KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2 – PDF DOWNLOAD

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KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2

KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 AND UP) KOMATSU 930E-2 – PDF DOWNLOAD:

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KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2

• 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 (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2

MAIN MENU.............................................................................  0
COVER.................................................................................  1
INTRODUCTION..........................................................................  5
	FOREWARD..........................................................................  5
	ALERTS............................................................................  6
	TABLE OF CONTENTS.................................................................  7
	TRUCK MODEL ILLUSTRATION.......................................................... 10
	ABOUT THIS MANUAL................................................................. 11
	STANDARD CHARTS AND TABLES........................................................ 13
SAFETY................................................................................ 19
	GENERAL SAFETY.................................................................... 19
	PRECAUTIONS DURING OPERATION...................................................... 23
		OPERATING MACHINE............................................................. 24
		TOWING........................................................................ 27
		BATTERY....................................................................... 28
	PRECAUTIONS FOR MAINTENANCE....................................................... 29
		BEFORE CARRYING OUT MAINTENANCE............................................... 29
		DURING MAINTENANCE............................................................ 30
		TIRES......................................................................... 33
		ADDITIONAL JOB SITE RULES..................................................... 34
	WHEN REPAIRS ARE NECESSARY........................................................ 35
		SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK............................... 36
	WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS................................... 39
OPERATION............................................................................. 49
	OPERATING INSTRUCTIONS............................................................ 49
		PREPARING FOR OPERATION....................................................... 49
		SAFETY IS THINKING AHEAD...................................................... 49
		AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION.......................... 49
	ENGINE START-UP SAFETY PRACTICES.................................................. 52
	AFTER ENGINE HAS STARTED.......................................................... 53
	MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 54
	MACHINE OPERATION ON THE HAUL ROAD................................................ 54
	STARTING ON A GRADE WITH A LOADED TRUCK........................................... 55
	PASSING........................................................................... 55
	LOADING........................................................................... 55
	DUMPING........................................................................... 56
	TOWING............................................................................ 57
	SAFE PARKING PROCEDURES........................................................... 58
	NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 58
	DELAYED ENGINE SHUTDOWN PROCEDURE................................................. 59
	SUDDEN LOSS OF ENGINE POWER....................................................... 60
	RESERVE ENGINE OIL SYSTEM......................................................... 61
	OPERATOR CAB AND CONTROLS......................................................... 63
		STEERING WHEEL AND CONTROLS................................................... 64
		DYNAMIC RETARDER/SERVICE BRAKE PEDAL.......................................... 65
		ACCELERATOR (THROTTLE) PEDAL.................................................. 65
		HEATER/AIR CONDITIONER VENTS.................................................. 65
		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................... 66
		GRADE SPEED CHART............................................................. 67
		CENTER CONSOLE CONTROLS AND FEATURES.......................................... 69
			HOIST CONTROL LEVER....................................................... 70
		OPERATOR SEAT................................................................. 73
	INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 75
		CONTROL SYMBOLS............................................................... 75
	INSTRUMENT PANEL (FIGURE 3-7)..................................................... 76
	PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)..... 77
	OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-8)........................ 83
	INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-8  BY ROWS (A-E) AND COLUMNS (1-6).... 84
		HAZARD WARNING LIGHTS (7)..................................................... 90
		LAMP TEST SWITCH (8).......................................................... 90
	LINK-ON WARNINGS LIGHT............................................................ 90
MAINTENANCE........................................................................... 91
	LUBRICATION AND SERVICE........................................................... 91
		SERVICE CAPACITIES............................................................ 91
		HYDRAULIC TANK SERVICE........................................................ 91
		COOLANT LEVEL CHECK........................................................... 92
		RADIATOR FILING PROCEDURE..................................................... 92
		COOLING SYSTEM RECOMMENDATIONS................................................ 92
		RESERVE ENGINE OIL SYSTEM..................................................... 92
		LUBRICATION CHART............................................................. 93
		10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS............................ 94
		50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 96
		100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 97
		250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 98
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................100
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101
		2500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................102
		5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................102
	LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)................................103
		GENERAL DESCRIPTION...........................................................103
		SYSTEM COMPONENTS.............................................................105
		SYSTEM OPERATION..............................................................106
		INJECTOR OPERATION............................................................110
		INJECTORS.....................................................................111
		GENERAL INSTRUCTIONS..........................................................108
			LUBRICANT REQUIRED........................................................108
			SYSTEM PRIMING............................................................108
			FILTER ASSEMBLY...........................................................108
			LUBRICANT PUMP............................................................109
		SYSTEM CHECK -OUT.............................................................112
			LUBRICATION CYCLE TIMER CHECK.............................................112
		SYSTEM TROUBLESHOOTING CHART..................................................113
		PREVENTATIVE MAINTENANCE PROCEDURES...........................................116
SPECIFICATIONS........................................................................117
	MAJOR COMPONENT DESCRIPTIONS......................................................117
	SPECIFICATIONS....................................................................119
OPTIONAL EQUIPMENT....................................................................121
	PAYLOAD METER 3 (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX)..........................121
		OPERATION SECTION.............................................................123
		INTRODUCTION..................................................................123
		DATA SUMMARY..................................................................123
		DATA GATHERING................................................................123
		COMPONENT DESCRIPTION.........................................................124
			SYSTEM DIAGRAM............................................................124
			SUSPENSION PRESSURE SENSORS...............................................124
			INCLINOMETER..............................................................124
			OPERATOR DISPLAY..........................................................124
			OPERATOR SWITCH...........................................................125
			SPEED INPUT...............................................................125
			BODY-UP SWITCH............................................................125
			BRAKE LOCK SWITCH.........................................................125
			PAYLOAD METER.............................................................125
			COMMUNICATIONS PORTS......................................................125
			KEYSWITCH INPUT...........................................................126
			PAYLOAD METER POWER.......................................................126
			LOAD LIGHTS...............................................................126
			WIRING AND TERMINATION....................................................127
			TCI OUTPUTS...............................................................127
		OPERATOR DISPLAY AND SWITCH...................................................128
			READING THE SPEEDOMETER...................................................128
			READING THE LOAD DISPLAY..................................................128
			USING THE OPERATOR ID.....................................................128
			USING THE LOAD AND TON COUNTER............................................128
				TOTAL TON COUNTER.....................................................128
				TOTAL LOAD COUNTER....................................................129
				CLEARING THE COUNTERS.................................................129
			VIEWING LIVE SENSOR DATA..................................................129
			OTHER DISPLAY MESSAGES....................................................129
		PAYLOAD OPERATION & CALCULATION...............................................130
			DESCRIPTION OF HAUL CYCLE STATES..........................................130
				STATES OR STAGES OF A TYPICAL HAUL CYCLE..............................130
				HAUL CYCLE DESCRIPTION................................................130
			LOAD CALCULATION..........................................................131
			CARRY BACK................................................................131
			MEASUREMENT ACCURACY......................................................131
			SOURCES FOR PAYLOAD ERROR.................................................131
				PAYLOAD ERROR.........................................................131
				LOAD CONDITIONS.......................................................132
				PRESSURE SENSORS......................................................132
				SWING LOADS...........................................................132
				SPEED AND DISTANCE....................................................132
		HAUL CYCLE DATA...............................................................132
			HAUL CYCLE DATA...........................................................133
			HAUL CYCLE WARNING FLAGS..................................................134
			ALARM RECORDS.............................................................135
			FRAME TORQUE DATA.........................................................135
			SPRUNG WEIGHT DATA........................................................136
			MAXIMUM SPEED DATA........................................................136
		PC SOFTWARE OVERVIEW..........................................................136
			PC OVERVIEW...............................................................136
			SYSTEM CONFIGURATION......................................................136
			INSTALLING THE PAYLOAD METER 3 SOFTWARE...................................136
		DOWNLOADING DATA..............................................................137
		PLM3 SYSTEM CONFIGURATION.....................................................138
			STARTING COMMUNICATIONS...................................................138
				DISPLAYED PAYLOAD UNITS...............................................138
				TIME UNITS............................................................138
			CONNECTION MENU...........................................................138
			CONNECTING TO THE PAYLOAD METER...........................................139
			CONFIGURE THE PAYLOAD METER...............................................139
				SETTING THE DATA AND TIME.............................................139
				SETTING THE TRUCK TYPE................................................140
				SETTING THE GAUGE DISPLAY UNITS.......................................140
				SETTING THE FRAME SERIAL NUMBER.......................................140
				SETTING THE TRUCK NUMBER..............................................140
				SETTING THE KMS DISTRIBUTOR...........................................140
				SETTING THE KMS CUSTOMER..............................................140
			CLEAN TRUCK TARE..........................................................141
			INCLINOMETER CALIBRATION..................................................141
		DATA ANALYSIS.................................................................142
			CREATING A QUERY..........................................................142
				SORTING ON A TRUCK UNIT NUMBER........................................142
				SORTING ON A TRUCK TYPE...............................................142
				SORTING ON DATE RANGE.................................................143
				SORTING ON TIME RANGE.................................................143
			PAYLOAD DETAIL SCREEN.....................................................144
			CREATING REPORTS..........................................................144
				SUMMARY - ONE PAGE REPORT.............................................145
				DETAILED - MULTI-PAGE REPORT..........................................145
			CREATING GRAPHS...........................................................146
			EXPORTING DATA............................................................146
				CSV EXPORT............................................................146
				COMPRESSED............................................................147
			IMPORTING DATA............................................................148
			DELETING HAUL CYCLE RECORDS...............................................148
			VIEWING ALARMS............................................................149
			DELETING ALARM RECORDS....................................................149
	RADIO, AM/FM STERO CASSETTE.......................................................151

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