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Komatsu Dump Truck 930E-4 Operation & Maintenance Manual SN A31693 & up – PDF DOWNLOAD
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Komatsu Dump Truck 930E-4 Operation & Maintenance Manual
Book Code : CEAM027800
SERIAL NUMBERS : A31693
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Description
Komatsu Dump Truck 930E-4 Operation & Maintenance Manual
FILE DETAILS:
Komatsu Dump Truck 930E-4 Operation & Maintenance Manual
Model Specification: KOMATSU 930E-4 DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 206
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU DUMP TRUCK 930E-4 OPERATION & MAINTENANCE MANUAL SN A31693 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu Dump Truck 930E-4 Operation & Maintenance Manual
FOREWORD:
- This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should 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 should be understood and followed when operating or accomplishing repairs on the truck. The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest.
- Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. 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 G.V.W. (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.
TABLE OF CONTENTS:
Komatsu Dump Truck 930E-4 Operation & Maintenance Manual
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 Before welding on the machine, obey the following guidelines:........... 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 ISOLATION BOX................................................... 63 HIGH VOLTAGE................................................................ 65 WELDING..................................................................... 67 LIFTING POINTS.............................................................. 68 EMERGENCY DUMPING........................................................... 69 AUTOMATIC LUBRICATION FILL.................................................. 69 ROPS/FOPS................................................................... 70 TOWING...................................................................... 70 LUBRICATION CHART........................................................... 70 5 OPERATING INSTRUCTIONS........................................................ 72 PREPARING FOR OPERATION..................................................... 72 Safety Is Thinking Ahead................................................ 72 Walk Around Inspection.................................................. 72 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 76 GENERAL INFORMATION..................................................... 76 LADDER SYSTEM DESCRIPTION............................................... 76 LADDER SYSTEM OPERATION................................................. 76 In-Cab Control Panel.................................................... 77 Ground Level Control Box................................................ 79 Emergency Down Valve.................................................... 80 PRE-SHIFT BRAKE TEST........................................................ 81 OPERATION............................................................... 81 Service Brake Test...................................................... 82 Parking Brake Test...................................................... 82 Retard System Test...................................................... 83 Brake Test Exit Criteria................................................ 83 TRUCK OPERATION............................................................. 84 ENGINE START-UP SAFETY.................................................. 84 After Engine Has Started............................................ 84 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 85 Machine Operation on the Haul Road.................................. 85 Starting on a Grade With a Loaded Truck............................. 86 Retarding on a Grade................................................ 86 Passing............................................................. 87 Loading............................................................. 87 Overload Speed Limit Function....................................... 88 Dumping............................................................. 88 Lowering the Dump Body (When Dumping on Flat Ground)................ 89 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 89 SUDDEN LOSS OF ENGINE POWER............................................. 90 EMERGENCY STEERING SYSTEM............................................... 90 Operation........................................................... 90 Pre-Operation Testing............................................... 91 Additional Guidelines............................................... 91 FUEL DEPLETION.......................................................... 91 SAFE PARKING PROCEDURES................................................. 92 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 92 DISABLED TRUCK CONNECTORS................................................... 93 GENERAL INFORMATION..................................................... 93 HOIST SYSTEM............................................................ 93 Hookup.............................................................. 93 Dumping Procedure................................................... 93 TOWING...................................................................... 95 SPECIAL WIRING HARNESS.................................................. 95 TOWING PROCEDURE........................................................ 95 PAYLOAD METER III SYSTEM.................................................... 97 GENERAL INFORMATION..................................................... 97 Data Summary........................................................ 97 Data Gathering...................................................... 97 COMPONENT DESCRIPTION................................................... 97 Operator Display.................................................... 97 Operator Switches................................................... 97 Brake Lock Switch................................................... 97 Payload Meter Module................................................ 98 Communications Ports................................................ 98 Load Lights......................................................... 98 OPERATOR’S DISPLAY AND SWITCH........................................... 98 Reading the Load Display............................................ 98 Setting the Operator ID............................................. 98 Load and Ton Counter................................................ 99 Viewing Live Sensor Data............................................ 99 Other Display Messages.............................................. 99 HAUL CYCLE WARNING FLAGS................................................ 99 Haul Cycle Data..................................................... 99 Haul Cycle Warning Flags............................................101 PC SOFTWARE OVERVIEW....................................................102 SYSTEM CONFIGURATION....................................................103 Connecting to the Payload Meter.....................................103 Displayed Payload Units.............................................103 Connection Menu.....................................................104 Configure the Payload Meter.........................................104 Setting the Date and Time...........................................104 Setting the Truck Type and Serial Number............................105 Setting the Gauge Display Units.....................................105 Setting the Carryback Alarm Threshold...............................105 Setting the Truck Number............................................105 Setting the Komatsu Distributor.....................................106 Setting the Komatsu Customer........................................106 Clean Truck Tare Calibration........................................106 Inclinometer Calibration............................................107 DOWNLOADING PAYLOAD DATA................................................107 UPLOADING DATA..........................................................108 DATA ANALYSIS...........................................................109 Creating a Query....................................................109 Payload Detail Screen...............................................109 Creating Reports....................................................110 Creating Graphs.....................................................110 Exporting Data......................................................111 Importing Data......................................................111 Deleting Haul Cycle Records.........................................111 Viewing Alarms......................................................112 Deleting Alarm Records..............................................112 Patent Acknowledgment...............................................112 AUTOMATIC LUBRICATION SYSTEM................................................113 GENERAL INFORMATION.....................................................113 COMPONENT DESCRIPTION...................................................113 Filter..............................................................114 Hydraulic Motor and Pump............................................114 Grease Reservoir....................................................114 Pressure Reducing Valve.............................................114 Flow Control Valve..................................................114 Solenoid Valve......................................................115 Vent Valve..........................................................115 Interface Module....................................................115 Pressure Cut Off Switch.............................................115 Injectors...........................................................116 Grease Pressure Failure Switch......................................117 Relief Valve (unloader valve).......................................117 SYSTEM OPERATION........................................................117 Filling The Reservoir...............................................117 Priming The Automatic Lubrication System............................118 PREVENTIVE MAINTENANCE PROCEDURES.......................................118 Daily Lubrication System Inspection.................................118 250 Hour Inspection.................................................119 1000 Hour Inspection................................................119 SYSTEM CHECKOUT.........................................................119 General Checks......................................................119 Lubrication Cycle Operation.........................................120 RESERVE ENGINE OIL SYSTEM...................................................121 Operation...............................................................121 Changing Oil............................................................121 6 OPERATOR CAB AND CONTROLS.....................................................124 CAB INTERIOR................................................................124 STEERING WHEEL AND CONTROLS.................................................125 Horn Button.............................................................125 Tilt / Telescope Lever..................................................125 Multi-Function Turn Signal Switch.......................................125 Turn Signal Operation...................................................125 High Beam Headlight Operation...........................................125 Windshield Wiper Operation..............................................125 PEDALS AND RETARDER LEVER...................................................126 DYNAMIC RETARDING.......................................................126 RETARDER LEVER..........................................................126 BRAKE/RETARDER PEDAL....................................................126 ACCELERATOR PEDAL.......................................................126 OVERHEAD PANEL AND DISPLAYS.................................................127 RADIO SPEAKERS..........................................................127 WARNING ALARM BUZZER....................................................127 CAB RADIO...............................................................127 AIR CLEANER VACUUM GAUGES...............................................127 CAMERA MONITOR (OPTIONAL)...............................................127 CENTER CONSOLE..............................................................128 DIRECTIONAL CONTROL LEVER...............................................128 OVERRIDE/FAULT RESET SWITCH.............................................128 ENGINE STOP SWITCH......................................................128 WINDOW CONTROL SWITCHES.................................................129 HOIST CONTROL LEVER.....................................................129 Raising The Dump Body...................................................129 Lowering The Dump Body..................................................129 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................129 RETARD SPEED CONTROL (RSC) SWITCH.......................................130 DATA STORE BUTTON.......................................................130 12V AUXILIARY POWER OUTLETS.............................................130 FIRE SUPPRESSION CONTROL OUTLET.........................................130 COMMUNICATION RADIO OUTLET..............................................130 DIAGNOSTIC PORTS............................................................131 KOMTRAX Plus ...........................................................131 INTERFACE MODULE (IM)...................................................131 PAYLOAD METER...........................................................131 DRIVE SYSTEM OR MODULAR MINING..........................................131 DRIVE SYSTEM CONTROLLER (DSC)...........................................131 ENGINE (CENSE)..........................................................131 ENGINE (QUANTUM)........................................................131 OPERATOR SEAT (Standard)....................................................132 SEAT BELTS..............................................................132 ADJUSTMENT..............................................................132 PASSENGER SEAT (Standard)...................................................134 SEAT BELTS..............................................................134 ADJUSTMENT..............................................................134 OPERATOR SEAT (Optional)....................................................135 SEAT BELTS..............................................................135 ADJUSTMENT..............................................................135 PASSENGER SEAT (Optional)...................................................136 SEAT BELTS..............................................................136 ADJUSTMENT..............................................................136 HEATER / AIR CONDITIONER CONTROLS...........................................137 Fan Speed Control Knob..................................................137 Temperature Control Knob................................................137 Air Flow Directional Knob...............................................137 Heater/Air Conditioner Vents............................................137 INSTRUMENT PANEL ...........................................................138 CONTROL SYMBOLS.........................................................138 Cab/Air Conditioner Vents...............................................139 Status Indicator Light Panel............................................139 Hydraulic Oil Temperature Gauge.........................................139 Coolant Temperature Gauge...............................................139 Speedometer/Digital Display.............................................139 Fuel Level Gauge........................................................139 Drive System Temperature Gauge..........................................139 Hazard Warning Light Switch.............................................140 Pre-Shift Brake Test Switch.............................................140 Wheel Brake Lock Control Switch.........................................140 Rest Switch.............................................................140 Engine Warm Up..........................................................141 Key Switch..............................................................141 Warning Light...........................................................141 Digital Display Contrast Buttons........................................141 Turn Signal Indicators..................................................141 Panel Light Dimmer......................................................141 Mode Switches...........................................................141 Fog Light Swich.........................................................142 Backup Light Switch.....................................................142 Ladder Light Switch.....................................................142 Headlight/Panel Illumination Light Switch...............................142 STATUS INDICATOR LIGHT PANEL................................................143 STATUS INDICATOR LIGHT SYMBOLS..........................................143 Body Up.............................................................143 Parking Brake.......................................................143 Propel System Not Ready.............................................143 No Propel...........................................................144 Engine Warm Up......................................................144 Engine Shutdown Delay...............................................144 Retarding Grid Drier................................................144 Wheel Brake Lock....................................................144 Traction Control....................................................144 Repair Monitor......................................................144 Retractable Ladder Down.............................................144 Snapshot In Progress................................................144 Pantograph Energized................................................144 Pantograph Up.......................................................145 Service Brake.......................................................145 Dynamic Retarding...................................................145 No DC Link Voltage..................................................145 DIGITAL DISPLAY OPERATION...................................................146 Toggling Through Main Level Screens.....................................146 Toggling Through Warning Screens........................................147 Entering Payload Meter Data.............................................148 KOMTRAX Plus................................................................149 KOMTRAX Plus OPERATION..................................................149 Basic Precautions...................................................149 Interface Module....................................................150 DOWNLOADING KOMTRAX Plus DATA...........................................151 GENERAL INFORMATION.................................................151 KOMTRAX Plus DOWNLOADING PROCEDURE..................................151 Location of Downloaded Files........................................152 UPLOADING KOMTRAX Plus DATA.............................................152 ORBCOMM.................................................................154 KOMATSU WIRELESS BRIDGE (Optional)......................................154 General Information.................................................154 Communication Setup.................................................155 Switching to the KWB_SETUP Network..................................155 Setting the Computer Subnet Mask and IP Address.....................155 Setting Up the KWB..................................................156 Adding Encryption...................................................156 Final Computer Settings.............................................157 Downloading Data....................................................157 Resetting the KWB...................................................157 FUSES AND CIRCUIT BREAKERS..................................................159 VEHICLE ELECTRICAL CENTER 89............................................159 VEHICLE ELECTRICAL CENTER 90............................................161 VEHICLE ELECTRICAL CENTER 91............................................163 CIRCUIT BREAKERS........................................................165 7 LUBRICATION AND SERVICE.......................................................168 GENERAL INFORMATION.........................................................168 HYDRAULIC SYSTEM SERVICE................................................168 Hydraulic Tank......................................................168 Hydraulic Filters...................................................169 Hydraulic Pump Drive Shaft..........................................169 WHEEL MOTOR SERVICE.....................................................169 COOLANT LEVEL SERVICE...................................................169 Radiator Filling Procedure..........................................170 Coolant Specifications..............................................170 Unacceptable Practices..............................................170 RESERVE ENGINE OIL SERVICE..............................................170 Reserve Oil Tank Filling Procedure (Remote Fill)....................171 Inline Screen.......................................................171 CAB AIR FILTER SERVICE..................................................171 FUEL SYSTEM SERVICE.....................................................172 Fuel Tank Cleaning..................................................172 Fuel Filter Service.................................................172 INTAKE AIR CLEANER SERVICE..............................................173 QUICK FILL SERVICE CENTER...............................................174 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................174 LUBRICATION CHART...........................................................175 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................176 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................178 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................179 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................180 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................182 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................184 EVERY 5000 HOUR MAINTENANCE.................................................185 8 SPECIFICATIONS................................................................188 MAJOR COMPONENT DESCRIPTION.................................................188 Truck and Engine........................................................188 Traction Alternator.....................................................188 Main Control Cabinet....................................................188 AC Induction Traction Motorized Wheels..................................188 Suspension..............................................................188 Operator's Cab..........................................................188 Power Steering..........................................................188 Dynamic Retarding Grid..................................................188 Brake System............................................................188 SPECIFICATIONS..............................................................189 Engine..................................................................189 AC Electric Drive System................................................189 Dynamic Retarding.......................................................189 Battery Electric System.................................................189 Service Capacities......................................................189 Hydraulic Systems.......................................................189 Service Brakes..........................................................190 Steering................................................................190 Standard Dump Body Capacities and Dimensions............................190 Tires...................................................................190 Weight Distribution.....................................................190 Overall Truck Dimensions................................................190 9 RADIO.........................................................................194 RADIO OPERATION.............................................................194 GENERAL RADIO RECEIVER FUNCTIONS........................................194 Turning On the Power....................................................194 One-Hour Timer..........................................................194 Finding a Station.......................................................194 Setting the Presets.....................................................195 Adjusting the Receiver Audio Settings...................................195 Display.................................................................196 Adjusting the Receiver Menu Settings....................................196 Front Auxiliary Mode....................................................196 Rear Auxiliary Mode.....................................................196 CLOCK.......................................................................197 Clock/Alarm Button......................................................197 Setting the Clock.......................................................197 Setting the Alarm.......................................................197 Turning the Alarm Off...................................................198 Activating Snooze.......................................................198 CD PLAYER...................................................................199 Playing a Compact Disc..................................................199 Playing an MP3 DISC.....................................................199 CD Mode Displays........................................................199 Button Functions........................................................199 MP3 PLAYER..................................................................201 Playing MP3 Files.......................................................201 MP3 Mode Displays.......................................................201 Button Functions........................................................201 iPod®.......................................................................203 Playing an iPod®........................................................203 iPod® Mode Displays.....................................................203 Button Functions........................................................203 WEATHERBAND (USA Only)......................................................205 TROUBLESHOOTING.............................................................206 Tips About the Audio System.............................................206 Understanding Radio Reception...........................................206 Care of the Compact Discs...............................................206
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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