
		TOWING........................................................................ 28
		BATTERY....................................................................... 29
	PRECAUTIONS FOR MAINTENANCE....................................................... 30
		BEFORE CARRYING OUT MAINTENANCE............................................... 30
		DURING MAINTENANCE............................................................ 31
		TIRES.........................................................................  8
		ADDITIONAL JOB SITE RULES..................................................... 35
	WHEN REPAIRS ARE NECESSARY........................................................ 36
		SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK............................... 37
	WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS................................... 40
OPERATION............................................................................. 50
	OPERATING INSTRUCTIONS............................................................ 50
		PREPARING FOR OPERATION....................................................... 50
		SAFETY IS THINKING AHEAD...................................................... 50
		AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION.......................... 50
	ENGINE START-UP SAFETY PRACTICES.................................................. 53
	AFTER ENGINE HAS STARTED.......................................................... 54
	MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 55
	MACHINE OPERATION ON THE HAUL ROAD................................................ 55
	STARTING ON A GRADE WITH A LOADED TRUCK........................................... 56
	PASSING........................................................................... 56
	LOADING........................................................................... 56
	DUMPING........................................................................... 57
	TOWING............................................................................ 58
	SAFE PARKING PROCEDURES........................................................... 59
	NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 59
	OPERATOR CAB AND CONTROLS......................................................... 62
		STEERING WHEEL AND CONTROLS................................................... 63
		DYNAMIC RETARDER/SERVER BRAKE PEDAL........................................... 64
		ACCELERATOR (THROTTLE) PEDAL.................................................. 64
		HEATER/AIR CONDITIONER VENTS.................................................. 64
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................... 65
		OVERHEAD PANEL AND DISPLAYS................................................... 66
		CENTER CONSOLE CONTROLS AND FEATURES.......................................... 68
			HOIST CONTROL LEVER....................................................... 69
		OPERATOR SEAT................................................................. 72
	INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 74
		CONTROL SYMBOLS............................................................... 74
	INSTRUMENT PANEL (FIGURE 3-6)..................................................... 74
	PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)..... 76
	OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)........................ 82
	INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-7  BY ROWS (A-E) AND COLUMNS (1-6).... 83
		HAZARD WARNING LIGHTS (7)..................................................... 89
		LAMP TEST SWITCH (8).......................................................... 89
	LINK-ON WARNINGS LIGHT............................................................ 89
MAINTENANCE........................................................................... 90
	LUBRICATION AND SERVICE........................................................... 90
		SERVICE CAPACITIES............................................................ 90
		HYDRAULIC TANK SERVICE........................................................ 90
		COOLANT LEVEL CHECK........................................................... 91
		RADIATOR FILING PROCEDURE..................................................... 91
		COOLING SYSTEM RECOMMENDATIONS................................................ 91
		LUBRICATION CHART............................................................. 92
		10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS............................ 93
		50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 95
		100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 96
		250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 97
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 99
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................100
		2500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101
		5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101
	LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)................................102
		GENERAL DESCRIPTION...........................................................102
		SYSTEM COMPONENTS.............................................................104
		SYSTEM OPERATION..............................................................105
		INJECTOR OPERATION............................................................109
		INJECTORS.....................................................................110
		GENERAL INSTRUCTIONS..........................................................107
			LUBRICANT REQUIRED........................................................107
			SYSTEM PRIMING............................................................107
			FILTER ASSEMBLY...........................................................107
			LUBRICANT PUMP............................................................108
		SYSTEM CHECK -OUT.............................................................111
			LUBRICATION CYCLE TIMER CHECK.............................................111
		SYSTEM TROUBLESHOOTING CHART..................................................112
		PREVENTATIVE MAINTENANCE PROCEDURES...........................................115
SPECIFICATIONS........................................................................116
	MAJOR COMPONENT DESCRIPTIONS......................................................116
	SPECIFICATIONS....................................................................118
OPTIONAL EQUIPMENT....................................................................120
	PAYLOAD METER II (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX).........................120
		GENERAL INFORMATION...........................................................122
		LIGHTS, SWITHES, AND COMPONENTS...............................................123
		TIPS FOR OPERATION............................................................124
		EXTERNAL DISPLAY LIGHTS.......................................................124
		THEORY OF OPERATION...........................................................125
			BASIC DESCRIPTION.........................................................125
			LINKAGE FACTOR............................................................125
			BRAKE LOCK................................................................126
			SOURCES OF ERROR..........................................................126
			TYPICAL DATA FROM SERVICE CHECK MODE......................................126
			EXAMPLE CALCULATION OF PAYLOAD............................................127
			CALCULATION OF THE CALIBRATION LOAD.......................................127
		TYPES OD DATA STORED..........................................................128
			CYCLE DATA................................................................128
			ENGINE ON/OFF DATA........................................................129
			FAULT CODES AND WARNINGS DATA.............................................129
			ENGINE OPERATION..........................................................130
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES..................................130
			OTHER DATA................................................................130
		OPERATOR FUNCTIONS............................................................131
			USING THE OPERATOR LOAD COUNTER...........................................131
				DESCRIPTION...........................................................131
				VIEWING THE OPERATOR LOAD COUNTER.....................................131
				CLEARING THE OPERATOR LOAD COUNTER....................................131
			DIMMING THE LIGHTS ONTHE DISPLAY..........................................131
		INITIAL SETUP OF PAYLOAD METER................................................132
			SWITCH SETTINGS...........................................................132
			CHECKING THE OPERATOR CHECK MODE..........................................132
			CHECKING THE SERVICE CHECK MODE...........................................133
				SETTING "UP:00".......................................................133
				SETTING "PL:00".......................................................133
			CHECKING THE Gt SETTING...................................................133
			CHECKING THE INCLINOMETER SETTINGS........................................133
			CALIBRATING A TRUCK.......................................................134
		DISPLAYS AT START-UP..........................................................135
		SETUP AND MAINTENANCE.........................................................136
			SETTING THE SPEED LIMIT...................................................136
			SETTINGS THE OPTION CODE..................................................136
			SETTING THE MACHINE I.D...................................................136
			SETTING THE OPERATOR I.D..................................................137
			SETTING THE TIME AND DATE.................................................137
		DOWNLOAD OF PAYLOAD FAULT CODES...............................................137
		DISPLAY OF FAULT CODES........................................................138
		CHARTS OF ERROR CODES AND OTHER INFORMATION...................................139
		SERVICE CHECK MODE............................................................141
			MONITORING INPUT SIGNALS .................................................141
			UP FACTOR - PAYLOAD CALCULATION GAIN......................................142
			PL MODE - LOAD CALCULATION................................................142
		FINAL GEAR RATIO SELECTION....................................................143
		BATTERY REPLACEMENT PROCEDURE.................................................144
			REPLACING THE BATTERY.....................................................144
			AFTER REPLACING THE BATTERY...............................................145
		SUSPENSION PRESSURE SENSOR....................................................145
			REMOVAL...................................................................145
			INSTALLATION..............................................................146
		INCLINOMETER..................................................................146
			REMOVAL...................................................................146
			INSTALLATION..............................................................146
		SCOREBOARD....................................................................147
			DESCRIPTION...............................................................147
			MAKING CONNECTIONS........................................................147
			WIRING DIAGRAM............................................................148
			NORMAL OPERATION OF THE SCOREBOARD........................................149
		PAYLOAD METER BACK PANEL......................................................149
			CONNECTIONS (AMP PIN IDENTIFICATION)......................................150
		PAYLOAD CIRCUIT NUMBERS.......................................................151
		PAYLOAD METER II RE-INITIALIZATION PROCEDURE..................................152
	RADIO, AM/FM STERO CASSETTE.......................................................154

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

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