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KOMATSU 930E-4SE Dump Truck OPERATION & MAINTENANCE MANUAL (SN:A31035 & UP) KOMATSU 930E-4SE – PDF DOWNLOAD
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- KOMATSU 930E-4SE Dump Truck OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A31035 & UP
- PUBLICATION NUMBER:CEAM024503
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Description
KOMATSU 930E-4SE Dump Truck OPERATION & MAINTENANCE MANUAL (SN:A31035 & UP) KOMATSU 930E-4SE
KOMATSU 930E-4SE DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A31035 & UP) KOMATSU 930E-4SE – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 930E-4SE Dump Truck OPERATION & MAINTENANCE MANUAL (SN:A31035 & UP) KOMATSU 930E-4SE
- 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-4SE Dump Truck OPERATION & MAINTENANCE MANUAL (SN:A31035 & UP) KOMATSU 930E-4SE
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............................................................ 44 Clearance/Turn Signal Lights............................................ 44 Backup Lights........................................................... 45 Retard Lights........................................................... 45 Brake Lights............................................................ 45 Backup Alarm............................................................ 45 HID Backup Light........................................................ 45 PRECAUTIONS FOR MAINTENANCE................................................. 46 BEFORE PERFORMING MAINTENANCE........................................... 46 Securing The Dump Body.............................................. 46 DURING MAINTENANCE...................................................... 47 Warning Tag......................................................... 47 Proper Tools........................................................ 47 Attachments......................................................... 47 Working Under The Machine........................................... 47 Keeping The Machine Clean........................................... 47 Adding Fuel Or Oil To The Machine................................... 47 Radiator Coolant Level.............................................. 48 Use of Lighting..................................................... 48 Handling High Pressure Hoses........................................ 48 Precautions With High Pressure Oil.................................. 48 Maintenance Near High Temperatures and High Pressures............... 48 Rotating Fan and Belts.............................................. 48 Waste Materials..................................................... 48 Use of Tie-Off Anchor During Maintenance............................ 49 Handling Tires...................................................... 49 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 50 BATTERY HAZARD PREVENTION........................................... 50 Jump Starting With Booster Cables............................... 51 Jump Starting With Receptacles.................................. 51 WHEN REPAIRS ARE NECESSARY.................................................. 52 Observe The Following Precautions....................................... 52 SPECIAL PRECAUTIONS......................................................... 53 Preliminary Procedures Before Welding or Performing Maintenance......... 53 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 53 Discharging Control Cabinet Capacitors.................................. 54 4 WARNING AND CAUTIONS.......................................................... 56 GENERAL INFORMATION......................................................... 56 PIN PLATE................................................................... 56 GRADE SPEED CHART........................................................... 57 MACHINE SAFETY.............................................................. 57 KEY SWITCH.................................................................. 59 OIL FILL AND CHECK.......................................................... 59 HIGH PRESSURES.............................................................. 60 BATTERY AND ENGINE SHUTDOWN................................................. 63 HIGH VOLTAGE................................................................ 64 WELDING..................................................................... 66 LIFTING POINTS.............................................................. 66 EMERGENCY DUMPING........................................................... 67 ROPS/FOPS................................................................... 68 TOWING...................................................................... 68 LUBRICATION CHART........................................................... 68 5 OPERATING INSTRUCTIONS........................................................ 70 PREPARING FOR OPERATION..................................................... 70 Safety Is Thinking Ahead................................................ 70 Walk Around Inspection.................................................. 70 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 74 GENERAL INFORMATION..................................................... 74 LADDER SYSTEM DESCRIPTION............................................... 74 LADDER SYSTEM OPERATION................................................. 74 In-Cab Control Panel.................................................... 75 Ground Level Control Box................................................ 77 Emergency Down Valve.................................................... 77 PRE-SHIFT BRAKE TEST........................................................ 78 OPERATION............................................................... 78 Service Brake Test...................................................... 79 Parking Brake Test...................................................... 79 Retard System Test...................................................... 80 Brake Test Exit Criteria................................................ 80 TRUCK OPERATION............................................................. 81 ENGINE START-UP SAFETY.................................................. 81 After Engine Has Started............................................ 81 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 82 Machine Operation on the Haul Road.................................. 83 Starting on a Grade With a Loaded Truck............................. 83 Retarding on a Grade................................................ 83 Passing............................................................. 84 Loading............................................................. 84 Overload Speed Limit Function....................................... 84 Dumping............................................................. 85 Lowering the Dump Body (When Dumping on Flat Ground)................ 86 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 86 SUDDEN LOSS OF ENGINE POWER............................................. 87 EMERGENCY STEERING SYSTEM............................................... 87 Operation........................................................... 87 Pre-Operation Testing............................................... 87 Additional Guidelines............................................... 88 FUEL DEPLETION.......................................................... 88 SAFE PARKING PROCEDURES................................................. 89 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 89 DISABLED TRUCK CONNECTORS................................................... 90 GENERAL INFORMATION..................................................... 90 HOIST SYSTEM............................................................ 90 Hookup.............................................................. 90 Dumping Procedure................................................... 90 TOWING...................................................................... 92 SPECIAL WIRING HARNESS.................................................. 92 TOWING PROCEDURE........................................................ 92 PAYLOAD METER III SYSTEM.................................................... 94 GENERAL INFORMATION..................................................... 94 Data Summary........................................................ 94 Data Gathering...................................................... 94 COMPONENT DESCRIPTION................................................... 94 Operator Display.................................................... 94 Operator Switch..................................................... 94 Brake Lock Switch................................................... 94 Payload Meter Module................................................ 95 Communications Ports................................................ 95 Load Lights......................................................... 95 OPERATORS DISPLAY AND SWITCH............................................ 95 Reading the Load Display............................................ 95 Setting the Operator ID............................................. 96 Load and Ton Counter................................................ 96 Viewing Live Sensor Data............................................ 96 Other Display Messages.............................................. 96 HAUL CYCLE WARNING FLAGS................................................ 97 Haul Cycle Data..................................................... 97 Haul Cycle Warning Flags............................................ 98 PC SOFTWARE OVERVIEW....................................................100 SYSTEM CONFIGURATION....................................................100 Connecting to the Payload Meter.....................................100 Displayed Payload Units.............................................101 Connection Menu.....................................................101 Configure the Payload Meter.........................................101 Setting the Date and Time...........................................101 Setting the Truck Type and Serial Number............................102 Setting the Gauge Display Units.....................................102 Setting the Carryback Alarm Threshold...............................102 Setting the Truck Number............................................103 Setting the Komatsu Distributor.....................................103 Setting the Komatsu Customer........................................103 Clean Truck Tare Calibration........................................103 Inclinometer Calibration............................................104 DOWNLOADING PAYLOAD DATA................................................104 UPLOADING DATA..........................................................105 DATA ANALYSIS...........................................................106 Creating a Query....................................................106 Payload Detail Screen...............................................107 Creating Reports....................................................107 Creating Graphs.....................................................107 Exporting Data......................................................108 Importing Data......................................................108 Deleting Haul Cycle Records.........................................108 Viewing Alarms......................................................109 Deleting Alarm Records..............................................109 Patent Acknowledgment...............................................109 AUTOMATIC LUBRICATION SYSTEM................................................110 GENERAL INFORMATION.....................................................110 COMPONENT DESCRIPTION...................................................110 Filter..............................................................111 Hydraulic Motor and Pump............................................111 Grease Reservoir....................................................111 Pressure Reducing Valve.............................................111 Flow Control Valve..................................................111 Solenoid Valve......................................................112 Vent Valve..........................................................112 Lubrication Cycle Timer.............................................112 Pressure Cut Off Switch.............................................112 Injectors...........................................................113 Grease Pressure Failure Switch......................................114 Relief Valve (unloader valve).......................................114 SYSTEM OPERATION........................................................114 Filling The Reservoir...............................................114 Priming The Automatic Lubrication System............................115 PREVENTIVE MAINTENANCE PROCEDURES.......................................115 Daily Lubrication System Inspection.................................115 250 Hour Inspection.................................................116 1000 Hour Inspection................................................116 SYSTEM CHECKOUT.............................................................117 General Checks..........................................................117 Lubrication Controller Components.......................................117 RESERVE ENGINE OIL SYSTEM (If Equipped).....................................118 Operation...............................................................118 Changing Oil............................................................118 6 OPERATOR CAB AND CONTROLS.....................................................120 CAB INTERIOR................................................................120 STEERING WHEEL AND CONTROLS.................................................121 Horn Button.............................................................121 Tilt / Telescope Lever..................................................121 Multi-Function Turn Signal Switch.......................................121 Turn Signal Operation...................................................121 High Beam Headlight Operation...........................................121 Windshield Wiper Operation..............................................121 PEDALS AND RETARDER LEVER...................................................122 DYNAMIC RETARDING.......................................................122 RETARDER LEVER..........................................................122 BRAKE/RETARDER PEDAL....................................................122 ACCELERATOR PEDAL.......................................................122 OVERHEAD PANEL AND DISPLAYS.................................................124 RADIO SPEAKERS..........................................................124 WARNING ALARM BUZZER....................................................124 CAB RADIO...............................................................124 WARNING LIGHT DIMMER CONTROL............................................124 STATUS/WARNING INDICATOR LIGHT PANEL....................................124 AIR CLEANER VACUUM GAUGES...............................................124 WINDSHIELD WIPERS.......................................................124 CENTER CONSOLE..............................................................125 DIRECTIONAL CONTROL LEVER...............................................125 OVERRIDE/FAULT RESET SWITCH.............................................125 ENGINE STOP SWITCH......................................................126 WINDOW CONTROL SWITCHES.................................................126 HOIST CONTROL LEVER.....................................................126 Raising The Dump Body...................................................126 Lowering The Dump Body..................................................126 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................126 RETARD SPEED CONTROL (RSC) SWITCH.......................................127 DATA STORE BUTTON.......................................................127 KOMTRAX PLUS SNAPSHOT IN PROGRESS LIGHT.................................127 LINK ENERGIZED LIGHT....................................................127 SERVICE ENGINE LIGHT....................................................127 12V AUXILIARY POWER OUTLETS.............................................127 FIRE SUPPRESSION CONTROL OUTLET.........................................127 COMMUNICATION RADIO OUTLET..............................................127 DIAGNOSTIC PORTS............................................................128 KOMTRAX Plus ...........................................................128 INTERFACE MODULE (IM)...................................................128 PAYLOAD METER...........................................................128 TRUCK CONTROL INTERFACE (TCI)...........................................128 PROPULSION SYSTEM CONTROLLER (PSC)......................................128 ENGINE (CENSE)..........................................................128 ENGINE (QUANTUM)........................................................128 OPERATOR SEAT (Standard)....................................................129 SEAT BELTS..............................................................129 ADJUSTMENT..............................................................129 PASSENGER SEAT (Standard)...................................................131 SEAT BELTS..............................................................131 ADJUSTMENT..............................................................131 OPERATOR SEAT (Optional)....................................................132 SEAT BELTS..............................................................132 ADJUSTMENT..............................................................132 PASSENGER SEAT (Optional)...................................................133 SEAT BELTS..............................................................133 ADJUSTMENT..............................................................133 HEATER / AIR CONDITIONER CONTROLS...........................................134 Fan Speed Control Knob..................................................134 Temperature Control Knob................................................134 Air Flow Directional Knob...............................................134 Heater/Air Conditioner Vents............................................134 INSTRUMENT PANEL ...........................................................135 CONTROL SYMBOLS.........................................................135 Key Switch..............................................................136 Grid Dryer (Optional)...................................................136 Camera System (Optional)................................................137 Rotating Beacon Light Switch (Optional).................................137 Heated Mirror Switch (Optional).........................................137 Rest Switch.............................................................137 Wheel Brake Lock Control Switch.........................................137 Hazard Warning Light Switch.............................................138 Cab/Air Conditioner Vents...............................................138 Engine Oil Pressure Gauge...............................................138 Right Turn Signal Indicator.............................................138 Tachometer..............................................................138 High Beam Indicator.....................................................138 Speedometer/Payload Meter Display.......................................138 Left Turn Signal Indicator..............................................138 Coolant Temperature Gauge...............................................138 Lamp Test Switch........................................................139 Light Switch............................................................139 Ladder Light Switch.....................................................139 Manual Backup Switch....................................................139 Fog Light Switch........................................................139 Payload Meter Switch....................................................139 Panel Light Dimmer......................................................139 Hydraulic Oil Temperature Gauge.........................................140 Hourmeter...............................................................140 Fuel Level Gauge........................................................140 OVERHEAD STATUS/WARNING INDICATOR...........................................141 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................141 High Hydraulic Oil Temperature......................................142 Low Steering Pressure...............................................142 Low Accumulator Precharge Pressure..................................143 Low Brake Pressure..................................................143 Low Hydraulic Tank Level............................................143 Automatic Lubrication System Pressure...............................143 Circuit Breaker Tripped.............................................143 Hydraulic Oil Filter Monitor........................................143 Low Fuel............................................................143 Parking Brake.......................................................144 Service Brake.......................................................144 Body Up.............................................................144 Dynamic Retarding...................................................144 Stop Engine.........................................................144 Cranking Motor Failure..............................................145 Manual Backup Lights................................................145 Engine Shutdown Timer...............................................145 Retard Speed Control (RSC) Indicator................................145 Check Engine........................................................145 No Power............................................................145 Propulsion System Warning...........................................145 Propulsion System Temperature.......................................145 System/Component Failure............................................146 Battery Charging System Failure.....................................146 No Propel...........................................................146 Propel System at Rest...............................................146 Propel System Not Ready.............................................146 Reduced Propulsion..................................................146 Retard at Continuous Level..........................................146 Brake Test Light (If Equipped)......................................147 Maintenance Monitor.................................................147 Brake Test Switch (If Equipped).....................................147 KOMTRAX Plus................................................................148 KOMTRAX Plus OPERATION..................................................148 Basic Precautions...................................................148 Interface Module....................................................149 DOWNLOADING KOMTRAX Plus DATA...........................................150 GENERAL INFORMATION.................................................150 KOMTRAX Plus DOWNLOADING PROCEDURE..................................150 Location of Downloaded Files........................................150 UPLOADING KOMTRAX Plus DATA.............................................151 ORBCOMM.................................................................152 KOMATSU WIRELESS BRIDGE (Optional)......................................153 General Information.................................................153 Communication Setup.................................................153 Switching to the KWB_SETUP Network..................................153 Setting the Computer Subnet Mask and IP Address.....................154 Setting Up the KWB..................................................154 Adding Encryption...................................................155 Final Computer Settings.............................................155 Downloading Data....................................................155 Resetting the KWB...................................................156 FUSES AND CIRCUIT BREAKERS..................................................157 FUSE BLOCK #1...........................................................157 FUSE BLOCK #2...........................................................158 FUSE BLOCK #3...........................................................158 FUSE BLOCK #4...........................................................159 FUSE HOLDERS............................................................159 CIRCUIT BREAKERS........................................................159 7 LUBRICATION AND SERVICE.......................................................162 GENERAL INFORMATION.........................................................162 HYDRAULIC SYSTEM SERVICE................................................162 Hydraulic Tank......................................................162 Hydraulic Filters...................................................163 Hydraulic Pump Drive Shaft..........................................163 WHEEL MOTOR SERVICE.....................................................163 COOLANT LEVEL SERVICE...................................................163 Radiator Filling Procedure..........................................164 Coolant Specifications..............................................164 Unacceptable Practices..............................................164 RESERVE ENGINE OIL SERVICE..............................................164 Reserve Oil Tank Filling Procedure (Remote Fill)....................165 Inline Screen.......................................................165 CAB AIR FILTER SERVICE..................................................165 FUEL SYSTEM SERVICE.....................................................166 Fuel Tank Cleaning..................................................166 Fuel Filter Service.................................................166 INTAKE AIR CLEANER SERVICE..............................................167 QUICK FILL SERVICE CENTER...............................................167 LUBRICATION CHART...........................................................169 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................170 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................172 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................173 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................174 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................176 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................178 EVERY 5000 HOUR MAINTENANCE.................................................179 8 SPECIFICATIONS................................................................182 MAJOR COMPONENT DESCRIPTION.................................................182 Truck and Engine........................................................182 Traction Alternator.....................................................182 Main Control Cabinet....................................................182 AC Induction Traction Motorized Wheels..................................182 Suspension..............................................................182 Operator's Cab..........................................................182 Power Steering..........................................................182 Dynamic Retarding Grid..................................................182 Brake System............................................................182 SPECIFICATIONS..............................................................183 Engine..................................................................183 AC Electric Drive System................................................183 Dynamic Retarding.......................................................183 Battery Electric System.................................................183 Service Capacities......................................................183 Hydraulic Systems.......................................................183 Service Brakes..........................................................184 Steering................................................................184 Standard Dump Body Capacities and Dimensions............................184 Tires...................................................................184 Weight Distribution.....................................................184 Overall Truck Dimensions................................................184 9 RADIO.........................................................................188 RADIO OPERATION.............................................................188 GENERAL RADIO RECEIVER FUNCTIONS........................................188 Turning On the Power....................................................188 One-Hour Timer..........................................................188 Finding a Station.......................................................188 Setting the Presets.....................................................189 Adjusting the Receiver Audio Settings...................................189 Display.................................................................190 Adjusting the Receiver Menu Settings....................................190 Front Auxiliary Mode....................................................190 Rear Auxiliary Mode.....................................................190 CLOCK.......................................................................191 Clock/Alarm Button......................................................191 Setting the Clock.......................................................191 Setting the Alarm.......................................................191 Turning the Alarm Off...................................................192 Activating Snooze.......................................................192 CD PLAYER...................................................................193 Playing a Compact Disc..................................................193 Playing an MP3 DISC.....................................................193 CD Mode Displays........................................................193 Button Functions........................................................193 MP3 PLAYER..................................................................195 Playing MP3 Files.......................................................195 MP3 Mode Displays.......................................................195 Button Functions........................................................195 iPod®.......................................................................197 Playing an iPod®........................................................197 iPod® Mode Displays.....................................................197 Button Functions........................................................197 WEATHERBAND (USA Only)......................................................199 TROUBLESHOOTING.............................................................200 Tips About the Audio System.............................................200 Understanding Radio Reception...........................................200 Care of the Compact Discs...............................................200
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]
