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KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT) – PDF DOWNLOAD
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- KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- Serial Number:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT
- Publication Number:CEAM024302
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Description
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT)
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT)
- 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.
- To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30990 & UP U.S.A. EPA TIER 2 & TIER 4 COMPLIANT)
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 RETRACTABLE LADDER SYSTEM (Optional)....................................... 69 Description............................................................ 69 Normal Operation....................................................... 69 General Safety......................................................... 69 IN-CAB CONTROL PANEL....................................................... 70 Digital Display Screen................................................. 70 Command Buttons........................................................ 70 USING THE IN-CAB CONTROL PANEL............................................. 71 Raising the Ladder..................................................... 72 Lowering the Ladder.................................................... 72 USING THE GROUND LEVEL CONTROL BOX......................................... 73 Raising the Ladder..................................................... 73 Lowering the Ladder.................................................... 73 EMERGENCY OPERATION........................................................ 73 ENGINE START-UP............................................................ 74 AFTER ENGINE START-UP...................................................... 75 PRE-SHIFT BRAKE CHECK...................................................... 75 Events................................................................. 75 OPERATION.................................................................. 76 Description............................................................ 76 Brake Test Exit Criteria............................................... 76 PERFORMING THE BRAKE TESTS................................................. 77 Setup.................................................................. 77 Service Brake Test..................................................... 77 Parking Brake Test..................................................... 78 Retard System Test..................................................... 79 EMERGENCY STEERING SYSTEM.................................................. 79 Operation.............................................................. 79 Pre-Operation Testing.................................................. 79 MACHINE OPERATION SAFETY PRECAUTIONS....................................... 80 OPERATING ON THE HAUL ROAD................................................. 81 STARTING ON A GRADE WITH A LOADED TRUCK.................................... 82 PASSING.................................................................... 82 LOADING.................................................................... 82 Overload Speed Limit Function.......................................... 82 DUMPING.................................................................... 83 Raising The Dump Body.................................................. 83 Lowering The Dump Body (When dumping on flat ground)................... 84 Lowering The Dump Body (When dumping over a berm or into a crusher).... 84 TOWING..................................................................... 85 Special Wiring Harness................................................. 85 SAFE PARKING PROCEDURES.................................................... 88 NORMAL ENGINE SHUTDOWN PROCEDURE........................................... 88 SUDDEN LOSS OF ENGINE POWER................................................ 89 FUEL DEPLETION............................................................. 89 DISABLED TRUCK DUMPING PROCEDURE........................................... 90 Hookup................................................................. 90 Raising the Body....................................................... 90 Lowering the Body...................................................... 90 RESERVE ENGINE OIL SYSTEM.................................................. 91 Operation.............................................................. 91 Changing Oil........................................................... 91 OPERATOR CAB AND CONTROLS...................................................... 93 STEERING WHEEL AND CONTROLS................................................ 94 Horn Button............................................................ 94 Tilt / Telescope Lever................................................. 94 Multi-Function Turn Signal Switch...................................... 94 DYNAMIC RETARDING.......................................................... 95 Retarder Lever......................................................... 95 Brake/Retarder Pedal................................................... 95 Throttle/Accelerator Pedal............................................. 95 GRADE/SPEED CHART.......................................................... 96 OVERHEAD PANEL AND DISPLAYS................................................ 97 CENTER CONSOLE............................................................. 98 Directional Control Lever.............................................. 98 Override/Fault Reset Switch............................................ 99 Engine Shutdown Switch................................................. 99 Window Control Switches................................................ 99 Hoist Control Lever.................................................... 99 Retard Speed Control (RSC) Adjustment Dial.............................100 Retard Speed Control (RSC) Switch......................................100 Data Store Button......................................................101 KOMTRAX Plus Snapshot In Progress Light................................101 Link Energized Light...................................................101 Service Engine Light...................................................101 12V Auxiliary Power Outlets............................................101 Fire Suppression Control Outlet........................................101 Communication Radio Outlet.............................................101 DIAGNOSTIC PORTS...........................................................101 KOMTRAX Plus Diagnostic Port...........................................101 Interface Module (IM) Diagnostic Port..................................101 Payload Meter Diagnostic Port..........................................101 Truck Control Interface (TCI) Diagnostic Port..........................101 Propulsion System Controller (PSC) Diagnostic Port.....................101 Engine Diagnostic Port (CENSE).........................................101 Engine Diagnostic Port (QUANTUM).......................................101 OPERATOR’S SEAT (STANDARD SEAT)............................................102 Seat Belts.............................................................102 Adjustment.............................................................102 PASSENGER SEAT (STANDARD SEAT).............................................103 Seat Belts.............................................................103 Adjustment.............................................................103 OPERATOR’S SEAT (OPTIONAL SEAT)............................................104 Seat Belts.............................................................104 Adjustment.............................................................104 PASSENGER SEAT (OPTIONAL SEAT).............................................105 Seat Belts.............................................................105 Adjustment.............................................................105 HEATER / AIR CONDITIONER CONTROLS..........................................106 Fan Speed Control Knob.................................................106 Temperature Control Knob...............................................106 Air Flow Directional Knob..............................................106 Heater/Air Conditioner Vents...........................................106 INSTRUMENT PANEL...........................................................107 Control Symbols........................................................107 Key Switch.............................................................109 Rotating Beacon Light Switch (optional)................................109 Heated Mirror Switch (optional)........................................109 AC Drive System Rest Switch............................................109 Wheel Brake Lock Switch................................................110 Hazard Warning Light Switch............................................110 Heater/Air Conditioner Vents...........................................110 Engine Oil Pressure Gauge..............................................110 Right Turn Signal Indicator............................................110 Digital Tachometer.....................................................110 High Beam Indicator....................................................110 Speedometer/Payload Meter Display......................................110 Left Turn Signal Indicator.............................................111 Coolant Temperature Gauge..............................................111 Lamp Check Switch......................................................111 Light Switch (3-Way)...................................................111 Ladder Light Switch....................................................111 Backup Light Switch....................................................111 Fog Light Switch.......................................................112 Payload Meter Switch...................................................112 Panel Illumination Light Dimmer Switch.................................112 Hydraulic Oil Temperature Gauge........................................112 Engine Hourmeter.......................................................112 Fuel Gauge.............................................................112 OVERHEAD STATUS / WARNING INDICATORS.......................................113 A1. High Brake Oil Temperature.........................................114 B1. Low Steering Pressure..............................................114 C1. Low Accumulator Precharge Pressure.................................115 D1. Not used...........................................................115 E1. Low Brake Pressure.................................................115 A2. Low Hydraulic Tank Level...........................................115 B2. Low Automatic Lubrication System Pressure..........................115 C2. Circuit Breaker Tripped............................................115 D2. Hydraulic Oil Filter Monitor.......................................116 E2. Low Fuel...........................................................116 A3. Parking Brake......................................................116 B3. Service Brake......................................................116 C3. Body Up............................................................116 D3. Dynamic Retarding..................................................116 E3. Stop Engine........................................................117 A4. Cranking Motor Failure.............................................117 B4. Backup Lights......................................................117 C4. Engine Shutdown Timer..............................................117 D4. Retard Speed Control (RSC) Indicator...............................117 E4. Check Engine.......................................................117 A5. No Power...........................................................118 B5. Propulsion System Warning..........................................118 C5. Propulsion System Temperature......................................118 D5. System/Component Failure...........................................118 A6. No Propel..........................................................118 B6. Propel System At Rest..............................................118 C6. Propel System Not Ready............................................119 D6. Reduced Propulsion.................................................119 E6. Retard At Continuous Level.........................................119 D7. Brake Test Light...................................................119 E7. Maintenance Monitor................................................119 8. Brake Test Switch...................................................119 REAR AXLE LIGHT BAR........................................................120 Backup Lights..........................................................120 Retard Lights..........................................................120 Brake Lights...........................................................120 Backup Alarm...........................................................120 KOMTRAX PLUS...............................................................121 Operation..............................................................121 Interface Module.......................................................123 Basic Precautions......................................................123 KOMATSU WIRELESS BRIDGE (Optional).........................................124 General Information....................................................124 Communication Setup....................................................124 Switching to the KWB_SETUP Network.....................................124 Setting the Computer Subnet Mask and IP Address........................125 Properties.............................................................125 Setting Up the KWB.....................................................126 Adding Encryption......................................................126 Final Computer Settings................................................126 Data Downloading.......................................................127 Resetting the KWB......................................................127 KWB Lights.............................................................127 FUSES AND CIRCUIT BREAKERS.................................................128 LUBRICATION AND SERVICE........................................................133 GENERAL....................................................................133 SERVICE CAPACITIES.........................................................133 HYDRAULIC TANK SERVICE.....................................................133 Adding Oil.............................................................133 COOLING SYSTEM SERVICE.....................................................134 Radiator Filling Procedure.............................................134 Coolant Specifications.................................................134 Unacceptable Practices.................................................134 WHEEL MOTOR SERVICE........................................................134 RESERVE OIL TANK SERVICE...................................................135 Filling the Reserve Oil Tank (Remote Fill).............................135 Inline Screen..........................................................135 QUICK FILL SERVICE CENTER..................................................136 LUBRICATION CHART..........................................................137 10 HOUR (DAILY) INSPECTIONS................................................138 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................141 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................141 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................141 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................144 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................146 5000 HOUR MAINTENANCE CHECKS...............................................146 AUTOMATIC LUBRICATION SYSTEM...................................................147 GENERAL DESCRIPTION........................................................147 SYSTEM COMPONENTS..........................................................149 Filter.................................................................149 Hydraulic Motor and Pump...............................................149 Grease Reservoir.......................................................149 Pressure Reducing Valve................................................149 Flow Control Valve.....................................................149 Solenoid Valve.........................................................149 Vent Valve.............................................................149 Lubrication Cycle Timer................................................149 Over Pressure Cut Off Switch...........................................149 Grease Pressure Failure Switch.........................................149 Injectors..............................................................149 Relief Valve (unloader valve)..........................................149 SYSTEM OPERATION...........................................................150 Normal Operation.......................................................150 GENERAL INSTRUCTIONS.......................................................151 Lubricant Required For System..........................................151 System Priming.........................................................151 Filter Assembly........................................................151 LUBRICANT PUMP.............................................................152 Pump Housing Oil Level.................................................152 Pump Pressure Control..................................................152 INJECTORS (SL-1 Series “H”)................................................153 Injector Specifications................................................153 Injector Adjustment....................................................153 INJECTOR OPERATION.....................................................154 PREVENTIVE MAINTENANCE PROCEDURES..........................................155 Daily Lubrication System Inspection....................................155 250 Hour Inspection....................................................155 1000 Hour Inspection...................................................155 SYSTEM CHECKOUT............................................................156 Lubrication Controller Check...........................................156 Lubrication Controller Components......................................156 Lubrication Controller Adjustment......................................156 SYSTEM TROUBLESHOOTING CHART...............................................158 COMPONENTS & SPECIFICATIONS....................................................161 MAJOR COMPONENT DESCRIPTIONS...............................................161 Truck And Engine.......................................................161 Main Alternator........................................................161 AC Induction Traction Motorized Wheels.................................161 Suspension.............................................................161 Operator's Cab.........................................................161 Power Steering.........................................................161 Dynamic Retarding......................................................161 Brake System...........................................................161 SPECIFICATIONS.............................................................163 ENGINE.................................................................163 AC ELECTRIC DRIVE SYSTEM...............................................163 DYNAMIC RETARDING......................................................163 BATTERY ELECTRIC SYSTEM................................................163 SERVICE CAPACITIES.....................................................163 HYDRAULIC SYSTEMS......................................................164 SERVICE BRAKES.........................................................164 STEERING...............................................................164 TIRES..................................................................164 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS...........................164 WEIGHT DISTRIBUTION....................................................165 PAYLOAD METER III..............................................................167 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER..............................197 OPERATING INSTRUCTIONS.....................................................197 GENERAL RADIO RECEIVER FUNCTIONS.......................................197 Turning On the Power...............................................197 One-Hour Timer.....................................................197 Adjusting the Volume...............................................198 Display............................................................198 Radio Mode Displays................................................198 CD Mode Displays...................................................198 MP3/USB/iPod Mode Displays.........................................198 AUX Input Displays.................................................199 CLOCK/ALARM Button.................................................199 Front Auxiliary Mode...............................................199 Rear Auxiliary Mode................................................199 Adjusting the Receiver Audio Settings..............................199 Adjusting the Receiver Menu Settings...............................200 USING THE RADIO........................................................201 Finding a Station..................................................201 Setting the Presets................................................201 USING THE CLOCK........................................................202 Setting the Clock..................................................202 USING THE ALARM........................................................202 Setting the Alarm..................................................202 Turning the Alarm Off..............................................203 Activating Snooze..................................................203 USING THE WEATHERBAND (USA Only).......................................203 USING THE COMPACT DISC PLAYER/USB......................................204 Playing A Compact Disc.............................................204 Button Functions...................................................204 PLAYING AN MP3 DISC/USB................................................205 Root Directory.....................................................205 Empty Directory or Folder..........................................205 No Folder..........................................................205 File Name Display..................................................205 PLAYING MP3 FILES......................................................205 Button Functions...................................................205 USING AN iPOD®.........................................................206 Playing an iPod....................................................206 Button Functions...................................................206 OPERATING TIPS.........................................................207 Tips About The Audio System........................................207 Understanding Radio Reception......................................207 Care of The Compact Discs..........................................207 TROUBLESHOOTING........................................................208
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