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KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30750 – A30872 Tier II) KOMATSU 930E-4 – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30750 – A30872 Tier II
- PUBLICATION NUMBER:CEAM021405
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Description
KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30750 – A30872 Tier II) KOMATSU 930E-4
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30750 – A30872 TIER II) KOMATSU 930E-4 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK Operation & Maintenance Manual (SN:A30750 – A30872 Tier II) 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:A30750 – A30872 Tier II) 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 PASSENGER SEAT............................................................. 97 Seat Belts............................................................. 97 Adjustment............................................................. 97 HEATER / AIR CONDITIONER CONTROLS.......................................... 98 Fan Speed Control Knob................................................. 98 Temperature Control Knob............................................... 98 Air Flow Directional Knob.............................................. 98 Heater/Air Conditioner Vents........................................... 98 INSTRUMENT PANEL........................................................... 99 Control Symbols........................................................ 99 Key Switch.............................................................101 Rotating Beacon Light Switch (optional)................................101 Heated Mirror Switch (optional)........................................101 AC Drive System Rest Switch............................................101 Wheel Brake Lock Switch................................................102 Hazard Warning Light Switch............................................102 Heater/Air Conditioner Vents...........................................102 Engine Oil Pressure Gauge..............................................102 Right Turn Signal Indicator............................................102 Digital Tachometer.....................................................102 High Beam Indicator....................................................102 Speedometer/Payload Meter Display......................................102 Left Turn Signal Indicator.............................................103 Coolant Temperature Gauge..............................................103 Lamp Check Switch......................................................103 Light Switch (3-Way)...................................................103 Ladder Light Switch....................................................103 Backup Light Switch....................................................103 Fog Light Switch.......................................................104 Payload Meter Switch...................................................104 Panel Illumination Light Dimmer Switch.................................104 Hydraulic Oil Temperature Gauge........................................104 Engine Hourmeter.......................................................104 Fuel Gauge.............................................................104 OVERHEAD STATUS / WARNING INDICATORS.......................................105 A1. High Brake Oil Temperature.........................................106 B1. Low Steering Pressure..............................................106 C1. Low Accumulator Precharge Pressure.................................107 D1. Not used...........................................................107 E1. Low Brake Pressure.................................................107 A2. Low Hydraulic Tank Level...........................................107 B2. Low Automatic Lubrication System Pressure..........................107 C2. Circuit Breaker Tripped............................................107 D2. Hydraulic Oil Filter Monitor.......................................108 E2. Low Fuel...........................................................108 A3. Parking Brake......................................................108 B3. Service Brake......................................................108 C3. Body Up............................................................108 D3. Dynamic Retarding..................................................108 E3. Stop Engine........................................................109 A4. Cranking Motor Failure.............................................109 B4. Backup Lights......................................................109 C4. Engine Shutdown Timer..............................................109 D4. Retard Speed Control (RSC) Indicator...............................109 E4. Check Engine.......................................................109 A5. No Power...........................................................110 B5. Propulsion System Warning..........................................110 C5. Propulsion System Temperature......................................110 D5. System/Component Failure...........................................110 E5. Battery Charging System Failure....................................110 A6. No Propel..........................................................110 B6. Propel System At Rest..............................................110 C6. Propel System Not Ready............................................111 D6. Reduced Propulsion.................................................111 E6. Retard At Continuous Level.........................................111 D7. Brake Test Light...................................................111 E7. Maintenance Monitor................................................111 8. Brake Test Switch...................................................111 REAR AXLE LIGHT BAR........................................................112 Backup Lights..........................................................112 Retard Lights..........................................................112 Brake Lights...........................................................112 Backup Alarm...........................................................112 KOMTRAX PLUS...............................................................113 Operation..............................................................113 Interface Module.......................................................115 Basic Precautions......................................................115 KOMATSU WIRELESS BRIDGE (Optional).........................................116 General Information....................................................116 Communication Setup....................................................116 Switching to the KWB_SETUP Network.....................................116 Setting the Computer Subnet Mask and IP Address........................117 Properties.............................................................117 Setting Up the KWB.....................................................118 Adding Encryption......................................................118 Final Computer Settings................................................118 Data Downloading.......................................................119 Resetting the KWB......................................................119 KWB Lights.............................................................119 FUSES AND CIRCUIT BREAKERS.................................................120 LUBRICATION AND SERVICE........................................................125 GENERAL....................................................................125 SERVICE CAPACITIES.........................................................125 HYDRAULIC TANK SERVICE.....................................................125 Adding Oil.............................................................125 COOLING SYSTEM SERVICE.....................................................126 Radiator Filling Procedure.............................................126 Coolant Specifications.................................................126 Unacceptable Practices.................................................126 WHEEL MOTOR SERVICE........................................................126 RESERVE OIL TANK SERVICE...................................................127 Filling the Reserve Oil Tank (Remote Fill).............................127 Inline Screen..........................................................127 QUICK FILL SERVICE CENTER..................................................128 LUBRICATION CHART..........................................................129 10 HOUR (DAILY) INSPECTIONS................................................130 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................133 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................133 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................133 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................136 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................138 5000 HOUR MAINTENANCE CHECKS...............................................138 AUTOMATIC LUBRICATION SYSTEM...................................................139 GENERAL DESCRIPTION........................................................139 SYSTEM COMPONENTS..........................................................141 Filter.................................................................141 Hydraulic Motor and Pump...............................................141 Grease Reservoir.......................................................141 Pressure Reducing Valve................................................141 Flow Control Valve.....................................................141 Solenoid Valve.........................................................141 Vent Valve.............................................................141 Lubrication Cycle Timer................................................141 Over Pressure Cut Off Switch...........................................141 Grease Pressure Failure Switch.........................................141 Injectors..............................................................141 Relief Valve (unloader valve)..........................................141 SYSTEM OPERATION...........................................................142 Normal Operation.......................................................142 GENERAL INSTRUCTIONS.......................................................143 Lubricant Required For System..........................................143 System Priming.........................................................143 Filter Assembly........................................................143 LUBRICANT PUMP.............................................................144 Pump Housing Oil Level.................................................144 Pump Pressure Control..................................................144 INJECTORS (SL-1 Series “H”)................................................145 Injector Specifications................................................145 Injector Adjustment....................................................145 Injector Operation.....................................................146 PREVENTIVE MAINTENANCE PROCEDURES..........................................147 Daily Lubrication System Inspection....................................147 250 Hour Inspection....................................................147 1000 Hour Inspection...................................................147 SYSTEM CHECKOUT............................................................148 Lubrication Controller Check...........................................148 Lubrication Controller Components......................................148 Lubrication Controller Adjustment......................................148 SYSTEM TROUBLESHOOTING CHART...............................................150 COMPONENTS & SPECIFICATIONS....................................................153 MAJOR COMPONENT DESCRIPTIONS...............................................153 Truck And Engine.......................................................153 Main Alternator........................................................153 AC Induction Traction Motorized Wheels.................................153 Suspension.............................................................153 Operator's Cab.........................................................153 Power Steering.........................................................153 Dynamic Retarding......................................................153 Brake System...........................................................153 SPECIFICATIONS.............................................................155 ENGINE.................................................................155 AC ELECTRIC DRIVE SYSTEM...............................................155 DYNAMIC RETARDING......................................................155 BATTERY ELECTRIC SYSTEM................................................155 SERVICE CAPACITIES.....................................................155 HYDRAULIC SYSTEMS......................................................156 SERVICE BRAKES.........................................................156 STEERING...............................................................156 TIRES..................................................................156 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS...........................156 WEIGHT DISTRIBUTION....................................................157 PAYLOAD METER III..............................................................159 AM/FM RADIO / CD PLAYER........................................................189 GENERAL RADIO RECEIVER FUNCTIONS...........................................189 Turning On the Power...................................................189 One-Hour Timer.........................................................189 Display................................................................190 Setting a Default Display..............................................190 Adjusting the Brightness of the Display................................190 Auxiliary Mode.........................................................190 Adjusting the Receiver Settings........................................190 USING THE CLOCK............................................................191 Setting the Clock......................................................191 USING THE ALARM............................................................191 Setting the Alarm......................................................191 Turning the Alarm Off..................................................191 Activating Snooze......................................................191 Setting Alarm Volume...................................................191 USING THE RADIO............................................................192 Finding a Station......................................................192 Setting the Presets....................................................192 USING THE WEATHERBAND......................................................193 USING THE COMPACT DISC PLAYER..............................................193 Playing a Compact Disc.................................................193 Button Functions.......................................................193 PLAYING AN MP3 DISC........................................................194 MP3 Format Compatibility...............................................194 Root Directory.........................................................194 Empty Directory or Folder..............................................194 No Folder..............................................................194 File Name Display......................................................194 Pre-Programmed Playlists...............................................195 Playing MP3 Files......................................................195 Button Functions.......................................................195 TROUBLESHOOTING............................................................196
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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