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Komatsu 930E-3SE Dump Truck Operation & Maintenance Manual SN A30366 & Up – PDF DOWNLOAD
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Komatsu 930E-3SE Dump Truck Operation & Maintenance Manual
SERIAL NUMBERS: A30366 & UP
Book Code : CEAM016000
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Description
Komatsu 930E-3SE Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 930E-3SE Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU 930E-3SE DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 170
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 930E-3SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30366 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 930E-3SE 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-3SE Dump Truck Operation & Maintenance Manual
MAIN MENU..................................................................... 0 COVER......................................................................... 1 FOREWORD...................................................................... 7 ALERTS PAGE............................................................... 8 TRUCK MODEL ILLUSTRATION.................................................. 16 ABOUT THIS MANUAL......................................................... 17 TABLE OF CONTENTS............................................................. 9 STANDARD CHARTS AND TABLES.................................................... 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...... 19 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Capscrews (SAE)........... 20 STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & 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.......................................... 57 AFTER STARTING THE ENGINE................................................. 58 Additional Guidelines................................................. 58 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 58 MACHINE OPERATION ON THE HAUL ROAD........................................ 59 STARTING ON A GRADE WITH A LOADED TRUCK................................... 60 PASSING................................................................... 60 LOADING................................................................... 60 DUMPING................................................................... 60 Raising The Dump Body................................................. 60 Lowering The Dump Body................................................ 61 TOWING.................................................................... 62 SAFE PARKING PROCEDURES................................................... 63 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 63 DELAYED ENGINE SHUTDOWN PROCEDURE......................................... 63 SUDDEN LOSS OF ENGINE POWER............................................... 64 DISABLED TRUCK DUMPING PROCEDURE.......................................... 65 Hookup................................................................ 65 Raising the Body...................................................... 65 Lowering the Body..................................................... 65 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 66 OPERATOR CAB AND CONTROLS..................................................... 67 STEERING WHEEL AND CONTROLS............................................... 68 Horn Button........................................................... 68 Tilt / Telescope Lever................................................ 68 Multi-Function Turn Signal Switch..................................... 68 DYNAMIC RETARDING......................................................... 69 Retarder Control Lever................................................ 69 Dynamic Retarder/Service Brake Pedal.................................. 69 Throttle/Accelerator Pedal............................................ 70 Starting on a Grade With a Loaded Truck............................... 70 GRADE/SPEED RETARD CHART.................................................. 70 OVERHEAD PANEL AND DISPLAYS............................................... 72 CENTER CONSOLE............................................................ 73 F-N-R Selector Switch................................................. 73 Hoist Control Lever................................................... 74 Raising The Dump Body................................................. 74 Lowering The Dump Body................................................ 74 Ash Tray.............................................................. 74 Lighter............................................................... 74 L.H. Window Control Switch............................................ 74 R.H. Window Control Switch............................................ 74 Engine Shutdown Switch................................................ 74 Override/Fault Reset Switch........................................... 75 Retard Speed Control (RSC) Switch..................................... 75 Retard Speed Control (RSC) Adjust Dial................................ 75 Data Store Button..................................................... 76 Engine Control System................................................. 76 Service Engine Light.................................................. 76 Engine Diagnostic Download Port....................................... 76 Payload Meter Port.................................................... 76 TCI Download Port..................................................... 76 Modular Mining System (Optional)...................................... 76 PSC Download Port..................................................... 76 Payload Meter And Download Connector.................................. 76 OPERATOR’S SEAT........................................................... 77 Adjustment............................................................ 77 Seat Removal.......................................................... 77 Seat Installation..................................................... 77 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................... 78 Heater/Air Conditioner Vents.......................................... 78 Defroster Control Switch.............................................. 78 Heat Control Switch................................................... 78 Temperature Control Knob.............................................. 78 Fan Control Knob...................................................... 78 Heater/Air Conditioner Selector Switch................................ 78 INSTRUMENT PANEL.......................................................... 79 Control Symbols....................................................... 79 Key Switch............................................................ 81 Starting.............................................................. 81 Engine Shutdown Switch with 5 Minute Idle Timer Delay................. 81 Fog Lights (Optional)................................................. 82 Ladder Light Switch................................................... 82 Manual Backup Switch.................................................. 82 Panel Illumination Lights............................................. 82 Cab/Air Conditioner Vents............................................. 82 Rotating Beacon Light Switch (Optional)............................... 82 Heated Mirror Switch (Optional)....................................... 82 Wheel Brake Lock Control.............................................. 83 Parking Brake Control................................................. 83 Tachometer............................................................ 83 Right Turn Signal Indicator........................................... 84 High Beam Indicator................................................... 84 Left Turn Signal Indicator............................................ 84 Speedometer/Payload Meter Display..................................... 84 Voltmeter............................................................. 84 Engine Oil Pressure Gauge............................................. 84 Water Temperature Gauge............................................... 84 Fuel Gauge............................................................ 84 AC Drive System Temperature Gauge..................................... 85 Hourmeter............................................................. 85 Hydraulic Oil Temperature Gauge....................................... 85 Rest Switch........................................................... 86 Light Switch.......................................................... 86 Panel Light Dimmer.................................................... 86 Payload Meter Switch.................................................. 86 OVERHEAD STATUS / WARNING INDICATORS...................................... 87 Status / Warning Indicator Light Symbols.............................. 88 Hazard Warning Lights................................................. 94 Lamp Test Switch...................................................... 94 Link-On Warning Light................................................. 94 VEHICLE HEALTH MONITORING SYSTEM (VHMS)................................... 95 Operation............................................................. 95 Interface Module...................................................... 96 Basic Precautions..................................................... 96 FUSE BLOCKS............................................................... 97 CIRCUIT BREAKERS.......................................................... 97 LUBRICATION AND SERVICE....................................................... 99 930E SERVICE CAPACITIES................................................... 99 HYDRAULIC TANK SERVICE.................................................... 99 Adding Oil............................................................ 99 WHEEL MOTOR SERVICE....................................................... 99 COOLANT LEVEL CHECK.......................................................100 RADIATOR FILLING PROCEDURE................................................100 RESERVE ENGINE OIL SYSTEM (Optional)......................................100 Reserve Oil Tank Filling Procedure (Remote fill)......................100 LUBRICATION CHART.........................................................101 10 HOUR (DAILY) INSPECTION................................................102 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................105 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................106 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................107 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................110 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................111 5000 HOUR MAINTENANCE CHECKS..............................................112 AUTOMATIC LUBRICATION SYSTEM..................................................113 GENERAL DESCRIPTION.......................................................113 SYSTEM COMPONENTS.........................................................115 SYSTEM OPERATION..........................................................116 Normal Operation......................................................116 Pressure Failure Detection Circuits...................................117 GENERAL INSTRUCTIONS......................................................118 Required Lubricant For System.........................................118 System Priming........................................................118 Filter Assembly.......................................................118 LUBRICANT PUMP............................................................119 Pump Housing Oil Level................................................119 Pump Pressure Control.................................................119 Pressure Control Valve Adjustment.....................................119 INJECTORS (SL-1 Series “H”)...............................................120 Injector Specifications...............................................120 Injector Adjustment...................................................120 INJECTOR OPERATION........................................................121 SYSTEM CHECKOUT...........................................................122 Lubrication Cycle Timer Check.........................................122 Lubrication Cycle Timer Adjustment....................................122 PREVENTIVE MAINTENANCE PROCEDURES.........................................123 Daily Lubrication System Inspection...................................123 250 Hour Inspection...................................................123 1000 Hour Inspection..................................................123 SYSTEM TROUBLESHOOTING CHART..............................................124 MAJOR COMPONENT DESCRIPTION...................................................127 PAYLOAD METER III™............................................................131 INDEX.....................................................................131 Introduction..............................................................133 Data Summary..........................................................133 Data Gathering........................................................133 COMPONENT DESCRIPTION.....................................................134 System Diagram........................................................134 Suspension Pressure Sensors...........................................134 Inclinometer..........................................................134 Operator Display......................................................134 Operator Switch.......................................................135 Speed Input...........................................................135 Body-Up Switch........................................................135 Brake Lock Switch.....................................................135 Payload Meter.........................................................135 Communications Ports..................................................135 Keyswitch Input.......................................................136 Payload Meter Power...................................................136 Load Lights...........................................................136 Wiring and Termination................................................137 TCI Outputs...........................................................137 OPERATOR’S DISPLAY AND SWITCH.............................................138 Reading the Speedometer...............................................138 Reading the Load Display..............................................138 Using the Operator ID.................................................138 Using the Load and Ton Counter........................................138 Total Ton Counter.....................................................138 Total Load Counter....................................................139 Clearing the Counters.................................................139 Viewing Live Sensor Data..............................................139 Other Display Messages................................................139 PAYLOAD OPERATION & CALCULATION...........................................140 Description of Haul Cycle States......................................140 Haul Cycle Description................................................140 Load Calculation......................................................141 Carry Back............................................................141 Measurement Accuracy..................................................141 SOURCES FOR PAYLOAD ERROR.................................................141 Payload Error.........................................................141 Loading Conditions....................................................142 Pressure Sensors......................................................142 Swingloads............................................................142 Speed and Distance....................................................142 HAUL CYCLE DATA...........................................................142 Haul Cycle Data.......................................................143 Haul Cycle Warning Flags..............................................144 M: Haul Cycle Too Long................................................145 N: Sensor Input Error.................................................145 Frame Torque Data.....................................................145 Sprung Weight Data....................................................145 Maximum Speed Data....................................................145 Alarm Records.........................................................145 Fault Code Data.......................................................146 PC SOFTWARE OVERVIEW......................................................147 PC Overview...........................................................147 System Configuration..................................................147 Installing the PLMIII Software........................................147 DOWNLOADING DATA..........................................................148 PLM III SYSTEM CONFIGURATION..............................................149 Starting Communications...............................................149 Displayed Payload Units...............................................149 Time Units............................................................149 Connection Menu.......................................................149 Connecting to the Payload Meter.......................................150 Configure the Payload Meter...........................................150 Setting the Date and Time.............................................150 Setting the Truck Type................................................151 Setting the Gauge Display Units.......................................151 Setting the Frame Serial Number.......................................151 Setting the Truck Number..............................................151 Setting the Komatsu Distributor.......................................151 Setting the Komatsu Customer..........................................151 Clean Truck Tare......................................................152 Inclinometer Calibration..............................................152 DATA ANALYSIS.............................................................153 Creating a Query......................................................153 Sorting on Truck Unit Number..........................................153 Sorting on Truck Type.................................................153 Sorting on Date Range.................................................154 Sorting on Time Range.................................................154 Payload Detail Screen.................................................155 Creating Reports......................................................155 Summary - one page report.............................................156 Detailed - multi-page report..........................................156 Creating Graphs.......................................................157 Exporting Data........................................................157 CSV Export............................................................157 Compressed............................................................158 Importing Data........................................................159 Deleting Haul Cycle Records...........................................159 Viewing Alarms........................................................160 Deleting Alarm Records................................................160 RADIO / CASSETTE PLAYER.......................................................163 GENERAL RECEIVER FUNCTIONS................................................163 Turning The Power On And Off..........................................163 Display...............................................................163 Setting The Default Display...........................................163 Adjusting Display Brightness..........................................163 SETTING THE TIME..........................................................164 OPERATING THE RADIO.......................................................164 BAND..................................................................164 TUNE/SEEK.............................................................164 Manual Tuning.........................................................164 SEEK Mode.............................................................164 SCAN..................................................................164 AUTO..................................................................164 ADJUSTING THE RECEIVER SETTINGS...........................................165 PROGRAMMING PRESET STATIONS...............................................165 OPERATION OF THE WEATHERBAND (U.S.).......................................165 SATELLITE RADIO...........................................................166 Operating Satellite Radio.............................................166 Program Type Search (PTY).............................................166 CASSETTE PLAYER...........................................................167 Playing A Cassette....................................................167 Cassette Functions....................................................167 Progrommable Eject Default............................................167 Bad Tape Detect.......................................................168 Cleaning The Cassette Player..........................................168
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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