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KOMATSU 930E-2 DUMP TRUCK Operation & Maintenance Manual (SN:A30300 thru A30303) KOMATSU 930E 2 – PDF DOWNLOAD
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- KOMATSU 930E-2 DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30300 thru A30303
- PUBLICATION NUMBER:CEAM012100
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Description
KOMATSU 930E-2 DUMP TRUCK Operation & Maintenance Manual (SN:A30300 thru A30303) KOMATSU 930E 2
KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30300 THRU A30303) KOMATSU 930E 2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-2 DUMP TRUCK Operation & Maintenance Manual (SN:A30300 thru A30303) 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) GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 930E-2 DUMP TRUCK Operation & Maintenance Manual (SN:A30300 thru A30303) KOMATSU 930E 2
MAIN MENU..................................................................................... 0 COVER......................................................................................... 1 SECTION 10 - INTRODUCTION .................................................................... 6 FOREWORD.................................................................................. 6 ALERTS PAGE............................................................................... 7 TABLE OF CONTENTS......................................................................... 8 TRUCK MODEL ILLUSTRATION.................................................................. 15 ABOUT THIS MANUAL......................................................................... 16 SECTION 12 - STANDARD CHARTS AND TABLES....................................................... 18 SECTION 20 - 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 Avoid 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 SECTION 22 - WARNINGS AND CAUTIONS............................................................ 44 SECTION 30 - 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 SECTION 32 - 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 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..................................... 78 Heater/Air Conditioner Vents...................................................... 78 Defroster Control Switch.......................................................... 78 Heat Control Switch............................................................... 78 Temperature Control Knob.......................................................... 78 Fan Control Knob.................................................................. 78 Heater/Air Conditioner Selector Switch............................................ 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 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 SECTION 40 - 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 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................................108 2500 HOUR MAINTENANCE CHECKS..............................................................109 5000 HOUR MAINTENANCE CHECKS..............................................................109 SECTION 42 - 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 SECTION 50 - MAJOR COMPONENT DESCRIPTION......................................................124 SECTION 60 - PAYLOAD METER III - 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 SECTION 70 - 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
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
