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Komatsu 930E-3 Dump Truck Operation & Maintenance Manual SN A30304 – A30309 – PDF DOWNLOAD
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Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
Book Code : CEAM010200
MACHINE MODEL SERIAL NUMBERS
930E-3 A30304 – A30309
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Description
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU 930E-3 DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 166
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 930E-3 DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30304 – A30309 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
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. 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.
TABLE OF CONTENTS:
Komatsu 930E-3 Dump Truck Operation & Maintenance Manual
MAIN MENU..................................................................................... 0 COVER......................................................................................... 1 INTRODUCTION.................................................................................. 7 FOREWORD.................................................................................. 7 ALERTS PAGE............................................................................... 8 TABLE OF CONTENTS......................................................................... 9 TRUCK MODEL ILLUSTRATION.................................................................. 16 ABOUT THIS MANUAL......................................................................... 17 STANDARD CHARTS AND TABLES................................................................ 19 SAFETY........................................................................................ 25 SAFETY.................................................................................... 25 Safety Rules.......................................................................... 25 Safety Features....................................................................... 25 Clothing And Personal Items........................................................... 25 Unauthorized Modification............................................................. 25 Leaving The Operator’s Seat........................................................... 26 Mounting And Dismounting.............................................................. 26 Fire Prevention For Fuel And Oil...................................................... 26 Precautions With High Temperature Fluids.............................................. 27 Asbestos Dust Hazard Prevention....................................................... 27 Prevention Of Injury By Work Equipment................................................ 27 Fire Extinguisher And First Aid Kit................................................... 27 Precautions When Using ROPS........................................................... 28 Precautions For Attachments........................................................... 28 Precautions For Starting Machine...................................................... 28 PRECAUTIONS DURING OPERATION.............................................................. 29 Safety Is Thinking Ahead.............................................................. 29 Safety At The Worksite................................................................ 29 Fire Prevention....................................................................... 29 Preparing For Operation............................................................... 29 Ventilation In Enclosed Areas......................................................... 29 In Operator’s Cab - Before Starting The Engine........................................ 30 Mirrors, Windows, And Lights.......................................................... 30 OPERATING THE MACHINE................................................................. 30 When Starting The Engine.......................................................... 30 Truck Operation - General......................................................... 30 Check When Traveling In Reverse................................................... 31 Traveling......................................................................... 31 Traveling On Slopes............................................................... 32 Ensure Good Visibility............................................................ 32 Operate Carefully On Snow......................................................... 32 Avoid Damage To Dump Body......................................................... 32 Driving Near High Voltage Cables.................................................. 32 When Dumping...................................................................... 33 Working On Loose Ground........................................................... 33 When Loading...................................................................... 33 Parking The Machine............................................................... 33 TOWING................................................................................ 33 WORKING NEAR BATTERIES................................................................ 34 Battery Hazard Prevention......................................................... 34 Starting With Booster Cables...................................................... 34 PRECAUTIONS FOR MAINTENANCE............................................................... 35 BEFORE PERFORMING MAINTENANCE......................................................... 35 Warning Tag....................................................................... 35 Proper Tools...................................................................... 35 Stopping The Engine Before Service................................................ 35 Securing The Dump Body............................................................ 35 DURING MAINTENANCE.................................................................... 36 Personnel......................................................................... 36 Attachments....................................................................... 36 Working Under The Machine......................................................... 36 Keep The Machine Clean............................................................ 36 Rules To Follow When Adding Fuel Or Oil........................................... 36 Radiator Water Level.............................................................. 37 Use Of Lighting................................................................... 37 Precautions With The Battery...................................................... 37 Handling High Pressure Hoses...................................................... 37 Precautions With High Pressure Oil................................................ 37 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 38 Rotating Fan And Belts............................................................ 38 Waste Materials................................................................... 38 TIRES................................................................................. 39 Handling Tires.................................................................... 39 Storing Tires After Removal....................................................... 39 ADDITIONAL JOB SITE RULES................................................................. 40 WHEN REPAIRS ARE NECESSARY................................................................ 41 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK........................................... 42 Preliminary Procedures Before Welding or Performing Maintenance....................... 42 Normal Engine Shutdown Procedure...................................................... 42 Engine Shutdown Procedure Before Welding or Performing Maintenance.................... 43 WARNINGS AND CAUTIONS..................................................................... 45 OPERATION..................................................................................... 55 OPERATING INSTRUCTIONS.................................................................... 55 PREPARING FOR OPERATION............................................................... 55 Safety Is Thinking Ahead.......................................................... 55 At The Truck - Ground Level Walk Around Inspection................................ 55 ENGINE START-UP SAFETY PRACTICES...................................................... 58 Cold Weather Starting............................................................. 59 AFTER ENGINE HAS STARTED.............................................................. 59 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 60 MACHINE OPERATION ON THE HAUL ROAD.................................................... 60 STARTING ON A GRADE WITH A LOADED TRUCK............................................... 61 PASSING............................................................................... 61 LOADING............................................................................... 61 DUMPING............................................................................... 62 Raising The Dump Body............................................................. 62 Lowering The Dump Body............................................................ 62 TOWING................................................................................ 64 SAFE PARKING PROCEDURES............................................................... 64 NORMAL ENGINE SHUTDOWN PROCEDURE...................................................... 64 DELAYED ENGINE SHUTDOWN PROCEDURE..................................................... 65 SUDDEN LOSS OF ENGINE POWER........................................................... 66 RESERVE ENGINE OIL SYSTEM (Optional).................................................. 67 OPERATOR CAB AND CONTROLS................................................................. 69 STEERING WHEEL AND CONTROLS........................................................... 70 Horn Button....................................................................... 70 Telescope Lock Ring............................................................... 70 Tilt Wheel Lever.................................................................. 70 Turn Signal/Headlight Dimmer...................................................... 70 DYNAMIC RETARDING..................................................................... 70 Retarder Control Lever............................................................ 71 Dynamic Retarder/Service Brake Pedal.............................................. 71 Accelerator (Throttle) Pedal...................................................... 71 Starting on a Grade With a Loaded Truck........................................... 71 GRADE/SPEED RETARD CHART.............................................................. 72 INSTRUMENT PANEL...................................................................... 73 OVERHEAD PANEL AND DISPLAYS........................................................... 73 CENTER CONSOLE........................................................................ 74 F-N-R Selector Switch............................................................. 74 Hoist Control Lever............................................................... 75 Raising The Dump Body............................................................. 75 Lowering The Dump Body:........................................................... 75 Ash Tray.......................................................................... 75 Lighter........................................................................... 75 L.H. Window Control Switch........................................................ 75 R.H. Window Control Switch........................................................ 75 Engine Shutdown Switch............................................................ 75 Override/Fault Reset Switch....................................................... 76 Retard Speed Control (RSC) Switch................................................. 76 Retard Speed Control (RSC) Adjust Dial............................................ 76 Data Store Button................................................................. 77 Engine Control System............................................................. 77 Service Engine Light (Blue)....................................................... 77 Engine Diagnostic Download Port................................................... 77 Payload Meter..................................................................... 77 TCI Download Port................................................................. 77 Modular Mining System (Optional).................................................. 77 PSC Download Port................................................................. 77 Payload Meter And Download Connector.............................................. 77 OPERATOR COMFORT...................................................................... 78 OPERATOR SEAT..................................................................... 78 Adjustment.................................................................... 78 Seat Removal.................................................................. 78 Seat Installation............................................................. 78 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS................................. 79 Heater/Air Conditioner Vents.................................................. 79 Defroster Control Switch...................................................... 79 Heat Control Switch........................................................... 79 Temperature Control Knob...................................................... 79 Fan Control Knob.............................................................. 79 Heater/Air Conditioner Selector Switch........................................ 79 INSTRUMENT PANEL AND INDICATOR LIGHTS..................................................... 81 CONTROL SYMBOLS....................................................................... 81 INSTRUMENT PANEL...................................................................... 81 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7)...................................... 83 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........................................................................... 87 Light Switch.......................................................................... 88 Windshield Wiper and Washer........................................................... 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 MAINTENANCE................................................................................... 97 LUBRICATION AND SERVICE................................................................... 97 930E SERVICE CAPACITIES............................................................... 97 HYDRAULIC TANK SERVICE................................................................ 97 Adding Oil........................................................................ 97 WHEEL MOTOR SERVICE................................................................... 97 COOLANT LEVEL CHECK................................................................... 98 RADIATOR FILLING PROCEDURE............................................................ 98 RESERVE ENGINE OIL SYSTEM (Optional).................................................. 98 Reserve Oil Tank Filling Procedure (Remote fill).................................. 98 LUBRICATION CHART..................................................................... 99 10 HOUR (DAILY) INSPECTION............................................................100 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................103 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................104 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................105 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................108 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.........................................109 2500 HOUR MAINTENANCE CHECKS..........................................................110 5000 HOUR MAINTENANCE CHECKS..........................................................110 AUTOMATIC LUBRICATION SYSTEM..............................................................111 GENERAL DESCRIPTION...................................................................111 SYSTEM COMPONENTS.....................................................................113 System Operation..................................................................114 Normal Operation..................................................................114 Pressure Failure Detection Circuits...............................................115 GENERAL INSTRUCTIONS..................................................................116 Lubricant Required For System.....................................................116 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 SYSTEM TROUBLESHOOTING CHART..........................................................121 PREVENTATIVE MAINTENANCE PROCEDURES...................................................123 Daily Lubrication System Inspection...............................................123 250 Hour Inspection...............................................................123 1000 Hour Inspection..............................................................123 MAJOR COMPONENT DESCRIPTION...................................................................125 OPTIONAL EQUIPMENT............................................................................129 PAYLOAD METER III.........................................................................129 OPERATION SECTION.....................................................................131 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 Keyswitch 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 Description of 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 A: Continuous Loading.............................................................142 B: Loading to Dumping Transition..................................................142 C: No Final Load..................................................................142 D: Maneuvering to Dumping Transition..............................................142 E: Average Load or Tare Used......................................................142 F: Final Zone to Dumping Transition...............................................142 H: False Body Up..................................................................142 I: Body Up Signal Failed..........................................................142 J: Speed Sensor Failed............................................................142 K: New Tare Not Calculated........................................................142 L: Incomplete Haul Cycle..........................................................142 M: Haul Cycle Too Long............................................................143 N: Sensor Input Error.............................................................143 Alarm Records.....................................................................143 Frame Torque Data.................................................................143 Sprung Weight Data................................................................144 Maximum Speed Data................................................................144 PC SOFTWARE OVERVIEW..................................................................144 PC Overview.......................................................................144 System Configuration..............................................................144 Installing the PLMIII Software....................................................144 DOWNLOADING DATA......................................................................145 PLMIII SYSTEM CONFIGURATION...........................................................146 Starting Communications...........................................................146 Displayed Payload Units...........................................................146 Time Units........................................................................146 Connection Menu...................................................................146 Connecting to the Payload Meter...................................................147 Configure the Payload Meter.......................................................147 Setting the Date and Time.........................................................147 Setting the Truck Type............................................................148 Setting the Gauge Display Units...................................................148 Setting the Frame Serial Number...................................................148 Setting the Truck Number..........................................................148 Setting the Komatsu Distributor...................................................148 Setting the Komatsu Customer......................................................148 Clean Truck Tare..................................................................149 Inclinometer Calibration..........................................................149 DATA ANALYSIS.........................................................................150 Sorting on Truck Unit Number......................................................150 Creating a Query..................................................................150 Sorting on Truck Type.............................................................150 Sorting on Date Range.............................................................151 Sorting on Time Range.............................................................151 Payload Detail Screen.............................................................152 Creating Reports..................................................................152 Summary - one page report.........................................................153 Detailed - multi-page report......................................................153 Creating Graphs...................................................................154 Exporting Data....................................................................154 CSV Export........................................................................154 Compressed........................................................................155 To export data in ZIP format:.....................................................156 Importing Data....................................................................156 Deleting Haul Cycle Records.......................................................156 Viewing Alarms....................................................................157 Deleting Alarm Records............................................................157 RADIO, AM / FM STEREO CASSETTE............................................................159 SETTING THE TIME......................................................................159 GENERAL RECEIVER FUNCTIONS............................................................159 Turning The Power On And Off......................................................159 Display...........................................................................159 Setting The Default Display.......................................................160 Adjusting Display Brightness......................................................160 OPERATING THE RADIO...................................................................160 BAND..............................................................................160 TUNE/SEEK.........................................................................160 Manual Tuning.....................................................................160 SEEK Mode.........................................................................160 SCAN..............................................................................160 AUTO..............................................................................160 ADJUSTING THE RECEIVER SETTINGS.......................................................161 PROGRAMMING PRESET STATIONS...........................................................161 OPERATION OF THE WEATHERBAND (U.S.)...................................................161 SATELLITE RADIO.......................................................................162 Operating Satellite Radio.........................................................162 Program Type Search (PTY).........................................................162 CASSETTE PLAYER.......................................................................163 Playing A Cassette................................................................163 Cassette Functions................................................................163 PROGRAMMABLE EJECT DEFAULT............................................................163 Bad Tape Detect...................................................................164 CASSETTE PLAYER CLEANING..............................................................164
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