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KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30601 – A30692) KOMATSU 930E-4 – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30601 – A30692
- PUBLICATION NUMBER:CEAM019604
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Description
KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30601 – A30692) KOMATSU 930E-4
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30601 – A30692) KOMATSU 930E-4 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30601 – A30692) KOMATSU 930E-4
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information 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 the truck or performing repairs on the truck.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system.
The letter “E”, when present, designates an Electrical wheel motor drive system. - The Product Identification Number (vehicle serial number) contains information which identifies 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 maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30601 – A30692) KOMATSU 930E-4
COVER.......................................................................... 1 INTRODUCTION................................................................... 5 FOREWORD................................................................... 5 TRUCK MODEL ILLUSTRATION................................................... 6 ABOUT THIS MANUAL.......................................................... 7 ALERTS PAGE................................................................ 8 TABLE OF CONTENTS.............................................................. 9 TORQUE TABLES AND CONVERSION CHARTS............................................ 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values....... 20 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts...... 20 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws......... 21 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws..................... 22 SAFETY......................................................................... 29 GENERAL.................................................................... 29 Safety Rules........................................................... 29 Safety Features........................................................ 29 Fire Extinguisher And First Aid Kit.................................... 29 Clothing And Personal Items............................................ 29 Leaving The Operator’s Seat............................................ 30 Mounting And Dismounting............................................... 30 Fire Prevention For Fuel And Oil....................................... 30 Precautions With High Temperature Fluids............................... 31 Asbestos Dust Hazard Prevention........................................ 31 Prevention Of Injury By Work Equipment................................. 31 Unauthorized Modification.............................................. 31 ROPS Precautions....................................................... 31 Precautions For Attachments............................................ 32 Precautions For Starting The Truck..................................... 32 PRECAUTIONS BEFORE OPERATION............................................... 32 Safety At The Worksite................................................. 32 Fire Prevention........................................................ 33 Ventilation In Enclosed Areas.......................................... 33 Preparing For Operation................................................ 33 Mirrors, Windows And Lights............................................ 33 In The Operator Cab (Before Starting The Engine)....................... 33 Seat Belts............................................................. 33 OPERATING THE TRUCK........................................................ 34 When Starting The Engine............................................... 34 General Truck Operation................................................ 34 Ensuring Good Visibility............................................... 34 Traveling.............................................................. 35 Traveling In Reverse................................................... 35 Traveling On Slopes.................................................... 35 Operating On Snow Or Ice............................................... 35 Avoid Damage To The Dump Body.......................................... 35 Driving Near High Voltage Cables....................................... 36 Working On Loose Ground................................................ 36 When Dumping........................................................... 36 When Loading........................................................... 36 Parking The Truck...................................................... 36 Towing................................................................. 36 WORKING NEAR BATTERIES..................................................... 37 Battery Hazard Prevention.............................................. 37 Starting With Booster Cables........................................... 37 BEFORE PERFORMING MAINTENANCE.............................................. 38 Stopping The Engine.................................................... 38 Warning Tag............................................................ 38 Proper Tools........................................................... 38 Securing The Dump Body................................................. 38 WHILE PERFORMING MAINTENANCE............................................... 39 Keep The Truck Clean................................................... 39 Attachments............................................................ 39 Working Under The Truck................................................ 39 Rotating Fan And Belts................................................. 39 Waste Materials........................................................ 39 Adding Fuel Or Oil..................................................... 40 Radiator Coolant Level................................................. 40 Use Of Lighting........................................................ 40 Precautions With The Battery........................................... 40 Handling High Pressure Hoses........................................... 40 Precautions With High Pressure Oil..................................... 40 Performing Maintenance Near High Temperature Or High Pressure.......... 40 TIRES...................................................................... 41 Handling Tires......................................................... 41 Storing Tires After Removal............................................ 41 WHEN REPAIRS ARE NECESSARY................................................. 42 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS......................... 43 PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE........ 43 ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE..... 43 CAPACITOR DISCHARGE SYSTEM............................................. 45 Necessary Tools.................................................... 45 Warnings And Cautions.............................................. 46 Manual DC Link Capacitor Discharge Procedure....................... 47 Failure of the Discharge System.................................... 49 Manual Discharge of Capacitors..................................... 50 Short Isolated Capacitor Terminals................................. 52 ADDITIONAL JOB SITE RULES.............................................. 54 WARNINGS AND CAUTIONS.......................................................... 55 GRADE/SPEED CHART.......................................................... 55 KEY SWITCH................................................................. 55 ROPS/FOPS.................................................................. 55 BATTERIES.................................................................. 56 CAPACITORS................................................................. 56 CRUSHING HAZARD............................................................ 57 CYLINDER PRESSURE.......................................................... 57 FILLING THE HYDRAULIC TANK................................................. 58 HYDRAULIC OIL PRESSURE..................................................... 58 HOT OIL SPRAY.............................................................. 59 WHEEL MOTOR OIL LEVEL...................................................... 59 HOT EXHAUST................................................................ 59 RADIATOR................................................................... 59 EMERGENCY LADDER........................................................... 59 ACCUMULATOR DRAIN VALVES................................................... 59 EMERGENCY DUMP PROCEDURE................................................... 60 EMERGENCY TOWING PROCEDURE................................................. 60 WELDING.................................................................... 60 EMERGENCY SHUTDOWN......................................................... 60 INFORMATION DISPLAY........................................................ 61 WIRELESS SIGNALS........................................................... 61 HIGH VOLTAGE............................................................... 61 LIFTING INSTRUCTIONS....................................................... 62 PRODUCT IDENTIFICATION PLATE............................................... 63 LUBRICATION CHART.......................................................... 64 OPERATING INSTRUCTIONS......................................................... 65 PREPARING FOR OPERATION.................................................... 65 WALK AROUND INSPECTION..................................................... 65 ENGINE START-UP............................................................ 69 AFTER ENGINE START-UP...................................................... 70 PRE-SHIFT BRAKE CHECK (if equipped)........................................ 70 Events................................................................. 70 OPERATION.............................................................. 71 Description........................................................ 71 Brake Test Exit Criteria........................................... 71 PERFORMING THE BRAKE TESTS............................................. 72 Setup.............................................................. 72 Service Brake Test................................................. 72 Parking Brake Test................................................. 73 Retard System Test................................................. 74 EMERGENCY STEERING SYSTEM.................................................. 74 Operation.............................................................. 74 Pre-Operation Testing.................................................. 74 MACHINE OPERATION SAFETY PRECAUTIONS....................................... 75 OPERATING ON THE HAUL ROAD................................................. 76 STARTING ON A GRADE WITH A LOADED TRUCK.................................... 77 PASSING.................................................................... 77 LOADING.................................................................... 77 Overload Speed Limit Function.......................................... 77 DUMPING.................................................................... 78 Raising The Dump Body.................................................. 78 Lowering The Dump Body (When dumping on flat ground)................... 79 Lowering The Dump Body (When dumping over a berm or into a crusher).... 79 TOWING..................................................................... 80 Special Wiring Harness................................................. 80 SAFE PARKING PROCEDURES.................................................... 83 NORMAL ENGINE SHUTDOWN PROCEDURE........................................... 83 SUDDEN LOSS OF ENGINE POWER................................................ 84 FUEL DEPLETION............................................................. 84 DISABLED TRUCK DUMPING PROCEDURE........................................... 85 Hookup................................................................. 85 Raising the Body....................................................... 85 Lowering the Body...................................................... 85 RESERVE ENGINE OIL SYSTEM.................................................. 86 Operation.............................................................. 86 Changing Oil........................................................... 86 OPERATOR CAB AND CONTROLS...................................................... 87 STEERING WHEEL AND CONTROLS................................................ 88 Horn Button............................................................ 88 Tilt / Telescope Lever................................................. 88 Multi-Function Turn Signal Switch...................................... 88 DYNAMIC RETARDING.......................................................... 89 Retarder Lever......................................................... 89 Brake/Retarder Pedal................................................... 89 Throttle/Accelerator Pedal............................................. 89 GRADE/SPEED CHART.......................................................... 90 OVERHEAD PANEL AND DISPLAYS................................................ 91 CENTER CONSOLE............................................................. 92 Directional Control Lever.............................................. 92 Override/Fault Reset Switch............................................ 93 Engine Shutdown Switch................................................. 93 Window Control Switches................................................ 93 Hoist Control Lever.................................................... 93 Retard Speed Control (RSC) Adjustment Dial............................. 94 Retard Speed Control (RSC) Switch...................................... 94 Data Store Button...................................................... 95 KOMTRAX Plus Snapshot In Progress Light................................ 95 Link Energized Light................................................... 95 Service Engine Light................................................... 95 12V Auxiliary Power Outlets............................................ 95 DIAGNOSTIC PORTS........................................................... 95 KOMTRAX Plus Diagnostic Port........................................... 95 Interface Module (IM) Diagnostic Port.................................. 95 Payload Meter Diagnostic Port.......................................... 95 Truck Control Interface (TCI) Diagnostic Port.......................... 95 Propulsion System Controller (PSC) Diagnostic Port..................... 95 Engine Diagnostic Port (CENSE)......................................... 95 Engine Diagnostic Port (QUANTUM)....................................... 95 OPERATOR’S SEAT............................................................ 96 Seat Belts............................................................. 96 Adjustment............................................................. 96 HEATER / AIR CONDITIONER CONTROLS.......................................... 97 Fan Speed Control Knob................................................. 97 Temperature Control Knob............................................... 97 Air Flow Directional Knob.............................................. 97 Heater/Air Conditioner Vents........................................... 97 INSTRUMENT PANEL........................................................... 98 Control Symbols........................................................ 98 Key Switch.............................................................100 Air Conditioner Compressor Switch......................................100 Rotating Beacon Light Switch (optional)................................100 Heated Mirror Switch (optional)........................................100 AC Drive System Rest Switch............................................100 Wheel Brake Lock Switch................................................101 Hazard Warning Light Switch............................................101 Heater/Air Conditioner Vents...........................................101 Engine Oil Pressure Gauge..............................................101 Right Turn Signal Indicator............................................101 Digital Tachometer.....................................................101 High Beam Indicator....................................................101 Speedometer/Payload Meter Display......................................101 Left Turn Signal Indicator.............................................102 Coolant Temperature Gauge..............................................102 Lamp Check Switch......................................................102 Light Switch (3-Way)...................................................102 Ladder Light Switch....................................................102 Backup Light Switch....................................................102 Fog Light Switch.......................................................103 Payload Meter Switch...................................................103 Panel Illumination Light Dimmer Switch.................................103 Hydraulic Oil Temperature Gauge........................................103 Engine Hourmeter.......................................................103 Fuel Gauge.............................................................103 OVERHEAD STATUS / WARNING INDICATORS.......................................104 A1. High Brake Oil Temperature.........................................105 B1. Low Steering Pressure..............................................105 C1. Low Accumulator Precharge Pressure.................................106 D1. Not used...........................................................106 E1. Low Brake Pressure.................................................106 A2. Low Hydraulic Tank Level...........................................106 B2. Low Automatic Lubrication System Pressure..........................106 C2. Circuit Breaker Tripped............................................106 D2. Hydraulic Oil Filter Monitor.......................................107 E2. Low Fuel...........................................................107 A3. Parking Brake......................................................107 B3. Service Brake......................................................107 C3. Body Up............................................................107 D3. Dynamic Retarding..................................................107 E3. Stop Engine........................................................107 A4. Cranking Motor Failure.............................................108 B4. Backup Lights......................................................108 C4. Engine Shutdown Timer..............................................108 D4. Retard Speed Control (RSC) Indicator...............................108 E4. Check Engine.......................................................108 A5. No Power...........................................................108 B5. Propulsion System Warning..........................................108 C5. Propulsion System Temperature......................................108 D5. System/Component Failure...........................................109 E5. Battery Charging System Failure....................................109 A6. No Propel..........................................................109 B6. Propel System At Rest..............................................109 C6. Propel System Not Ready............................................109 D6. Reduced Propulsion.................................................109 E6. Retard At Continuous Level.........................................109 REAR AXLE LIGHT BAR........................................................110 Backup Lights..........................................................110 Retard Lights..........................................................110 Brake Lights...........................................................110 Backup Alarm...........................................................110 KOMTRAX PLUS...............................................................111 Operation..............................................................111 Interface Module.......................................................113 Basic Precautions......................................................113 KOMATSU WIRELESS BRIDGE (Optional).........................................114 General Information....................................................114 Communication Setup....................................................114 Switching to the KWB_SETUP Network.....................................114 Setting the Computer Subnet Mask and IP Address........................115 Properties.............................................................115 Setting Up the KWB.....................................................116 Adding Encryption......................................................116 Final Computer Settings................................................116 Data Downloading.......................................................117 Resetting the KWB......................................................117 KWB Lights.............................................................117 FUSES AND CIRCUIT BREAKERS.................................................118 LUBRICATION AND SERVICE........................................................121 GENERAL....................................................................121 SERVICE CAPACITIES.........................................................121 HYDRAULIC TANK SERVICE.....................................................121 Adding Oil.............................................................121 COOLING SYSTEM SERVICE.....................................................122 Radiator Filling Procedure.............................................122 Coolant Specifications.................................................122 Unacceptable Practices.................................................122 WHEEL MOTOR SERVICE........................................................122 RESERVE OIL TANK SERVICE...................................................123 Filling the Reserve Oil Tank (Remote Fill).............................123 Inline Screen..........................................................123 QUICK FILL SERVICE CENTER..................................................124 LUBRICATION CHART..........................................................125 10 HOUR (DAILY) INSPECTIONS................................................126 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................128 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................128 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................128 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................131 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................133 5000 HOUR MAINTENANCE CHECKS...............................................133 AUTOMATIC LUBRICATION SYSTEM...................................................135 GENERAL DESCRIPTION........................................................135 SYSTEM COMPONENTS..........................................................137 Filter.................................................................137 Hydraulic Motor and Pump...............................................137 Grease Reservoir.......................................................137 Pressure Reducing Valve................................................137 Flow Control Valve.....................................................137 Solenoid Valve.........................................................137 Vent Valve.............................................................137 Lubrication Cycle Timer................................................137 Over Pressure Cut Off Switch...........................................137 Grease Pressure Failure Switch.........................................137 Injectors..............................................................137 Relief Valve (unloader valve)..........................................137 SYSTEM OPERATION...........................................................138 Normal Operation.......................................................138 GENERAL INSTRUCTIONS.......................................................139 Lubricant Required For System..........................................139 System Priming.........................................................139 Filter Assembly........................................................139 LUBRICANT PUMP.............................................................140 Pump Housing Oil Level.................................................140 Pump Pressure Control..................................................140 INJECTORS (SL-1 Series “H”)................................................141 Injector Specifications................................................141 Injector Adjustment....................................................141 Injector Operation.....................................................142 PREVENTIVE MAINTENANCE PROCEDURES..........................................143 Daily Lubrication System Inspection....................................143 250 Hour Inspection....................................................143 1000 Hour Inspection...................................................143 SYSTEM CHECKOUT............................................................144 Lubrication Controller Check...........................................144 Lubrication Controller Components......................................144 Lubrication Controller Adjustment......................................144 SYSTEM TROUBLESHOOTING CHART...............................................146 COMPONENTS & SPECIFICATIONS....................................................149 MAJOR COMPONENT DESCRIPTIONS...............................................149 Truck And Engine.......................................................149 Main Alternator........................................................149 AC Induction Traction Motorized Wheels.................................149 Suspension.............................................................149 Operator's Cab.........................................................149 Power Steering.........................................................149 Dynamic Retarding......................................................149 Brake System...........................................................149 SPECIFICATIONS.............................................................151 ENGINE.................................................................151 AC ELECTRIC DRIVE SYSTEM...............................................151 DYNAMIC RETARDING......................................................151 BATTERY ELECTRIC SYSTEM................................................151 SERVICE CAPACITIES.....................................................151 HYDRAULIC SYSTEMS......................................................152 SERVICE BRAKES.........................................................152 STEERING...............................................................152 TIRES..................................................................152 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS...........................152 WEIGHT DISTRIBUTION....................................................153 PAYLOAD METER III..............................................................155 AM/FM RADIO / CD PLAYER........................................................185 GENERAL RADIO RECEIVER FUNCTIONS...........................................185 Turning On the Power...................................................185 One-Hour Timer.........................................................185 Display................................................................186 Setting a Default Display..............................................186 Adjusting the Brightness of the Display................................186 Auxiliary Mode.........................................................186 Adjusting the Receiver Settings........................................186 USING THE CLOCK............................................................187 Setting the Clock......................................................187 USING THE ALARM............................................................187 Setting the Alarm......................................................187 Turning the Alarm Off..................................................187 Activating Snooze......................................................187 Setting Alarm Volume...................................................187 USING THE RADIO............................................................188 Finding a Station......................................................188 Setting the Presets....................................................188 USING THE WEATHERBAND......................................................189 USING THE COMPACT DISC PLAYER..............................................189 Playing a Compact Disc.................................................189 Button Functions.......................................................189 PLAYING AN MP3 DISC........................................................190 MP3 Format Compatibility...............................................190 Root Directory.........................................................190 Empty Directory or Folder..............................................190 No Folder..............................................................190 File Name Display......................................................190 Pre-Programmed Playlists...............................................191 Playing MP3 Files......................................................191 Button Functions.......................................................191 TROUBLESHOOTING............................................................192
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