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Komatsu 930E-2 Dump Truck Operation & Maintenance Manual - PDF DOWNLOAD
Komatsu 930E-2 Dump Truck Operation & Maintenance Manual
Description:
Komatsu 930E-2 Dump Truck Operation & Maintenance Manual
- 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
MAIN MENU............................................................................. 0 COVER................................................................................. 1 INTRODUCTION.......................................................................... 8 FOREWARD.......................................................................... 6 ALERTS............................................................................ 7 CONTENTS.......................................................................... 8 TRUCK MODEL ILLUSTRATION.......................................................... 11 ABOUT THIS MANUAL................................................................. 12 STANDARD CHARTS AND TABLES........................................................ 14 SAFETY................................................................................ 20 GENERAL SAFETY.................................................................... 20 PRECAUTIONS DURING OPERATION...................................................... 24 OPERATING MACHINE............................................................. 25 TOWING........................................................................ 28 BATTERY....................................................................... 29 PRECAUTIONS FOR MAINTENANCE....................................................... 30 BEFORE CARRYING OUT MAINTENANCE............................................... 30 DURING MAINTENANCE............................................................ 31 TIRES......................................................................... 8 ADDITIONAL JOB SITE RULES..................................................... 35 WHEN REPAIRS ARE NECESSARY........................................................ 36 SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK............................... 37 WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS................................... 40 OPERATION............................................................................. 50 OPERATING INSTRUCTIONS............................................................ 50 PREPARING FOR OPERATION....................................................... 50 SAFETY IS THINKING AHEAD...................................................... 50 AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION.......................... 50 ENGINE START-UP SAFETY PRACTICES.................................................. 53 AFTER ENGINE HAS STARTED.......................................................... 54 MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 55 MACHINE OPERATION ON THE HAUL ROAD................................................ 55 STARTING ON A GRADE WITH A LOADED TRUCK........................................... 56 PASSING........................................................................... 56 LOADING........................................................................... 56 DUMPING........................................................................... 57 TOWING............................................................................ 58 SAFE PARKING PROCEDURES........................................................... 59 NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 59 OPERATOR CAB AND CONTROLS......................................................... 62 STEERING WHEEL AND CONTROLS................................................... 63 DYNAMIC RETARDER/SERVER BRAKE PEDAL........................................... 64 ACCELERATOR (THROTTLE) PEDAL.................................................. 64 HEATER/AIR CONDITIONER VENTS.................................................. 64 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................... 65 OVERHEAD PANEL AND DISPLAYS................................................... 66 CENTER CONSOLE CONTROLS AND FEATURES.......................................... 68 HOIST CONTROL LEVER....................................................... 69 OPERATOR SEAT................................................................. 72 INSTRUMENT PANEL AND INDICATOR LIGHTS............................................. 74 CONTROL SYMBOLS............................................................... 74 INSTRUMENT PANEL (FIGURE 3-6)..................................................... 74 PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)..... 76 OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)........................ 82 INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6).... 83 HAZARD WARNING LIGHTS (7)..................................................... 89 LAMP TEST SWITCH (8).......................................................... 89 LINK-ON WARNINGS LIGHT............................................................ 89 MAINTENANCE........................................................................... 90 LUBRICATION AND SERVICE........................................................... 90 SERVICE CAPACITIES............................................................ 90 HYDRAULIC TANK SERVICE........................................................ 90 COOLANT LEVEL CHECK........................................................... 91 RADIATOR FILING PROCEDURE..................................................... 91 COOLING SYSTEM RECOMMENDATIONS................................................ 91 LUBRICATION CHART............................................................. 92 10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS............................ 93 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................... 95 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 96 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 97 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................... 99 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................100 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..................................101 LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)................................102 GENERAL DESCRIPTION...........................................................102 SYSTEM COMPONENTS.............................................................104 SYSTEM OPERATION..............................................................105 INJECTOR OPERATION............................................................109 INJECTORS.....................................................................110 GENERAL INSTRUCTIONS..........................................................107 LUBRICANT REQUIRED........................................................107 SYSTEM PRIMING............................................................107 FILTER ASSEMBLY...........................................................107 LUBRICANT PUMP............................................................108 SYSTEM CHECK -OUT.............................................................111 LUBRICATION CYCLE TIMER CHECK.............................................111 SYSTEM TROUBLESHOOTING CHART..................................................112 PREVENTATIVE MAINTENANCE PROCEDURES...........................................115 SPECIFICATIONS........................................................................116 MAJOR COMPONENT DESCRIPTIONS......................................................116 SPECIFICATIONS....................................................................118 OPTIONAL EQUIPMENT....................................................................120 PAYLOAD METER II (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX).........................120 GENERAL INFORMATION...........................................................122 LIGHTS, SWITHES, AND COMPONENTS...............................................123 TIPS FOR OPERATION............................................................124 EXTERNAL DISPLAY LIGHTS.......................................................124 THEORY OF OPERATION...........................................................125 BASIC DESCRIPTION.........................................................125 LINKAGE FACTOR............................................................125 BRAKE LOCK................................................................126 SOURCES OF ERROR..........................................................126 TYPICAL DATA FROM SERVICE CHECK MODE......................................126 EXAMPLE CALCULATION OF PAYLOAD............................................127 CALCULATION OF THE CALIBRATION LOAD.......................................127 TYPES OD DATA STORED..........................................................128 CYCLE DATA................................................................128 ENGINE ON/OFF DATA........................................................129 FAULT CODES AND WARNINGS DATA.............................................129 ENGINE OPERATION..........................................................130 TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES..................................130 OTHER DATA................................................................130 OPERATOR FUNCTIONS............................................................131 USING THE OPERATOR LOAD COUNTER...........................................131 DESCRIPTION...........................................................131 VIEWING THE OPERATOR LOAD COUNTER.....................................131 CLEARING THE OPERATOR LOAD COUNTER....................................131 DIMMING THE LIGHTS ONTHE DISPLAY..........................................131 INITIAL SETUP OF PAYLOAD METER................................................132 SWITCH SETTINGS...........................................................132 CHECKING THE OPERATOR CHECK MODE..........................................132 CHECKING THE SERVICE CHECK MODE...........................................133 SETTING "UP:00".......................................................133 SETTING "PL:00".......................................................133 CHECKING THE Gt SETTING...................................................133 CHECKING THE INCLINOMETER SETTINGS........................................133 CALIBRATING A TRUCK.......................................................134 DISPLAYS AT START-UP..........................................................135 SETUP AND MAINTENANCE.........................................................136 SETTING THE SPEED LIMIT...................................................136 SETTINGS THE OPTION CODE..................................................136 SETTING THE MACHINE I.D...................................................136 SETTING THE OPERATOR I.D..................................................137 SETTING THE TIME AND DATE.................................................137 DOWNLOAD OF PAYLOAD FAULT CODES...............................................137 DISPLAY OF FAULT CODES........................................................138 CHARTS OF ERROR CODES AND OTHER INFORMATION...................................139 SERVICE CHECK MODE............................................................141 MONITORING INPUT SIGNALS .................................................141 UP FACTOR - PAYLOAD CALCULATION GAIN......................................142 PL MODE - LOAD CALCULATION................................................142 FINAL GEAR RATIO SELECTION....................................................143 BATTERY REPLACEMENT PROCEDURE.................................................144 REPLACING THE BATTERY.....................................................144 AFTER REPLACING THE BATTERY...............................................145 SUSPENSION PRESSURE SENSOR....................................................145 REMOVAL...................................................................145 INSTALLATION..............................................................146 INCLINOMETER..................................................................146 REMOVAL...................................................................146 INSTALLATION..............................................................146 SCOREBOARD....................................................................147 DESCRIPTION...............................................................147 MAKING CONNECTIONS........................................................147 WIRING DIAGRAM............................................................148 NORMAL OPERATION OF THE SCOREBOARD........................................149 PAYLOAD METER BACK PANEL......................................................149 CONNECTIONS (AMP PIN IDENTIFICATION)......................................150 PAYLOAD CIRCUIT NUMBERS.......................................................151 PAYLOAD METER II RE-INITIALIZATION PROCEDURE..................................152 RADIO, AM/FM STERO CASSETTE.......................................................154
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