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KOMATSU 930E-3 DUMP TRUCK Operation & Maintenance Manual (SN:A30329 – A30363) KOMATSU 930E-3 – PDF DOWNLOAD
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- KOMATSU 930E-3 DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30329 – A30363
- PUBLICATION NUMBER:CEAM014600
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Description
KOMATSU 930E-3 DUMP TRUCK Operation & Maintenance Manual (SN:A30329 – A30363) KOMATSU 930E-3
KOMATSU 930E-3 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30329 – A30363) KOMATSU 930E-3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-3 DUMP TRUCK Operation & Maintenance Manual (SN:A30329 – A30363) KOMATSU 930E-3
- 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-3 DUMP TRUCK Operation & Maintenance Manual (SN:A30329 – A30363) KOMATSU 930E-3
MAIN MENU......................................................................................... 0 COVER............................................................................................. 1 SECTION 10 - INTRODUCTION......................................................................... 6 FOREWORD...................................................................................... 6 ALERTS PAGE................................................................................... 7 TRUCK MODEL ILLUSTRATION...................................................................... 15 ABOUT THIS MANUAL............................................................................. 16 TABLE OF CONTENTS................................................................................. 8 SECTION 12 - STANDARD CHARTS AND TABLES........................................................... 18 SECTION 20 - SAFETY............................................................................... 24 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 For Starting Machine.......................................................... 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 DISABLED TRUCK DUMPING PROCEDURE.............................................................. 66 Hookup.................................................................................... 66 DUMPING PROCEDURE......................................................................... 66 Raising the Body.......................................................................... 66 Lowering the Body......................................................................... 66 RESERVE ENGINE OIL SYSTEM (Optional).......................................................... 67 SECTION 32 - OPERATOR CAB AND CONTROLS............................................................ 68 STEERING WHEEL AND CONTROLS................................................................... 69 Horn Button............................................................................... 69 Telescope Lock Ring....................................................................... 69 Tilt Wheel Lever.......................................................................... 69 Multi-Function Turn Signal Switch......................................................... 69 DYNAMIC RETARDING............................................................................. 70 Retarder Control Lever.................................................................... 70 Dynamic Retarder/Service Brake Pedal...................................................... 70 Accelerator (Throttle) Pedal.............................................................. 71 Starting on a Grade With a Loaded Truck................................................... 71 GRADE/SPEED RETARD CHART...................................................................... 71 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...................................................................... 77 Engine Diagnostic Download Port........................................................... 77 Payload Meter Port........................................................................ 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......................................................... 80 CONTROL SYMBOLS........................................................................... 80 INSTRUMENT PANEL.......................................................................... 80 PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7).......................................... 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............................................................................... 87 Light Switch.............................................................................. 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 FUSE BLOCKS............................................................................... 96 CIRCUIT BREAKERS.......................................................................... 96 SECTION 40 - LUBRICATION AND SERVICE.............................................................. 98 930E SERVICE CAPACITIES....................................................................... 98 HYDRAULIC TANK SERVICE........................................................................ 98 Adding Oil................................................................................ 98 WHEEL MOTOR SERVICE........................................................................... 98 COOLANT LEVEL CHECK........................................................................... 99 RADIATOR FILLING PROCEDURE.................................................................... 99 RESERVE ENGINE OIL SYSTEM (Optional).......................................................... 99 Reserve Oil Tank Filling Procedure (Remote fill).......................................... 99 LUBRICATION CHART.............................................................................100 10 HOUR (DAILY) INSPECTION....................................................................101 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................................104 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................105 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................106 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................................109 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................................110 2500 HOUR MAINTENANCE CHECKS..................................................................111 5000 HOUR MAINTENANCE CHECKS..................................................................111 SECTION 42 - AUTOMATIC LUBRICATION SYSTEM.........................................................112 GENERAL DESCRIPTION...........................................................................112 SYSTEM COMPONENTS.............................................................................114 Filter....................................................................................114 Hydraulic Motor and Pump..................................................................114 Grease Reservoir..........................................................................114 Pressure Reducing Valve...................................................................114 Flow Control Valve........................................................................114 Solenoid Valve............................................................................114 Vent Valve................................................................................114 Lubrication Cycle Timer...................................................................114 Time Delay Module.........................................................................114 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])..................................114 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])...............................114 Pressure Gauge............................................................................114 Injectors.................................................................................114 SYSTEM OPERATION..............................................................................115 Pressure Failure Detection Circuits.......................................................116 GENERAL INSTRUCTIONS..........................................................................117 Required Lubricant For System.............................................................117 System Priming............................................................................117 Filter Assembly...........................................................................117 LUBRICANT PUMP................................................................................118 Pump Housing Oil Level....................................................................118 Pump Pressure Control.....................................................................118 Pressure Control Valve Adjustment.........................................................118 INJECTORS (SL-1 Series “H”))..................................................................119 Injector Specifications...................................................................119 Injector Adjustment.......................................................................119 INJECTOR OPERATION............................................................................120 SYSTEM CHECKOUT...............................................................................121 Lubrication Cycle Timer Check.............................................................121 Lubrication Cycle Timer Adjustment........................................................121 SYSTEM TROUBLESHOOTING CHART..................................................................122 PREVENTATIVE MAINTENANCE PROCEDURES...........................................................124 Daily Lubrication System Inspection.......................................................124 250 Hour Inspection.......................................................................124 1000 Hour Inspection......................................................................124 SECTION 50 - MAJOR COMPONENT DESCRIPTION..........................................................126 SECTION 60 - PAYLOAD METER III INDEX..............................................................130 OPERATION SECTION.............................................................................132 Introduction..............................................................................132 Data Summary..............................................................................132 Data Gathering............................................................................132 COMPONENT DESCRIPTION.........................................................................133 System Diagram............................................................................133 Suspension Pressure Sensors...............................................................133 Inclinometer..............................................................................133 Operator Display..........................................................................133 Operator Switch...........................................................................134 Speed Input...............................................................................134 Body-Up Switch............................................................................134 Brake Lock Switch.........................................................................134 Payload Meter.............................................................................134 Communications Ports......................................................................134 Keyswitch Input...........................................................................135 Payload Meter Power.......................................................................135 Load Lights...............................................................................135 Wiring and Termination....................................................................136 TCI Outputs...............................................................................136 OPERATOR’S DISPLAY AND SWITCH.................................................................137 Reading the Speedometer...................................................................137 Reading the Load Display..................................................................137 Using the Operator ID.....................................................................137 Using the Load and Ton Counter............................................................137 Total Ton Counter.........................................................................137 Total Load Counter........................................................................138 Clearing the Counters.....................................................................138 Viewing Live Sensor Data..................................................................138 Other Display Messages....................................................................138 PAYLOAD OPERATION & CALCULATION...............................................................139 Description of Haul Cycle States..........................................................139 Haul Cycle Description....................................................................139 Load Calculation..........................................................................140 Carry Back................................................................................140 Measurement Accuracy......................................................................140 SOURCES FOR PAYLOAD ERROR.....................................................................140 Payload Error.............................................................................140 Loading Conditions........................................................................141 Pressure Sensors..........................................................................141 Swingloads................................................................................141 Speed and Distance........................................................................141 HAUL CYCLE DATA...............................................................................141 Haul Cycle Data...........................................................................142 Haul Cycle Warning Flags..................................................................143 A: Continuous Loading.....................................................................143 B: Loading to Dumping Transition..........................................................143 C: No Final Load..........................................................................143 D: Maneuvering to Dumping Transition......................................................143 E: Average Load or Tare Used..............................................................143 F: Final Zone to Dumping Transition.......................................................143 H: False Body Up..........................................................................143 I: Body Up Signal Failed..................................................................143 J: Speed Sensor Failed....................................................................143 K: New Tare Not Calculated................................................................143 L: Incomplete Haul Cycle..................................................................143 M: Haul Cycle Too Long....................................................................144 N: Sensor Input Error.....................................................................144 Alarm Records.............................................................................144 Frame Torque Data.........................................................................144 Sprung Weight Data........................................................................145 Maximum Speed Data........................................................................145 PC SOFTWARE OVERVIEW..........................................................................145 PC Overview...............................................................................145 System Configuration......................................................................145 Installing the PLMIII Software............................................................145 DOWNLOADING DATA..............................................................................146 PLMIII 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 Sorting on Truck Unit Number..............................................................151 Creating a Query..........................................................................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 To export data in ZIP format:.............................................................157 Importing Data............................................................................157 Deleting Haul Cycle Records...............................................................157 Viewing Alarms............................................................................158 Deleting Alarm Records....................................................................158 SECTION 70 - RADIO, AM / FM STEREO CASSETTE.......................................................160 SETTING THE TIME..............................................................................160 GENERAL RECEIVER FUNCTIONS....................................................................160 Turning The Power On And Off..............................................................160 Display...................................................................................160 Setting The Default Display...............................................................161 Adjusting Display Brightness..............................................................161 OPERATING THE RADIO...........................................................................161 BAND......................................................................................161 TUNE/SEEK.................................................................................161 Manual Tuning.............................................................................161 SEEK Mode.................................................................................161 SCAN......................................................................................161 AUTO......................................................................................161 ADJUSTING THE RECEIVER SETTINGS...............................................................162 PROGRAMMING PRESET STATIONS...................................................................162 OPERATION OF THE WEATHERBAND (U.S.)...........................................................162 SATELLITE RADIO...............................................................................163 Operating Satellite Radio.................................................................163 Program Type Search (PTY).................................................................163 CASSETTE PLAYER...............................................................................164 Playing A Cassette........................................................................164 Cassette Functions........................................................................164 PROGRAMMABLE EJECT DEFAULT....................................................................164 Bad Tape Detect...........................................................................165 CASSETTE PLAYER CLEANING......................................................................165
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
