Komatsu 930E-2 Dump Truck Operation & Maintenance Manual 930E A30181 thru A30223 W/ MTU / DDC / 4000 Engine – PDF Download

Description

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual 

Description:

• Komatsu 930E-2 Dump Truck Operation & Maintenance Manual
• Series Number:930E A30181 thru A30223 W/ MTU / DDC / 4000 Engine
• 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
• Series Number:930E A30181 thru A30223 W/ MTU / DDC / 4000 Engine

• MAIN MENU.............................................................................  0
  COVER.................................................................................  1
  INTRODUCTION..........................................................................  9
  	FOREWARD..........................................................................  7
  	ALERTS............................................................................  8
  	TABLE OF CONTENTS.................................................................  9
  	TRUCK MODEL ILLUSTRATION.......................................................... 12
  	ABOUT THIS MANUAL................................................................. 13
  	STANDARD CHARTS AND TABLES........................................................ 15
  SAFETY................................................................................ 21
  	GENERAL SAFETY.................................................................... 21
  	PRECAUTIONS DURING OPERATION...................................................... 25
  		OPERATING MACHINE............................................................. 26
  		TOWING........................................................................ 29
  		BATTERY....................................................................... 30
  	PRECAUTIONS FOR MAINTENANCE....................................................... 31
  		BEFORE CARRYING OUT MAINTENANCE............................................... 31
  		DURING MAINTENANCE............................................................ 32
  		TIRES......................................................................... 35
  		ADDITIONAL JOB SITE RULES..................................................... 36
  	WHEN REPAIRS ARE NECESSARY........................................................ 37
  		SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK............................... 38
  	WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS................................... 41
  OPERATION............................................................................. 51
  	OPERATING INSTRUCTIONS............................................................ 51
  		PREPARING FOR OPERATION....................................................... 51
  		SAFETY IS THINKING AHEAD...................................................... 51
  		AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION.......................... 51
  	ENGINE START-UP SAFETY PRACTICES.................................................. 54
  	AFTER ENGINE HAS STARTED.......................................................... 55
  	MACHINE OPERATION SAFETY PRECAUTIONS.............................................. 56
  	MACHINE OPERATION ON THE HAUL ROAD................................................ 56
  	STARTING ON A GRADE WITH A LOADED TRUCK........................................... 57
  	PASSING........................................................................... 57
  	LOADING........................................................................... 57
  	DUMPING........................................................................... 58
  	TOWING............................................................................ 59
  	SAFE PARKING PROCEDURES........................................................... 60
  	NORMAL ENGINE SHUTDOWN PROCEDURE.................................................. 60
  	OPERATOR CAB AND CONTROLS......................................................... 63
  		STEERING WHEEL AND CONTROLS................................................... 64
  		DYNAMIC RETARDER/SERVER BRAKE PEDAL........................................... 64
  		ACCELERATOR (THROTTLE) PEDAL.................................................. 65
  		HEATER/AIR CONDITIONER VENTS.................................................. 65
  		HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS............................... 66
  		OVERHEAD PANEL AND DISPLAYS................................................... 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 3-6)..................................................... 76
  	PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)..... 77
  	OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)........................ 83
  	INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-7  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 FILLING PROCEDURE.................................................... 92
  		COOLING SYSTEM RECOMMENDATIONS................................................ 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
  		GENERAL INSTRUCTIONS..........................................................108
  			LUBRICANT REQUIRED........................................................108
  			SYSTEM PRIMING............................................................108
  			FILTER ASSEMBLY...........................................................108
  			LUBRICANT PUMP............................................................109
  		INJECTOR OPERATION............................................................110
  		INJECTORS.....................................................................111
  		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 II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)..........................121
  		GENERAL INFORMATION...........................................................123
  		LIGHTS, SWITHES, AND COMPONENTS...............................................124
  		TIPS FOR OPERATION............................................................125
  		EXTERNAL DISPLAY LIGHTS.......................................................125
  		THEORY OF OPERATION...........................................................126
  			BASIC DESCRIPTION.........................................................126
  			LINKAGE FACTOR............................................................126
  			BRAKE LOCK................................................................127
  			SOURCES OF ERROR..........................................................127
  			TYPICAL DATA FROM SERVICE CHECK MODE......................................127
  			EXAMPLE CALCULATION OF PAYLOAD............................................128
  			CALCULATION OF THE CALIBRATION LOAD.......................................128
  		TYPES OF DATA STORED..........................................................129
  			CYCLE DATA................................................................129
  			ENGINE ON/OFF DATA........................................................130
  			FAULT CODES AND WARNING DATA..............................................130
  			ENGINE OPERATION..........................................................131
  			TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES..................................131
  			OTHER DATA................................................................131
  		OPERATOR FUNCTIONS............................................................132
  			USING THE OPERATOR LOAD COUNTER...........................................132
  				DESCRIPTION...........................................................132
  				VIEWING THE OPERATOR LOAD COUNTER.....................................  0
  				CLEARING THE OPERATOR LOAD COUNTER....................................  0
  			DIMMING THE LIGHTS ONTHE DISPLAY..........................................132
  		INITIAL SETUP OF PAYLOAD METER................................................133
  			SWITCH SETTINGS...........................................................133
  			CHECKING THE OPERATOR CHECK MODE..........................................133
  			CHECKING THE SERVICE CHECK MODE...........................................134
  				SETTING "UP:00".......................................................134
  				SETTING "PL:00".......................................................134
  			CHECKING THE Gt SETTING...................................................134
  			CHECKING THE INCLINOMETER SETTINGS........................................134
  			CALIBRATING A TRUCK.......................................................135
  		DISPLAYS AT START-UP..........................................................136
  		SETUP AND MAINTENANCE.........................................................137
  			SETTING THE SPEED LIMIT...................................................137
  			SETTINGS THE OPTION CODE..................................................137
  			SETTING THE MACHINE I.D...................................................137
  			SETTING THE OPERATOR I.D..................................................138
  			SETTING THE TIME AND DATE.................................................138
  		DOWNLOAD OF PAYLOAD FAULT CODES...............................................138
  		DISPLAY OF FAULT CODES........................................................139
  		CHARTS OF ERROR CODES AND OTHER INFORMATION...................................140
  		SERVICE CHECK MODE............................................................142
  		MONITORING INPUT SIGNALS .....................................................142
  		UP FACTOR - PAYLOAD CALCULATION GAIN..........................................143
  		PL MODE - LOAD CALCULATION....................................................143
  		FINAL GEAR RATIO SELECTION....................................................144
  		BATTERY REPLACEMENT PROCEDURE.................................................145
  			REPLACING THE BATTERY.....................................................145
  			AFTER REPLACING THE BATTERY...............................................146
  		SUSPENSION PRESSURE SENSOR....................................................146
  			REMOVAL...................................................................146
  			INSTALLATION..............................................................147
  		INCLINOMETER..................................................................147
  			REMOVAL...................................................................147
  			INSTALLATION..............................................................147
  		SCOREBOARD....................................................................148
  			DESCRIPTION...............................................................148
  			MAKING CONNECTIONS........................................................148
  			WIRING DIAGRAM............................................................149
  			NORMAL OPERATION OF THE SCOREBOARD........................................150
  		PAYLOAD METER BACK PANEL......................................................150
  			CONNECTIONS (AMP PIN IDENTIFICATION)......................................151
  		PAYLOAD CIRCUIT NUMBERS.......................................................152
  		PAYLOAD METER II RE-INITIALIZATION PROCEDURE..................................153
  	RADIO, AM/FM STERO CASSETTE.......................................................155
  

Screenshot Of The Manual:

KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL 930E A30181 THRU A30223 W/ MTU / DDC / 4000 ENGINE – PDF DOWNLOAD:

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