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Komatsu 930E-3 Dump Truck Operation & Maintenance Manual A30364-A30461 – PDF DOWNLOAD
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Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
SERIAL NUMBERS : A30364 – A30461
Book Code: CEAM015901
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Description
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
Language : English
Pages : 170
Downloadable : Yes
File Type : PDF
Size: 2.44MB
Book Code: CEAM015901
KOMATSU 930E-3 DUMP TRUCK OPERATION & MAINTENANCE MANUAL A30364-A30461 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
FOREWORD:
- This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
- All operators and maintenance personnel should read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when operating or accomplishing repairs on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
The letter “E”, when present, designates an Electrical wheel motor drive system.
The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
MAIN MENU..................................................................... 0 COVER......................................................................... 1 INTRODUCTION.................................................................. 7 FOREWORD.................................................................. 7 TRUCK MODEL ILLUSTRATION.................................................. 8 ABOUT THIS MANUAL......................................................... 9 ALERTS PAGE............................................................... 10 TABLE OF CONTENTS............................................................. 11 STANDARD CHARTS AND TABLES.................................................... 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...... 19 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE).......... 20 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts....... 20 GENERAL SAFETY................................................................ 25 Safety Rules.............................................................. 25 Truck Safety Features..................................................... 25 Clothing And Personal Items............................................... 25 Unauthorized Modification................................................. 25 Leaving The Operator’s Seat............................................... 25 Mounting And Dismounting.................................................. 25 Fire Extinguishers And First Aid Kits..................................... 26 Precautions For High Temperature Fluids................................... 26 Asbestos Dust Hazard Prevention........................................... 26 Fire Prevention For Fuel And Oil.......................................... 26 ROPS Precautions.......................................................... 27 Preventing Injury From Work Equipment..................................... 27 Precautions For Optional Attachments...................................... 27 Precautions When Starting The Machine..................................... 27 PRECAUTIONS FOR TRUCK OPERATION........................................... 28 Safety Is Thinking Ahead.............................................. 28 Safety At The Worksite................................................ 28 Fire Prevention....................................................... 28 Preparing For Operation............................................... 28 Ventilation For Enclosed Areas........................................ 28 Mirrors, Windows, And Lights.......................................... 28 In The Operator’s Cab - Before Starting The Engine.................... 29 OPERATING THE MACHINE..................................................... 29 Starting The Engine................................................... 29 Truck Operation - General............................................. 29 Traveling In The Truck................................................ 30 Precautions When Traveling In Reverse................................. 30 Traveling On Slopes................................................... 30 Ensuring Good Visibility.............................................. 31 Operating On Snow..................................................... 31 Avoid Damage To The Dump Body......................................... 31 Driving Near High Voltage Cables...................................... 31 When Loading The Truck................................................ 31 When Dumping.......................................................... 31 Working On Loose Ground............................................... 31 Parking The Machine................................................... 32 TOWING.................................................................... 32 WORKING NEAR BATTERIES.................................................... 32 Jump Starting With Booster Cables..................................... 32 PRECAUTIONS FOR MAINTENANCE............................................... 33 BEFORE PERFORMING MAINTENANCE......................................... 33 Stopping The Engine Before Service................................ 33 Warning Tag....................................................... 33 Proper Tools...................................................... 33 Securing The Dump Body............................................ 33 DURING MAINTENANCE.................................................... 34 Personnel......................................................... 34 Attachments....................................................... 34 Working Under The Machine......................................... 34 Keeping The Machine Clean......................................... 34 Rules To Follow When Adding Fuel Or Oil........................... 34 Radiator Coolant Level............................................ 34 Use Of Lighting................................................... 34 Precautions With The Battery...................................... 35 Handling High Pressure Hoses...................................... 35 Precautions With High Pressure Oil................................ 35 Maintenance Near High Temperatures And High Pressures............. 35 Rotating Fan And Belts............................................ 35 Waste Materials................................................... 35 TIRES................................................................. 36 Handling Tires.................................................... 36 Storing Tires After Removal....................................... 36 ADDITIONAL JOB SITE RULES................................................. 37 WHEN REPAIRS ARE NECESSARY................................................ 38 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................... 39 Preliminary Procedures before Welding or Performing Maintenance....... 39 Normal Engine Shutdown Procedure...................................... 39 Engine Shutdown Procedure before Welding or Performing Maintenance.... 39 WARNINGS AND CAUTIONS......................................................... 43 TRUCK OPERATION............................................................... 53 PREPARING FOR OPERATION................................................... 53 Safety Is Thinking Ahead.............................................. 53 WALK AROUND INSPECTION.................................................... 53 ENGINE START-UP SAFETY PRACTICES.......................................... 56 AFTER STARTING THE ENGINE................................................. 57 Additional Guidelines................................................. 57 EMERGENCY STEERING SYSTEM................................................. 58 Operation............................................................. 58 Pre-Operation Testing................................................. 58 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 59 MACHINE OPERATION ON THE HAUL ROAD........................................ 60 STARTING ON A GRADE WITH A LOADED TRUCK................................... 60 PASSING................................................................... 60 LOADING................................................................... 61 DUMPING................................................................... 61 Raising The Dump Body................................................. 61 Lowering The Dump Body................................................ 62 TOWING.................................................................... 63 SAFE PARKING PROCEDURES................................................... 63 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 64 DELAYED ENGINE SHUTDOWN PROCEDURE......................................... 64 SUDDEN LOSS OF ENGINE POWER............................................... 65 DISABLED TRUCK DUMPING PROCEDURE.......................................... 66 Hookup................................................................ 66 Raising the Body...................................................... 66 Lowering the Body..................................................... 66 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 67 OPERATOR CAB AND CONTROLS..................................................... 69 STEERING WHEEL AND CONTROLS............................................... 70 Horn Button........................................................... 70 Tilt / Telescope Lever................................................ 70 Multi-Function Turn Signal Switch..................................... 70 DYNAMIC RETARDING......................................................... 71 Retarder Control Lever................................................ 71 Dynamic Retarder/Service Brake Pedal.................................. 71 Throttle/Accelerator Pedal............................................ 72 Starting on a Grade With a Loaded Truck............................... 72 GRADE/SPEED RETARD CHART.................................................. 72 OVERHEAD PANEL AND DISPLAYS............................................... 74 CENTER CONSOLE............................................................ 75 F-N-R Selector Switch................................................. 75 Hoist Control Lever................................................... 76 Raising The Dump Body................................................. 76 Lowering The Dump Body................................................ 76 Ash Tray.............................................................. 76 Lighter............................................................... 76 L.H. Window Control Switch............................................ 76 R.H. Window Control Switch............................................ 76 Engine Shutdown Switch................................................ 76 Override/Fault Reset Switch........................................... 77 Retard Speed Control (RSC) Switch..................................... 77 Retard Speed Control (RSC) Adjust Dial................................ 77 Data Store Button..................................................... 78 Engine Control System................................................. 78 Service Engine Light.................................................. 78 Engine Diagnostic Download Port....................................... 78 Payload Meter Port.................................................... 78 TCI Download Port..................................................... 78 Modular Mining System (Optional)...................................... 78 PSC Download Port..................................................... 78 Payload Meter And Download Connector.................................. 78 OPERATOR’S SEAT........................................................... 79 Adjustment............................................................ 79 Seat Removal.......................................................... 79 Seat Installation..................................................... 79 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................... 80 Heater/Air Conditioner Vents.......................................... 80 Defroster Control Switch.............................................. 80 Heat Control Switch................................................... 80 Temperature Control Knob.............................................. 80 Fan Control Knob...................................................... 80 Heater/Air Conditioner Selector Switch................................ 80 INSTRUMENT PANEL.......................................................... 81 Control Symbols....................................................... 81 Key Switch............................................................ 83 Starting.............................................................. 83 Engine Shutdown Switch with 5 Minute Idle Timer Delay................. 83 Fog Lights (Optional)................................................. 84 Ladder Light Switch................................................... 84 Manual Backup Switch.................................................. 84 Panel Illumination Lights............................................. 84 Cab/Air Conditioner Vents............................................. 84 Rotating Beacon Light Switch (Optional)............................... 84 Heated Mirror Switch (Optional)....................................... 84 Wheel Brake Lock Control.............................................. 85 Parking Brake Control................................................. 85 Tachometer............................................................ 85 Right Turn Signal Indicator........................................... 86 High Beam Indicator................................................... 86 Left Turn Signal Indicator............................................ 86 Speedometer/Payload Meter Display..................................... 86 Voltmeter............................................................. 86 Engine Oil Pressure Gauge............................................. 86 Water Temperature Gauge............................................... 86 Fuel Gauge............................................................ 86 AC Drive System Temperature Gauge..................................... 87 Hourmeter............................................................. 87 Hydraulic Oil Temperature Gauge....................................... 87 Rest Switch........................................................... 88 Light Switch.......................................................... 88 Panel Light Dimmer.................................................... 88 Payload Meter Switch.................................................. 88 OVERHEAD STATUS / WARNING INDICATORS...................................... 89 Status / Warning Indicator Light Symbols.............................. 90 Hazard Warning Lights................................................. 96 Lamp Test Switch...................................................... 96 Link-On Warning Light................................................. 96 VEHICLE HEALTH MONITORING SYSTEM (VHMS)................................... 97 Operation............................................................. 97 Interface Module...................................................... 98 Basic Precautions..................................................... 98 FUSE BLOCKS............................................................... 99 CIRCUIT BREAKERS.......................................................... 99 LUBRICATION AND SERVICE.......................................................101 GENERAL...................................................................101 930E SERVICE CAPACITIES...................................................101 HYDRAULIC TANK SERVICE....................................................101 Adding Hydraulic Oil..................................................101 WHEEL MOTOR SERVICE.......................................................101 COOLING SYSTEM SERVICE....................................................102 Radiator Filling Procedure............................................102 RESERVE ENGINE OIL SYSTEM.................................................102 Reserve Oil Tank Filling Procedure (Remote Fill)......................102 LUBRICATION CHART.........................................................103 10 HOUR (DAILY) INSPECTIONS...............................................104 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................106 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................106 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................106 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................109 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................110 5000 HOUR MAINTENANCE CHECKS..............................................110 AUTOMATIC LUBRICATION SYSTEM..................................................111 GENERAL DESCRIPTION.......................................................111 SYSTEM COMPONENTS.........................................................113 Filter................................................................113 Hydraulic Motor and Pump..............................................113 Grease Reservoir......................................................113 Pressure Reducing Valve...............................................113 Flow Control Valve....................................................113 Solenoid Valve........................................................113 Vent Valve............................................................113 Lubrication Cycle Timer...............................................113 Time Delay Module.....................................................113 Pump Cutoff Pressure Switch...........................................113 Grease Pressure Failure Switch........................................113 Pressure Gauge........................................................113 Injectors.............................................................113 SYSTEM OPERATION..........................................................114 Normal Operation......................................................114 Pressure Failure Detection Circuits...................................115 System Priming........................................................116 Filter Assembly.......................................................116 LUBRICANT PUMP............................................................117 Pump Housing Oil Level................................................117 Pump Pressure Control.................................................117 Pressure Control Valve Adjustment.....................................117 INJECTORS (SL-1 Series “H”))..............................................118 Injector Specifications...............................................118 Injector Adjustment...................................................118 INJECTOR OPERATION........................................................119 SYSTEM CHECKOUT...........................................................120 Lubrication Cycle Timer Check.........................................120 Lubrication Cycle Timer Adjustment....................................120 PREVENTIVE MAINTENANCE PROCEDURES.........................................121 Daily Lubrication System Inspection...................................121 250 Hour Inspection...................................................121 1000 Hour Inspection..................................................121 SYSTEM TROUBLESHOOTING CHART..............................................122 COMPONENTS & SPECIFICATIONS...................................................125 MAJOR COMPONENT DESCRIPTIONS..............................................125 Truck And Engine......................................................125 Alternator (GE-GTA41).................................................125 AC Induction Traction Motorized Wheels................................125 Suspension............................................................125 Operator's Cab........................................................125 Power Steering........................................................125 Dynamic Retarding.....................................................125 Brake System..........................................................125 SPECIFICATIONS............................................................127 ENGINE................................................................127 AC ELECTRIC DRIVE SYSTEM..............................................127 DYNAMIC RETARDING.....................................................127 BATTERY ELECTRIC SYSTEM...............................................127 SERVICE CAPACITIES....................................................127 HYDRAULIC SYSTEMS.....................................................127 SERVICE BRAKES........................................................127 STEERING..............................................................127 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS..........................128 TIRES.................................................................128 WEIGHT DISTRIBUTION...................................................128 Loaded Vehicle........................................................128 PAYLOAD METER III™............................................................129 INDEX.....................................................................129 Introduction..............................................................131 Data Summary..........................................................131 Data Gathering........................................................131 COMPONENT DESCRIPTION.....................................................132 System Diagram........................................................132 Suspension Pressure Sensors...........................................132 Inclinometer..........................................................132 Operator Display......................................................132 Operator Switch.......................................................133 Speed Input...........................................................133 Body-Up Switch........................................................133 Brake Lock Switch.....................................................133 Payload Meter.........................................................133 Communications Ports..................................................133 Key Switch Input......................................................134 Payload Meter Power...................................................134 Load Lights...........................................................134 Wiring and Termination................................................135 TCI Outputs...........................................................135 OPERATOR’S DISPLAY AND SWITCH.............................................136 Reading the Speedometer...............................................136 Reading the Load Display..............................................136 Using the Operator ID.................................................136 Using the Load and Ton Counter........................................136 Total Ton Counter.....................................................136 Total Load Counter....................................................137 Clearing the Counters.................................................137 Viewing Live Sensor Data..............................................137 Other Display Messages................................................137 PAYLOAD OPERATION & CALCULATION...........................................138 Haul Cycle States.....................................................138 Haul Cycle Description................................................138 Load Calculation......................................................139 Carry Back............................................................139 Measurement Accuracy..................................................139 SOURCES FOR PAYLOAD ERROR.................................................139 Payload Error.........................................................139 Loading Conditions....................................................140 Pressure Sensors......................................................140 Swingloads............................................................140 Speed and Distance....................................................140 HAUL CYCLE DATA...........................................................140 Haul Cycle Data.......................................................141 Haul Cycle Warning Flags..............................................142 Frame Torque Data.....................................................143 Sprung Weight Data....................................................143 Maximum Speed Data....................................................143 Alarm Records.........................................................143 Fault Code Data.......................................................144 PC SOFTWARE OVERVIEW......................................................145 PC Overview...........................................................145 System Configuration..................................................145 Installing the PLMIII Software........................................145 DOWNLOADING DATA..........................................................146 PLM III SYSTEM CONFIGURATION..............................................147 Starting Communications...............................................147 Displayed Payload Units...............................................147 Time Units............................................................147 Connection Menu.......................................................147 Connecting to the Payload Meter.......................................148 Configure the Payload Meter...........................................148 Setting the Date and Time.............................................148 Setting the Truck Type................................................149 Setting the Gauge Display Units.......................................149 Setting the Frame Serial Number.......................................149 Setting the Truck Number..............................................149 Setting the Komatsu Distributor.......................................149 Setting the Komatsu Customer..........................................149 Clean Truck Tare......................................................150 Inclinometer Calibration..............................................150 DATA ANALYSIS.............................................................151 Creating a Query......................................................151 Sorting on Truck Unit Number..........................................151 Sorting on Truck Type.................................................151 Sorting on Date Range.................................................152 Sorting on Time Range.................................................152 Payload Detail Screen.................................................153 Creating Reports......................................................153 Summary - one page report.............................................154 Detailed - multi-page report..........................................154 Creating Graphs.......................................................155 Exporting Data........................................................155 CSV Export............................................................155 Compressed............................................................156 Importing Data........................................................157 Deleting Haul Cycle Records...........................................157 Viewing Alarms........................................................158 Deleting Alarm Records................................................158 RADIO / CASSETTE PLAYER.......................................................161 GENERAL RECEIVER FUNCTIONS................................................161 Turning The Power On And Off..........................................161 Display...............................................................161 Setting The Default Display...........................................161 Adjusting Display Brightness..........................................161 SETTING THE TIME..........................................................162 OPERATING THE RADIO.......................................................162 BAND..................................................................162 TUNE/SEEK.............................................................162 Manual Tuning.........................................................162 SEEK Mode.............................................................162 SCAN..................................................................162 AUTO..................................................................162 ADJUSTING THE RECEIVER SETTINGS...........................................163 PROGRAMMING PRESET STATIONS...............................................163 OPERATION OF THE WEATHERBAND (U.S.).......................................163 SATELLITE RADIO...........................................................164 Operating Satellite Radio.............................................164 Program Type Search (PTY).............................................164 CASSETTE PLAYER...........................................................165 Playing A Cassette....................................................165 Cassette Functions....................................................165 Programmable Eject Default............................................165 Bad Tape Detect.......................................................166 Cleaning The Cassette Player..........................................166
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Orlando Walker –
ok ,but will no more once I review the product.