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Komatsu 930E-2 Dump Truck Operation & Maintenance Manual PDF Download
KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2
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KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2
- 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. 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 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 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 total maximum Gross Vehicle Weight (GVW) and this means the TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX:A30245 and up) KOMATSU 930E-2
MAIN MENU............................................................................. 0 COVER................................................................................. 1 INTRODUCTION.......................................................................... 5 FOREWARD.......................................................................... 5 ALERTS............................................................................ 6 TABLE OF CONTENTS................................................................. 7 TRUCK MODEL ILLUSTRATION.......................................................... 10 ABOUT THIS MANUAL................................................................. 11 STANDARD CHARTS AND TABLES........................................................ 13 SAFETY................................................................................ 19 GENERAL SAFETY.................................................................... 19 PRECAUTIONS DURING OPERATION...................................................... 23 OPERATING MACHINE............................................................. 24 TOWING........................................................................ 27 BATTERY....................................................................... 28 PRECAUTIONS FOR MAINTENANCE....................................................... 29 BEFORE CARRYING OUT MAINTENANCE............................................... 29 DURING MAINTENANCE............................................................ 30 TIRES......................................................................... 33 ADDITIONAL JOB SITE RULES..................................................... 34 WHEN REPAIRS ARE NECESSARY........................................................ 35 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK............................... 36 WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS................................... 39 OPERATION............................................................................. 49 OPERATING INSTRUCTIONS............................................................ 49 PREPARING FOR OPERATION....................................................... 49 SAFETY IS THINKING AHEAD...................................................... 49 AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION.......................... 49 ENGINE START-UP SAFETY PRACTICES.................................................. 52 AFTER ENGINE HAS STARTED.......................................................... 53 MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 54 MACHINE OPERATION ON THE HAUL ROAD................................................ 54 STARTING ON A GRADE WITH A LOADED TRUCK........................................... 55 PASSING........................................................................... 55 LOADING........................................................................... 55 DUMPING........................................................................... 56 TOWING............................................................................ 57 SAFE PARKING PROCEDURES........................................................... 58 NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 58 DELAYED ENGINE SHUTDOWN PROCEDURE................................................. 59 SUDDEN LOSS OF ENGINE POWER....................................................... 60 RESERVE ENGINE OIL SYSTEM......................................................... 61 OPERATOR CAB AND CONTROLS......................................................... 63 STEERING WHEEL AND CONTROLS................................................... 64 DYNAMIC RETARDER/SERVICE BRAKE PEDAL.......................................... 65 ACCELERATOR (THROTTLE) PEDAL.................................................. 65 HEATER/AIR CONDITIONER VENTS.................................................. 65 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................... 66 GRADE SPEED CHART............................................................. 67 CENTER CONSOLE CONTROLS AND FEATURES.......................................... 69 HOIST CONTROL LEVER....................................................... 70 OPERATOR SEAT................................................................. 73 INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 75 CONTROL SYMBOLS............................................................... 75 INSTRUMENT PANEL (FIGURE 3-7)..................................................... 76 PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)..... 77 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-8)........................ 83 INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-8 BY ROWS (A-E) AND COLUMNS (1-6).... 84 HAZARD WARNING LIGHTS (7)..................................................... 90 LAMP TEST SWITCH (8).......................................................... 90 LINK-ON WARNINGS LIGHT............................................................ 90 MAINTENANCE........................................................................... 91 LUBRICATION AND SERVICE........................................................... 91 SERVICE CAPACITIES............................................................ 91 HYDRAULIC TANK SERVICE........................................................ 91 COOLANT LEVEL CHECK........................................................... 92 RADIATOR FILING PROCEDURE..................................................... 92 COOLING SYSTEM RECOMMENDATIONS................................................ 92 RESERVE ENGINE OIL SYSTEM..................................................... 92 LUBRICATION CHART............................................................. 93 10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS............................ 94 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 96 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 97 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 98 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................100 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................102 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................102 LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)................................103 GENERAL DESCRIPTION...........................................................103 SYSTEM COMPONENTS.............................................................105 SYSTEM OPERATION..............................................................106 INJECTOR OPERATION............................................................110 INJECTORS.....................................................................111 GENERAL INSTRUCTIONS..........................................................108 LUBRICANT REQUIRED........................................................108 SYSTEM PRIMING............................................................108 FILTER ASSEMBLY...........................................................108 LUBRICANT PUMP............................................................109 SYSTEM CHECK -OUT.............................................................112 LUBRICATION CYCLE TIMER CHECK.............................................112 SYSTEM TROUBLESHOOTING CHART..................................................113 PREVENTATIVE MAINTENANCE PROCEDURES...........................................116 SPECIFICATIONS........................................................................117 MAJOR COMPONENT DESCRIPTIONS......................................................117 SPECIFICATIONS....................................................................119 OPTIONAL EQUIPMENT....................................................................121 PAYLOAD METER 3 (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX)..........................121 OPERATION SECTION.............................................................123 INTRODUCTION..................................................................123 DATA SUMMARY..................................................................123 DATA GATHERING................................................................123 COMPONENT DESCRIPTION.........................................................124 SYSTEM DIAGRAM............................................................124 SUSPENSION PRESSURE SENSORS...............................................124 INCLINOMETER..............................................................124 OPERATOR DISPLAY..........................................................124 OPERATOR SWITCH...........................................................125 SPEED INPUT...............................................................125 BODY-UP SWITCH............................................................125 BRAKE LOCK SWITCH.........................................................125 PAYLOAD METER.............................................................125 COMMUNICATIONS PORTS......................................................125 KEYSWITCH INPUT...........................................................126 PAYLOAD METER POWER.......................................................126 LOAD LIGHTS...............................................................126 WIRING AND TERMINATION....................................................127 TCI OUTPUTS...............................................................127 OPERATOR DISPLAY AND SWITCH...................................................128 READING THE SPEEDOMETER...................................................128 READING THE LOAD DISPLAY..................................................128 USING THE OPERATOR ID.....................................................128 USING THE LOAD AND TON COUNTER............................................128 TOTAL TON COUNTER.....................................................128 TOTAL LOAD COUNTER....................................................129 CLEARING THE COUNTERS.................................................129 VIEWING LIVE SENSOR DATA..................................................129 OTHER DISPLAY MESSAGES....................................................129 PAYLOAD OPERATION & CALCULATION...............................................130 DESCRIPTION OF HAUL CYCLE STATES..........................................130 STATES OR STAGES OF A TYPICAL HAUL CYCLE..............................130 HAUL CYCLE DESCRIPTION................................................130 LOAD CALCULATION..........................................................131 CARRY BACK................................................................131 MEASUREMENT ACCURACY......................................................131 SOURCES FOR PAYLOAD ERROR.................................................131 PAYLOAD ERROR.........................................................131 LOAD CONDITIONS.......................................................132 PRESSURE SENSORS......................................................132 SWING LOADS...........................................................132 SPEED AND DISTANCE....................................................132 HAUL CYCLE DATA...............................................................132 HAUL CYCLE DATA...........................................................133 HAUL CYCLE WARNING FLAGS..................................................134 ALARM RECORDS.............................................................135 FRAME TORQUE DATA.........................................................135 SPRUNG WEIGHT DATA........................................................136 MAXIMUM SPEED DATA........................................................136 PC SOFTWARE OVERVIEW..........................................................136 PC OVERVIEW...............................................................136 SYSTEM CONFIGURATION......................................................136 INSTALLING THE PAYLOAD METER 3 SOFTWARE...................................136 DOWNLOADING DATA..............................................................137 PLM3 SYSTEM CONFIGURATION.....................................................138 STARTING COMMUNICATIONS...................................................138 DISPLAYED PAYLOAD UNITS...............................................138 TIME UNITS............................................................138 CONNECTION MENU...........................................................138 CONNECTING TO THE PAYLOAD METER...........................................139 CONFIGURE THE PAYLOAD METER...............................................139 SETTING THE DATA AND TIME.............................................139 SETTING THE TRUCK TYPE................................................140 SETTING THE GAUGE DISPLAY UNITS.......................................140 SETTING THE FRAME SERIAL NUMBER.......................................140 SETTING THE TRUCK NUMBER..............................................140 SETTING THE KMS DISTRIBUTOR...........................................140 SETTING THE KMS CUSTOMER..............................................140 CLEAN TRUCK TARE..........................................................141 INCLINOMETER CALIBRATION..................................................141 DATA ANALYSIS.................................................................142 CREATING A QUERY..........................................................142 SORTING ON A TRUCK UNIT NUMBER........................................142 SORTING ON A TRUCK TYPE...............................................142 SORTING ON DATE RANGE.................................................143 SORTING ON TIME RANGE.................................................143 PAYLOAD DETAIL SCREEN.....................................................144 CREATING REPORTS..........................................................144 SUMMARY - ONE PAGE REPORT.............................................145 DETAILED - MULTI-PAGE REPORT..........................................145 CREATING GRAPHS...........................................................146 EXPORTING DATA............................................................146 CSV EXPORT............................................................146 COMPRESSED............................................................147 IMPORTING DATA............................................................148 DELETING HAUL CYCLE RECORDS...............................................148 VIEWING ALARMS............................................................149 DELETING ALARM RECORDS....................................................149 RADIO, AM/FM STERO CASSETTE.......................................................151
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