Komatsu 930E-2 Dump Truck Operation & Maintenance Manual – PDF Download

Description

Komatsu 930E-2 Dump Truck Operation & Maintenance Manual

Description:

• Komatsu 930E-2 Dump Truck Operation & Maintenance Manual
• SERIAL NUMBERS 930E A30156 thru A30180
  W/ Cummins QSK60 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 wheelmotor 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 NUMBERS 930E A30156 thru A30180
  W/ Cummins QSK60 Engine

MAIN MENU.............................................................................  0
COVER.................................................................................  1
INTRODUCTION..........................................................................  7
	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
	 DELAYED ENGINE SHUTDOWN PROCEDURE................................................ 61
	OPERATOR CAB AND CONTROLS......................................................... 63
		STEERING WHEEL AND CONTROLS................................................... 64
		DYNAMIC RETARDER/SERVER BRAKE PEDAL........................................... 65
		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 (RECIPROCATING  PUMP)........................103
		SYSTEM COMPONENTS.............................................................103
		SYSTEM OPERATION..............................................................105
		GENERAL INSTRUCTIONS..........................................................106
			LUBRICANT REQUIRED........................................................106
			SYSTEM PRIMING............................................................106
		SYSTEM CHECK -OUT.............................................................106
		24VDC SOLID STATE TIMER CHECK-OUT & ADJUSTMENT................................107
		INJECTORS AND ADJUSTMENT......................................................108
		PUMP CYCLE ("FLASHER") TIMER, INSTALLATION & ADJUSTMENT.......................110
		PRESSURE SWITCH...............................................................110
		PRESSURE REDUCER ADJUSTMENT...................................................112
		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.....................................132
				CLEARING THE OPERATOR LOAD COUNTER....................................132
			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

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KOMATSU 930E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL – PDF DOWNLOAD:

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