Komatsu 930E-2 Dump Truck Operation and Maintenance Manual (CEAD012000)

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Komatsu 930E-2 Dump Truck Index:

MAIN MENU
COVER
SECTION 10 – INTRODUCTION
- FOREWORD
  - ALERTS PAGE
- TABLE OF CONTENTS
  - TRUCK MODEL ILLUSTRATION
- ABOUT THIS MANUAL
SECTION 12 – STANDARD CHARTS AND TABLES
SECTION 20 – SAFETY
- Safety Rules
- Safety Features
- Clothing And Personal Items
- Unauthorized Modification
- Leaving The Operator’s Seat
- Mounting And Dismounting
- Fire Prevention For Fuel And Oil
- Precautions With High Temperature Fluids
- Asbestos Dust Hazard Prevention
- Prevention Of Injury By Work Equipment
- Fire Extinguisher And First Aid Kit
- Precautions When Using ROPS
- Precautions For Attachments
- PRECAUTIONS DURING OPERATION
  - Safety Is Thinking Ahead
  - Safety At The Worksite
  - Fire Prevention
  - Preparing For Operation
  - Ventilation In Enclosed Areas
  - In Operator’s Cab – Before Starting The Engine
  - Mirrors, Windows, And Lights
  - OPERATING THE MACHINE
  - TOWING
  - WORKING NEAR BATTERIES
- PRECAUTIONS FOR MAINTENANCE
  - BEFORE PERFORMING MAINTENANCE
  - DURING MAINTENANCE
  - TIRES
- ADDITIONAL JOB SITE RULES
- WHEN REPAIRS ARE NECESSARY
- SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK
  - Preliminary Procedures Before Welding or Performing Maintenance
  - Normal Engine Shutdown Procedure
  - Engine Shutdown Procedure Before Welding or Performing Maintenance
SECTION 22 – WARNINGS AND CAUTIONS
SECTION 30 – OPERATING INSTRUCTIONS
- PREPARING FOR OPERATION
  - Safety Is Thinking Ahead
  - At The Truck – Ground Level Walk Around Inspection
  - Cold Weather Starting
- AFTER ENGINE HAS STARTED
- MACHINE OPERATION SAFETY PRECAUTIONS
- MACHINE OPERATION ON THE HAUL ROAD
- STARTING ON A GRADE WITH A LOADED TRUCK
- PASSING
- LOADING
- DUMPING
  - Raising The Dump Body
  - Lowering The Dump Body
- TOWING
- SAFE PARKING PROCEDURES
- NORMAL ENGINE SHUTDOWN PROCEDURE
- DELAYED ENGINE SHUTDOWN PROCEDURE
- SUDDEN LOSS OF ENGINE POWER
- RESERVE ENGINE OIL SYSTEM (Optional)
SECTION 32 – OPERATOR CAB AND CONTROLS
- STEERING WHEEL AND CONTROLS
  - Horn Button
  - Telescope Lock Ring
  - Tilt Wheel Lever
  - Turn Signal/Headlight Dimmer
- DYNAMIC RETARDING
  - Retarder Control Lever
  - Dynamic Retarder/Service Brake Pedal
  - Accelerator (Throttle) Pedal
  - Starting on a Grade With a Loaded Truck
- GRADE/SPEED RETARD CHART
- INSTRUMENT PANEL
- OVERHEAD PANEL AND DISPLAYS
- CENTER CONSOLE
  - F-N-R Selector Switch
  - Hoist Control Lever
  - Raising The Dump Body
  - Lowering The Dump Body:
  - Ash Tray
  - Lighter
  - L.H. Window Control Switch
  - R.H. Window Control Switch
  - Engine Shutdown Switch
  - Override/Fault Reset Switch
  - Retard Speed Control (RSC) Switch
  - Retard Speed Control (RSC) Adjust Dial
  - PSC Download Port
  - Engine Diagnostics Download Port
  - TCI Download Port
  - Passenger Seat
  - Engine Control System
  - Modular Mining System
  - Payload Meter And Download Connector
- OPERATOR COMFORT
  - OPERATOR SEAT
  - HEATER / AIR CONDITIONER COMPART MENT AND CONTROLS
- INSTRUMENT PANEL AND INDICATOR LIGHTS
  - CONTROL SYMBOLS
  - INSTRUMENT PANEL
- PANEL GAUGES, INDICATORS, AND CONTROLS
  - Key Switch
  - Starting
  - Engine Shutdown Switch with 5 Minute Idle Timer Delay
  - Fog Lights (Optional)
  - Ladder Light Switch
  - Manual Backup Switch
  - Panel Illumination Lights
  - Cab/Air Conditioner Vents
  - Rotating Beacon Light Switch (Optional)
  - Heated Mirror Switch (Optional)
  - Wheel Brake Lock Control
  - Parking Brake Control
  - Tachometer
  - Right Turn Signal Indicator
  - High Beam Indicator
  - Left Turn Signal Indicator
  - Speedometer/Payload Meter Display
  - Voltmeter
  - Engine Oil Pressure Gauge
  - Water Temperature Gauge
  - Fuel Gauge
  - AC Drive System Temperature Gauge
  - Hourmeter
  - Hydraulic Oil Temperature Gauge
  - Rest Switch
  - Light Switch
  - Windshield Wiper and Washer
  - Panel Light Dimmer
  - Payload Meter Switch
  - OVERHEAD STATUS / WARNING INDICATORS
  - STATUS / WARNING INDICATOR LIGHT SYMBOLS
SECTION 40 – LUBRICATION AND SERVICE
- 930E SERVICE CAPACITIES
- HYDRAULIC TANK SERVICE
  - Adding Oil
- WHEEL MOTOR SERVICE
- COOLANT LEVEL CHECK
- RADIATOR FILLING PROCEDURE
- RESERVE ENGINE OIL SYSTEM (Optional)
  - Reserve Oil Tank Filling Procedure (Remote fill)
- LUBRICATION CHART
- 10 HOUR (DAILY) INSPECTION
- 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 500 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
- 2500 HOUR MAINTENANCE CHECKS
- 5000 HOUR MAINTENANCE CHECKS
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM
- GENERAL DESCRIPTION
- SYSTEM COMPONENTS
- SYSTEM OPERATION
  - Normal Operation
  - Pressure Failure Detection Circuits
- GENERAL INSTRUCTIONS
  - Required Lubricant For System
  - System Priming
  - Filter Assembly
- LUBRICANT PUMP
  - Pump Housing Oil Level
  - Pump Pressure Control
  - Pressure Control Valve Adjustment
- INJECTOR OPERATION
- INJECTORS (SL-1 Series “H”))
  - Injector Specifications
  - Injector Adjustment
- SYSTEM CHECKOUT
  - Lubrication Cycle Timer Check
  - Lubrication Cycle Timer Adjustment
- SYSTEM TROUBLESHOOTING CHART
- PREVENTATIVE MAINTENANCE PROCEDURES
  - Daily Lubrication System Inspection
  - 250 Hour Inspection
  - 1000 Hour Inspection
SECTION 50 – MAJOR COMPONENT DESCRIPTION
SECTION 60 – PAYLOAD METER III™ – INDEX
- OPERATION SECTION
  - Introduction
  - Data Summary
  - Data Gathering
- COMPONENT DESCRIPTION
  - System Diagram
  - Suspension Pressure Sensors
  - Inclinometer
  - Operator Display
  - Operator Switch
  - Speed Input
  - Body-Up Switch
  - Brake Lock Switch
  - Payload Meter
  - Communications Ports
  - Keyswitch Input
  - Payload Meter Power
  - Load Lights
  - Wiring and Termination
  - TCI Outputs
- OPERATOR’S DISPLAY AND SWITCH
  - Reading the Speedometer
  - Reading the Load Display
  - Using the Operator ID
  - Using the Load and Ton Counter
  - Total Ton Counter
  - Total Load Counter
  - Clearing the Counters
  - Viewing Live Sensor Data
  - Other Display Messages
- PAYLOAD OPERATION & CALCULATION
  - Description of Haul Cycle States
  - Haul Cycle Description
  - Load Calculation
  - Carry Back
  - Measurement Accuracy
- SOURCES FOR PAYLOAD ERROR
  - Payload Error
  - Loading Conditions
  - Pressure Sensors
  - Swingloads
  - Speed and Distance
- HAUL CYCLE DATA
  - Haul Cycle Data
  - Haul Cycle Warning Flags
  - A: Continuous Loading
  - B: Loading to Dumping Transition
  - C: No Final Load
  - D: Maneuvering to Dumping Transition
  - E: Average Load or Tare Used
  - F: Final Zone to Dumping Transition
  - H: False Body Up
  - I: Body Up Signal Failed
  - J: Speed Sensor Failed
  - K: New Tare Not Calculated
  - L: Incomplete Haul Cycle
  - M: Haul Cycle Too Long
  - N: Sensor Input Error
  - Alarm Records
  - Frame Torque Data
  - Sprung Weight Data
  - Maximum Speed Data
- PC SOFTWARE OVERVIEW
  - PC Overview
  - System Configuration
  - Installing the PLMIII Software
- DOWNLOADING DATA
- PLMIII SYSTEM CONFIGURATION
  - Starting Communications
  - Displayed Payload Units
  - Time Units
  - Connection Menu
  - Connecting to the Payload Meter
  - Configure the Payload Meter
  - Setting the Date and Time
  - Setting the Truck Type
  - Setting the Gauge Display Units
  - Setting the Frame Serial Number
  - Setting the Truck Number
  - Setting the Komatsu Distributor
  - Setting the Komatsu Customer
  - Clean Truck Tare
  - Inclinometer Calibration
- DATA ANALYSIS
  - Sorting on Truck Unit Number
  - Creating a Query
  - Sorting on Truck Type
  - Sorting on Date Range
  - Sorting on Time Range
  - Payload Detail Screen
  - Creating Reports
  - Summary – one page report
  - Detailed – multi-page report
  - Creating Graphs
  - Exporting Data
  - CSV Export
  - Compressed
  - To export data in ZIP format:
  - Importing Data
  - Deleting Haul Cycle Records
  - Viewing Alarms
  - Deleting Alarm Records
SECTION 70 – RADIO, AM / FM STEREO CASSETTE
- SETTING THE TIME
- GENERAL RECEIVER FUNCTIONS
  - Turning The Power On And Off
  - Display
  - Setting The Default Display
  - Adjusting Display Brightness
- OPERATING THE RADIO
  - BAND
  - TUNE/SEEK
  - Manual Tuning
  - SEEK Mode
  - SCAN
  - AUTO
- PROGRAMMING PRESET STATIONS
- OPERATION OF THE WEATHERBAND (U.S.)
- ADJUSTING THE RECEIVER SETTINGS
- PROGRAMMABLE EJECT DEFAULT
- CASSETTE PLAYER
  - Playing A Cassette
  - Cassette Functions
  - Bad Tape Detect
- CASSETTE PLAYER CLEANING