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KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30727 – A30756) KOMATSU 930E-4SE
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- KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30727 – A30756
- PUBLICATION NUMBER:CEAM020504
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Description
KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30727 – A30756) KOMATSU 930E-4SE
KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30727 – A30756) KOMATSU 930E-4SE:
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DESCRIPTION:
KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30727 – A30756) KOMATSU 930E-4SE
- 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-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30727 – A30756) KOMATSU 930E-4SE
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 (S/N A30727-A30741)........................................ 96 Seat Belts............................................................. 96 Adjustment............................................................. 96 OPERATOR’S SEAT (S/N A30749 & Up).......................................... 97 Seat Belts............................................................. 97 Adjustment............................................................. 97 PASSENGER SEAT............................................................. 98 Seat Belts............................................................. 98 Adjustment............................................................. 98 HEATER / AIR CONDITIONER CONTROLS.......................................... 99 Fan Speed Control Knob................................................. 99 Temperature Control Knob............................................... 99 Air Flow Directional Knob.............................................. 99 Heater/Air Conditioner Vents........................................... 99 INSTRUMENT PANEL...........................................................100 Control Symbols........................................................100 Key Switch.............................................................102 Rotating Beacon Light Switch (optional)................................102 Heated Mirror Switch (optional)........................................102 AC Drive System Rest Switch............................................102 Wheel Brake Lock Switch................................................103 Hazard Warning Light Switch............................................103 Heater/Air Conditioner Vents...........................................103 Engine Oil Pressure Gauge..............................................103 Right Turn Signal Indicator............................................103 Digital Tachometer.....................................................103 High Beam Indicator....................................................103 Speedometer/Payload Meter Display......................................103 Left Turn Signal Indicator.............................................104 Coolant Temperature Gauge..............................................104 Lamp Check Switch......................................................104 Light Switch (3-Way)...................................................104 Ladder Light Switch....................................................104 Backup Light Switch....................................................104 Fog Light Switch.......................................................105 Payload Meter Switch...................................................105 Panel Illumination Light Dimmer Switch.................................105 Hydraulic Oil Temperature Gauge........................................105 Engine Hourmeter.......................................................105 Fuel Gauge.............................................................105 OVERHEAD STATUS / WARNING INDICATORS.......................................106 A1. High Brake Oil Temperature.........................................107 B1. Low Steering Pressure..............................................107 C1. Low Accumulator Precharge Pressure.................................108 D1. Not used...........................................................108 E1. Low Brake Pressure.................................................108 A2. Low Hydraulic Tank Level...........................................108 B2. Low Automatic Lubrication System Pressure..........................108 C2. Circuit Breaker Tripped............................................108 D2. Hydraulic Oil Filter Monitor.......................................108 E2. Low Fuel...........................................................109 A3. Parking Brake......................................................109 B3. Service Brake......................................................109 C3. Body Up............................................................109 D3. Dynamic Retarding..................................................109 E3. Stop Engine........................................................109 A4. Cranking Motor Failure.............................................110 B4. Backup Lights......................................................110 C4. Engine Shutdown Timer..............................................110 D4. Retard Speed Control (RSC) Indicator...............................110 E4. Check Engine.......................................................110 A5. No Power...........................................................110 B5. Propulsion System Warning..........................................110 C5. Propulsion System Temperature......................................110 D5. System/Component Failure...........................................111 E5. Battery Charging System Failure....................................111 A6. No Propel..........................................................111 B6. Propulsion System At Rest..........................................111 C6. Propulsion System Not Ready........................................111 D6. Reduced Propulsion.................................................111 E6. Retard At Continuous Level.........................................111 REAR AXLE LIGHT BAR........................................................112 Backup Lights..........................................................112 Retard Lights..........................................................112 Brake Light............................................................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........................................................124 GENERAL....................................................................124 SERVICE CAPACITIES.........................................................124 HYDRAULIC TANK SERVICE.....................................................124 Adding Oil.............................................................124 COOLING SYSTEM SERVICE.....................................................125 Radiator Filling Procedure.............................................125 Coolant Specifications.................................................125 Unacceptable Practices.................................................125 WHEEL MOTOR SERVICE........................................................125 RESERVE OIL TANK SERVICE...................................................126 Filling the Reserve Oil Tank (Remote Fill).............................126 Inline Screen..........................................................126 QUICK FILL SERVICE CENTER..................................................127 LUBRICATION CHART..........................................................128 10 HOUR (DAILY) INSPECTIONS................................................129 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................131 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................131 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................131 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................134 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................136 5000 HOUR MAINTENANCE CHECKS...............................................136 AUTOMATIC LUBRICATION SYSTEM...................................................138 GENERAL DESCRIPTION........................................................138 SYSTEM COMPONENTS..........................................................140 Filter.................................................................140 Hydraulic Motor and Pump...............................................140 Grease Reservoir.......................................................140 Pressure Reducing Valve................................................140 Flow Control Valve.....................................................140 Solenoid Valve.........................................................140 Vent Valve.............................................................140 Lubrication Cycle Timer................................................140 Over Pressure Cut Off Switch...........................................140 Grease Pressure Failure Switch.........................................140 Injectors..............................................................140 Relief Valve (unloader valve)..........................................140 SYSTEM OPERATION...........................................................141 Normal Operation.......................................................141 GENERAL INSTRUCTIONS.......................................................142 Lubricant Required For System..........................................142 System Priming.........................................................142 Filter Assembly........................................................142 LUBRICANT PUMP.............................................................143 Pump Housing Oil Level.................................................143 Pump Pressure Control..................................................143 INJECTORS (SL-1 Series “H”)................................................144 Injector Specifications................................................144 Injector Adjustment....................................................144 Injector Operation.....................................................145 PREVENTIVE MAINTENANCE PROCEDURES..........................................146 Daily Lubrication System Inspection....................................146 250 Hour Inspection....................................................146 1000 Hour Inspection...................................................146 SYSTEM CHECKOUT............................................................147 Lubrication Controller Check...........................................147 Lubrication Controller Components......................................147 Lubrication Controller Adjustment......................................147 SYSTEM TROUBLESHOOTING CHART...............................................149 COMPONENTS & SPECIFICATIONS....................................................152 MAJOR COMPONENT DESCRIPTIONS...............................................152 Truck And Engine.......................................................152 Main Alternator........................................................152 AC Induction Traction Motorized Wheels.................................152 Suspension.............................................................152 Operator's Cab.........................................................152 Power Steering.........................................................152 Dynamic Retarding......................................................152 Brake System...........................................................152 SPECIFICATIONS.............................................................154 ENGINE.................................................................154 AC ELECTRIC DRIVE SYSTEM...............................................154 DYNAMIC RETARDING......................................................154 BATTERY ELECTRIC SYSTEM................................................154 SERVICE CAPACITIES.....................................................154 HYDRAULIC SYSTEMS......................................................155 SERVICE BRAKES.........................................................155 STEERING...............................................................155 TIRES..................................................................155 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS...........................155 WEIGHT DISTRIBUTION....................................................156 PAYLOAD METER III..............................................................158 AM/FM RADIO / CD PLAYER........................................................188 GENERAL RADIO RECEIVER FUNCTIONS...........................................188 Turning On the Power...................................................188 One-Hour Timer.........................................................188 Display................................................................189 Setting a Default Display..............................................189 Adjusting the Brightness of the Display................................189 Auxiliary Mode.........................................................189 Adjusting the Receiver Settings........................................189 USING THE CLOCK............................................................190 Setting the Clock......................................................190 USING THE ALARM............................................................190 Setting the Alarm......................................................190 Turning the Alarm Off..................................................190 Activating Snooze......................................................190 Setting Alarm Volume...................................................190 USING THE RADIO............................................................191 Finding a Station......................................................191 Setting the Presets....................................................191 USING THE WEATHERBAND......................................................192 USING THE COMPACT DISC PLAYER..............................................192 Playing a Compact Disc.................................................192 Button Functions.......................................................192 PLAYING AN MP3 DISC........................................................193 MP3 Format Compatibility...............................................193 Root Directory.........................................................193 Empty Directory or Folder..............................................193 No Folder..............................................................193 File Name Display......................................................193 Pre-Programmed Playlists...............................................194 Playing MP3 Files......................................................194 Button Functions.......................................................194 TROUBLESHOOTING............................................................195
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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