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KOMATSU 930E-4 Dump Truck Operation & Maintenance Manual (SN:A31002 & UP) KOMATSU 930E-4 – PDF DOWNLOAD
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- KOMATSU 930E-4 Dump Truck Operation & Maintenance Manual
- SERIAL NUMBER:A31002 & UP
- PUBLICATION NUMBER:CEAM024203
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Description
KOMATSU 930E-4 Dump Truck Operation & Maintenance Manual (SN:A31002 & UP) KOMATSU 930E-4
KOMATSU 930E-4 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A31002 & UP) KOMATSU 930E-4 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4 Dump Truck Operation & Maintenance Manual (SN:A31002 & UP) KOMATSU 930E-4
- This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
- All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system; The letter “E”, when present, designates an Electrical wheel motor drive system. The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit.
- This complete number will be necessary for proper ordering of many service parts and/or warranty consideration. The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
- To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 930E-4 Dump Truck Operation & Maintenance Manual (SN:A31002 & UP) KOMATSU 930E-4
1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 WARNINGS.................................................................... 16 CALIFORNIA PROPOSITION 65 WARNINGS...................................... 16 ALERTS...................................................................... 17 TRUCK MODEL ILLUSTRATION.................................................... 18 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 19 2 STANDARD CHARTS AND TABLES.................................................... 22 GENERAL INFORMATION......................................................... 22 EFFECT OF SPECIAL LUBRICANTS............................................ 22 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 22 STANDARD TIGHTENING TORQUES................................................. 23 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 23 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 24 SAE GRADE 9 CAP SCREWS.................................................. 25 T-BOLT CLAMPS........................................................... 25 SPLIT FLANGE CLAMPS..................................................... 26 FLARED TUBE AND HOSE FITTINGS........................................... 26 JIC 37° SWIVEL NUTS..................................................... 27 PIPE THREAD FITTINGS.................................................... 28 O-RING BOSS FITTINGS.................................................... 29 O-RING FACE SEAL FITTINGS............................................... 30 CONVERSION MULTIPLIERS...................................................... 31 METRIC TO ENGLISH....................................................... 31 ENGLISH TO METRIC....................................................... 32 TEMPERATURE CONVERSIONS................................................. 33 3 GENERAL SAFETY................................................................ 36 GENERAL SAFETY.............................................................. 36 Safety Rules............................................................ 36 Truck Safety Features................................................... 36 Clothing And Personal Items............................................. 36 Unauthorized Modification............................................... 36 Leaving The Operator’s Seat............................................. 36 Mounting And Dismounting................................................ 36 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 ROPS Precautions........................................................ 37 Preventing Injury From Work Equipment................................... 38 Precautions For Optional Attachments.................................... 38 Precautions When Starting The Machine................................... 38 PRECAUTIONS FOR TRUCK OPERATION............................................. 39 Safety Is Thinking Ahead................................................ 39 Safety At The Worksite.................................................. 39 Preparing For Operation................................................. 39 Ventilation For Enclosed Areas.......................................... 39 Mirrors, Windows, And Lights............................................ 39 Before Starting The Engine.............................................. 39 Seat Belts.............................................................. 39 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 41 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 42 Avoid Damage To The Dump Body........................................... 42 Safe Parking Of The Machine............................................. 42 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING........................................................... 44 Fog Lights.............................................................. 44 Headlights.............................................................. 44 Brake Light............................................................. 44 Retard Light............................................................ 45 Clearance/Turn Signal Lights............................................ 45 Backup Lights........................................................... 46 Retard Lights........................................................... 46 Brake Lights............................................................ 46 Backup Alarm............................................................ 46 HID Backup Light........................................................ 46 PRECAUTIONS FOR MAINTENANCE................................................. 47 BEFORE PERFORMING MAINTENANCE........................................... 47 Securing The Dump Body.............................................. 47 DURING MAINTENANCE...................................................... 48 Warning Tag......................................................... 48 Proper Tools........................................................ 48 Attachments......................................................... 48 Working Under The Machine........................................... 48 Keeping The Machine Clean........................................... 48 Adding Fuel Or Oil To The Machine................................... 48 Radiator Coolant Level.............................................. 49 Use of Lighting..................................................... 49 Handling High Pressure Hoses........................................ 49 Precautions With High Pressure Oil.................................. 49 Maintenance Near High Temperatures and High Pressures............... 49 Rotating Fan and Belts.............................................. 49 Waste Materials..................................................... 49 Use of Tie-Off Anchor During Maintenance............................ 50 Handling Tires...................................................... 50 Tire Maintenance.................................................... 50 Storing Tires After Removal......................................... 51 Battery Hazard Prevention........................................... 51 Jump Starting With Booster Cables............................... 52 Jump Starting With Receptacles.................................. 52 WHEN REPAIRS ARE NECESSARY.................................................. 53 Observe The Following Precautions....................................... 53 SPECIAL PRECAUTIONS......................................................... 54 Preliminary Procedures Before Welding or Performing Maintenance......... 54 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 54 Discharging Control Cabinet Capacitors.................................. 55 4 WARNING AND CAUTIONS.......................................................... 58 GENERAL INFORMATION......................................................... 58 PIN PLATE................................................................... 58 GRADE SPEED CHART........................................................... 59 MACHINE SAFETY.............................................................. 59 KEY SWITCH.................................................................. 61 OIL FILL AND CHECK.......................................................... 62 HIGH PRESSURES.............................................................. 63 BATTERY AND ENGINE SHUTDOWN................................................. 65 HIGH VOLTAGE................................................................ 67 WELDING..................................................................... 68 LIFTING POINTS.............................................................. 69 EMERGENCY DUMPING........................................................... 70 ROPS/FOPS................................................................... 70 TOWING...................................................................... 70 LUBRICATION CHART........................................................... 71 5 OPERATING INSTRUCTIONS........................................................ 74 PREPARING FOR OPERATION..................................................... 74 Safety Is Thinking Ahead................................................ 74 Walk Around Inspection.................................................. 74 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 78 GENERAL INFORMATION..................................................... 78 LADDER SYSTEM DESCRIPTION............................................... 78 LADDER SYSTEM OPERATION................................................. 78 In-Cab Control Panel.................................................... 79 Ground Level Control Box................................................ 81 Emergency Down Valve.................................................... 81 PRE-SHIFT BRAKE TEST........................................................ 82 OPERATION............................................................... 82 Service Brake Test...................................................... 83 Parking Brake Test...................................................... 83 Retard System Test...................................................... 84 Brake Test Exit Criteria................................................ 84 TRUCK OPERATION............................................................. 85 ENGINE START-UP SAFETY.................................................. 85 After Engine Has Started............................................ 85 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 86 Machine Operation on the Haul Road.................................. 87 Starting on a Grade With a Loaded Truck............................. 87 Retarding on a Grade................................................ 87 Passing............................................................. 88 Loading............................................................. 88 Overload Speed Limit Function....................................... 89 Dumping............................................................. 89 Lowering the Dump Body (When Dumping on Flat Ground)................ 90 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 90 SUDDEN LOSS OF ENGINE POWER............................................. 91 EMERGENCY STEERING SYSTEM............................................... 91 Operation........................................................... 91 Pre-Operation Testing............................................... 91 Additional Guidelines............................................... 92 FUEL DEPLETION.......................................................... 92 SAFE PARKING PROCEDURES................................................. 93 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 93 DISABLED TRUCK CONNECTORS................................................... 95 GENERAL INFORMATION..................................................... 95 HOIST SYSTEM............................................................ 95 Hookup.............................................................. 95 Dumping Procedure................................................... 95 TOWING...................................................................... 97 SPECIAL WIRING HARNESS.................................................. 97 TOWING PROCEDURE........................................................ 97 PAYLOAD METER III SYSTEM....................................................100 GENERAL INFORMATION.....................................................100 Data Summary........................................................100 Data Gathering......................................................100 COMPONENT DESCRIPTION...................................................100 Operator Display....................................................100 Operator Switch.....................................................100 Brake Lock Switch...................................................100 Payload Meter Module................................................101 Communications Ports................................................101 Load Lights.........................................................101 OPERATORS DISPLAY AND SWITCH............................................101 Reading the Load Display............................................101 Setting the Operator ID.............................................102 Load and Ton Counter................................................102 Viewing Live Sensor Data............................................102 Other Display Messages..............................................102 HAUL CYCLE WARNING FLAGS................................................103 Haul Cycle Data.....................................................103 Haul Cycle Warning Flags............................................104 PC SOFTWARE OVERVIEW....................................................106 SYSTEM CONFIGURATION....................................................106 Connecting to the Payload Meter.....................................106 Displayed Payload Units.............................................107 Connection Menu.....................................................107 Configure the Payload Meter.........................................107 Setting the Date and Time...........................................107 Setting the Truck Type and Serial Number............................108 Setting the Gauge Display Units.....................................108 Setting the Carryback Alarm Threshold...............................108 Setting the Truck Number............................................109 Setting the Komatsu Distributor.....................................109 Setting the Komatsu Customer........................................109 Clean Truck Tare Calibration........................................109 Inclinometer Calibration............................................110 DOWNLOADING PAYLOAD DATA................................................110 UPLOADING DATA..........................................................111 DATA ANALYSIS...........................................................112 Creating a Query....................................................112 Payload Detail Screen...............................................113 Creating Reports....................................................113 Creating Graphs.....................................................113 Exporting Data......................................................114 Importing Data......................................................114 Deleting Haul Cycle Records.........................................114 Viewing Alarms......................................................115 Deleting Alarm Records..............................................115 Patent Acknowledgment...............................................115 AUTOMATIC LUBRICATION SYSTEM................................................116 GENERAL INFORMATION.....................................................116 COMPONENT DESCRIPTION...................................................116 Filter..............................................................117 Hydraulic Motor and Pump............................................117 Grease Reservoir....................................................117 Pressure Reducing Valve.............................................117 Flow Control Valve..................................................117 Solenoid Valve......................................................118 Vent Valve..........................................................118 Lubrication Cycle Timer.............................................118 Pressure Cut Off Switch.............................................118 Injectors...........................................................120 Grease Pressure Failure Switch......................................120 Relief Valve (unloader valve).......................................120 SYSTEM OPERATION........................................................120 Filling The Reservoir...............................................120 Priming The Automatic Lubrication System............................121 PREVENTIVE MAINTENANCE PROCEDURES.......................................121 Daily Lubrication System Inspection.................................121 250 Hour Inspection.................................................122 1000 Hour Inspection................................................122 SYSTEM CHECKOUT.........................................................122 General Checks......................................................122 Lubrication Controller Components...................................123 RESERVE ENGINE OIL SYSTEM (If Equipped).....................................124 Operation...............................................................124 Changing Oil............................................................124 6 OPERATOR CAB AND CONTROLS.....................................................128 CAB INTERIOR................................................................128 STEERING WHEEL AND CONTROLS.................................................129 Horn Button.............................................................129 Tilt / Telescope Lever..................................................129 Multi-Function Turn Signal Switch.......................................129 Turn Signal Operation...................................................129 High Beam Headlight Operation...........................................129 Windshield Wiper Operation..............................................129 PEDALS AND RETARDER LEVER...................................................130 DYNAMIC RETARDING.......................................................130 RETARDER LEVER..........................................................130 BRAKE/RETARDER PEDAL....................................................130 ACCELERATOR PEDAL.......................................................130 OVERHEAD PANEL AND DISPLAYS.................................................131 RADIO SPEAKERS..........................................................131 WARNING ALARM BUZZER....................................................131 CAB RADIO...............................................................131 WARNING LIGHT DIMMER CONTROL............................................131 STATUS/WARNING INDICATOR LIGHT PANEL....................................131 AIR CLEANER VACUUM GAUGES...............................................131 WINDSHIELD WIPERS.......................................................131 CAMERA MONITOR (OPTIONAL)...............................................131 CENTER CONSOLE..............................................................132 DIRECTIONAL CONTROL LEVER...............................................132 OVERRIDE/FAULT RESET SWITCH.............................................132 ENGINE STOP SWITCH......................................................133 WINDOW CONTROL SWITCHES.................................................133 HOIST CONTROL LEVER.....................................................133 Raising The Dump Body...................................................133 Lowering The Dump Body..................................................133 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................133 RETARD SPEED CONTROL (RSC) SWITCH.......................................134 DATA STORE BUTTON.......................................................134 KOMTRAX PLUS SNAPSHOT IN PROGRESS LIGHT.................................134 LINK ENERGIZED LIGHT....................................................134 SERVICE ENGINE LIGHT....................................................134 12V AUXILIARY POWER OUTLETS.............................................134 FIRE SUPPRESSION CONTROL OUTLET.........................................134 COMMUNICATION RADIO OULET...............................................134 DIAGNOSTIC PORTS............................................................135 KOMTRAX Plus ...........................................................135 INTERFACE MODULE (IM)...................................................135 PAYLOAD METER...........................................................135 TRUCK CONTROL INTERFACE (TCI)...........................................135 PROPULSION SYSTEM CONTROLLER (PSC)......................................135 ENGINE (CENSE)..........................................................135 ENGINE (QUANTUM)........................................................135 OPERATOR SEAT (Standard)....................................................136 SEAT BELTS..............................................................136 ADJUSTMENT..............................................................136 PASSENGER SEAT (Standard)...................................................138 SEAT BELTS..............................................................138 ADJUSTMENT..............................................................138 OPERATOR SEAT (Optional)....................................................139 SEAT BELTS..............................................................139 ADJUSTMENT..............................................................139 PASSENGER SEAT (Optional)...................................................140 SEAT BELTS..............................................................140 ADJUSTMENT..............................................................140 HEATER / AIR CONDITIONER CONTROLS...........................................142 Fan Speed Control Knob..................................................142 Temperature Control Knob................................................142 Air Flow Directional Knob...............................................142 Heater/Air Conditioner Vents............................................142 INSTRUMENT PANEL ...........................................................143 CONTROL SYMBOLS.........................................................143 Key Switch..............................................................144 Grid Dryer (Optional)...................................................144 Camera System (Optional)................................................145 Rotating Beacon Light Switch (Optional).................................145 Heated Mirror Switch (Optional).........................................145 Rest Switch.............................................................145 Wheel Brake Lock Control Switch.........................................146 Hazard Warning Light Switch.............................................146 Cab/Air Conditioner Vents...............................................146 Engine Oil Pressure Gauge...............................................146 Right Turn Signal Indicator.............................................147 Tachometer..............................................................147 High Beam Indicator.....................................................147 Speedometer/Payload Meter Display.......................................147 Left Turn Signal Indicator..............................................147 Coolant Temperature Gauge...............................................147 Lamp Test Switch........................................................147 Light Switch............................................................147 Ladder Light Switch.....................................................148 Manual Backup Switch....................................................148 Fog Light Switch........................................................148 Payload Meter Switch....................................................148 Panel Light Dimmer......................................................148 Hydraulic Oil Temperature Gauge.........................................148 Hourmeter...............................................................149 Fuel Level Gauge........................................................149 OVERHEAD STATUS/WARNING INDICATOR...........................................150 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................151 High Hydraulic Oil Temperature......................................151 Low Steering Pressure...............................................151 Low Accumulator Precharge Pressure..................................152 Low Brake Pressure..................................................152 Low Hydraulic Tank Level............................................152 Automatic Lubrication System Pressure...............................152 Circuit Breaker Tripped.............................................152 Hydraulic Oil Filter Monitor........................................152 Low Fuel............................................................153 Parking Brake.......................................................153 Service Brake.......................................................153 Body Up.............................................................153 Dynamic Retarding...................................................153 Stop Engine.........................................................153 Cranking Motor Failure..............................................154 Manual Backup Lights................................................154 Engine Shutdown Timer...............................................154 Retard Speed Control (RSC) Indicator................................154 Check Engine........................................................154 No Power............................................................154 Propulsion System Warning...........................................155 Propulsion System Temperature.......................................155 System/Component Failure............................................155 Battery Charging System Failure.....................................155 No Propel...........................................................155 Propel System at Rest...............................................155 Propel System Not Ready.............................................155 Reduced Propulsion..................................................156 Retard at Continuous Level..........................................156 Brake Test Light (If Equipped)......................................156 Maintenance Monitor.................................................156 Brake Test Switch (If Equipped).....................................156 KOMTRAX Plus................................................................157 KOMTRAX Plus OPERATION..................................................157 Basic Precautions...................................................157 Interface Module....................................................158 DOWNLOADING KOMTRAX Plus DATA...........................................159 GENERAL INFORMATION.................................................159 KOMTRAX Plus DOWNLOADING PROCEDURE..................................159 Location of Downloaded Files........................................159 UPLOADING KOMTRAX Plus DATA.............................................160 ORBCOMM.................................................................161 KOMATSU WIRELESS BRIDGE (Optional)......................................162 General Information.................................................162 Communication Setup.................................................162 Switching to the KWB_SETUP Network..................................162 Setting the Computer Subnet Mask and IP Address.....................163 Setting Up the KWB..................................................163 Adding Encryption...................................................164 Final Computer Settings.............................................164 Downloading Data....................................................164 Resetting the KWB...................................................165 FUSES AND CIRCUIT BREAKERS..................................................166 FUSE BLOCK #1...........................................................166 FUSE BLOCK #2...........................................................167 FUSE BLOCK #3...........................................................167 FUSE BLOCK #4...........................................................168 FUSE HOLDERS............................................................168 CIRCUIT BREAKERS........................................................168 7 LUBRICATION AND SERVICE.......................................................170 GENERAL INFORMATION.........................................................170 HYDRAULIC SYSTEM SERVICE................................................170 Hydraulic Tank......................................................170 Hydraulic Filters...................................................171 Hydraulic Pump Drive Shaft..........................................171 WHEEL MOTOR SERVICE.....................................................171 COOLANT LEVEL SERVICE...................................................171 Radiator Filling Procedure..........................................172 Coolant Specifications..............................................172 Unacceptable Practices..............................................172 RESERVE ENGINE OIL SERVICE..............................................172 Reserve Oil Tank Filling Procedure (Remote Fill)....................173 Inline Screen.......................................................173 CAB AIR FILTER SERVICE..................................................173 FUEL SYSTEM SERVICE.....................................................174 Fuel Tank Cleaning..................................................174 Fuel Filter Service.................................................174 INTAKE AIR CLEANER SERVICE..............................................175 QUICK FILL SERVICE CENTER...............................................176 LUBRICATION CHART...........................................................177 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................178 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................180 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................181 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................182 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................184 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................186 EVERY 5000 HOUR MAINTENANCE.................................................187 8 SPECIFICATIONS................................................................190 MAJOR COMPONENT DESCRIPTION.................................................190 Truck and Engine........................................................190 Traction Alternator.....................................................190 Main Control Cabinet....................................................190 AC Induction Traction Motorized Wheels..................................190 Suspension..............................................................190 Operator's Cab..........................................................190 Power Steering..........................................................190 Dynamic Retarding Grid..................................................190 Brake System............................................................190 SPECIFICATIONS..............................................................191 Engine..................................................................191 AC Electric Drive System................................................191 Dynamic Retarding.......................................................191 Battery Electric System.................................................191 Service Capacities......................................................191 Hydraulic Systems.......................................................191 Service Brakes..........................................................191 Steering................................................................191 Standard Dump Body Capacities and Dimensions............................191 Tires...................................................................191 Weight Distribution.....................................................192 Overall Truck Dimensions................................................192 9 RADIO.........................................................................194 RADIO OPERATION.............................................................194 GENERAL RADIO RECEIVER FUNCTIONS........................................194 Turning On the Power....................................................194 One-Hour Timer..........................................................195 Finding a Station.......................................................195 Setting the Presets.....................................................195 Adjusting the Receiver Audio Settings...................................195 Display.................................................................196 Adjusting the Receiver Menu Settings....................................196 Front Auxiliary Mode....................................................197 Rear Auxiliary Mode.....................................................197 CLOCK.......................................................................198 Clock/Alarm Button......................................................198 Setting the Clock.......................................................198 Setting the Alarm.......................................................198 Turning the Alarm Off...................................................199 Activating Snooze.......................................................199 CD PLAYER...................................................................200 Playing a Compact Disc..................................................200 Playing an MP3 DISC.....................................................200 CD Mode Displays........................................................200 Button Functions........................................................200 MP3 PLAYER..................................................................202 Playing MP3 Files.......................................................202 MP3 Mode Displays.......................................................202 Button Functions........................................................203 iPod®.......................................................................204 Playing an iPod®........................................................204 iPod® Mode Displays.....................................................204 Button Functions........................................................204 WEATHERBAND (USA Only)......................................................206 TROUBLESHOOTING.............................................................207 Tips About the Audio System.............................................207 Understanding Radio Reception...........................................207 Care of the Compact Discs...............................................207
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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