Day: June 5, 2025

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Complete service repair manual with electrical wiring diagrams for Komatsu 980E Dump Trucks, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu 980E Dump Trucks workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

CEBM031002 – 980E-4 Dump Truck Shop Manual (SN A40003-A40051, Engine SSDA18V170).pdf
CEBM031601 – 980E-4 Dump Truck Shop Manual (SN A40052 & up, Engine 18V170).pdf

PRODUCT DETAILS:
Total Pages: 1,154 + 1,070 pages
File Format: PDF
Language: English

TABLE OF CONTENTS
00 Index and foreword
Index
Foreword, safety and general information
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
Steering circuit
Hoist circuit
Brake circuits
Electrical system, 24 volt
Electrical system, AC drive
Cab air conditioning
Reserve engine oil system
20 Standard value table
Standard service value table
30 Testing and adjusting
Steering, brake cooling and hoist hydraulic system
Brake system
Accumulators and suspensions
Interface module (IM)
KOMTRAX Plus
Payload meter IV
Komatsu Wireless Bridge (KWB)
Electrical system, AC Drive
Cab air conditioning
40 Troubleshooting
Fuse, diode and relay locations
AC drive system fault codes
Troubleshooting by failure code, Part 1
Troubleshooting by failure code, Part 2
Troubleshooting by failure code, Part 3
Troubleshooting by failure code, Part 4
Troubleshooting by failure code, Part 5
Troubleshooting by failure code, Part 6
Orbcomm
Cab air conditioning
Steering system
50 Disassembly and assembly
Service tools
Wheels, spindles and rear axle
Brake system
Steering system
Suspensions
Hoist circuit
Body and structures
Operator cab
Cab air conditioning
Power module
90 Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams

CEBM031002 – 980E-4 Dump Truck Shop Manual (SN A40003-A40051, Engine SSDA18V170)….2
  00 Index and foreword….4
    Index….4
      Composition of shop manual….5
      Table of contents….7
    Foreword, safety and general information….22
      Foreword….25
      How to read the shop manual….26
        Composition of shop manual….26
        Revision and distribution….26
        Symbols….27
      General safety….28
        Safety rules….28
        Safety features….28
        Fire extinguisher and first aid kit….28
        Clothing and personal items….28
        Leaving the operator seat….29
        Mounting and dismounting….29
        Fire prevention for fuel and oil….29
        Precautions with high temperature fluids….30
        Asbestos dust hazard prevention….30
        Prevention of injury by work equipment….30
        Unauthorized modification….30
        Precautions when using ROPS….30
        Precautions for attachments….31
        Precautions for starting the truck….31
      Precautions before operating the truck….31
        Safety at the worksite….31
        Fire prevention….32
        Ventilation in enclosed areas….32
        Preparing for operation….32
        Mirrors, windows and lights….32
        In operator cab (before starting the engine)….32
        Seat Belts….32
      Precautions while operating the truck….33
        When starting the engine….33
        General truck operation….33
        Ensuring good visibility….33
        Traveling….34
        Traveling in reverse….34
        Traveling on slopes….34
        Operating on snow or ice….34
        Avoid damage to dump body….34
        Driving near high voltage cables….35
        When dumping….35
        When loading….35
        Working on loose ground….35
        Parking the truck….35
        Towing….35
      Working near batteries….36
        Battery hazard prevention….36
        Starting with jumper cables….37
        Jump starting with receptacles….37
      Precautions before performing service….38
        Warning tag….38
        Stopping the engine….38
        Proper tools….38
        Use of Tie-Off Anchor During Maintenance and Repair….38
        Securing the dump body….39
        Jack point locations….40
      Precautions while performing service….41
        Keep the truck clean….41
        Attachments….41
        Working under the truck….41
        Rotating fan and belts….41
        Adding fuel or oil….41
        Use of lighting….41
        Radiator coolant level….42
        Precautions with the battery….42
        Precautions with high pressure oil….42
        Handling high pressure hoses….42
        Precautions when performing maintenance near high temperature or high pressure….42
        Waste materials….42
      Tires….43
        Inspection….43
        Maintenance….43
        Storage….44
        Handling….45
      Precautions for performing repairs….46
        Engine shutdown procedure after AC drive system failure….46
      Precautions for welding on the truck….47
      Capacitor discharge system….48
        Necessary tools….48
        Warnings and cautions….49
        Manual DC link capacitor discharge procedure….50
        Failure of the discharge system….52
        Manual discharge of capacitors….53
        Short isolated capacitor terminals….55
      Handling electrical equipment and hydraulic components….56
        Points to remember when handling electrical equipment….56
        Points to remember when handling hydraulic equipment….62
      Standard tightening torques….64
        Effect of special lubricants on fasteners and standard torque values….64
        Suggested sources for rust preventive grease….64
        SAE grade 5 and grade 8 hex head capscrew and nut assemblies….65
        SAE grade 9 capscrews….66
        Class 10.9 capscrews and class 10 nuts….66
        Standard tightening torques for fittings….67
      Conversion tables….69
        Common conversion multipliers….69
    Operating instructions….74
      Preparing for operation….76
        Walk around inspection….76
      Retractable ladder system….80
        Using the in-cab control panel….81
        Using the ground level control box….84
        Emergency operation….85
      Engine start-up….86
      After engine start-up….87
      Pre-shift brake check….87
        Operation….88
        Brake test setup….89
        Service brake test….89
        Parking brake test….90
        Retard system test….91
      Emergency steering system….91
        Operation….91
        Pre-operation testing….91
      Precautions during truck operation….92
      Operating on a haul road….93
      Starting on a grade with a loaded truck….94
      Sudden loss of engine power or loss of drive system function….94
      Fuel depletion….95
      Towing….95
        Special Wiring Harness….96
        Towing Procedure….96
      Loading the dump body….97
        Overload speed limit function….98
      Dumping a load….98
        Raising the dump body….98
        Lowering the dump body (on flat ground)….99
        Lowering the dump body (over a berm or into a crusher)….100
      Disabled truck dumping procedure….100
        Hookup….101
        Raising the body….101
        Lowering the body….101
      Safe parking procedure….102
      Normal engine shutdown procedure….102
  01 Specification….104
    Specification and technical data….104
      Specification drawing….106
      Specifications….107
      Weight table….109
      Fuel, coolant and lubricants….110
        Suspension cylinder oil and nitrogen specifications….111
  10 Structure, functions and maintenance standard….114
    Steering circuit….114
      Steering circuit operation….116
      Steering circuit components….120
        Steering control unit….120
        High pressure filter….120
        Steering accumulators….120
        Bleeddown manifold….121
        Steering accumulator bleeddown solenoid….121
        Hoist up limit solenoid….121
        Quick disconnect ports….121
        Flow amplifier….121
      Steering/brake pump operation….122
    Hoist circuit….124
      Hoist circuit operation….126
      Hoist circuit components….127
        Hydraulic tank….127
        Hoist pump….127
        High pressure filters….127
        Hoist valve….128
        Inlet sections….128
        Tank ports (front) spool section….128
        Work ports (rear) spool section….129
        Hoist pilot valve….129
        Hoist limit solenoid….130
        Pilot operated check valve….130
        Overcenter manifold….130
      Hoist pilot valve operation….131
        Float position with body down….131
        Power up operation….133
        Hold operation….135
        Power down operation….137
        Float operation….139
    Brake circuits….142
      General information….144
      Service brake circuit operation….145
      Secondary braking….147
      Automatic brake application (Auto apply)….147
      Parking brake circuit operation….148
        Normal operation (key switch ON, engine on)….148
      Wheel brake lock circuit operation….149
      Brake warning circuit operation….149
      Brake assembly wear data….151
    Electrical system, 24 volt….154
      Battery supply system….156
        Batteries….156
        24VDC auxiliary battery receptacles….156
        Engine shutdown switch….157
        Battery disconnect switches….157
        Propel lockout lever….157
        System busy light….157
        LED lights….157
      Engine starting system with prelube….158
        Prelube operation….158
        Cranking operation….159
      Auxiliary control cabinet components….160
        24VDC to 12VDC converter….160
        Interface module (IM)….160
        VEC blocks….161
        Light timers….161
        Relays….161
        Ground terminals….161
        24VDC power terminals….161
      Body-up switch….162
      Hoist limit switch….163
    Electrical system, AC drive….166
      General system operation….167
      System components….169
        Drive system controller (DSC)….169
        Diagnostic information display (DID) panel….170
      DSC software functions….170
        Input processing….170
        State machine….170
        DC link state….173
        Engine control….174
      Alternator field control….175
        Desired DC link voltage….175
        Self-load….175
        Propel torque control….175
        Retard torque control….176
        Wheel slide control….176
        Resistor grid control….176
        Chopper voltage control….176
      Event detection and processing….177
        Power-on tests….177
        Initiated tests….178
        Periodic tests….178
        Event restrictions….178
      Event logging and storage….178
        Data packs….179
        Event reset….179
      Abnormal conditions/overriding functions….180
        Engine shutdown/Engine not running….180
        Limp home mode….180
      AC drive system component table….181
      Electronic accelerator and retarder pedals….188
    Cab air conditioning….190
      General information….191
        Environmental impact of air conditioning….191
        Air conditioning for off-highway vehicles….191
      Principles of refrigeration….192
        Air conditioning….192
        Refrigeration – the act of cooling….192
        The refrigeration cycle….192
      Air conditioning system components….194
        Relays….194
        Fan motor and speed control….194
        Cab air filter….194
        Heater core….194
        Actuators….194
        Compressor (refrigerant pump)….196
        Service valves….196
        Condenser….196
        Receiver-drier….196
        Expansion valve….197
        Accumulator….197
        Evaporator core….197
      Air conditioning system electrical circuit….198
        Thermostat….198
        Compressor clutch….198
        Trinary™ switch….199
    Reserve engine oil system….202
      General information….204
      Operation….205
        Pumping unit….205
        LED monitor lights….206
        Tank auto fill control….207
        Filling procedure (remote fill feature)….207
      Service….208
        Every 10 hours (each shift)….208
        Every 500 hours….208
        Changing oil….208
      Troubleshooting….209
        Circuit fuses….209
      Auto fill system electrical schematic….210
  20 Standard value table….212
    Standard value table….212
      Standard value table for truck….214
  30 Testing and adjusting….220
    Steering, brake cooling and hoist hydraulic system….220
      General information on system checkout….222
      Hydraulic system checkout procedures….223
        Required equipment….223
        Bleeddown procedure….223
        Preliminary steps….225
        Hydraulic system flushing procedure….225
        Flow amplifier adjustment….229
        Steering pump unloader valve adjustment….229
        Auxiliary accumulator pressure verification….230
        System diagnostics….230
        Hoist counterbalance valve adjustment….232
        Final steps….233
        Oil cleanliness check….233
      Hydraulic system checkout data sheet….234
      Toe-in adjustment….237
      Hoist cylinder leakage test….238
      Steering cylinder leakage test….238
    Brake system….240
      General information on system checkout….242
      Brake system checkout procedures….242
        Required equipment….242
        Initial system setup….244
        Brake lock / secondary braking checkout….244
        Parking brake checkout….245
        Service brake checkout….246
        Low brake accumulator pressure and auto apply checkout….247
        Parking brake control logic checkout….249
        Brake lock control logic checkout….250
      Brake system checkout data sheet….253
      Brake piston leakage test….261
      Brake seal pressure test….261
      Oil separator seal pressure test….261
      Wet disc brake bleeding procedure….262
      Parking brake bleeding procedure….263
      Service brake disc wear inspection….264
      Parking brake disc wear inspection….265
      Brake valve bench test and adjustment….266
        Test setup procedure….267
        Brake valve output pressure adjustment….267
        Final test and adjustment….268
      Dual relay valve bench test and adjustment….269
        Test setup procedure….270
        Relay valve output pressure adjustment….270
    Accumulators and suspensions….274
      Accumulator charging precautions….275
        Temperature during precharge….275
      Bladder accumulator charging procedure….276
        Precharge maintenance….279
      Bladder accumulator storage….280
        Bladder storage….280
        Installing a bladder accumulator from storage….280
      Bladder accumulator leak testing….281
      Piston accumulator charging procedure….282
      Piston accumulator storage….284
      Piston accumulator leak testing….284
      Suspension oiling and charging procedures….285
        Equipment list….286
        Installing the charging kit….286
        Removing the charging kit….286
        Support blocks for oiling and charging dimensions….287
        Front suspension oiling….287
        Front suspension nitrogen charging….288
        Rear suspension oiling….290
        Rear suspension nitrogen charging….291
      Suspension pressure test….292
    Interface module (IM)….294
      Interface module software….296
        Flashburn program installation….296
        Interface module application code installation….297
        Interface module realtime data monitor software installation….297
      Interface module checkout procedures….298
        Necessary equipment….298
        Preliminary….299
        Check digital inputs to the interface module….300
        Check analog inputs to the interface module….303
        Check serial interfaces to the interface module….303
        Check outputs from the interface module….304
      CHECKOUT PROCEDURE….305
    KOMTRAX Plus….310
      KOMTRAX Plus software and tools….312
      KOMTRAX Plus controller setup procedure….312
        Preliminary steps….312
        Setup procedure….312
      KOMTRAX Plus initialization form….316
      Precautions when replacing the KOMTRAX Plus controller….317
      KOMTRAX Plus controller checkout procedure….319
        Preliminary steps….319
        Checkout procedure….319
    Payload meter IV….322
      Payload meter IV software and tools….323
      Payload meter IV system configuration….323
        Connecting to the payload meter IV web server….323
        Configuring a static IP address….323
      Payload meter IV software installation….325
      Payload meter IV checkout procedure….326
      PLM IV system checkout data sheet….330
    Electrical system, AC drive….332
      General information….333
        Test equipment….333
        Circuit continuity and resistance checks….333
        Megger test for grounds….334
        Troubleshooting for grounds….337
        Low voltage power supply checks….337
        Drive System Controller (DSC) card checks….338
        Propulsion system software installation….339
        Software installation procedure….340
        DSC manual test procedures….341
        Accelerator pedal, retarder pedal, and retarder lever calibration and checks….344
        Set truck ID number….348
        Control cabinet pressure switch check….349
      Checks prior to self load engine test (loadbox)….351
        Verifying DSC Software Version….351
        Resetting and erasing DSC event data….352
      Engine running tests….353
        Battery boost circuit verification….353
        Selector switch check….356
        Ground detection network tests….358
        Self load engine test (loadbox) procedure….363
      Diagnostic information display (DID) panel….365
        DID panel display selection….365
        DID modes display….367
        Function key F1 – DID events or faults display….368
        Function key F4 – DID menu display….371
        DID self load engine test (loadbox)….372
        DID link capacitance test….374
        DID speedometer test….375
        DID view software version….377
        DID view overspeed setting….379
        DID view data menu….380
        DID inverter cutout menu….385
        DID truck configuration menu….387
        Language selection….394
      Viewing event and statistical data….395
        Viewing the DSC event summary, trigger data, and data packs….395
        Viewing the statistical data….398
      Logic screens….399
      Datalogger function….401
        Setting up the datalogger….401
        Starting the datalogger….403
      Uploading data….405
        Consolidated truck data save….405
        USB drive….406
    Cab air conditioning….408
      General information….409
      Service tools and equipment….410
        Recovery/recycle station….410
        Leak detector….410
        Manifold gauge set….411
        Service valves….412
        Vacuum pump….412
      Detecting leaks….413
      System performance test….414
      Checking system oil….415
      System flushing….416
      Installing the manifold gauge set….417
        Purging air from the service hoses….417
      Recovering and recycling refrigerant….418
        Draining oil from previous recovery cycle….419
        Recovery cycle….419
        Recycling procedure….419
      Evacuating the air conditioning system….420
      Charging the air conditioning system….421
  40 Troubleshooting….424
    Fuse, diode and relay locations….424
      Vehicle Electrical Center (VEC-89)….425
      Vehicle Electrical Center (VEC-90)….427
      Vehicle Electrical Center (VEC-91)….429
      Vehicle Electrical Center (RTMR1)….431
    AC drive system fault codes (DSC)….434
      DID panel fault code tables….436
    Troubleshooting by fault code, Part 1….460
      Fault Code A001: Left front suspension pressure sensor signal high….462
      Fault Code A002: Left front suspension pressure sensor signal low….463
      Fault Code A003: Right front suspension pressure sensor signal high….464
      Fault Code A004: Right front suspension pressure sensor signal low….465
      Fault Code A005: Left rear suspension pressure sensor signal high….466
      Fault Code A006: Left rear suspension pressure sensor signal low….467
      Fault Code A007: Right rear suspension pressure sensor signal high….468
      Fault Code A008: Right rear suspension pressure sensor signal low….469
      Fault Code A009: Incline sensor signal high….470
      Fault Code A010: Incline sensor signal low….471
      Fault Code A011: Payload meter speed sensor signal has failed….472
      Fault Code A013: Body up switch has failed….473
      Fault Code A014: Payload meter checksum computation has failed….474
      Fault Code A018: Right rear flat suspension cylinder warning….475
      Fault Code A019: Left rear flat suspension cylinder warning….476
      Fault Code A022: Carryback load excessive….477
      Fault Code A101: High pressure detected across an hydraulic pump filter….478
      Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level….480
      Fault Code A107: GE has generated a propel system caution….481
      Fault Code A108: GE has generated a propel system temperature caution….482
      Fault Code A109: GE has generated a propel system reduced level signal….483
      Fault Code A111: Low steering pressure warning….484
      Fault Code A115: Low steering precharge pressure detected….485
      Fault Code A117: Low brake accumulator pressure warning….486
      Fault Code A118: Brake pressure is low while in brake lock….487
      Fault Code A123: GE has generated a reduced retarding caution….488
      Fault Code A124: GE has generated a no propel / no retard warning….489
      Fault Code A125: GE has generated a no propel warning….490
      Fault Code A126: Oil level in the hydraulic tank is low….491
      Fault Code A127: IM-furnished +5 volt output for sensors is low….492
      Fault Code A128: IM-furnished +5 volt output for sensors is high….493
      Fault Code A139: Low fuel warning….494
    Troubleshooting by fault code, Part 2….498
      Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil….500
      Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil….501
      Fault Code A152: Starter failure….502
      Fault Code A153: Battery voltage is low with the truck in operation….503
      Fault Code A154: Battery charging voltage is excessive….504
      Fault Code A155: Battery charging voltage is low….505
      Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level….506
      Fault Code A166: Left rear hydraulic oil temperature sensor is low….507
      Fault Code A167: Right rear hydraulic oil temperature sensor is low….508
      Fault Code A168: Left front hydraulic oil temperature sensor is low….509
      Fault Code A169: Right front hydraulic oil temperature sensor is low….510
      Fault Code A170: Left rear hydraulic oil temperature sensor is high….511
      Fault Code A171: Right rear hydraulic oil temperature sensor is high….512
      Fault Code A172: Left front hydraulic oil temperature sensor is high….513
      Fault Code A173: Right front hydraulic oil temperature sensor is high….514
      Fault Code A184: J1939 data link is not connected….515
      Fault Code A190: Auto lube control has detected an incomplete lube cycle….516
      Fault Code A194: Left front hydraulic oil temperature is high….517
      Fault Code A195: Right front hydraulic oil temperature is high….518
      Fault Code A196: Left rear hydraulic oil temperature is high….519
      Fault Code A197: Right rear hydraulic oil temperature is high….520
      Fault Code A198: Hoist pressure 1 sensor is high….521
      Fault Code A199: Hoist pressure 2 sensor is high….522
      Fault Code A200: Steering pressure sensor is high….523
      Fault Code A201: Brake pressure sensor is high….524
      Fault Code A202: Hoist pressure 1 sensor is low….525
      Fault Code A203: Hoist pressure 2 sensor is low….526
      Fault Code A204: Steering pressure sensor is low….527
      Fault Code A205: Brake pressure sensor is low….528
      Fault Code A206: Ambient temperature sensor is high….529
      Fault Code A207: Ambient temperature sensor is low….530
    Troubleshooting by fault code, Part 3….532
      Fault Code A212: Bad truck speed signal….534
      Fault Code A213: Parking brake should have applied but is detected as not having applied….535
      Fault Code A214: Parking brake should have released but is detected as not having released….537
      Fault Code A215: Brake auto apply valve circuit is defective….539
      Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit….541
      Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted….542
      Fault Code A230: Parking brake has been requested while truck still moving….543
      Fault Code A231: The body is up with engine running and brakes not on….544
      Fault Code A235: Steering accumulator is in the process of being bled down….545
      Fault Code A236: The steering accumulator has not properly bled down after 90 seconds….546
      Fault Code A237: The CAN/RPC connection to the display is open….547
      Fault Code A240: The key switch input to the interface module is open….548
      Fault Code A242: Fuel gauge within the dash display panel is defective….549
      Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective….550
      Fault Code A244: Drive system temperature gauge within the dash display panel is defective….551
      Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective….552
      Fault Code A246: Payload meter reports truck overload….553
      Fault Code A247: Low steering pressure warning….554
      Fault Code A248: Status module within the dash display panel is defective….555
      Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted….556
      Fault Code A250: Battery voltage is low with the truck parked….557
      Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground….559
      Fault Code A252: Start enable output circuit is either open or shorted to ground….560
      Fault Code A253: Steering bleed circuit is not open while running….561
      Fault Code A256: Red warning lamp in the dash display (driven by IM) is open….562
      Fault Code A257: Payload CAN/RPC is not connected….563
      Fault Code A258: Steering accumulator bleed pressure switch circuit is defective….564
    Troubleshooting by fault code, Part 4….566
      Fault Code A260: Parking brake failure….568
      Fault Code A261: Low brake accumulator pressure warning….569
      Fault Code A262: Steering bleed valve circuit open during shutdown….570
      Fault Code A264: Parking brake relay circuit is defective….571
      Fault Code A265: Service brake failure….572
      Fault Code A266: Shift lever was not in park while attempting to crank engine….573
      Fault Code A267: Parking brake was not set while attempting to crank engine….574
      Fault Code A268: Secondary engine shutdown while cranking….575
      Fault Code A270: Brake lock switch power supply is not on when required….576
      Fault Code A271: Shift lever not in gear….578
      Fault Code A272: Brake lock switch power supply is not off when required….579
      Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit….581
      Fault Code A274: A brake setting fault has been detected….582
      Fault Code A275: A starter has been detected as engaged without a cranking attempt….583
      Fault Code A276: The drive system data link is not connected….584
      Fault Code A277: Parking brake applied while loading….585
      Fault Code A278: Service brake applied while loading….586
      Fault Code A279: Low steering pressure switch is defective….587
      Fault Code A280: Steering accumulator bleed down switch is defective….588
      Fault Code A281: Brake lock degrade switch is defective….589
      Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7….590
      Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set….591
      Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated….592
      Fault Code A285: The parking brake was not set when the keyswitch was turned off….593
      Fault Code A286: A fault was detected in the shutdown delay relay circuit….594
      Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off….595
    Troubleshooting by fault code, Part 5….598
      Fault Code A303: Shift lever is defective….600
      Fault Code A304: Auto lube grease level fault….601
      Fault Code A305: Auto lube circuit is defective….602
      Fault Code A307: Both GE inverters are disabled….603
      Fault Code A309: No brakes applied when expected….604
      Fault Code A310: Low fuel warning….605
      Fault Code A311: Brake lock switch is on when it should not be….606
      Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings….607
      Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings….608
      Fault Code A315: DCDC converter 12 volt circuit is low….609
      Fault Code A316: Starter engagement has been attempted with engine running….610
      Fault Code A317: Operation of brake auto apply valve without a detected response….611
      Fault Code A318: Unexpected power loss to interface module….613
      Fault Code A320: Data link reports GE propel system caution fault but wired input does not….614
      Fault Code A321: Data link reports GE propel system temperature caution fault but wired input does not….615
      Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not….616
      Fault Code A323: Data link reports GE reduced retard level fault but wired input does not….617
      Fault Code A324: Data link reports DC link voltage but wired input does not….618
      Fault Code A325: Data link reports GE no propel/retard fault but wired input does not….619
      Fault Code A326: Data link reports GE no propel fault but wired input does not….620
      Fault Code A327: Data link reports GE at rest but wired input does not….621
      Fault Code A328: Drive system not powered up….622
      Fault Code A329: Data link reports the body is not down but wired input says it is….623
      Fault Code A330: Data link reports dynamic retard operating state but wired input does not….624
      Fault Code A332: Seat belt not buckled….625
      Fault Code A333: The hydraulic ladder controller has declared a ladder fault….627
      Fault Code A334: Shift lever not in park when propel was either not ready or at rest…..628
    Troubleshooting by fault code, Part 6….630
      Fault Code A350: Overload on output 1B….632
      Fault Code A351: Overload on output 1E….633
      Fault Code A352: Overload on output 1H….634
      Fault Code A353: Overload on output 1J….635
      Fault Code A354: Overload on output 1K….636
      Fault Code A355: Overload on output 1L….637
      Fault Code A356: Overload on output 1M….638
      Fault Code A357: Overload on output 1N….639
      Fault Code A358: Overload on output 1P….640
      Fault Code A359: Overload on output 1R….641
      Fault Code A360: Overload on output 1S….642
      Fault Code A361: Overload on output 1T….643
      Fault Code A362: Overload on output 1U….644
      Fault Code A363: Overload on output 1X….645
      Fault Code A364: Overload on output 1Y….646
      Fault Code A365: Overload on output 1Z….647
    Orbcomm….650
      Orbcomm satellite connection….652
        Required equipment….652
        Truck has never communicated with Orbcomm….652
        Poor connection or no connection to WebCARE….653
        Confirmed satellite communication but not reporting correctly to WebCARE….657
    Cab air conditioning….660
      Preliminary checks….662
      Diagnosis of gauge readings and system performance….662
      Troubleshooting by manifold gauge set readings….663
  50 Disassembly and assembly….670
    Service tools….670
      Special tool group….672
      Additional service tools….672
      Locally made tools….673
    Wheels, spindles and rear axle….676
      General precautions for tires and rims….678
      Rim components….679
        Smart rim component layout….679
      Wheel stud maintenance….680
      Removal and installation of front wheel….681
        Removal….681
        Installation….682
      Removal and installation of rear wheel….683
        Removal….683
        Installation….684
      Rim and tire service….686
        Lubricants….686
        Tire inflation….686
        Lock ring retainer installation….686
        Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual….687
        Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual….688
        Removal (5-piece standard rim)….689
        Removal (7-piece Smart rim)….692
        Removal (5-piece Smart rim)….694
        Preparation before assembly….696
        Installation (5-piece standard rim)….696
        Installation – horizontal mount (Smart rim)….698
        Installation – vertical mount (5-piece Smart rim)….700
        Installation – vertical mount (7-piece Smart rim)….702
      Removal and installation of front wheel hub and spindle….703
        Removal….703
        Spindle removal (off the truck)….708
        Installation….710
      Disassembly and assembly of front wheel hub and spindle….711
        Cross Section View….711
        Disassembly….712
        Cleaning and inspection….718
        Assembly….719
        Wheel bearing adjustment….720
        Seal assembly gap adjustment….721
        Seal installation….722
        Brake installation….724
        Speed sensor installation and adjustment….726
      Hub floating ring seal assembly and installation….727
      Removal and installation of rear axle….732
        Removal….732
        Cleaning and inspection….733
        Installation….734
      Removal and installation of anti-sway bar….734
        Removal….734
        Installation….737
      Removal and installation of pivot pin….738
        Removal….738
        Installation….739
      Pivot eye and bearing service….740
        Bearing replacement….740
        Pivot eye repair….741
      Removal and installation of wheel motor….742
        Preparation….742
        Removal….742
        Cleaning and inspection….745
        Installation….745
      Removal and installation of rear brake assembly….749
    Brake system….752
      Removal and installation of brake valve….754
        Removal….754
        Installation….756
      Disassembly and assembly of brake valve….757
        Disassembly….757
        Cleaning and inspection….758
        Assembly….760
      Removal and installation of dual relay valve….764
        Removal….764
        Installation….765
      Disassembly and assembly of dual relay valve….766
        Disassembly….766
        Cleaning and inspection….767
        Assembly….767
      Removal and installation of brake manifold….768
        Removal….768
        Installation….768
      Disassembly and assembly of brake manifold….769
        Disassembly….769
        Assembly….769
      Removal and installation of piston brake accumulator….770
        Removal….770
        Installation….772
      Disassembly and assembly of piston brake accumulator….772
        Disassembly….772
        Cleaning and inspection….774
        Piston seal replacement….774
        Assembly….775
      Disassembly and assembly of front wheel brake….776
        Disassembly….776
        Cleaning and inspection….779
        Assembly….780
      Disassembly and assembly of rear wheel brake….782
        Disassembly….782
        Cleaning and inspection….786
        Assembly….787
      Brake floating ring seal assembly and installation….790
      Removal and installation of parking brake….796
        Removal….796
        Installation….798
      Disassembly and assembly of parking brake….798
        Disassembly….798
        Cleaning and inspection….800
        Cleaning and inspecting new discs….802
        Assembly….803
    Steering system….806
      Removal and installation of steering control unit….808
        Removal….808
        Installation….809
      Disassembly and assembly of steering control unit….810
        Disassembly….810
        Assembly….812
      Removal and installation of steering column….815
        Removal….815
        Inspection….816
        Installation….817
      Removal and installation of steering wheel….818
        Removal….818
        Installation….818
      Removal and installation of bleeddown manifold….819
        Removal….819
        Installation….820
      Removal and installation of flow amplifier….821
        Removal….821
        Installation….822
      Removal and installation of steering cylinders and tie rod….823
        Removal….823
        Installation….823
      Disassembly and assembly of steering cylinders….825
        Disassembly….825
        Cleaning and inspection….827
        Assembly….827
      Removal and installation of steering/brake pump….828
        Removal….828
        Installation….829
      Removal and installation of piston steering accumulator….830
        Removal….830
        Installation….832
      Disassembly and assembly of piston steering accumulator….832
        Disassembly….832
        Cleaning and inspection….834
        Piston seal replacement….834
        Assembly….835
    Suspensions….838
      Removal and installation of front suspension….840
        General information….840
        Removal….840
        Installation….842
        Upper mounting joint – 60° advance….846
        Lower mounting joint – 90° advance….847
        Inspection….847
      Disassembly and assembly of front suspension….848
        Disassembly….848
        Cleaning and inspection….851
        Assembly….851
      Removal and installation of rear suspension….853
        General information….853
        Removal….853
        Installation….856
      Disassembly and assembly of rear suspension….857
        Disassembly….857
        Cleaning and inspection….859
        Assembly….860
    Hoist circuit….862
      Removal and installation of hoist pump….864
        Removal….864
        Installation….869
      Disassembly and assembly of hoist pump….870
        Disassembly….870
        Inspection….875
        Assembly….876
      Removal and installation of hoist valve….879
        Removal….879
        Installation….883
      Disassembly and assembly of hoist valve….883
        O-ring replacement….883
        Disassembly of inlet section….885
        Assembly of inlet section….886
        Disassembly of rear spool section….887
        Assembly of rear spool section….889
        Disassembly of front spool section….890
        Assembly of front spool section….891
      Overcenter manifold service….891
      Removal and installation of hoist pilot valve….892
        Removal….892
        Installation….892
      Disassembly and assembly of hoist pilot valve….893
        Disassembly….893
        Cleaning and inspection….894
        Assembly….894
      Removal and installation of hoist cylinders….895
        Removal….895
        Installation….897
      Disassembly and assembly of hoist cylinders….898
        Disassembly….898
        Cleaning and inspection….902
        Installation of the quill….903
        Assembly….905
    Body and structures….910
      Removal and installation of dump body….912
        Removal….912
        Inspection….913
        Installation….914
      Removal and installation of body pads….915
        Removal….915
        Installation….915
        Body pad shimming procedure….916
      Removal and installation of diagonal ladder/hood and grille assembly….917
        Removal….917
        Installation….917
      Removal and installation of RH deck….919
        Removal….919
        Installation….919
      Removal and installation of LH deck….921
        Removal….921
        Installation….921
      Removal and installation of fuel tank….923
        Removal….923
        Cleaning and inspection….923
        Installation….925
      Removal and installation of fuel gauge sender….925
        Removal….925
        Installation….925
      Removal and installation of hydraulic tank….926
        Removal….926
        Installation….927
      Removal and installation of hydraulic tank strainers….928
        Removal….928
        Cleaning and inspection….929
        Installation….929
    Operator cab….932
      Removal and installation of operator cab….934
        Removal….934
        Installation….937
      Removal and installation of cab door….937
        Removal….937
        Installation….938
      Disassembly and assembly of cab door….939
        Removing inner door panel….939
        Installing inner door panel….940
        Replacing the door window regulator….940
        Replacing door handle or latch assembly….941
        Replacing door assembly seal and door hinge seal….942
        Replacing door opening seal….942
        Removing door glass….943
        Installing door glass….944
      Adjustment of cab door….946
        Door jamb bolt adjustment….946
        Door handle plunger adjustment….947
      Removal and installation of side window glass….948
        Recommended tools and supplies….948
        Removal….949
        Installation….949
      Removal and installation of windshield and rear window glass….950
        Removal….950
        Installation….950
      Removal and installation of windshield wiper motor….951
        Removal….951
        Installation….952
      Removal and installation of windshield wiper arm….952
        Removal….952
        Installation….952
      Removal and installation of windshield wiper linkage….953
        Removal….953
        Installation….953
      Removal and installation of optional seats….954
        Removal….954
        Installation….954
      Removal and installation of seat belts (optional seats)….955
        General….955
        Removal….955
        Installation….957
      Removal and installation of electronic accelerator and retard pedals….959
        Removal….959
        Installation….959
        Disassembly….959
        Assembly….959
    Cab air conditioning….962
      Replacement of air conditioning system components….964
        Hoses and fittings….964
        Lines….964
        Expansion valve….964
        Receiver-drier….964
        Thermostat….964
        Compressor….965
        Accumulator….965
        Clutch….965
    Power module….968
      Removal and installation of power module….970
        General….970
        Removal….971
        Installation….979
      Removal and installation of alternator….982
        Removal….982
        Installation….985
      Removal and installation of radiator….994
        Removal….994
        Installation….999
      Repairing the radiator….1000
        Internal inspection….1000
        External cleaning….1000
        Disassembly….1000
        Cleaning and inspection….1001
        Assembly….1002
        Pressure testing….1003
      Removal and installation of engine….1003
        Removal….1003
        Service….1003
        Installation….1004
  90 Diagrams and drawings….1006
    Hydraulic circuit diagrams….1006
      Steering, hoist & brake cooling….1008
      Brake hydraulics….1009
      Auxiliary system hydraulics….1010
    Electrical circuit diagrams….1013
      Electrical system….1015
      Electrical sub-systems….1039
CEBM031601 – 980E-4 Dump Truck Shop Manual (SN A40052 & up, Engine 18V170)….1072
  00 Index and foreword….1074
    Index….1074
      Composition of shop manual….1075
      Table of contents….1077
    Foreword, safety and general information….1090
      Foreword….1093
      How to read the shop manual….1094
        Composition of shop manual….1094
        Revision and distribution….1094
        Symbols….1095
      General safety….1096
        Safety rules….1096
        Safety features….1096
        Fire extinguisher and first aid kit….1096
        Clothing and personal items….1096
        Leaving the operator seat….1097
        Mounting and dismounting….1097
        Fire prevention for fuel and oil….1097
        Precautions with high temperature fluids….1098
        Asbestos dust hazard prevention….1098
        Prevention of injury by work equipment….1098
        Unauthorized modification….1098
        Precautions when using ROPS….1098
        Precautions for attachments….1099
        Precautions for starting the truck….1099
      Precautions before operating the truck….1099
        Safety at the worksite….1099
        Fire prevention….1100
        Ventilation in enclosed areas….1100
        Preparing for operation….1100
        Mirrors, windows and lights….1100
        In operator cab (before starting the engine)….1100
        Seat Belts….1100
      Precautions while operating the truck….1101
        When starting the engine….1101
        General truck operation….1101
        Ensuring good visibility….1101
        Traveling….1102
        Traveling in reverse….1102
        Traveling on slopes….1102
        Operating on snow or ice….1102
        Avoid damage to dump body….1102
        Driving near high voltage cables….1103
        When dumping….1103
        When loading….1103
        Working on loose ground….1103
        Parking the truck….1103
        Towing….1103
      Working near batteries….1104
        Battery hazard prevention….1104
        Starting with jumper cables….1105
        Jump starting with receptacles….1105
      Precautions before performing service….1106
        Warning tag….1106
        Stopping the engine….1106
        Proper tools….1106
        Use of Tie-Off Anchor During Maintenance and Repair….1106
        Securing the dump body….1107
        Jack point locations….1108
      Precautions while performing service….1109
        Keep the truck clean….1109
        Attachments….1109
        Working under the truck….1109
        Rotating fan and belts….1109
        Adding fuel or oil….1109
        Use of lighting….1109
        Radiator coolant level….1110
        Precautions with the battery….1110
        Precautions with high pressure oil….1110
        Handling high pressure hoses….1110
        Precautions when performing maintenance near high temperature or high pressure….1110
        Waste materials….1110
      Tires….1111
        Inspection….1111
        Maintenance….1111
        Storage….1112
        Handling….1113
      Precautions for performing repairs….1114
        Engine shutdown procedure after AC drive system failure….1114
      Precautions for welding on the truck….1115
      Capacitor discharge system….1116
        Necessary tools….1116
        Warnings and cautions….1117
        Manual DC link capacitor discharge procedure….1118
        Failure of the discharge system….1120
        Manual discharge of capacitors….1121
        Short isolated capacitor terminals….1123
      Handling electrical equipment and hydraulic components….1124
        Points to remember when handling electrical equipment….1124
        Points to remember when handling hydraulic equipment….1130
      Standard tightening torques….1132
        Effect of special lubricants on fasteners and standard torque values….1132
        Suggested sources for rust preventive grease….1132
        SAE grade 5 and grade 8 hex head capscrew and nut assemblies….1133
        SAE grade 9 capscrews….1134
        Class 10.9 capscrews and class 10 nuts….1134
        Standard tightening torques for fittings….1135
      Conversion tables….1137
        Common conversion multipliers….1137
  01 Specification….1142
    Specification and technical data….1142
      Specification drawing….1144
      Specifications….1145
      Weight table….1147
      Fuel, coolant and lubricants….1148
        Suspension cylinder oil and nitrogen specifications….1149
  10 Structure, functions and maintenance standard….1152
    Steering circuit….1152
      Steering circuit operation….1153
      Steering circuit components….1158
        Steering control unit….1158
        High pressure filter….1158
        Steering accumulators….1158
        Bleeddown manifold….1159
        Steering accumulator bleeddown solenoid….1159
        Hoist up limit solenoid….1159
        Quick disconnect ports….1159
        Flow amplifier….1159
      Steering/brake pump operation….1160
        High altitude operation….1160
        Neutral position….1161
        Full pump volume….1162
        Half pump volume….1162
      Flow amplifier operation….1163
        No steer….1163
        Steering left….1165
        Steering right….1167
        No steer, external shock load….1169
    Hoist circuit….1172
      Hoist circuit operation….1174
      Hoist circuit components….1175
        Hydraulic tank….1175
        Hoist pump….1175
        High pressure filters….1175
        Hoist valve….1176
        Inlet sections….1176
        Tank ports (front) spool section….1176
        Work ports (rear) spool section….1177
        Hoist pilot valve….1177
        Hoist limit solenoid….1178
        Pilot operated check valve….1178
        Overcenter manifold….1178
      Hoist pilot valve operation….1179
        Float position with body down….1179
        Power up operation….1181
        Hold operation….1183
        Power down operation….1185
        Float operation….1187
    Brake circuits….1190
      General information….1192
      Service brake circuit operation….1193
      Secondary braking….1195
      Automatic brake application (Auto apply)….1195
      Parking brake circuit operation….1196
        Normal operation (key switch ON, engine on)….1196
      Wheel brake lock circuit operation….1197
      Brake warning circuit operation….1197
      Brake assembly wear data….1199
    Electrical system, 24 volt….1202
      Battery supply system….1204
        Batteries….1204
        24VDC auxiliary battery receptacles….1204
        Engine shutdown switch….1205
        Battery disconnect switches….1205
        Propel lockout lever….1205
        System busy light….1205
        LED lights….1205
      Engine starting system with prelube….1206
        Prelube operation….1206
        Cranking operation….1207
      Auxiliary control cabinet components….1208
        24VDC to 12VDC converter….1208
        Interface module (IM)….1208
        VEC blocks….1209
        Light timers….1209
        Relays….1209
        Ground terminals….1209
        24VDC power terminals….1209
      Body-up switch….1210
      Hoist limit switch….1211
    Electrical system, AC drive….1214
      General system operation….1215
      System components….1217
        Drive system controller (DSC)….1217
        Diagnostic information display (DID) panel….1218
      DSC software functions….1218
        Input processing….1218
        State machine….1218
        DC link state….1221
        Engine control….1222
      Alternator field control….1223
        Desired DC link voltage….1223
        Self-load….1223
        Propel torque control….1223
        Retard torque control….1224
        Wheel slide control….1224
        Resistor grid control….1224
        Chopper voltage control….1224
      Event detection and processing….1225
        Power-on tests….1225
        Initiated tests….1226
        Periodic tests….1226
        Event restrictions….1226
      Event logging and storage….1226
        Data packs….1227
        Event reset….1227
      Abnormal conditions/overriding functions….1228
        Engine shutdown/Engine not running….1228
        Limp home mode….1228
      AC drive system component table….1229
      Electronic accelerator and retarder pedals….1236
    Cab air conditioning….1238
      General information….1239
        Environmental impact of air conditioning….1239
        Air conditioning for off-highway vehicles….1239
      Principles of refrigeration….1240
        Air conditioning….1240
        Refrigeration – the act of cooling….1240
        The refrigeration cycle….1240
      Air conditioning system components….1242
        Relays….1242
        Fan motor and speed control….1242
        Cab air filter….1242
        Heater core….1242
        Actuators….1242
        Compressor (refrigerant pump)….1244
        Service valves….1244
        Condenser….1244
        Receiver-drier….1244
        Expansion valve….1245
        Accumulator….1245
        Evaporator core….1245
      Air conditioning system electrical circuit….1246
        Thermostat….1246
        Compressor clutch….1246
        Trinary™ switch….1247
    Reserve engine oil system….1250
      General information….1252
      Operation….1253
        Pumping unit….1253
        LED monitor lights….1254
        Tank auto fill control….1255
        Filling procedure (remote fill feature)….1255
      Service….1256
        Every 10 hours (each shift)….1256
        Every 500 hours….1256
        Changing oil….1256
      Troubleshooting….1257
        Circuit fuses….1257
      Auto fill system electrical schematic….1258
  20 Standard value table….1260
    Standard value table….1260
      Standard value table for truck….1262
  30 Testing and adjusting….1268
    Steering, brake cooling and hoist hydraulic system….1268
      General information on system checkout….1270
      Hydraulic system checkout procedures….1271
        Required equipment….1271
        Bleeddown procedure….1271
        Preliminary steps….1273
        Hydraulic system flushing procedure….1273
        Flow amplifier adjustment….1277
        Steering pump unloader valve adjustment….1277
        Auxiliary accumulator pressure verification….1278
        System diagnostics….1278
        Hoist counterbalance valve adjustment….1280
        Final steps….1281
        Oil cleanliness check….1281
      Hydraulic system checkout data sheet….1282
      Toe-in adjustment….1285
      Hoist cylinder leakage test….1286
      Steering cylinder leakage test….1286
    Brake system….1288
      General information on system checkout….1290
      Brake system checkout procedures….1290
        Required equipment….1290
        Initial system setup….1292
        Brake lock / secondary braking checkout….1292
        Parking brake checkout….1293
        Service brake checkout….1294
        Low brake accumulator pressure and auto apply checkout….1295
        Parking brake control logic checkout….1297
        Brake lock control logic checkout….1298
      Brake system checkout data sheet….1301
      Brake piston leakage test….1309
      Brake seal pressure test….1309
      Oil separator seal pressure test….1309
      Wet disc brake bleeding procedure….1310
      Parking brake bleeding procedure….1311
      Service brake disc wear inspection….1312
      Parking brake disc wear inspection….1313
      Brake valve bench test and adjustment….1314
        Test setup procedure….1315
        Brake valve output pressure adjustment….1315
        Final test and adjustment….1316
      Dual relay valve bench test and adjustment….1317
        Test setup procedure….1318
        Relay valve output pressure adjustment….1318
    Accumulators and suspensions….1320
      Accumulator charging precautions….1321
        Temperature during precharge….1321
      Bladder accumulator charging procedure….1322
        Precharge maintenance….1325
      Bladder accumulator storage….1326
        Bladder storage….1326
        Installing a bladder accumulator from storage….1326
      Bladder accumulator leak testing….1327
      Piston accumulator charging procedure….1328
      Piston accumulator storage….1330
      Piston accumulator leak testing….1330
      Checking for improper suspension charge….1331
      Suspension oiling and charging procedures….1332
        Required equipment….1332
        Installing the charging kit….1333
        Removing the charging kit….1333
        Support blocks for oiling and charging dimensions….1334
        Front suspensions….1335
        Rear suspensions….1338
      Suspension pressure test….1341
    Interface module (IM)….1344
      Interface module software….1346
        Flashburn program installation….1346
        Interface module application code installation….1347
        Interface module realtime data monitor software installation….1347
      Interface module checkout procedures….1348
        Necessary equipment….1348
        Preliminary….1349
        Check digital inputs to the interface module….1350
        Check analog inputs to the interface module….1353
        Check serial interfaces to the interface module….1353
        Check outputs from the interface module….1354
      CHECKOUT PROCEDURE….1355
    KOMTRAX Plus….1360
      KOMTRAX Plus software and tools….1362
      KOMTRAX Plus controller setup procedure….1362
        Preliminary steps….1362
        Setup procedure….1362
      KOMTRAX Plus initialization form….1366
      Precautions when replacing the KOMTRAX Plus controller….1367
      KOMTRAX Plus controller checkout procedure….1369
        Preliminary steps….1369
        Checkout procedure….1369
    Payload meter IV….1372
      Payload meter IV software and tools….1373
      Payload meter IV system configuration….1373
        Connecting to the payload meter IV web server….1373
        Configuring a static IP address….1373
      Payload meter IV software installation….1375
      Payload meter IV checkout procedure….1376
      PLM IV system checkout data sheet….1380
    Komatsu wireless bridge (KWB)….1382
      General information….1383
      Software download and setup….1384
        Bullet M2 Titanium / PicoStation M2….1385
        Bullet M2….1387
      Configuring a KWB_Connect device….1388
        Access point configuration….1388
        Bullet M2 configuration….1389
        KOMTRAX Plus downloads….1390
      Configuring a TRUCK_NET device….1391
        Access point configuration….1391
        Bullet M2 configuration….1392
        Onboard controller access….1393
      Changing a service computer’s IP address….1394
      Connecting to a wireless network….1395
      KWB_Connect troubleshooting….1396
        Step 1. Verify communication to the access point….1396
        Step 2. Verify communication to the Bullet M2….1396
        Step 3. Verify communication to KOMTRAX Plus….1397
      TRUCK_NET troubleshooting….1398
        Step 1. Verify communication to the access point….1398
        Step 2. Verify communication to the Bullet M2….1399
      KWB_Connect checkout data sheet….1400
      TRUCK_NET checkout data sheet….1401
    Electrical system, AC drive….1404
      General information….1405
        Test equipment….1405
        Circuit continuity and resistance checks….1405
        Megger test for grounds….1406
        Troubleshooting for grounds….1409
        Low voltage power supply checks….1409
        Drive System Controller (DSC) card checks….1410
        Propulsion system software installation….1411
        Software installation procedure….1412
        DSC manual test procedures….1413
        Accelerator pedal, retarder pedal, and retarder lever calibration and checks….1416
        Set truck ID number….1420
        Control cabinet pressure switch check….1421
      Checks prior to self load engine test (loadbox)….1423
        Verifying DSC Software Version….1423
        Resetting and erasing DSC event data….1424
      Engine running tests….1425
        Battery boost circuit verification….1425
        Selector switch check….1428
        Ground detection network tests….1430
        Self load engine test (loadbox) procedure….1435
      Diagnostic information display (DID) panel….1437
        DID panel display selection….1437
        DID modes display….1439
        Function key F1 – DID events or faults display….1440
        Function key F4 – DID menu display….1443
        DID self load engine test (loadbox)….1444
        DID link capacitance test….1446
        DID speedometer test….1447
        DID view software version….1449
        DID view overspeed setting….1451
        DID view data menu….1452
        DID inverter cutout menu….1457
        DID truck configuration menu….1459
        Language selection….1466
      Viewing event and statistical data….1467
        Viewing the DSC event summary, trigger data, and data packs….1467
        Viewing the statistical data….1470
      Logic screens….1471
      Datalogger function….1473
        Setting up the datalogger….1473
        Starting the datalogger….1475
      Uploading data….1477
        Consolidated truck data save….1477
        USB drive….1478
    Cab air conditioning….1480
      General information….1482
      Service tools and equipment….1483
        Recovery/recycle station….1483
        Leak detector….1483
        Manifold gauge set….1484
        Service valves….1485
        Vacuum pump….1485
      Detecting leaks….1486
      System performance test….1487
      Checking system oil….1488
      System flushing….1489
      Installing the manifold gauge set….1490
        Purging air from the service hoses….1490
      Recovering and recycling refrigerant….1491
        Draining oil from previous recovery cycle….1492
        Recovery cycle….1492
        Recycling procedure….1492
      Evacuating the air conditioning system….1493
      Charging the air conditioning system….1494
  40 Troubleshooting….1496
    Fuse, diode and relay locations….1496
      Vehicle Electrical Center (VEC-89)….1497
      Vehicle Electrical Center (VEC-90)….1499
      Vehicle Electrical Center (VEC-91)….1501
      Vehicle Electrical Center (RTMR1)….1503
    AC drive system fault codes (DSC)….1506
      DID panel fault code tables….1508
    Troubleshooting by fault code, Part 1….1532
      Fault Code A001: Left front suspension pressure sensor signal high….1534
      Fault Code A002: Left front suspension pressure sensor signal low….1535
      Fault Code A003: Right front suspension pressure sensor signal high….1536
      Fault Code A004: Right front suspension pressure sensor signal low….1537
      Fault Code A005: Left rear suspension pressure sensor signal high….1538
      Fault Code A006: Left rear suspension pressure sensor signal low….1539
      Fault Code A007: Right rear suspension pressure sensor signal high….1540
      Fault Code A008: Right rear suspension pressure sensor signal low….1541
      Fault Code A009: Incline sensor signal high….1542
      Fault Code A010: Incline sensor signal low….1543
      Fault Code A011: Payload meter speed sensor signal has failed….1544
      Fault Code A013: Body up switch has failed….1545
      Fault Code A014: Payload meter checksum computation has failed….1546
      Fault Code A018: Right rear flat suspension cylinder warning….1547
      Fault Code A019: Left rear flat suspension cylinder warning….1549
      Fault Code A022: Carryback load excessive….1551
      Fault Code A101: High pressure detected across an hydraulic pump filter….1553
      Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level….1555
      Fault Code A107: GE has generated a propel system caution….1556
      Fault Code A108: GE has generated a propel system temperature caution….1557
      Fault Code A109: GE has generated a propel system reduced level signal….1558
      Fault Code A111: Low steering pressure warning….1559
      Fault Code A115: Low steering precharge pressure detected….1562
      Fault Code A117: Low brake accumulator pressure warning….1564
      Fault Code A118: Brake pressure is low while in brake lock….1566
      Fault Code A123: GE has generated a reduced retarding caution….1568
      Fault Code A124: GE has generated a no propel / no retard warning….1569
      Fault Code A125: GE has generated a no propel warning….1571
      Fault Code A126: Oil level in the hydraulic tank is low….1572
      Fault Code A127: IM-furnished +5 volt output for sensors is low….1573
      Fault Code A128: IM-furnished +5 volt output for sensors is high….1574
      Fault Code A139: Low fuel warning….1575
    Troubleshooting by fault code, Part 2….1578
      Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil….1580
      Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil….1581
      Fault Code A152: Starter failure….1582
      Fault Code A153: Battery voltage is low with the truck in operation….1583
      Fault Code A154: Battery charging voltage is excessive….1585
      Fault Code A155: Battery charging voltage is low….1586
      Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level….1587
      Fault Code A166: Left rear hydraulic oil temperature sensor is low….1589
      Fault Code A167: Right rear hydraulic oil temperature sensor is low….1590
      Fault Code A168: Left front hydraulic oil temperature sensor is low….1591
      Fault Code A169: Right front hydraulic oil temperature sensor is low….1592
      Fault Code A170: Left rear hydraulic oil temperature sensor is high….1593
      Fault Code A171: Right rear hydraulic oil temperature sensor is high….1594
      Fault Code A172: Left front hydraulic oil temperature sensor is high….1595
      Fault Code A173: Right front hydraulic oil temperature sensor is high….1596
      Fault Code A184: J1939 data link is not connected….1597
      Fault Code A190: Auto lube control has detected an incomplete lube cycle….1599
      Fault Code A194: Left front hydraulic oil temperature is high….1601
      Fault Code A195: Right front hydraulic oil temperature is high….1602
      Fault Code A196: Left rear hydraulic oil temperature is high….1603
      Fault Code A197: Right rear hydraulic oil temperature is high….1604
      Fault Code A198: Hoist pressure 1 sensor is high….1605
      Fault Code A199: Hoist pressure 2 sensor is high….1606
      Fault Code A200: Steering pressure sensor is high….1607
      Fault Code A201: Brake pressure sensor is high….1608
      Fault Code A202: Hoist pressure 1 sensor is low….1609
      Fault Code A203: Hoist pressure 2 sensor is low….1610
      Fault Code A204: Steering pressure sensor is low….1611
      Fault Code A205: Brake pressure sensor is low….1612
      Fault Code A206: Ambient temperature sensor is high….1613
      Fault Code A207: Ambient temperature sensor is low….1614
    Troubleshooting by fault code, Part 3….1618
      Fault Code A212: Bad truck speed signal….1621
      Fault Code A213: Parking brake should have applied but is detected as not having applied….1622
      Fault Code A214: Parking brake should have released but is detected as not having released….1625
      Fault Code A215: Brake auto apply valve circuit is defective….1628
      Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit….1630
      Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted….1632
      Fault Code A230: Parking brake has been requested while truck still moving….1634
      Fault Code A231: The body is up with engine running and brakes not on….1636
      Fault Code A233: Drive system CAN/RPC Control Link not connected….1639
      Fault Code A235: Steering accumulator is in the process of being bled down….1641
      Fault Code A236: The steering accumulator has not properly bled down after 90 seconds….1643
      Fault Code A237: The CAN/RPC connection to the display is open….1645
      Fault Code A240: The key switch input to the interface module is open….1646
      Fault Code A242: Fuel gauge within the dash display panel is defective….1648
      Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective….1649
      Fault Code A244: Drive system temperature gauge within the dash display panel is defective….1650
      Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective….1651
      Fault Code A246: Payload meter reports truck overload….1652
      Fault Code A247: Low steering pressure warning….1653
      Fault Code A248: Status module within the dash display panel is defective….1655
      Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted….1656
      Fault Code A250: Battery voltage is low with the truck parked….1657
      Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground….1659
      Fault Code A252: Start enable output circuit is either open or shorted to ground….1661
      Fault Code A253: Steering bleed circuit is not open while running….1663
      Fault Code A256: Red warning lamp in the dash display (driven by IM) is open….1665
      Fault Code A257: Payload CAN/RPC is not connected….1666
      Fault Code A258: Steering accumulator bleed pressure switch circuit is defective….1667
    Troubleshooting by fault code, Part 4….1670
      Fault Code A260: Parking brake failure….1672
      Fault Code A261: Low brake accumulator pressure warning….1674
      Fault Code A262: Steering bleed valve circuit open during shutdown….1675
      Fault Code A264: Parking brake relay circuit is defective….1677
      Fault Code A265: Service brake failure….1679
      Fault Code A266: Shift lever was not in park while attempting to crank engine….1681
      Fault Code A267: Parking brake was not set while attempting to crank engine….1683
      Fault Code A268: Secondary engine shutdown while cranking….1685
      Fault Code A270: Brake lock switch power supply is not on when required….1686
      Fault Code A271: Shift lever not in gear….1688
      Fault Code A272: Brake lock switch power supply is not off when required….1690
      Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit….1692
      Fault Code A274: A brake setting fault has been detected….1693
      Fault Code A275: A starter has been detected as engaged without a cranking attempt….1695
      Fault Code A276: The drive system data link is not connected….1697
      Fault Code A277: Parking brake applied while loading….1698
      Fault Code A278: Service brake applied while loading….1700
      Fault Code A279: Low steering pressure switch is defective….1701
      Fault Code A280: Steering accumulator bleed down switch is defective….1703
      Fault Code A281: Brake lock degrade switch is defective….1705
      Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7….1707
      Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set….1709
      Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated….1711
      Fault Code A285: The parking brake was not set when the keyswitch was turned off….1713
      Fault Code A286: A fault was detected in the shutdown delay relay circuit….1715
      Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off….1717
    Troubleshooting by fault code, Part 5….1720
      Fault Code A303: Shift lever is defective….1722
      Fault Code A304: Auto lube grease level fault….1723
      Fault Code A305: Auto lube circuit is defective….1724
      Fault Code A307: Both GE inverters are disabled….1725
      Fault Code A309: No brakes applied when expected….1726
      Fault Code A310: Low fuel warning….1728
      Fault Code A311: Brake lock switch is on when it should not be….1730
      Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings….1732
      Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings….1733
      Fault Code A315: DCDC converter 12 volt circuit is low….1734
      Fault Code A316: Starter engagement has been attempted with engine running….1736
      Fault Code A317: Operation of brake auto apply valve without a detected response….1738
      Fault Code A318: Unexpected power loss to interface module….1740
      Fault Code A320: Data link reports GE propel system caution fault but wired input does not….1741
      Fault Code A321: Data link reports GE propel system temperature caution fault but wired input does not….1742
      Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not….1743
      Fault Code A323: Data link reports GE reduced retard level fault but wired input does not….1744
      Fault Code A324: Data link reports DC link voltage but wired input does not….1745
      Fault Code A325: Data link reports GE no propel/retard fault but wired input does not….1746
      Fault Code A326: Data link reports GE no propel fault but wired input does not….1747
      Fault Code A327: Data link reports GE at rest but wired input does not….1748
      Fault Code A328: Drive system not powered up….1749
      Fault Code A329: Data link reports the body is not down but wired input says it is….1750
      Fault Code A330: Data link reports dynamic retard operating state but wired input does not….1751
      Fault Code A332: Seat belt not buckled….1752
      Fault Code A333: The hydraulic ladder controller has declared a ladder fault….1754
      Fault Code A334: Shift lever not in park when propel was either not ready or at rest….1755
      Fault Code A337: Engine Air Filter Circuit Fault….1757
      Fault Code A338: Engine Air Filter Fault….1758
    Troubleshooting by fault code, Part 6….1760
      Fault Code A350: Overload on output 1B….1762
      Fault Code A351: Overload on output 1E….1763
      Fault Code A352: Overload on output 1H….1765
      Fault Code A353: Overload on output 1J….1766
      Fault Code A354: Overload on output 1K….1767
      Fault Code A355: Overload on output 1L….1768
      Fault Code A356: Overload on output 1M….1769
      Fault Code A357: Overload on output 1N….1770
      Fault Code A358: Overload on output 1P….1771
      Fault Code A359: Overload on output 1R….1773
      Fault Code A360: Overload on output 1S….1775
      Fault Code A361: Overload on output 1T….1776
      Fault Code A362: Overload on output 1U….1777
      Fault Code A363: Overload on output 1X….1778
      Fault Code A364: Overload on output 1Y….1779
      Fault Code A365: Overload on output 1Z….1780
    Orbcomm….1784
      Orbcomm satellite connection….1786
        Required equipment….1786
        Truck has never communicated with Orbcomm….1786
        Poor connection or no connection to WebCARE….1787
        Confirmed satellite communication but not reporting correctly to WebCARE….1791
    Cab air conditioning….1794
      Preliminary checks….1796
      Diagnosis of gauge readings and system performance….1796
      Troubleshooting by manifold gauge set readings….1797
    Steering system….1804
      Steering circuit troubleshooting chart….1805
      Steering circuit troubleshooting guidelines….1809
      Basic hydraulic system checks….1810
      System leakage check….1811
      Steering pump troubleshooting guide….1813
      Pump pressure control checks….1816
        Pump fails to unload….1817
        Pump fails to develop pressure….1817
        Pump slow in developing pressure….1818
        Pump control valve inspection and trouble shooting….1818
        Pump case drain check….1820
        Setting pump pressure controls….1820
  50 Disassembly and assembly….1824
    Service tools….1824
      Special tool group….1826
      Additional service tools….1826
      Locally made tools….1827
    Wheels, spindles and rear axle….1830
      General precautions for tires and rims….1832
      Rim components….1833
        Smart rim component layout….1833
      Wheel stud maintenance….1834
      Removal and installation of front wheel….1835
        Removal….1835
        Installation….1836
      Removal and installation of rear wheel….1837
        Removal….1837
        Installation….1838
      Rim and tire service….1840
        Lubricants….1840
        Tire inflation….1840
        Lock ring retainer installation….1840
        Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual….1841
        Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual….1842
        Removal (5-piece standard rim)….1843
        Removal (7-piece Smart rim)….1846
        Removal (5-piece Smart rim)….1848
        Preparation before assembly….1850
        Installation (5-piece standard rim)….1850
        Installation – horizontal mount (Smart rim)….1852
        Installation – vertical mount (5-piece Smart rim)….1854
        Installation – vertical mount (7-piece Smart rim)….1856
      Removal and installation of front wheel hub and spindle….1857
        Removal….1857
        Spindle removal (off the truck)….1862
        Installation….1864
      Disassembly and assembly of front wheel hub and spindle….1865
        Cross Section View….1865
        Disassembly….1866
        Cleaning and inspection….1872
        Assembly….1873
        Wheel bearing adjustment….1874
        Seal assembly gap adjustment….1875
        Seal installation….1876
        Brake installation….1878
        Speed sensor installation and adjustment….1880
      Hub floating ring seal assembly and installation….1881
      Removal and installation of rear axle….1886
        Removal….1886
        Cleaning and inspection….1887
        Installation….1888
      Removal and installation of anti-sway bar….1888
        Removal….1888
        Installation….1891
      Removal and installation of pivot pin….1892
        Removal….1892
        Installation….1893
      Pivot eye and bearing service….1894
        Bearing replacement….1894
        Pivot eye repair….1895
      Removal and installation of wheel motor….1896
        Preparation….1896
        Removal….1896
        Cleaning and inspection….1899
        Installation….1899
      Removal and installation of rear brake assembly….1903
    Brake system….1906
      Removal and installation of brake valve….1908
        Removal….1908
        Installation….1910
      Disassembly and assembly of brake valve….1911
        Disassembly….1911
        Cleaning and inspection….1912
        Assembly….1914
      Removal and installation of dual relay valve….1918
        Removal….1918
        Installation….1919
      Removal and installation of brake manifold….1920
        Removal….1920
        Installation….1920
      Disassembly and assembly of brake manifold….1921
        Disassembly….1921
        Assembly….1921
      Removal and installation of piston brake accumulator….1922
        Removal….1922
        Installation….1924
      Disassembly and assembly of piston brake accumulator….1924
        Disassembly….1924
        Cleaning and inspection….1926
        Piston seal replacement….1926
        Assembly….1927
      Disassembly and assembly of front wheel brake….1928
        Disassembly….1928
        Cleaning and inspection….1931
        Assembly….1932
      Disassembly and assembly of rear wheel brake….1934
        Disassembly….1934
        Cleaning and inspection….1938
        Assembly….1939
      Brake floating ring seal assembly and installation….1942
      Removal and installation of parking brake….1948
        Removal….1948
        Installation….1950
      Disassembly and assembly of parking brake….1950
        Disassembly….1950
        Cleaning and inspection….1952
        Cleaning and inspecting new discs….1954
        Assembly….1955
    Steering system….1958
      Removal and installation of steering control unit….1960
        Removal….1960
        Installation….1961
      Disassembly and assembly of steering control unit….1962
        Disassembly….1962
        Assembly….1964
      Removal and installation of steering column….1967
        Removal….1967
        Inspection….1968
        Installation….1969
      Removal and installation of steering wheel….1970
        Removal….1970
        Installation….1970
      Removal and installation of bleeddown manifold….1971
        Removal….1971
        Installation….1972
      Removal and installation of flow amplifier….1973
        Removal….1973
        Installation….1974
      Removal and installation of steering cylinders and tie rod….1975
        Removal….1975
        Installation….1975
      Disassembly and assembly of steering cylinders….1977
        Disassembly….1977
        Cleaning and inspection….1979
        Assembly….1979
      Removal and installation of steering/brake pump….1980
        Removal….1980
        Installation….1981
      Removal and installation of piston steering accumulator….1982
        Removal….1982
        Installation….1984
      Disassembly and assembly of piston steering accumulator….1984
        Disassembly….1984
        Cleaning and inspection….1986
        Piston seal replacement….1986
        Assembly….1987
    Suspensions….1990
      Removal and installation of front suspension….1992
        General information….1992
        Removal….1992
        Installation….1994
        Upper mounting joint – 60° advance….1998
        Lower mounting joint – 90° advance….1999
        Inspection….1999
      Disassembly and assembly of front suspension….2000
        Disassembly….2000
        Cleaning and inspection….2003
        Assembly….2003
      Removal and installation of rear suspension….2005
        General information….2005
        Removal….2005
        Installation….2008
      Disassembly and assembly of rear suspension….2009
        Disassembly….2009
        Cleaning and inspection….2011
        Assembly….2012
    Hoist circuit….2014
      Removal and installation of hoist pump….2016
        Removal….2016
        Installation….2021
      Disassembly and assembly of hoist pump….2022
        Disassembly….2022
        Inspection….2027
        Assembly….2028
      Removal and installation of hoist valve….2031
        Removal….2031
        Installation….2035
      Disassembly and assembly of hoist valve….2035
        O-ring replacement….2035
        Disassembly of inlet section….2037
        Assembly of inlet section….2038
        Disassembly of rear spool section….2039
        Assembly of rear spool section….2041
        Disassembly of front spool section….2042
        Assembly of front spool section….2043
      Overcenter manifold service….2043
      Removal and installation of hoist pilot valve….2044
        Removal….2044
        Installation….2044
      Disassembly and assembly of hoist pilot valve….2045
        Disassembly….2045
        Cleaning and inspection….2046
        Assembly….2046
      Removal and installation of hoist cylinders….2047
        Removal….2047
        Installation….2049
      Disassembly and assembly of hoist cylinders….2050
        Disassembly….2050
        Cleaning and inspection….2054
        Installation of the quill….2055
        Assembly….2057
    Body and structures….2062
      Removal and installation of dump body….2064
        Removal….2064
        Inspection….2065
        Installation….2066
      Removal and installation of body pads….2067
        Removal….2067
        Installation….2067
        Body pad shimming procedure….2068
      Removal and installation of diagonal ladder/hood and grille assembly….2069
        Removal….2069
        Installation….2069
      Removal and installation of RH deck….2071
        Removal….2071
        Installation….2071
      Removal and installation of LH deck….2073
        Removal….2073
        Installation….2073
      Removal and installation of fuel tank….2075
        Removal….2075
        Cleaning and inspection….2075
        Installation….2077
      Removal and installation of fuel gauge sender….2077
        Removal….2077
        Installation….2077
      Removal and installation of hydraulic tank….2078
        Removal….2078
        Installation….2079
      Removal and installation of hydraulic tank strainers….2080
        Removal….2080
        Cleaning and inspection….2081
        Installation….2081
    Operator cab….2084
      Removal and installation of operator cab….2086
        Removal….2086
        Installation….2089
      Removal and installation of cab door….2089
        Removal….2089
        Installation….2090
      Disassembly and assembly of cab door….2091
        Removing inner door panel….2091
        Installing inner door panel….2092
        Replacing the door window regulator….2092
        Replacing door handle or latch assembly….2093
        Replacing door assembly seal and door hinge seal….2094
        Replacing door opening seal….2094
        Removing door glass….2095
        Installing door glass….2096
      Adjustment of cab door….2098
        Door jamb bolt adjustment….2098
        Door handle plunger adjustment….2099
      Removal and installation of side window glass….2100
        Recommended tools and supplies….2100
        Removal….2101
        Installation….2101
      Removal and installation of windshield and rear window glass….2102
        Removal….2102
        Installation….2102
      Removal and installation of windshield wiper motor….2103
        Removal….2103
        Installation….2104
      Removal and installation of windshield wiper arm….2104
        Removal….2104
        Installation….2104
      Removal and installation of windshield wiper linkage….2105
        Removal….2105
        Installation….2105
      Removal and installation of optional seats….2106
        Removal….2106
        Installation….2106
      Removal and installation of seat belts (optional seats)….2107
        General….2107
        Removal….2107
        Installation….2109
      Removal and installation of electronic accelerator and retard pedals….2111
        Removal….2111
        Installation….2111
        Disassembly….2111
        Assembly….2111
    Cab air conditioning….2114
      Replacement of air conditioning system components….2116
        Hoses and fittings….2116
        Lines….2116
        Expansion valve….2116
        Receiver-drier….2116
        Thermostat….2116
        Compressor….2117
        Accumulator….2117
        Clutch….2117
    Power module….2120
      Removal and installation of power module….2122
        General….2122
        Removal….2123
        Installation….2131
      Removal and installation of alternator….2134
        Removal….2134
        Installation….2137
      Removal and installation of radiator….2146
        Removal….2146
        Installation….2151
      Repairing the radiator….2152
        Internal inspection….2152
        External cleaning….2152
        Disassembly….2152
        Cleaning and inspection….2153
        Assembly….2154
        Pressure testing….2155
      Removal and installation of engine….2155
        Removal….2155
        Service….2155
        Installation….2156
  90 Diagrams and drawings….2158
    Hydraulic circuit diagrams….2158
    Electrical circuit diagrams….2166
  Blank Page….1073
  Blank Page….2163

Komatsu 980E Dump Trucks Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete operator’s maintenance manuals for Komatsu Dump Trucks 930E, with all the service information to maintain & operate.

CEAM006400 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM006500 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM006600 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM006900 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM007000 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM010001 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM010200 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM010500 – Dump Truck 930E-2SE Operation & Maintenance Manual.pdf
CEAM011600 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM011700 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM011900 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM012000 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM012100 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
CEAM013500 – Dump Truck 930E-3 Operation & Maintenance Manual.pdf
CEAM014001 – Dump Truck 930E-3SE Operation & Maintenance Manual.pdf
CEAM014600 – Dump Truck 930E-3 Operation & Maintenance Manual.pdf
CEAM015901 – Dump Truck 930E-3 Operation & Maintenance Manual.pdf
CEAM016000 – Dump Truck 930E-3SE Operation & Maintenance Manual.pdf
CEAM017906 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM019403 – Dump Truck 930E-4SE Operation & Maintenance Manual.pdf
CEAM019604 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM020205 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM020305 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM020504 – Dump Truck 930E-4SE Operation & Maintenance Manual.pdf
CEAM021005 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM021304 – Dump Truck 930E-4SE Operation & Maintenance Manual.pdf
CEAM021405 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM022602 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM022701 – Dump Truck 930E-4SE Operation & Maintenance Manual.pdf
CEAM024203 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM024302 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAM024503 – Dump Truck 930E-4SE Operation & Maintenance Manual.pdf
CEAM027800 – Dump Truck 930E-4 Operation & Maintenance Manual.pdf
CEAW003900 – Dump Truck 930E-3 Field Assembly Manual.pdf
CEAW004001 – Dump Truck 930E-3SE Field Assembly Manual.pdf
CEAW004600 – Dump Truck 930E-4 Field Assembly Manual.pdf
CEAW005000 – Dump Truck 930E-4SE Field Assembly Manual.pdf
CEAW006103 – Dump Truck 930E-4 Field Assembly Manual.pdf
CEAW006203 – Dump Truck 930E-4SE Field Assembly Manual.pdf
CEAW006600 – Dump Truck 930E-4 Field Assembly Manual.pdf
CEAW006901 – Dump Truck 930E-4 Field Assembly Manual.pdf
CEAW007001 – Dump Truck 930E-4SE Field Assembly Manual.pdf
CEAWD03300 – Dump Truck 930E-2 Field Assembly Manual.pdf
CSAM019400 – Manual de Operación y Mantenimiento 930E-4SE Camion Tolva.pdf
DG711 – Dump Truck 930E Operation & Maintenance Manual.pdf
DG748 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf
DG750 – Dump Truck 930E-2 Operation & Maintenance Manual.pdf

Total Pages: 9,772 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
FOREWORD . . i
SAFETY RULES, TOOLS & EQUIPMENT . . 1-1
TRUCK COMPONENT AND SPECIFICATIONS. . 2-1
MAJOR COMPONENT WEIGHTS . . 3-1
FIELD WELDING FOR ASSEMBLY OR REPAIR . . 4-1
RECEIVING AND ASSEMBLY PREPARATION . . 5-1
CHASSIS ASSEMBLY. . 6-1
DUMP BODY ASSEMBLY . . 7-1
FINAL ASSEMBLY . . 8-1
FINAL CHECK-OUT . . 9-1
APPENDIX . . 10-1

CEAM006400 – Dump Truck 930E-2 Operation & Maintenance Manual…3
COVER…3
INTRODUCTION…11
FOREWARD…9
ALERTS…10
TABLE OF CONTENTS…11
TRUCK MODEL ILLUSTRATION…14
ABOUT THIS MANUAL…15
STANDARD CHARTS AND TABLES…17
SAFETY…23
GENERAL SAFETY…23
PRECAUTIONS DURING OPERATION…27
OPERATING MACHINE…28
TOWING…31
BATTERY…32
PRECAUTIONS FOR MAINTENANCE…33
BEFORE CARRYING OUT MAINTENANCE…33
DURING MAINTENANCE…34
TIRES…37
ADDITIONAL JOB SITE RULES…38
WHEN REPAIRS ARE NECESSARY…39
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…40
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…43
OPERATION…53
OPERATING INSTRUCTIONS…53
PREPARING FOR OPERATION…53
SAFETY IS THINKING AHEAD…53
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…53
ENGINE START-UP SAFETY PRACTICES…56
AFTER ENGINE HAS STARTED…57
MACHINE OPERATION SAFETY PRECAUTIONS…58
MACHINE OPERATION ON THE HAUL ROAD…58
STARTING ON A GRADE WITH A LOADED TRUCK…59
PASSING…59
LOADING…59
DUMPING…60
TOWING…61
SAFE PARKING PROCEDURES…62
NORMAL ENGINE SHUTDOWN PROCEDURE…62
OPERATOR CAB AND CONTROLS…65
STEERING WHEEL AND CONTROLS…66
DYNAMIC RETARDER/SERVER BRAKE PEDAL…66
ACCELERATOR (THROTTLE) PEDAL…67
HEATER/AIR CONDITIONER VENTS…67
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…68
OVERHEAD PANEL AND DISPLAYS…69
CENTER CONSOLE CONTROLS AND FEATURES…71
HOIST CONTROL LEVER…72
OPERATOR SEAT…75
INSTRUMENT PANEL AND INDICATOR LIGHTS…77
CONTROL SYMBOLS…77
INSTRUMENT PANEL (FIGURE 3-6)…78
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…79
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…85
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…86
HAZARD WARNING LIGHTS (7)…92
LAMP TEST SWITCH (8)…92
LINK-ON WARNINGS LIGHT…92
MAINTENANCE…93
LUBRICATION AND SERVICE…93
SERVICE CAPACITIES…93
HYDRAULIC TANK SERVICE…93
COOLANT LEVEL CHECK…94
RADIATOR FILLING PROCEDURE…94
COOLING SYSTEM RECOMMENDATIONS…94
LUBRICATION CHART…95
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…96
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…98
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…99
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…100
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…102
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…103
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…104
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…104
LINCOLN AUTOMATIC LUBRICATION SYSTEM (RECIPROCATING PUMP)…105
SYSTEM COMPONENTS…105
SYSTEM OPERATION…107
GENERAL INSTRUCTIONS…108
LUBRICANT REQUIRED…108
SYSTEM PRIMING…108
SYSTEM CHECK -OUT…108
24VDC SOLID STATE TIMER CHECK-OUT & ADJUSTMENT…109
INJECTORS AND ADJUSTMENT…110
PUMP CYCLE ("FLASHER") TIMER, INSTALLATION & ADJUSTMENT…112
PRESSURE SWITCH…112
PRESSURE REDUCER ADJUSTMENT…114
TROUBLESHOOTING CHART…115
PREVENTATIVE MAINTENANCE PROCEDURES…118
SPECIFICATIONS…119
MAJOR COMPONENT DESCRIPTIONS…119
SPECIFICATIONS…121
OPTIONAL EQUIPMENT…123
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…123
GENERAL INFORMATION…125
LIGHTS, SWITHES, AND COMPONENTS…126
TIPS FOR OPERATION…127
EXTERNAL DISPLAY LIGHTS…127
THEORY OF OPERATION…128
BASIC DESCRIPTION…128
LINKAGE FACTOR…128
BRAKE LOCK…129
SOURCES OF ERROR…129
TYPICAL DATA FROM SERVICE CHECK MODE…129
EXAMPLE CALCULATION OF PAYLOAD…130
CALCULATION OF THE CALIBRATION LOAD…130
TYPES OF DATA STORED…131
CYCLE DATA…131
ENGINE ON/OFF DATA…132
FAULT CODES AND WARNING DATA…132
ENGINE OPERATION…133
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…133
OTHER DATA…133
OPERATOR FUNCTIONS…134
USING THE OPERATOR LOAD COUNTER…134
DESCRIPTION…134
DIMMING THE LIGHTS ONTHE DISPLAY…134
INITIAL SETUP OF PAYLOAD METER…135
SWITCH SETTINGS…135
CHECKING THE OPERATOR CHECK MODE…135
CHECKING THE SERVICE CHECK MODE…136
SETTING "UP:00"…136
SETTING "PL:00"…136
CHECKING THE Gt SETTING…136
CHECKING THE INCLINOMETER SETTINGS…136
CALIBRATING A TRUCK…137
DISPLAYS AT START-UP…138
SETUP AND MAINTENANCE…139
SETTING THE SPEED LIMIT…139
SETTINGS THE OPTION CODE…139
SETTING THE MACHINE I.D…139
SETTING THE OPERATOR I.D…140
SETTING THE TIME AND DATE…140
DOWNLOAD OF PAYLOAD FAULT CODES…140
DISPLAY OF FAULT CODES…141
CHARTS OF ERROR CODES AND OTHER INFORMATION…142
SERVICE CHECK MODE…144
MONITORING INPUT SIGNALS …144
UP FACTOR – PAYLOAD CALCULATION GAIN…145
PL MODE – LOAD CALCULATION…145
FINAL GEAR RATIO SELECTION…146
BATTERY REPLACEMENT PROCEDURE…147
REPLACING THE BATTERY…147
AFTER REPLACING THE BATTERY…148
SUSPENSION PRESSURE SENSOR…148
REMOVAL…148
INSTALLATION…149
INCLINOMETER…149
REMOVAL…149
INSTALLATION…149
SCOREBOARD…150
DESCRIPTION…150
MAKING CONNECTIONS…150
WIRING DIAGRAM…151
NORMAL OPERATION OF THE SCOREBOARD…152
PAYLOAD METER BACK PANEL…152
CONNECTIONS (AMP PIN IDENTIFICATION)…153
PAYLOAD CIRCUIT NUMBERS…154
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…155
RADIO, AM/FM STERO CASSETTE…157
CEAM006500 – Dump Truck 930E-2 Operation & Maintenance Manual…161
COVER…161
INTRODUCTION…167
FOREWARD…167
ALERTS…168
TABLE OF CONTENTS…169
TRUCK MODEL ILLUSTRATION…172
ABOUT THIS MANUAL…173
STANDARD CHARTS AND TABLES…175
SAFETY…181
GENERAL SAFETY…181
PRECAUTIONS DURING OPERATION…185
OPERATING MACHINE…186
TOWING…189
BATTERY…190
PRECAUTIONS FOR MAINTENANCE…191
BEFORE CARRYING OUT MAINTENANCE…191
DURING MAINTENANCE…192
TIRES…195
ADDITIONAL JOB SITE RULES…196
WHEN REPAIRS ARE NECESSARY…197
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…198
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…201
OPERATION…211
OPERATING INSTRUCTIONS…211
PREPARING FOR OPERATION…211
SAFETY IS THINKING AHEAD…211
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…211
ENGINE START-UP SAFETY PRACTICES…214
AFTER ENGINE HAS STARTED…215
MACHINE OPERATION SAFETY PRECAUTIONS…216
MACHINE OPERATION ON THE HAUL ROAD…216
STARTING ON A GRADE WITH A LOADED TRUCK…217
PASSING…217
LOADING…217
DUMPING…218
TOWING…219
SAFE PARKING PROCEDURES…220
NORMAL ENGINE SHUTDOWN PROCEDURE…220
DELAYED ENGINE SHUTDOWN PROCEDURE…221
OPERATOR CAB AND CONTROLS…223
STEERING WHEEL AND CONTROLS…224
DYNAMIC RETARDER/SERVER BRAKE PEDAL…225
ACCELERATOR (THROTTLE) PEDAL…225
HEATER/AIR CONDITIONER VENTS…225
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…226
OVERHEAD PANEL AND DISPLAYS…227
CENTER CONSOLE CONTROLS AND FEATURES…229
HOIST CONTROL LEVER…230
OPERATOR SEAT…233
INSTRUMENT PANEL AND INDICATOR LIGHTS…235
CONTROL SYMBOLS…235
INSTRUMENT PANEL (FIGURE 3-6)…236
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…237
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…243
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…244
HAZARD WARNING LIGHTS (7)…250
LAMP TEST SWITCH (8)…250
LINK-ON WARNINGS LIGHT…250
MAINTENANCE…251
LUBRICATION AND SERVICE…251
SERVICE CAPACITIES…251
HYDRAULIC TANK SERVICE…251
COOLANT LEVEL CHECK…252
RADIATOR FILLING PROCEDURE…252
COOLING SYSTEM RECOMMENDATIONS…252
LUBRICATION CHART…253
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…254
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…256
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…257
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…258
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…260
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…261
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…262
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…262
LINCOLN AUTOMATIC LUBRICATION SYSTEM (RECIPROCATING PUMP)…263
SYSTEM COMPONENTS…263
SYSTEM OPERATION…265
GENERAL INSTRUCTIONS…266
LUBRICANT REQUIRED…266
SYSTEM PRIMING…266
SYSTEM CHECK -OUT…266
24VDC SOLID STATE TIMER CHECK-OUT & ADJUSTMENT…267
INJECTORS AND ADJUSTMENT…268
PUMP CYCLE ("FLASHER") TIMER, INSTALLATION & ADJUSTMENT…270
PRESSURE SWITCH…270
PRESSURE REDUCER ADJUSTMENT…272
TROUBLESHOOTING CHART…273
PREVENTATIVE MAINTENANCE PROCEDURES…276
SPECIFICATIONS…277
MAJOR COMPONENT DESCRIPTIONS…277
SPECIFICATIONS…279
OPTIONAL EQUIPMENT…281
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…281
GENERAL INFORMATION…283
LIGHTS, SWITHES, AND COMPONENTS…284
TIPS FOR OPERATION…285
EXTERNAL DISPLAY LIGHTS…285
THEORY OF OPERATION…286
BASIC DESCRIPTION…286
LINKAGE FACTOR…286
BRAKE LOCK…287
SOURCES OF ERROR…287
TYPICAL DATA FROM SERVICE CHECK MODE…287
EXAMPLE CALCULATION OF PAYLOAD…288
CALCULATION OF THE CALIBRATION LOAD…288
TYPES OF DATA STORED…289
CYCLE DATA…289
ENGINE ON/OFF DATA…290
FAULT CODES AND WARNING DATA…290
ENGINE OPERATION…291
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…291
OTHER DATA…291
OPERATOR FUNCTIONS…292
USING THE OPERATOR LOAD COUNTER…292
DESCRIPTION…292
VIEWING THE OPERATOR LOAD COUNTER…292
CLEARING THE OPERATOR LOAD COUNTER…292
DIMMING THE LIGHTS ONTHE DISPLAY…292
INITIAL SETUP OF PAYLOAD METER…293
SWITCH SETTINGS…293
CHECKING THE OPERATOR CHECK MODE…293
CHECKING THE SERVICE CHECK MODE…294
SETTING "UP:00"…294
SETTING "PL:00"…294
CHECKING THE Gt SETTING…294
CHECKING THE INCLINOMETER SETTINGS…294
CALIBRATING A TRUCK…295
DISPLAYS AT START-UP…296
SETUP AND MAINTENANCE…297
SETTING THE SPEED LIMIT…297
SETTINGS THE OPTION CODE…297
SETTING THE MACHINE I.D…297
SETTING THE OPERATOR I.D…298
SETTING THE TIME AND DATE…298
DOWNLOAD OF PAYLOAD FAULT CODES…298
DISPLAY OF FAULT CODES…299
CHARTS OF ERROR CODES AND OTHER INFORMATION…300
SERVICE CHECK MODE…302
MONITORING INPUT SIGNALS …302
UP FACTOR – PAYLOAD CALCULATION GAIN…303
PL MODE – LOAD CALCULATION…303
FINAL GEAR RATIO SELECTION…304
BATTERY REPLACEMENT PROCEDURE…305
REPLACING THE BATTERY…305
AFTER REPLACING THE BATTERY…306
SUSPENSION PRESSURE SENSOR…306
REMOVAL…306
INSTALLATION…307
INCLINOMETER…307
REMOVAL…307
INSTALLATION…307
SCOREBOARD…308
DESCRIPTION…308
MAKING CONNECTIONS…308
WIRING DIAGRAM…309
NORMAL OPERATION OF THE SCOREBOARD…310
PAYLOAD METER BACK PANEL…310
CONNECTIONS (AMP PIN IDENTIFICATION)…311
PAYLOAD CIRCUIT NUMBERS…312
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…313
RADIO, AM/FM STERO CASSETTE…315
CEAM006600 – Dump Truck 930E-2 Operation & Maintenance Manual…319
COVER…319
INTRODUCTION…326
FOREWARD…324
ALERTS…325
CONTENTS…326
TRUCK MODEL ILLUSTRATION…329
ABOUT THIS MANUAL…330
STANDARD CHARTS AND TABLES…332
SAFETY…338
GENERAL SAFETY…338
PRECAUTIONS DURING OPERATION…342
OPERATING MACHINE…343
TOWING…346
BATTERY…347
PRECAUTIONS FOR MAINTENANCE…348
BEFORE CARRYING OUT MAINTENANCE…348
DURING MAINTENANCE…349
TIRES…326
ADDITIONAL JOB SITE RULES…353
WHEN REPAIRS ARE NECESSARY…354
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…355
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…358
OPERATION…368
OPERATING INSTRUCTIONS…368
PREPARING FOR OPERATION…368
SAFETY IS THINKING AHEAD…368
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…368
ENGINE START-UP SAFETY PRACTICES…371
AFTER ENGINE HAS STARTED…372
MACHINE OPERATION SAFETY PRECAUTIONS…373
MACHINE OPERATION ON THE HAUL ROAD…373
STARTING ON A GRADE WITH A LOADED TRUCK…374
PASSING…374
LOADING…374
DUMPING…375
TOWING…376
SAFE PARKING PROCEDURES…377
NORMAL ENGINE SHUTDOWN PROCEDURE…377
OPERATOR CAB AND CONTROLS…380
STEERING WHEEL AND CONTROLS…381
DYNAMIC RETARDER/SERVER BRAKE PEDAL…382
ACCELERATOR (THROTTLE) PEDAL…382
HEATER/AIR CONDITIONER VENTS…382
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…383
OVERHEAD PANEL AND DISPLAYS…384
CENTER CONSOLE CONTROLS AND FEATURES…386
HOIST CONTROL LEVER…387
OPERATOR SEAT…390
INSTRUMENT PANEL AND INDICATOR LIGHTS…392
CONTROL SYMBOLS…392
INSTRUMENT PANEL (FIGURE 3-6)…392
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…394
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…400
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…401
HAZARD WARNING LIGHTS (7)…407
LAMP TEST SWITCH (8)…407
LINK-ON WARNINGS LIGHT…407
MAINTENANCE…408
LUBRICATION AND SERVICE…408
SERVICE CAPACITIES…408
HYDRAULIC TANK SERVICE…408
COOLANT LEVEL CHECK…409
RADIATOR FILING PROCEDURE…409
COOLING SYSTEM RECOMMENDATIONS…409
LUBRICATION CHART…410
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…411
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…413
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…414
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…415
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…417
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…418
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…419
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…419
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…420
GENERAL DESCRIPTION…420
SYSTEM COMPONENTS…422
SYSTEM OPERATION…423
INJECTOR OPERATION…427
INJECTORS…428
GENERAL INSTRUCTIONS…425
LUBRICANT REQUIRED…425
SYSTEM PRIMING…425
FILTER ASSEMBLY…425
LUBRICANT PUMP…426
SYSTEM CHECK -OUT…429
LUBRICATION CYCLE TIMER CHECK…429
SYSTEM TROUBLESHOOTING CHART…430
PREVENTATIVE MAINTENANCE PROCEDURES…433
SPECIFICATIONS…434
MAJOR COMPONENT DESCRIPTIONS…434
SPECIFICATIONS…436
OPTIONAL EQUIPMENT…438
PAYLOAD METER II (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX)…438
GENERAL INFORMATION…440
LIGHTS, SWITHES, AND COMPONENTS…441
TIPS FOR OPERATION…442
EXTERNAL DISPLAY LIGHTS…442
THEORY OF OPERATION…443
BASIC DESCRIPTION…443
LINKAGE FACTOR…443
BRAKE LOCK…444
SOURCES OF ERROR…444
TYPICAL DATA FROM SERVICE CHECK MODE…444
EXAMPLE CALCULATION OF PAYLOAD…445
CALCULATION OF THE CALIBRATION LOAD…445
TYPES OD DATA STORED…446
CYCLE DATA…446
ENGINE ON/OFF DATA…447
FAULT CODES AND WARNINGS DATA…447
ENGINE OPERATION…448
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…448
OTHER DATA…448
OPERATOR FUNCTIONS…449
USING THE OPERATOR LOAD COUNTER…449
DESCRIPTION…449
VIEWING THE OPERATOR LOAD COUNTER…449
CLEARING THE OPERATOR LOAD COUNTER…449
DIMMING THE LIGHTS ONTHE DISPLAY…449
INITIAL SETUP OF PAYLOAD METER…450
SWITCH SETTINGS…450
CHECKING THE OPERATOR CHECK MODE…450
CHECKING THE SERVICE CHECK MODE…451
SETTING "UP:00"…451
SETTING "PL:00"…451
CHECKING THE Gt SETTING…451
CHECKING THE INCLINOMETER SETTINGS…451
CALIBRATING A TRUCK…452
DISPLAYS AT START-UP…453
SETUP AND MAINTENANCE…454
SETTING THE SPEED LIMIT…454
SETTINGS THE OPTION CODE…454
SETTING THE MACHINE I.D…454
SETTING THE OPERATOR I.D…455
SETTING THE TIME AND DATE…455
DOWNLOAD OF PAYLOAD FAULT CODES…455
DISPLAY OF FAULT CODES…456
CHARTS OF ERROR CODES AND OTHER INFORMATION…457
SERVICE CHECK MODE…459
MONITORING INPUT SIGNALS …459
UP FACTOR – PAYLOAD CALCULATION GAIN…460
PL MODE – LOAD CALCULATION…460
FINAL GEAR RATIO SELECTION…461
BATTERY REPLACEMENT PROCEDURE…462
REPLACING THE BATTERY…462
AFTER REPLACING THE BATTERY…463
SUSPENSION PRESSURE SENSOR…463
REMOVAL…463
INSTALLATION…464
INCLINOMETER…464
REMOVAL…464
INSTALLATION…464
SCOREBOARD…465
DESCRIPTION…465
MAKING CONNECTIONS…465
WIRING DIAGRAM…466
NORMAL OPERATION OF THE SCOREBOARD…467
PAYLOAD METER BACK PANEL…467
CONNECTIONS (AMP PIN IDENTIFICATION)…468
PAYLOAD CIRCUIT NUMBERS…469
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…470
RADIO, AM/FM STERO CASSETTE…472
CEAM006900 – Dump Truck 930E-2 Operation & Maintenance Manual…475
COVER…475
INTRODUCTION…483
FOREWARD…481
ALERTS…482
TABLE OF CONTENTS…483
TRUCK MODEL ILLUSTRATION…486
ABOUT THIS MANUAL…487
STANDARD CHARTS AND TABLES…489
SAFETY…495
GENERAL SAFETY…495
PRECAUTIONS DURING OPERATION…499
OPERATING MACHINE…500
TOWING…503
BATTERY…504
PRECAUTIONS FOR MAINTENANCE…505
BEFORE CARRYING OUT MAINTENANCE…505
DURING MAINTENANCE…506
TIRES…509
ADDITIONAL JOB SITE RULES…510
WHEN REPAIRS ARE NECESSARY…511
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…512
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…515
OPERATION…525
OPERATING INSTRUCTIONS…525
PREPARING FOR OPERATION…525
SAFETY IS THINKING AHEAD…525
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…525
ENGINE START-UP SAFETY PRACTICES…528
AFTER ENGINE HAS STARTED…529
MACHINE OPERATION SAFETY PRECAUTIONS…530
MACHINE OPERATION ON THE HAUL ROAD…530
STARTING ON A GRADE WITH A LOADED TRUCK…531
PASSING…531
LOADING…531
DUMPING…532
TOWING…533
SAFE PARKING PROCEDURES…534
NORMAL ENGINE SHUTDOWN PROCEDURE…534
OPERATOR CAB AND CONTROLS…537
STEERING WHEEL AND CONTROLS…538
DYNAMIC RETARDER/SERVER BRAKE PEDAL…538
ACCELERATOR (THROTTLE) PEDAL…539
HEATER/AIR CONDITIONER VENTS…539
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…540
OVERHEAD PANEL AND DISPLAYS…541
CENTER CONSOLE CONTROLS AND FEATURES…543
HOIST CONTROL LEVER…544
OPERATOR SEAT…547
INSTRUMENT PANEL AND INDICATOR LIGHTS…549
CONTROL SYMBOLS…549
INSTRUMENT PANEL (FIGURE 3-6)…550
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…551
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…557
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…558
HAZARD WARNING LIGHTS (7)…564
LAMP TEST SWITCH (8)…564
LINK-ON WARNINGS LIGHT…564
MAINTENANCE…565
LUBRICATION AND SERVICE…565
SERVICE CAPACITIES…565
HYDRAULIC TANK SERVICE…565
COOLANT LEVEL CHECK…566
RADIATOR FILLING PROCEDURE…566
COOLING SYSTEM RECOMMENDATIONS…566
LUBRICATION CHART…567
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…568
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…570
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…571
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…572
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…574
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…575
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…576
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…576
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…577
GENERAL DESCRIPTION…577
SYSTEM COMPONENTS…579
SYSTEM OPERATION…580
GENERAL INSTRUCTIONS…582
LUBRICANT REQUIRED…582
SYSTEM PRIMING…582
FILTER ASSEMBLY…582
LUBRICANT PUMP…583
INJECTOR OPERATION…584
INJECTORS…585
SYSTEM CHECK -OUT…586
LUBRICATION CYCLE TIMER CHECK…586
SYSTEM TROUBLESHOOTING CHART…587
PREVENTATIVE MAINTENANCE PROCEDURES…590
SPECIFICATIONS…591
MAJOR COMPONENT DESCRIPTIONS…591
SPECIFICATIONS…593
OPTIONAL EQUIPMENT…595
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…595
GENERAL INFORMATION…597
LIGHTS, SWITHES, AND COMPONENTS…598
TIPS FOR OPERATION…599
EXTERNAL DISPLAY LIGHTS…599
THEORY OF OPERATION…600
BASIC DESCRIPTION…600
LINKAGE FACTOR…600
BRAKE LOCK…601
SOURCES OF ERROR…601
TYPICAL DATA FROM SERVICE CHECK MODE…601
EXAMPLE CALCULATION OF PAYLOAD…602
CALCULATION OF THE CALIBRATION LOAD…602
TYPES OF DATA STORED…603
CYCLE DATA…603
ENGINE ON/OFF DATA…604
FAULT CODES AND WARNING DATA…604
ENGINE OPERATION…605
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…605
OTHER DATA…605
OPERATOR FUNCTIONS…606
USING THE OPERATOR LOAD COUNTER…606
DESCRIPTION…606
DIMMING THE LIGHTS ONTHE DISPLAY…606
INITIAL SETUP OF PAYLOAD METER…607
SWITCH SETTINGS…607
CHECKING THE OPERATOR CHECK MODE…607
CHECKING THE SERVICE CHECK MODE…608
SETTING "UP:00"…608
SETTING "PL:00"…608
CHECKING THE Gt SETTING…608
CHECKING THE INCLINOMETER SETTINGS…608
CALIBRATING A TRUCK…609
DISPLAYS AT START-UP…610
SETUP AND MAINTENANCE…611
SETTING THE SPEED LIMIT…611
SETTINGS THE OPTION CODE…611
SETTING THE MACHINE I.D…611
SETTING THE OPERATOR I.D…612
SETTING THE TIME AND DATE…612
DOWNLOAD OF PAYLOAD FAULT CODES…612
DISPLAY OF FAULT CODES…613
CHARTS OF ERROR CODES AND OTHER INFORMATION…614
SERVICE CHECK MODE…616
MONITORING INPUT SIGNALS …616
UP FACTOR – PAYLOAD CALCULATION GAIN…617
PL MODE – LOAD CALCULATION…617
FINAL GEAR RATIO SELECTION…618
BATTERY REPLACEMENT PROCEDURE…619
REPLACING THE BATTERY…619
AFTER REPLACING THE BATTERY…620
SUSPENSION PRESSURE SENSOR…620
REMOVAL…620
INSTALLATION…621
INCLINOMETER…621
REMOVAL…621
INSTALLATION…621
SCOREBOARD…622
DESCRIPTION…622
MAKING CONNECTIONS…622
WIRING DIAGRAM…623
NORMAL OPERATION OF THE SCOREBOARD…624
PAYLOAD METER BACK PANEL…624
CONNECTIONS (AMP PIN IDENTIFICATION)…625
PAYLOAD CIRCUIT NUMBERS…626
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…627
RADIO, AM/FM STERO CASSETTE…629
CEAM007000 – Dump Truck 930E-2 Operation & Maintenance Manual…633
COVER…633
INTRODUCTION…639
FOREWARD…639
ALERTS…640
CONTENTS…641
TRUCK MODEL ILLUSTRATION…644
ABOUT THIS MANUAL…645
STANDARD CHARTS AND TABLES…647
SAFETY…653
GENERAL SAFETY…653
PRECAUTIONS DURING OPERATION…657
OPERATING MACHINE…658
TOWING…661
BATTERY…662
PRECAUTIONS FOR MAINTENANCE…663
BEFORE CARRYING OUT MAINTENANCE…663
DURING MAINTENANCE…664
TIRES…667
ADDITIONAL JOB SITE RULES…668
WHEN REPAIRS ARE NECESSARY…669
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…670
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…673
OPERATION…683
OPERATING INSTRUCTIONS…683
PREPARING FOR OPERATION…683
SAFETY IS THINKING AHEAD…683
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…683
ENGINE START-UP SAFETY PRACTICES…686
AFTER ENGINE HAS STARTED…687
MACHINE OPERATION SAFETY PRECAUTIONS…688
MACHINE OPERATION ON THE HAUL ROAD…688
STARTING ON A GRADE WITH A LOADED TRUCK…689
PASSING…689
LOADING…689
DUMPING…690
TOWING…691
SAFE PARKING PROCEDURES…692
NORMAL ENGINE SHUTDOWN PROCEDURE…692
DELAYED ENGINE SHUTDOWN PROCEDURE…693
OPERATOR CAB AND CONTROLS…695
STEERING WHEEL AND CONTROLS…696
DYNAMIC RETARDER/SERVER BRAKE PEDAL…697
ACCELERATOR (THROTTLE) PEDAL…697
HEATER/AIR CONDITIONER VENTS…697
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…698
OVERHEAD PANEL AND DISPLAYS…699
CENTER CONSOLE CONTROLS AND FEATURES…701
HOIST CONTROL LEVER…702
OPERATOR SEAT…705
INSTRUMENT PANEL AND INDICATOR LIGHTS…707
CONTROL SYMBOLS…707
INSTRUMENT PANEL (FIGURE 3-6)…708
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…709
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…715
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…716
HAZARD WARNING LIGHTS (7)…722
LAMP TEST SWITCH (8)…722
LINK-ON WARNINGS LIGHT…722
MAINTENANCE…723
LUBRICATION AND SERVICE…723
SERVICE CAPACITIES…723
HYDRAULIC TANK SERVICE…723
COOLANT LEVEL CHECK…724
RADIATOR FILLING PROCEDURE…724
COOLING SYSTEM RECOMMENDATIONS…724
LUBRICATION CHART…725
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…726
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…728
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…729
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…730
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…732
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…733
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…734
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…734
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…735
GENERAL DESCRIPTION…735
SYSTEM COMPONENTS…737
SYSTEM OPERATION…738
GENERAL INSTRUCTIONS…740
LUBRICANT REQUIRED…740
SYSTEM PRIMING…740
FILTER ASSEMBLY…740
LUBRICANT PUMP…741
INJECTOR OPERATION…742
INJECTORS…743
SYSTEM CHECK-OUT…744
LUBRICATION CYCLE TIMER CHECK…744
SYSTEM TROUBLESHOOTING CHART…745
PREVENTATIVE MAINTENANCE PROCEDURES…748
SPECIFICATIONS…749
MAJOR COMPONENT DESCRIPTIONS…749
SPECIFICATIONS…751
OPTIONAL EQUIPMENT…753
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…753
GENERAL INFORMATION…755
LIGHTS, SWITHES, AND COMPONENTS…756
TIPS FOR OPERATION…757
EXTERNAL DISPLAY LIGHTS…757
THEORY OF OPERATION…758
BASIC DESCRIPTION…758
LINKAGE FACTOR…758
BRAKE LOCK…759
SOURCES OF ERROR…759
TYPICAL DATA FROM SERVICE CHECK MODE…759
EXAMPLE CALCULATION OF PAYLOAD…760
CALCULATION OF THE CALIBRATION LOAD…760
TYPES OF DATA STORED…761
CYCLE DATA…761
ENGINE ON/OFF DATA…762
FAULT CODES AND WARNING DATA…762
ENGINE OPERATION…763
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…763
OTHER DATA…763
OPERATOR FUNCTIONS…764
USING THE OPERATOR LOAD COUNTER…764
DESCRIPTION…764
VIEWING THE OPERATOR LOAD COUNTER…764
CLEARING THE OPERATOR LOAD COUNTER…764
DIMMING THE LIGHTS ONTHE DISPLAY…764
INITIAL SETUP OF PAYLOAD METER…765
SWITCH SETTINGS…765
CHECKING THE OPERATOR CHECK MODE…765
CHECKING THE SERVICE CHECK MODE…766
SETTING "UP:00"…766
SETTING "PL:00"…766
CHECKING THE Gt SETTING…766
CHECKING THE INCLINOMETER SETTINGS…766
CALIBRATING A TRUCK…767
DISPLAYS AT START-UP…768
SETUP AND MAINTENANCE…769
SETTING THE SPEED LIMIT…769
SETTINGS THE OPTION CODE…769
SETTING THE MACHINE I.D…769
SETTING THE OPERATOR I.D…770
SETTING THE TIME AND DATE…770
DOWNLOAD OF PAYLOAD FAULT CODES…770
DISPLAY OF FAULT CODES…771
CHARTS OF ERROR CODES AND OTHER INFORMATION…772
SERVICE CHECK MODE…774
MONITORING INPUT SIGNALS …774
UP FACTOR – PAYLOAD CALCULATION GAIN…775
PL MODE – LOAD CALCULATION…775
FINAL GEAR RATIO SELECTION…776
BATTERY REPLACEMENT PROCEDURE…777
REPLACING THE BATTERY…777
AFTER REPLACING THE BATTERY…778
SUSPENSION PRESSURE SENSOR…778
REMOVAL…778
INSTALLATION…779
INCLINOMETER…779
REMOVAL…779
INSTALLATION…779
SCOREBOARD…780
DESCRIPTION…780
MAKING CONNECTIONS…780
WIRING DIAGRAM…781
NORMAL OPERATION OF THE SCOREBOARD…782
PAYLOAD METER BACK PANEL…782
CONNECTIONS (AMP PIN IDENTIFICATION)…783
PAYLOAD CIRCUIT NUMBERS…784
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…785
RADIO, AM/FM STERO CASSETTE…787
CEAM010001 – Dump Truck 930E-2 Operation & Maintenance Manual…791
COVER…791
INTRODUCTION…795
FOREWARD…795
ALERTS…796
TABLE OF CONTENTS…797
TRUCK MODEL ILLUSTRATION…800
ABOUT THIS MANUAL…801
STANDARD CHARTS AND TABLES…803
SAFETY…809
GENERAL SAFETY…809
PRECAUTIONS DURING OPERATION…813
OPERATING MACHINE…814
TOWING…817
BATTERY…818
PRECAUTIONS FOR MAINTENANCE…819
BEFORE CARRYING OUT MAINTENANCE…819
DURING MAINTENANCE…820
TIRES…823
ADDITIONAL JOB SITE RULES…824
WHEN REPAIRS ARE NECESSARY…825
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…826
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…829
OPERATION…839
OPERATING INSTRUCTIONS…839
PREPARING FOR OPERATION…839
SAFETY IS THINKING AHEAD…839
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…839
ENGINE START-UP SAFETY PRACTICES…842
AFTER ENGINE HAS STARTED…843
MACHINE OPERATION SAFETY PRECAUTIONS…844
MACHINE OPERATION ON THE HAUL ROAD…844
STARTING ON A GRADE WITH A LOADED TRUCK…845
PASSING…845
LOADING…845
DUMPING…846
TOWING…847
SAFE PARKING PROCEDURES…848
NORMAL ENGINE SHUTDOWN PROCEDURE…848
DELAYED ENGINE SHUTDOWN PROCEDURE…849
SUDDEN LOSS OF ENGINE POWER…850
RESERVE ENGINE OIL SYSTEM…851
OPERATOR CAB AND CONTROLS…853
STEERING WHEEL AND CONTROLS…854
DYNAMIC RETARDER/SERVICE BRAKE PEDAL…855
ACCELERATOR (THROTTLE) PEDAL…855
HEATER/AIR CONDITIONER VENTS…855
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…856
GRADE SPEED CHART…857
CENTER CONSOLE CONTROLS AND FEATURES…859
HOIST CONTROL LEVER…860
OPERATOR SEAT…863
INSTRUMENT PANEL AND INDICATOR LIGHTS…865
CONTROL SYMBOLS…865
INSTRUMENT PANEL (FIGURE 3-7)…866
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…867
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-8)…873
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-8 BY ROWS (A-E) AND COLUMNS (1-6)…874
HAZARD WARNING LIGHTS (7)…880
LAMP TEST SWITCH (8)…880
LINK-ON WARNINGS LIGHT…880
MAINTENANCE…881
LUBRICATION AND SERVICE…881
SERVICE CAPACITIES…881
HYDRAULIC TANK SERVICE…881
COOLANT LEVEL CHECK…882
RADIATOR FILING PROCEDURE…882
COOLING SYSTEM RECOMMENDATIONS…882
RESERVE ENGINE OIL SYSTEM…882
LUBRICATION CHART…883
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…884
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…886
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…887
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…888
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…890
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…891
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…892
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…892
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…893
GENERAL DESCRIPTION…893
SYSTEM COMPONENTS…895
SYSTEM OPERATION…896
INJECTOR OPERATION…900
INJECTORS…901
GENERAL INSTRUCTIONS…898
LUBRICANT REQUIRED…898
SYSTEM PRIMING…898
FILTER ASSEMBLY…898
LUBRICANT PUMP…899
SYSTEM CHECK -OUT…902
LUBRICATION CYCLE TIMER CHECK…902
SYSTEM TROUBLESHOOTING CHART…903
PREVENTATIVE MAINTENANCE PROCEDURES…906
SPECIFICATIONS…907
MAJOR COMPONENT DESCRIPTIONS…907
SPECIFICATIONS…909
OPTIONAL EQUIPMENT…911
PAYLOAD METER 3 (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX)…911
OPERATION SECTION…913
INTRODUCTION…913
DATA SUMMARY…913
DATA GATHERING…913
COMPONENT DESCRIPTION…914
SYSTEM DIAGRAM…914
SUSPENSION PRESSURE SENSORS…914
INCLINOMETER…914
OPERATOR DISPLAY…914
OPERATOR SWITCH…915
SPEED INPUT…915
BODY-UP SWITCH…915
BRAKE LOCK SWITCH…915
PAYLOAD METER…915
COMMUNICATIONS PORTS…915
KEYSWITCH INPUT…916
PAYLOAD METER POWER…916
LOAD LIGHTS…916
WIRING AND TERMINATION…917
TCI OUTPUTS…917
OPERATOR DISPLAY AND SWITCH…918
READING THE SPEEDOMETER…918
READING THE LOAD DISPLAY…918
USING THE OPERATOR ID…918
USING THE LOAD AND TON COUNTER…918
TOTAL TON COUNTER…918
TOTAL LOAD COUNTER…919
CLEARING THE COUNTERS…919
VIEWING LIVE SENSOR DATA…919
OTHER DISPLAY MESSAGES…919
PAYLOAD OPERATION & CALCULATION…920
DESCRIPTION OF HAUL CYCLE STATES…920
STATES OR STAGES OF A TYPICAL HAUL CYCLE…920
HAUL CYCLE DESCRIPTION…920
LOAD CALCULATION…921
CARRY BACK…921
MEASUREMENT ACCURACY…921
SOURCES FOR PAYLOAD ERROR…921
PAYLOAD ERROR…921
LOAD CONDITIONS…922
PRESSURE SENSORS…922
SWING LOADS…922
SPEED AND DISTANCE…922
HAUL CYCLE DATA…922
HAUL CYCLE DATA…923
HAUL CYCLE WARNING FLAGS…924
ALARM RECORDS…925
FRAME TORQUE DATA…925
SPRUNG WEIGHT DATA…926
MAXIMUM SPEED DATA…926
PC SOFTWARE OVERVIEW…926
PC OVERVIEW…926
SYSTEM CONFIGURATION…926
INSTALLING THE PAYLOAD METER 3 SOFTWARE…926
DOWNLOADING DATA…927
PLM3 SYSTEM CONFIGURATION…928
STARTING COMMUNICATIONS…928
DISPLAYED PAYLOAD UNITS…928
TIME UNITS…928
CONNECTION MENU…928
CONNECTING TO THE PAYLOAD METER…929
CONFIGURE THE PAYLOAD METER…929
SETTING THE DATA AND TIME…929
SETTING THE TRUCK TYPE…930
SETTING THE GAUGE DISPLAY UNITS…930
SETTING THE FRAME SERIAL NUMBER…930
SETTING THE TRUCK NUMBER…930
SETTING THE KMS DISTRIBUTOR…930
SETTING THE KMS CUSTOMER…930
CLEAN TRUCK TARE…931
INCLINOMETER CALIBRATION…931
DATA ANALYSIS…932
CREATING A QUERY…932
SORTING ON A TRUCK UNIT NUMBER…932
SORTING ON A TRUCK TYPE…932
SORTING ON DATE RANGE…933
SORTING ON TIME RANGE…933
PAYLOAD DETAIL SCREEN…934
CREATING REPORTS…934
SUMMARY – ONE PAGE REPORT…935
DETAILED – MULTI-PAGE REPORT…935
CREATING GRAPHS…936
EXPORTING DATA…936
CSV EXPORT…936
COMPRESSED…937
IMPORTING DATA…938
DELETING HAUL CYCLE RECORDS…938
VIEWING ALARMS…939
DELETING ALARM RECORDS…939
RADIO, AM/FM STERO CASSETTE…941
CEAM010200 – Dump Truck 930E-2 Operation & Maintenance Manual…949
COVER…949
INTRODUCTION…955
FOREWORD…955
ALERTS PAGE…956
TABLE OF CONTENTS…957
TRUCK MODEL ILLUSTRATION…964
ABOUT THIS MANUAL…965
STANDARD CHARTS AND TABLES…967
SAFETY…973
SAFETY…973
Safety Rules…973
Safety Features…973
Clothing And Personal Items…973
Unauthorized Modification…973
Leaving The Operator’s Seat…974
Mounting And Dismounting…974
Fire Prevention For Fuel And Oil…974
Precautions With High Temperature Fluids…975
Asbestos Dust Hazard Prevention…975
Prevention Of Injury By Work Equipment…975
Fire Extinguisher And First Aid Kit…975
Precautions When Using ROPS…976
Precautions For Attachments…976
Precautions For Starting Machine…976
PRECAUTIONS DURING OPERATION…977
Safety Is Thinking Ahead…977
Safety At The Worksite…977
Fire Prevention…977
Preparing For Operation…977
Ventilation In Enclosed Areas…977
In Operator’s Cab – Before Starting The Engine…978
Mirrors, Windows, And Lights…978
OPERATING THE MACHINE…978
When Starting The Engine…978
Truck Operation – General…978
Check When Traveling In Reverse…979
Traveling…979
Traveling On Slopes…980
Ensure Good Visibility…980
Operate Carefully On Snow…980
Avoid Damage To Dump Body…980
Driving Near High Voltage Cables…980
When Dumping…981
Working On Loose Ground…981
When Loading…981
Parking The Machine…981
TOWING…981
WORKING NEAR BATTERIES…982
Battery Hazard Prevention…982
Starting With Booster Cables…982
PRECAUTIONS FOR MAINTENANCE…983
BEFORE PERFORMING MAINTENANCE…983
Warning Tag…983
Proper Tools…983
Stopping The Engine Before Service…983
Securing The Dump Body…983
DURING MAINTENANCE…984
Personnel…984
Attachments…984
Working Under The Machine…984
Keep The Machine Clean…984
Rules To Follow When Adding Fuel Or Oil…984
Radiator Water Level…985
Use Of Lighting…985
Precautions With The Battery…985
Handling High Pressure Hoses…985
Precautions With High Pressure Oil…985
Precautions When Performing Maintenance Near High Temperature Or High Pressure…986
Rotating Fan And Belts…986
Waste Materials…986
TIRES…987
Handling Tires…987
Storing Tires After Removal…987
ADDITIONAL JOB SITE RULES…988
WHEN REPAIRS ARE NECESSARY…989
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…990
Preliminary Procedures Before Welding or Performing Maintenance…990
Normal Engine Shutdown Procedure…990
Engine Shutdown Procedure Before Welding or Performing Maintenance…991
WARNINGS AND CAUTIONS…993
OPERATION…1003
OPERATING INSTRUCTIONS…1003
PREPARING FOR OPERATION…1003
Safety Is Thinking Ahead…1003
At The Truck – Ground Level Walk Around Inspection…1003
ENGINE START-UP SAFETY PRACTICES…1006
Cold Weather Starting…1007
AFTER ENGINE HAS STARTED…1007
MACHINE OPERATION SAFETY PRECAUTIONS…1008
MACHINE OPERATION ON THE HAUL ROAD…1008
STARTING ON A GRADE WITH A LOADED TRUCK…1009
PASSING…1009
LOADING…1009
DUMPING…1010
Raising The Dump Body…1010
Lowering The Dump Body…1010
TOWING…1012
SAFE PARKING PROCEDURES…1012
NORMAL ENGINE SHUTDOWN PROCEDURE…1012
DELAYED ENGINE SHUTDOWN PROCEDURE…1013
SUDDEN LOSS OF ENGINE POWER…1014
RESERVE ENGINE OIL SYSTEM (Optional)…1015
OPERATOR CAB AND CONTROLS…1017
STEERING WHEEL AND CONTROLS…1018
Horn Button…1018
Telescope Lock Ring…1018
Tilt Wheel Lever…1018
Turn Signal/Headlight Dimmer…1018
DYNAMIC RETARDING…1018
Retarder Control Lever…1019
Dynamic Retarder/Service Brake Pedal…1019
Accelerator (Throttle) Pedal…1019
Starting on a Grade With a Loaded Truck…1019
GRADE/SPEED RETARD CHART…1020
INSTRUMENT PANEL…1021
OVERHEAD PANEL AND DISPLAYS…1021
CENTER CONSOLE…1022
F-N-R Selector Switch…1022
Hoist Control Lever…1023
Raising The Dump Body…1023
Lowering The Dump Body:…1023
Ash Tray…1023
Lighter…1023
L.H. Window Control Switch…1023
R.H. Window Control Switch…1023
Engine Shutdown Switch…1023
Override/Fault Reset Switch…1024
Retard Speed Control (RSC) Switch…1024
Retard Speed Control (RSC) Adjust Dial…1024
Data Store Button…1025
Engine Control System…1025
Service Engine Light (Blue)…1025
Engine Diagnostic Download Port…1025
Payload Meter…1025
TCI Download Port…1025
Modular Mining System (Optional)…1025
PSC Download Port…1025
Payload Meter And Download Connector…1025
OPERATOR COMFORT…1026
OPERATOR SEAT…1026
Adjustment…1026
Seat Removal…1026
Seat Installation…1026
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1027
Heater/Air Conditioner Vents…1027
Defroster Control Switch…1027
Heat Control Switch…1027
Temperature Control Knob…1027
Fan Control Knob…1027
Heater/Air Conditioner Selector Switch…1027
INSTRUMENT PANEL AND INDICATOR LIGHTS…1029
CONTROL SYMBOLS…1029
INSTRUMENT PANEL…1029
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7)…1031
Key Switch…1031
Starting…1031
Engine Shutdown Switch with 5 Minute Idle Timer Delay…1031
Fog Lights (Optional)…1032
Ladder Light Switch…1032
Manual Backup Switch…1032
Panel Illumination Lights…1032
Cab/Air Conditioner Vents…1032
Rotating Beacon Light Switch (Optional)…1032
Heated Mirror Switch (Optional)…1032
Wheel Brake Lock Control…1033
Parking Brake Control…1033
Tachometer…1033
Right Turn Signal Indicator…1034
High Beam Indicator…1034
Left Turn Signal Indicator…1034
Speedometer/Payload Meter Display…1034
Voltmeter…1034
Engine Oil Pressure Gauge…1034
Water Temperature Gauge…1034
Fuel Gauge…1034
AC Drive System Temperature Gauge…1035
Hourmeter…1035
Hydraulic Oil Temperature Gauge…1035
Rest Switch…1035
Light Switch…1036
Windshield Wiper and Washer…1036
Panel Light Dimmer…1036
Payload Meter Switch…1036
OVERHEAD STATUS / WARNING INDICATORS…1037
STATUS / WARNING INDICATOR LIGHT SYMBOLS…1038
Hazard Warning Lights…1044
Lamp Test Switch…1044
Link-On Warning Light…1044
MAINTENANCE…1045
LUBRICATION AND SERVICE…1045
930E SERVICE CAPACITIES…1045
HYDRAULIC TANK SERVICE…1045
Adding Oil…1045
WHEEL MOTOR SERVICE…1045
COOLANT LEVEL CHECK…1046
RADIATOR FILLING PROCEDURE…1046
RESERVE ENGINE OIL SYSTEM (Optional)…1046
Reserve Oil Tank Filling Procedure (Remote fill)…1046
LUBRICATION CHART…1047
10 HOUR (DAILY) INSPECTION…1048
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1051
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1052
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1053
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1056
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1057
2500 HOUR MAINTENANCE CHECKS…1058
5000 HOUR MAINTENANCE CHECKS…1058
AUTOMATIC LUBRICATION SYSTEM…1059
GENERAL DESCRIPTION…1059
SYSTEM COMPONENTS…1061
System Operation…1062
Normal Operation…1062
Pressure Failure Detection Circuits…1063
GENERAL INSTRUCTIONS…1064
Lubricant Required For System…1064
System Priming…1064
Filter Assembly…1064
LUBRICANT PUMP…1065
Pump Housing Oil Level…1065
Pump Pressure Control…1065
Pressure Control Valve Adjustment…1065
INJECTORS (SL-1 Series "H")…1066
Injector Specifications…1066
Injector Adjustment…1066
INJECTOR OPERATION…1067
SYSTEM CHECKOUT…1068
Lubrication Cycle Timer Check…1068
Lubrication Cycle Timer Adjustment…1068
SYSTEM TROUBLESHOOTING CHART…1069
PREVENTATIVE MAINTENANCE PROCEDURES…1071
Daily Lubrication System Inspection…1071
250 Hour Inspection…1071
1000 Hour Inspection…1071
MAJOR COMPONENT DESCRIPTION…1073
OPTIONAL EQUIPMENT…1077
PAYLOAD METER III…1077
OPERATION SECTION…1079
Introduction…1079
Data Summary…1079
Data Gathering…1079
COMPONENT DESCRIPTION…1080
System Diagram…1080
Suspension Pressure Sensors…1080
Inclinometer…1080
Operator Display…1080
Operator Switch…1081
Speed Input…1081
Body-Up Switch…1081
Brake Lock Switch…1081
Payload Meter…1081
Communications Ports…1081
Keyswitch Input…1082
Payload Meter Power…1082
Load Lights…1082
Wiring and Termination…1083
TCI Outputs…1083
OPERATOR’S DISPLAY AND SWITCH…1084
Reading the Speedometer…1084
Reading the Load Display…1084
Using the Operator ID…1084
Using the Load and Ton Counter…1084
Total Ton Counter…1084
Total Load Counter…1085
Clearing the Counters…1085
Viewing Live Sensor Data…1085
Other Display Messages…1085
PAYLOAD OPERATION & CALCULATION…1086
Description of Haul Cycle States…1086
Haul Cycle Description…1086
Load Calculation…1087
Carry Back…1087
Measurement Accuracy…1087
SOURCES FOR PAYLOAD ERROR…1087
Payload Error…1087
Loading Conditions…1088
Pressure Sensors…1088
Swingloads…1088
Speed and Distance…1088
HAUL CYCLE DATA…1088
Haul Cycle Data…1089
Haul Cycle Warning Flags…1090
A: Continuous Loading…1090
B: Loading to Dumping Transition…1090
C: No Final Load…1090
D: Maneuvering to Dumping Transition…1090
E: Average Load or Tare Used…1090
F: Final Zone to Dumping Transition…1090
H: False Body Up…1090
I: Body Up Signal Failed…1090
J: Speed Sensor Failed…1090
K: New Tare Not Calculated…1090
L: Incomplete Haul Cycle…1090
M: Haul Cycle Too Long…1091
N: Sensor Input Error…1091
Alarm Records…1091
Frame Torque Data…1091
Sprung Weight Data…1092
Maximum Speed Data…1092
PC SOFTWARE OVERVIEW…1092
PC Overview…1092
System Configuration…1092
Installing the PLMIII Software…1092
DOWNLOADING DATA…1093
PLMIII SYSTEM CONFIGURATION…1094
Starting Communications…1094
Displayed Payload Units…1094
Time Units…1094
Connection Menu…1094
Connecting to the Payload Meter…1095
Configure the Payload Meter…1095
Setting the Date and Time…1095
Setting the Truck Type…1096
Setting the Gauge Display Units…1096
Setting the Frame Serial Number…1096
Setting the Truck Number…1096
Setting the Komatsu Distributor…1096
Setting the Komatsu Customer…1096
Clean Truck Tare…1097
Inclinometer Calibration…1097
DATA ANALYSIS…1098
Sorting on Truck Unit Number…1098
Creating a Query…1098
Sorting on Truck Type…1098
Sorting on Date Range…1099
Sorting on Time Range…1099
Payload Detail Screen…1100
Creating Reports…1100
Summary – one page report…1101
Detailed – multi-page report…1101
Creating Graphs…1102
Exporting Data…1102
CSV Export…1102
Compressed…1103
To export data in ZIP format:…1104
Importing Data…1104
Deleting Haul Cycle Records…1104
Viewing Alarms…1105
Deleting Alarm Records…1105
RADIO, AM / FM STEREO CASSETTE…1107
SETTING THE TIME…1107
GENERAL RECEIVER FUNCTIONS…1107
Turning The Power On And Off…1107
Display…1107
Setting The Default Display…1108
Adjusting Display Brightness…1108
OPERATING THE RADIO…1108
BAND…1108
TUNE/SEEK…1108
Manual Tuning…1108
SEEK Mode…1108
SCAN…1108
AUTO…1108
ADJUSTING THE RECEIVER SETTINGS…1109
PROGRAMMING PRESET STATIONS…1109
OPERATION OF THE WEATHERBAND (U.S.)…1109
SATELLITE RADIO…1110
Operating Satellite Radio…1110
Program Type Search (PTY)…1110
CASSETTE PLAYER…1111
Playing A Cassette…1111
Cassette Functions…1111
PROGRAMMABLE EJECT DEFAULT…1111
Bad Tape Detect…1112
CASSETTE PLAYER CLEANING…1112
CEAM010500 – Dump Truck 930E-2SE Operation & Maintenance Manual…1115
COVER…1115
INTRODUCTION…1119
FOREWARD…1119
ALERTS…1120
TABLE OF CONTENTS…1121
TRUCK MODEL ILLUSTRATION…1124
ABOUT THIS MANUAL…1125
STANDARD CHARTS AND TABLES…1127
SAFETY…1133
GENERAL SAFETY…1133
PRECAUTIONS DURING OPERATION…1137
OPERATING MACHINE…1138
TOWING…1141
BATTERY…1142
PRECAUTIONS FOR MAINTENANCE…1143
BEFORE CARRYING OUT MAINTENANCE…1143
DURING MAINTENANCE…1144
TIRES…1147
ADDITIONAL JOB SITE RULES…1148
WHEN REPAIRS ARE NECESSARY…1149
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1150
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…1153
OPERATION…1163
OPERATING INSTRUCTIONS…1163
PREPARING FOR OPERATION…1163
SAFETY IS THINKING AHEAD…1163
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…1163
ENGINE START-UP SAFETY PRACTICES…1166
AFTER ENGINE HAS STARTED…1167
MACHINE OPERATION SAFETY PRECAUTIONS…1168
MACHINE OPERATION ON THE HAUL ROAD…1168
STARTING ON A GRADE WITH A LOADED TRUCK…1169
PASSING…1169
LOADING…1169
DUMPING…1170
TOWING…1171
SAFE PARKING PROCEDURES…1172
NORMAL ENGINE SHUTDOWN PROCEDURE…1172
DELAYED ENGINE SHUTDOWN PROCEDURE…1173
SUDDEN LOSS OF ENGINE POWER…1174
RESERVE ENGINE OIL SYSTEM…1175
OPERATOR CAB AND CONTROLS…1177
STEERING WHEEL AND CONTROLS…1178
DYNAMIC RETARDER/SERVICE BRAKE PEDAL…1179
ACCELERATOR (THROTTLE) PEDAL…1179
HEATER/AIR CONDITIONER VENTS…1179
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…1180
GRADE SPEED CHART…1181
CENTER CONSOLE CONTROLS AND FEATURES…1183
HOIST CONTROL LEVER…1184
OPERATOR SEAT…1187
INSTRUMENT PANEL AND INDICATOR LIGHTS…1189
CONTROL SYMBOLS…1189
INSTRUMENT PANEL (FIGURE 3-7)…1190
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…1191
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-8)…1197
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-8 BY ROWS (A-E) AND COLUMNS (1-6)…1198
HAZARD WARNING LIGHTS (7)…1204
LAMP TEST SWITCH (8)…1204
LINK-ON WARNINGS LIGHT…1204
MAINTENANCE…1205
LUBRICATION AND SERVICE…1205
SERVICE CAPACITIES…1205
HYDRAULIC TANK SERVICE…1205
COOLANT LEVEL CHECK…1206
RADIATOR FILING PROCEDURE…1206
COOLING SYSTEM RECOMMENDATIONS…1206
RESERVE ENGINE OIL SYSTEM…1206
LUBRICATION CHART…1207
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…1208
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1210
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1211
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1212
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1214
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1215
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1216
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1216
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…1217
GENERAL DESCRIPTION…1217
SYSTEM COMPONENTS…1219
SYSTEM OPERATION…1220
INJECTOR OPERATION…1224
INJECTORS…1225
GENERAL INSTRUCTIONS…1222
LUBRICANT REQUIRED…1222
SYSTEM PRIMING…1222
FILTER ASSEMBLY…1222
LUBRICANT PUMP…1223
SYSTEM CHECK -OUT…1225
LUBRICATION CYCLE TIMER CHECK…1225
SYSTEM TROUBLESHOOTING CHART…1226
PREVENTATIVE MAINTENANCE PROCEDURES…1228
SPECIFICATIONS…1229
MAJOR COMPONENT DESCRIPTIONS…1229
SPECIFICATIONS…1231
OPTIONAL EQUIPMENT…1233
PAYLOAD METER 3 (ON BOARD WEIGHTING SYSTEM (OBWS) INDEX)…1233
OPERATION SECTION…1235
INTRODUCTION…1235
DATA SUMMARY…1235
DATA GATHERING…1235
COMPONENT DESCRIPTION…1236
SYSTEM DIAGRAM…1236
SUSPENSION PRESSURE SENSORS…1236
INCLINOMETER…1236
OPERATOR DISPLAY…1236
OPERATOR SWITCH…1237
SPEED INPUT…1237
BODY-UP SWITCH…1237
BRAKE LOCK SWITCH…1237
PAYLOAD METER…1237
COMMUNICATIONS PORTS…1237
KEYSWITCH INPUT…1238
PAYLOAD METER POWER…1238
LOAD LIGHTS…1238
WIRING AND TERMINATION…1239
TCI OUTPUTS…1239
OPERATOR DISPLAY AND SWITCH…1240
READING THE SPEEDOMETER…1240
READING THE LOAD DISPLAY…1240
USING THE OPERATOR ID…1240
USING THE LOAD AND TON COUNTER…1240
TOTAL TON COUNTER…1240
TOTAL LOAD COUNTER…1241
CLEARING THE COUNTERS…1241
VIEWING LIVE SENSOR DATA…1241
OTHER DISPLAY MESSAGES…1241
PAYLOAD OPERATION & CALCULATION…1242
DESCRIPTION OF HAUL CYCLE STATES…1242
STATES OR STAGES OF A TYPICAL HAUL CYCLE…1242
HAUL CYCLE DESCRIPTION…1242
LOAD CALCULATION…1243
CARRY BACK…1243
MEASUREMENT ACCURACY…1243
SOURCES FOR PAYLOAD ERROR…1243
PAYLOAD ERROR…1243
LOAD CONDITIONS…1244
PRESSURE SENSORS…1244
SWING LOADS…1244
SPEED AND DISTANCE…1244
HAUL CYCLE DATA…1244
HAUL CYCLE DATA…1245
HAUL CYCLE WARNING FLAGS…1246
ALARM RECORDS…1247
FRAME TORQUE DATA…1247
SPRUNG WEIGHT DATA…1248
MAXIMUM SPEED DATA…1248
PC SOFTWARE OVERVIEW…1248
PC OVERVIEW…1248
SYSTEM CONFIGURATION…1248
INSTALLING THE PAYLOAD METER 3 SOFTWARE…1248
DOWNLOADING DATA…1249
PLM3 SYSTEM CONFIGURATION…1250
STARTING COMMUNICATIONS…1250
DISPLAYED PAYLOAD UNITS…1250
TIME UNITS…1250
CONNECTION MENU…1250
CONNECTING TO THE PAYLOAD METER…1251
CONFIGURE THE PAYLOAD METER…1251
SETTING THE DATA AND TIME…1251
SETTING THE TRUCK TYPE…1252
SETTING THE GAUGE DISPLAY UNITS…1252
SETTING THE FRAME SERIAL NUMBER…1252
SETTING THE TRUCK NUMBER…1252
SETTING THE KMS DISTRIBUTOR…1252
SETTING THE KMS CUSTOMER…1252
CLEAN TRUCK TARE…1253
INCLINOMETER CALIBRATION…1253
DATA ANALYSIS…1254
CREATING A QUERY…1254
SORTING ON A TRUCK UNIT NUMBER…1254
SORTING ON A TRUCK TYPE…1254
SORTING ON DATE RANGE…1255
SORTING ON TIME RANGE…1255
PAYLOAD DETAIL SCREEN…1256
CREATING REPORTS…1256
SUMMARY – ONE PAGE REPORT…1257
DETAILED – MULTI-PAGE REPORT…1257
CREATING GRAPHS…1258
EXPORTING DATA…1258
CSV EXPORT…1258
COMPRESSED…1259
IMPORTING DATA…1260
DELETING HAUL CYCLE RECORDS…1260
VIEWING ALARMS…1261
DELETING ALARM RECORDS…1261
RADIO, AM/FM STERO CASSETTE…1263
CEAM011600 – Dump Truck 930E-2 Operation & Maintenance Manual…1271
COVER…1271
FOREWARD…1276
ALERTS PAGE…1277
TABLE OF CONTENTS…1278
TRUCK MODEL ILLUSTRATION…1285
ABOUT THIS MANUAL…1286
STANDARD CHARTS AND TABLES…1288
SAFETY…1294
Safety Rules…1294
Safety Features…1294
Clothing And Personal Items…1294
Unauthorized Modification…1294
Leaving The Operator's Seat…1295
Mounting And Dismounting…1295
Fire Prevention For Fuel And Oil…1295
Precautions With High Temperature Fluids…1296
Asbestos Dust Hazard Prevention…1296
Prevention Of Injury By Work Equipment…1296
Fire Extinguisher And First Aid Kit…1296
Precautions When Using ROPS…1297
Precautions For Attachments…1297
PRECAUTIONS DURING OPERATION…1298
Safety Is Thinking Ahead…1298
Safety At The Worksite…1298
Fire Prevention…1298
Preparing For Operation…1298
Ventilation In Enclosed Areas…1298
In Operator's Cab – Before Starting The Engine…1299
Mirrors, Windows, And Lights…1299
OPERATING THE MACHINE…1299
When Starting The Engine…1299
Truck Operation – General…1299
Check When Traveling In Reverse…1300
Traveling…1300
Traveling On Slopes…1301
Ensure Good Visibility…1301
Operate Carefully On Snow…1301
Avoide Damage To Dump Body…1301
Driving Near High Voltage Cables…1301
When Dumping…1302
Working On Loose Ground…1302
When Loading…1302
Parking The Machine…1302
TOWING…1302
WORKING NEAR BATTERIES…1303
Battery Hazard Prevention…1303
Starting With Booster Cables…1303
PRECAUTIONS FOR MAINTENANCE…1304
BEFORE PERFORMING MAINTENANCE…1304
Warning Tag…1304
Proper Tools…1304
Stopping The Engine Before Service…1304
Securing The Dump Body…1304
DURING MAINTENANCE…1305
Personnel…1305
Attachments…1305
Working Under The Machine…1305
Keep The Machine Clean…1305
Rules To Follow When Adding Fuel Or Oil…1305
Radiator Water Level…1306
Use Of Lighting…1306
Precautions With The Battery…1306
Handling High Pressure Hoses…1306
Precautions With High Pressure Oil …1306
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1307
Rotating Fan And Belts…1307
Waste Materials…1307
TIRES…1308
Handling Tires…1308
Storing Tires After Removal…1308
ADDITIONAL JOB SITE RULES…1309
WHEN REPAIRS ARE NECESSARY…1310
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1311
Preliminary Procedures Before Welding Or Performing Maintenance…1311
Normal Engine Shutdown Procedure…1311
Engine Shutdown Procedure Before Welding Or Performing Maintenance…1312
WARNINGS AND CAUTIONS…1314
OPERATING INSTRUCTIONS…1324
PREPARING FOR OPERATION…1324
Safety Is Thinking Ahead…1324
At The Truck – Ground Level Walk Around Inspection…1324
ENGINE START-UP SAFETY PRACTICES…1327
Cold Weather Starting…1328
AFTER ENGINE HAS STARTED…1328
MACHINE OPERATION SAFETY PRECAUTIONS…1329
MACHINE OPERATION ON THE HAUL ROAD…1329
STARTING ON A GRADE WITH A LOADED TRUCK…1330
PASSING …1330
LOADING …1330
DUMPING…1331
Raising The Dump Body…1331
Lowering The Dump Body…1331
TOWING…1333
SAFE PARKING PROCEDURES…1333
NORMAL ENGINE SHUTDOWN PROCEDURE…1333
DELAYED ENGINE SHUTDOWN PROCEDURE…1334
SUDDEN LOSS OF ENGINE POWER…1335
RESERVE ENGINE OIL SYSTEM (OPTIONAL)…1336
OPERATOR CAB AND CONTROLS…1338
STEERING WHEEL AND CONTROLS…1339
Horn Button…1339
Telescope Lock Ring…1339
Tilt Wheel Lever…1339
Turn Signal/Headlight Dimmer…1339
DYNAMIC RETARDING…1339
Retarder Control Lever…1340
Dynamic Retarder/Service Brake Pedal…1340
Accelerator (Throttle) Pedal…1340
Starting On A Grade With A Loaded Truck…1340
GRADE/SPEED RETARD CHART…1341
INSTRUMENT PANEL…1342
OVERHEAD PANEL AND DISPLAYS…1342
CENTER CONSOLE…1343
F-N-R Selector Switch…1343
Hoist Control Lever…1344
Raising The Dump Body…1344
Lowering The Dump Body…1344
Ash Tray…1344
Lighter…1344
L.H. Window Control Switch…1344
R.H. Window Control Switch…1344
Engine Shutdown Switch…1344
Override/Fault Reset Switch…1345
Retard Speed Control (RSC) Switch…1345
Retard Speed Control (RSC) Adjust Dial…1345
PSC Download Port…1346
Engine Diagnostics Download Port…1346
TCI Download Port…1346
Passenger Seat…1346
Engine Control System…1346
Modular Mining System…1346
Payload Meter And Download Connector…1346
OPERATOR COMFORT…1347
OPERATOR SEAT…1347
Adjustment…1347
Seat Removal…1347
Seat Installation…1347
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…1348
Defroster Vent Control Switch…1348
Outside/Inside Air Control Switch…1348
Heater Control Switch…1348
Temperature Control Knob…1348
Fan Control Knob…1348
Heater/Air Conditioner Selector Switch…1348
Heater/Air Conditioner Selector Vents…1348
INSTRUMENT PANEL AND INDICATOR LIGHTS…1350
CONTROL SYMBOLS…1350
INSTRUMENT PANEL…1350
PANEL GAUGES, INDICATORS, AND CONTROLS…1352
Key Switch…1352
Starting…1352
Engine Shutdown Switch With 5 Minute Idle Timer Delay…1352
Fog Lights (Optional)…1353
Ladder Light Switch…1353
Manual Backup Switch…1353
Panel Illumination Lights…1353
Cab/Air Conditioner Vents…1353
Rotating Beacon Light Switch (Optional)…1353
Heated Mirror Switch (Optional)…1353
Wheel Brake Lock Control…1354
Parking Brake Control…1354
Tachometer…1354
Right Turn Signal Indicator …1355
High Beam Indicator…1355
Left Turn Signal Indicator…1355
Speedometer/Payload Meter Display…1355
Voltmeter…1355
Engine Oil Pressure Gauge…1355
Water Temperature Gauge…1355
Fuel Gauge…1355
AC Drive System Temperature Gauge…1356
Hourmeter…1356
Hydraulic Oil Temperature Gauge…1356
Rest Switch…1356
Light Switch…1357
Windshield Wiper And Washer…1357
Panel Light And DImmer…1357
Payload Meter Switch…1357
OVERHEAD STATUS/WARNING INDICATORS…1358
STATUS/WARNING INDICATOR LIGHT SYMBOLS…1359
Hazard Warning Lights…1365
Lamp Test Switch…1365
Link-On Warning Light…1365
LUBRICATION AND SERVICE…1366
930E SERVICE CAPACITIES…1366
HYDRAULIC TANK SERVICE…1366
Adding Oil…1366
WHEEL MOTOR SERVICE…1366
COOLANT LEVEL CHECK…1367
RADIATOR FILLING PROCEDURE…1367
RESERVE ENGINE OIL SYSTEM (OPTIONAL)…1367
Reserve Oil Tank Filling Procedure (Remote Fill)…1367
LUBRICATION CHART…1368
10 HOUR (DAILY) INSPECTION…1369
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1372
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1373
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1374
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1377
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1378
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1379
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1379
AUTOMATIC LUBRICATION SYSTEM…1380
GENERAL DESCRIPTION…1380
SYSTEM COMPONENTS…1382
SYSTEM OPERATION…1383
Normal Operation…1383
Pressure Failure Detection Circuits…1384
GENERAL INSTRUCTIONS…1385
Required Lubricant For System…1385
System Priming…1385
Filter Assembly…1385
LUBRICANT PUMP…1386
Pump Housing Oil Level…1386
Pump Pressure Control…1386
Pressure Control Valve Adjustment…1386
INJECTOR OPERATION…1387
INJECTORS (SL-1 SERIES "H")…1388
Injector Specifications…1388
Injector Adjustment…1388
SYSTEM CHECKOUT…1389
Lubrication Cycle Timer Check…1389
Lubrication Cycle Timer Adjustment…1389
SYSTEM TROUBLESHOOTING CHART…1390
PREVENTATIVE MAINTENANCE PROCEDURES…1393
Daily Lubrication System Inspection…1393
250 Hour Inspection…1393
1000 Hour Inspection…1393
MAJOR COMPONENT DESCRIPTION…1394
PAYLOAD METER III TM…1398
INDEX…1398
OPERATION SECTION…1400
Introduction…1400
Data Summary…1400
Data Gathering…1400
COMPONENT DESCRIPTION…1401
System Diagram…1401
Suspension Pressure Sensors…1401
Inclinometer…1401
Operator Display…1401
Operator Switch…1402
Speed Input…1402
Body-Up Switch…1402
Brake Lock Switch…1402
Payload Meter…1402
Communications Ports…1402
Keyswitch Input…1403
Payload Meter Power…1403
Load Lights…1403
Wiring and Termination…1404
TCI Outputs…1404
OPERATOR’S DISPLAY AND SWITCH…1405
Reading the Speedometer…1405
Reading the Load Display…1405
Using the Operator ID…1405
Using the Load and Ton Counter…1405
Total Ton Counter…1405
Total Load Counter…1406
Clearing the Counters…1406
Viewing Live Sensor Data…1406
Other Display Messages…1406
PAYLOAD OPERATION & CALCULATION…1407
Description of Haul Cycle States…1407
Haul Cycle Description…1407
Load Calculation…1408
Carry Back…1408
Measurement Accuracy…1408
SOURCES FOR PAYLOAD ERROR…1408
Payload Error…1408
Loading Conditions…1409
Pressure Sensors…1409
Swingloads…1409
Speed and Distance…1409
HAUL CYCLE DATA…1409
Haul Cycle Data…1410
Haul Cycle Warning Flags…1411
A: Continuous Loading…1411
B: Loading to Dumping Transition…1411
C: No Final Load…1411
D: Maneuvering to Dumping Transition…1411
E: Average Load or Tare Used…1411
F: Final Zone to Dumping Transition…1411
H: False Body Up…1411
I: Body Up Signal Failed…1411
J: Speed Sensor Failed…1411
K: New Tare Not Calculated…1411
L: Incomplete Haul Cycle…1411
M: Haul Cycle Too Long…1412
N: Sensor Input Error…1412
Alarm Records…1412
Frame Torque Data…1412
Sprung Weight Data…1413
Maximum Speed Data…1413
PC SOFTWARE OVERVIEW…1413
PC Overview…1413
System Configuration…1413
Installing the PLMIII Software…1413
DOWNLOADING DATA…1414
PLMIII SYSTEM CONFIGURATION…1415
Starting Communications…1415
Displayed Payload Units…1415
Time Units…1415
Connection Menu…1415
Connecting to the Payload Meter…1416
Configure the Payload Meter…1416
Setting the Date and Time…1416
Setting the Truck Type…1417
Setting the Gauge Display Units…1417
Setting the Frame Serial Number…1417
Setting the Truck Number…1417
Setting the Komatsu Distributor…1417
Setting the Komatsu Customer…1417
Clean Truck Tare…1418
Inclinometer Calibration…1418
DATA ANALYSIS…1419
Sorting on Truck Unit Number…1419
Creating a Query…1419
Sorting on Truck Type…1419
Sorting on Date Range…1420
Sorting on Time Range…1420
Payload Detail Screen…1421
Creating Reports…1421
Summary – one page report…1422
Detailed – multi-page report…1422
Creating Graphs…1423
Exporting Data…1423
CSV Export…1423
Compressed…1424
To export data in ZIP format:…1425
Importing Data…1425
Deleting Haul Cycle Records…1425
Viewing Alarms…1426
Deleting Alarm Records…1426
RADIO AM/FM STEREO CASSETTE…1428
SETTING THE TIME…1428
GENERAL RECEIVER FUNCTIONS…1428
Turning The Power On And Off…1428
Display…1428
Setting The Default Display…1429
Adjusting Display Brightness…1429
OPERATING THE RADIO…1429
BAND…1429
TUNE/SEEK…1429
Manual Tuning…1429
SEEK Mode…1429
SCAN…1429
AUTO…1429
PROGRAMMING PRESET STATIONS…1430
OPERATION OF THE WEATHERBAND (U.S.)…1430
ADJUSTING THE RECEIVER SETTINGS…1430
PROGRAMMABLE EJECT DEFAULT…1431
CASSETTE PLAYER…1431
Playing A Cassette…1431
Cassette Functions…1431
Bad Tape Detect…1432
CASSETTE PLAYER CLEANING…1432
CEAM011700 – Dump Truck 930E-2 Operation & Maintenance Manual…1436
COVER…1436
SECTION 10 – INTRODUCTION…1442
FOREWORD…1442
ALERTS PAGE…1443
TABLE OF CONTENTS…1444
TRUCK MODEL ILLUSTRATION…1451
ABOUT THIS MANUAL…1452
SECTION 12 – STANDARD CHARTS AND TABLES…1454
SECTION 20 – SAFETY…1460
Safety Rules…1460
Safety Features…1460
Clothing And Personal Items…1460
Unauthorized Modification…1460
Leaving The Operator’s Seat…1461
Mounting And Dismounting…1461
Fire Prevention For Fuel And Oil…1461
Precautions With High Temperature Fluids…1462
Asbestos Dust Hazard Prevention…1462
Prevention Of Injury By Work Equipment…1462
Fire Extinguisher And First Aid Kit…1462
Precautions When Using ROPS…1463
Precautions For Attachments…1463
PRECAUTIONS DURING OPERATION…1464
Safety Is Thinking Ahead…1464
Safety At The Worksite…1464
Fire Prevention…1464
Preparing For Operation…1464
Ventilation In Enclosed Areas…1464
In Operator’s Cab – Before Starting The Engine…1465
Mirrors, Windows, And Lights…1465
OPERATING THE MACHINE…1465
When Starting The Engine…1465
Truck Operation – General…1465
Check When Traveling In Reverse…1466
Traveling…1466
Traveling On Slopes…1467
Ensure Good Visibility…1467
Operate Carefully On Snow…1467
Avoid Damage To Dump Body…1467
Driving Near High Voltage Cables…1467
When Dumping…1468
Working On Loose Ground…1468
When Loading…1468
Parking The Machine…1468
TOWING…1468
WORKING NEAR BATTERIES…1469
Battery Hazard Prevention…1469
Starting With Booster Cables…1469
PRECAUTIONS FOR MAINTENANCE…1470
BEFORE PERFORMING MAINTENANCE…1470
Warning Tag…1470
Proper Tools…1470
Stopping The Engine Before Service…1470
Securing The Dump Body…1470
DURING MAINTENANCE…1471
Personnel…1471
Attachments…1471
Working Under The Machine…1471
Keep The Machine Clean…1471
Rules To Follow When Adding Fuel Or Oil…1471
Radiator Water Level…1472
Use Of Lighting…1472
Precautions With The Battery…1472
Handling High Pressure Hoses…1472
Precautions With High Pressure Oil…1472
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1473
Rotating Fan And Belts…1473
Waste Materials…1473
TIRES…1474
Handling Tires…1474
Storing Tires After Removal…1474
ADDITIONAL JOB SITE RULES…1475
WHEN REPAIRS ARE NECESSARY…1476
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1477
Preliminary Procedures Before Welding or Performing Maintenance…1477
Normal Engine Shutdown Procedure…1477
Engine Shutdown Procedure Before Welding or Performing Maintenance…1478
SECTION 22 – WARNINGS AND CAUTIONS…1480
SECTION 30 – OPERATING INSTRUCTIONS…1490
PREPARING FOR OPERATION…1490
Safety Is Thinking Ahead…1490
At The Truck – Ground Level Walk Around Inspection…1490
ENGINE START-UP SAFETY PRACTICES…1493
Cold Weather Starting…1494
AFTER ENGINE HAS STARTED…1494
MACHINE OPERATION SAFETY PRECAUTIONS…1495
MACHINE OPERATION ON THE HAUL ROAD…1495
STARTING ON A GRADE WITH A LOADED TRUCK…1496
PASSING…1496
LOADING…1496
DUMPING…1497
Raising The Dump Body…1497
Lowering The Dump Body…1497
TOWING…1499
SAFE PARKING PROCEDURES…1499
NORMAL ENGINE SHUTDOWN PROCEDURE…1499
DELAYED ENGINE SHUTDOWN PROCEDURE…1500
SUDDEN LOSS OF ENGINE POWER…1501
RESERVE ENGINE OIL SYSTEM (Optional)…1502
SECTION 32 – OPERATOR CAB AND CONTROLS…1504
STEERING WHEEL AND CONTROLS…1505
Horn Button…1505
Telescope Lock Ring…1505
Tilt Wheel Lever…1505
Turn Signal/Headlight Dimmer…1505
DYNAMIC RETARDING…1505
Retarder Control Lever…1506
Dynamic Retarder/Service Brake Pedal…1506
Accelerator (Throttle) Pedal…1506
Starting on a Grade With a Loaded Truck…1506
GRADE/SPEED RETARD CHART…1507
INSTRUMENT PANEL…1508
OVERHEAD PANEL AND DISPLAYS…1508
CENTER CONSOLE…1509
F-N-R Selector Switch…1509
Hoist Control Lever…1510
Raising The Dump Body…1510
Lowering The Dump Body:…1510
Ash Tray…1510
Lighter…1510
L.H. Window Control Switch…1510
R.H. Window Control Switch…1510
Engine Shutdown Switch…1510
Override/Fault Reset Switch…1511
Retard Speed Control (RSC) Switch…1511
Retard Speed Control (RSC) Adjust Dial…1511
PSC Download Port…1512
Engine Diagnostics Download Port…1512
TCI Download Port…1512
Passenger Seat…1512
Engine Control System…1512
Modular Mining System…1512
Payload Meter And Download Connector…1512
OPERATOR COMFORT…1513
OPERATOR SEAT…1513
Adjustment…1513
HEATER / AIR CONDITIONER COMPART MENT AND CONTROLS…1514
Defroster Vent Control Switch…1514
Outside/Inside Air Control Switch…1514
Heater Control Switch…1514
Temperature Control Knob…1514
Fan Control Knob…1514
Heater/Air Conditioner Selector Switch…1514
Heater/Air Conditioner Vents…1514
INSTRUMENT PANEL AND INDICATOR LIGHTS…1516
CONTROL SYMBOLS…1516
INSTRUMENT PANEL…1516
PANEL GAUGES, INDICATORS, AND CONTROLS…1518
Key Switch…1518
Starting…1518
Engine Shutdown Switch with 5 Minute Idle Timer Delay…1518
Fog Lights (Optional)…1519
Ladder Light Switch…1519
Manual Backup Switch…1519
Panel Illumination Lights…1519
Cab/Air Conditioner Vents…1519
Rotating Beacon Light Switch (Optional)…1519
Heated Mirror Switch (Optional)…1519
Wheel Brake Lock Control…1520
Parking Brake Control…1520
Tachometer…1520
Right Turn Signal Indicator…1521
High Beam Indicator…1521
Left Turn Signal Indicator…1521
Speedometer/Payload Meter Display…1521
Voltmeter…1521
Engine Oil Pressure Gauge…1521
Water Temperature Gauge…1521
Fuel Gauge…1521
AC Drive System Temperature Gauge…1522
Hourmeter…1522
Hydraulic Oil Temperature Gauge…1522
Rest Switch…1522
Light Switch…1523
Windshield Wiper and Washer…1523
Panel Light Dimmer…1523
Payload Meter Switch…1523
OVERHEAD STATUS / WARNING INDICATORS…1524
STATUS / WARNING INDICATOR LIGHT SYMBOLS…1525
Hazard Warning Lights…1531
Lamp Test Switch…1531
Link-On Warning Light…1531
SECTION 40 – LUBRICATION AND SERVICE…1532
930E SERVICE CAPACITIES…1532
HYDRAULIC TANK SERVICE…1532
Adding Oil…1532
WHEEL MOTOR SERVICE…1532
COOLANT LEVEL CHECK…1533
RADIATOR FILLING PROCEDURE…1533
RESERVE ENGINE OIL SYSTEM (Optional)…1533
Reserve Oil Tank Filling Procedure (Remote fill)…1533
LUBRICATION CHART…1534
10 HOUR (DAILY) INSPECTION…1535
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1538
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1539
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1540
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1543
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1544
2500 HOUR MAINTENANCE CHECKS…1545
5000 HOUR MAINTENANCE CHECKS…1545
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…1546
GENERAL DESCRIPTION…1546
SYSTEM COMPONENTS…1548
SYSTEM OPERATION…1549
Normal Operation…1549
Pressure Failure Detection Circuits…1550
GENERAL INSTRUCTIONS…1551
Required Lubricant For System…1551
System Priming…1551
Filter Assembly…1551
LUBRICANT PUMP…1552
Pump Housing Oil Level…1552
Pump Pressure Control…1552
Pressure Control Valve Adjustment…1552
INJECTOR OPERATION…1553
INJECTORS (SL-1 Series “H”))…1554
Injector Specifications…1554
Injector Adjustment…1554
SYSTEM CHECKOUT…1555
Lubrication Cycle Timer Check…1555
Lubrication Cycle Timer Adjustment…1555
SYSTEM TROUBLESHOOTING CHART…1556
PREVENTATIVE MAINTENANCE PROCEDURES…1559
Daily Lubrication System Inspection…1559
250 Hour Inspection…1559
1000 Hour Inspection…1559
SECTION 50 – MAJOR COMPONENT DESCRIPTION…1560
SECTION 60 – PAYLOAD METER III™ – INDEX…1564
OPERATION SECTION…1566
Introduction…1566
Data Summary…1566
Data Gathering…1566
COMPONENT DESCRIPTION…1567
System Diagram…1567
Suspension Pressure Sensors…1567
Inclinometer…1567
Operator Display…1567
Operator Switch…1568
Speed Input…1568
Body-Up Switch…1568
Brake Lock Switch…1568
Payload Meter…1568
Communications Ports…1568
Keyswitch Input…1569
Payload Meter Power…1569
Load Lights…1569
Wiring and Termination…1570
TCI Outputs…1570
OPERATOR’S DISPLAY AND SWITCH…1571
Reading the Speedometer…1571
Reading the Load Display…1571
Using the Operator ID…1571
Using the Load and Ton Counter…1571
Total Ton Counter…1571
Total Load Counter…1572
Clearing the Counters…1572
Viewing Live Sensor Data…1572
Other Display Messages…1572
PAYLOAD OPERATION & CALCULATION…1573
Description of Haul Cycle States…1573
Haul Cycle Description…1573
Load Calculation…1574
Carry Back…1574
Measurement Accuracy…1574
SOURCES FOR PAYLOAD ERROR…1574
Payload Error…1574
Loading Conditions…1575
Pressure Sensors…1575
Swingloads…1575
Speed and Distance…1575
HAUL CYCLE DATA…1575
Haul Cycle Data…1576
Haul Cycle Warning Flags…1577
A: Continuous Loading…1577
B: Loading to Dumping Transition…1577
C: No Final Load…1577
D: Maneuvering to Dumping Transition…1577
E: Average Load or Tare Used…1577
F: Final Zone to Dumping Transition…1577
H: False Body Up…1577
I: Body Up Signal Failed…1577
J: Speed Sensor Failed…1577
K: New Tare Not Calculated…1577
L: Incomplete Haul Cycle…1577
M: Haul Cycle Too Long…1578
N: Sensor Input Error…1578
Alarm Records…1578
Frame Torque Data…1578
Sprung Weight Data…1579
Maximum Speed Data…1579
PC SOFTWARE OVERVIEW…1579
PC Overview…1579
System Configuration…1579
Installing the PLMIII Software…1579
DOWNLOADING DATA…1580
PLMIII SYSTEM CONFIGURATION…1581
Starting Communications…1581
Displayed Payload Units…1581
Time Units…1581
Connection Menu…1581
Connecting to the Payload Meter…1582
Configure the Payload Meter…1582
Setting the Date and Time…1582
Setting the Truck Type…1583
Setting the Gauge Display Units…1583
Setting the Frame Serial Number…1583
Setting the Truck Number…1583
Setting the Komatsu Distributor…1583
Setting the Komatsu Customer…1583
Clean Truck Tare…1584
Inclinometer Calibration…1584
DATA ANALYSIS…1585
Sorting on Truck Unit Number…1585
Creating a Query…1585
Sorting on Truck Type…1585
Sorting on Date Range…1586
Sorting on Time Range…1586
Payload Detail Screen…1587
Creating Reports…1587
Summary – one page report…1588
Detailed – multi-page report…1588
Creating Graphs…1589
Exporting Data…1589
CSV Export…1589
Compressed…1590
To export data in ZIP format:…1591
Importing Data…1591
Deleting Haul Cycle Records…1591
Viewing Alarms…1592
Deleting Alarm Records…1592
SECTION 70 – RADIO, AM / FM STEREO CASSETTE…1594
SETTING THE TIME…1594
GENERAL RECEIVER FUNCTIONS…1594
Turning The Power On And Off…1594
Display…1594
Setting The Default Display…1595
Adjusting Display Brightness…1595
OPERATING THE RADIO…1595
BAND…1595
TUNE/SEEK…1595
Manual Tuning…1595
SEEK Mode…1595
SCAN…1595
AUTO…1595
PROGRAMMING PRESET STATIONS…1596
OPERATION OF THE WEATHERBAND (U.S.)…1596
ADJUSTING THE RECEIVER SETTINGS…1596
PROGRAMMABLE EJECT DEFAULT…1597
CASSETTE PLAYER…1597
Playing A Cassette…1597
Cassette Functions…1597
Bad Tape Detect…1598
CASSETTE PLAYER CLEANING…1598
CEAM011900 – Dump Truck 930E-2 Operation & Maintenance Manual…1601
COVER…1601
FOREWARD…1606
ALERTS PAGE…1607
TABLE OF CONTENTS…1608
TRUCK MODEL ILLUSTRATION…1615
ABOUT THIS MANUAL…1616
STANDARD CHARTS AND TABLES…1618
SAFETY…1624
Safety Rules…1624
Safety Features…1624
Clothing And Personal Items…1624
Unauthorized Modification…1624
Leaving The Operator's Seat…1625
Mounting And Dismounting…1625
Fire Prevention For Fuel And Oil…1625
Precautions With High Temperature Fluids…1626
Asbestos Dust Hazard Prevention…1626
Prevention Of Injury By Work Equipment…1626
Fire Extinguisher And First Aid Kit…1626
Precautions When Using ROPS…1627
Precautions For Attachments…1627
PRECAUTIONS DURING OPERATION…1628
Safety Is Thinking Ahead…1628
Safety At The Worksite…1628
Fire Prevention…1628
Preparing For Operation…1628
Ventilation In Enclosed Areas…1628
In Operator's Cab – Before Starting The Engine…1629
Mirrors, Windows, And Lights…1629
OPERATING THE MACHINE…1629
When Starting The Engine…1629
Truck Operation – General…1629
Check When Traveling In Reverse…1630
Traveling…1630
Traveling On Slopes…1631
Ensure Good Visibility…1631
Operate Carefully On Snow…1631
Avoide Damage To Dump Body…1631
Driving Near High Voltage Cables…1631
When Dumping…1632
Working On Loose Ground…1632
When Loading…1632
Parking The Machine…1632
TOWING…1632
WORKING NEAR BATTERIES…1633
Battery Hazard Prevention…1633
Starting With Booster Cables…1633
PRECAUTIONS FOR MAINTENANCE…1634
BEFORE PERFORMING MAINTENANCE…1634
Warning Tag…1634
Proper Tools…1634
Stopping The Engine Before Service…1634
Securing The Dump Body…1634
DURING MAINTENANCE…1635
Personnel…1635
Attachments…1635
Working Under The Machine…1635
Keep The Machine Clean…1635
Rules To Follow When Adding Fuel Or Oil…1635
Radiator Water Level…1636
Use Of Lighting…1636
Precautions With The Battery…1636
Handling High Pressure Hoses…1636
Precautions With High Pressure Oil …1636
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1637
Rotating Fan And Belts…1637
Waste Materials…1637
TIRES…1638
Handling Tires…1638
Storing Tires After Removal…1638
ADDITIONAL JOB SITE RULES…1639
WHEN REPAIRS ARE NECESSARY…1640
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1641
Preliminary Procedures Before Welding Or Performing Maintenance…1641
Normal Engine Shutdown Procedure…1641
Engine Shutdown Procedure Before Welding Or Performing Maintenance…1642
WARNINGS AND CAUTIONS…1644
OPERATING INSTRUCTIONS…1654
PREPARING FOR OPERATION…1654
Safety Is Thinking Ahead…1654
At The Truck – Ground Level Walk Around Inspection…1654
ENGINE START-UP SAFETY PRACTICES…1657
Cold Weather Starting…1658
AFTER ENGINE HAS STARTED…1658
MACHINE OPERATION SAFETY PRECAUTIONS…1659
MACHINE OPERATION ON THE HAUL ROAD…1659
STARTING ON A GRADE WITH A LOADED TRUCK…1660
PASSING …1660
LOADING …1660
DUMPING…1661
Raising The Dump Body…1661
Lowering The Dump Body…1661
TOWING…1663
SAFE PARKING PROCEDURES…1663
NORMAL ENGINE SHUTDOWN PROCEDURE…1663
DELAYED ENGINE SHUTDOWN PROCEDURE…1664
SUDDEN LOSS OF ENGINE POWER…1665
RESERVE ENGINE OIL SYSTEM (OPTIONAL)…1666
OPERATOR CAB AND CONTROLS…1668
STEERING WHEEL AND CONTROLS…1669
Horn Button…1669
Telescope Lock Ring…1669
Tilt Wheel Lever…1669
Turn Signal/Headlight Dimmer…1669
DYNAMIC RETARDING…1669
Retarder Control Lever…1670
Dynamic Retarder/Service Brake Pedal…1670
Accelerator (Throttle) Pedal…1670
Starting On A Grade With A Loaded Truck…1670
GRADE/SPEED RETARD CHART…1671
INSTRUMENT PANEL…1672
OVERHEAD PANEL AND DISPLAYS…1672
CENTER CONSOLE…1673
F-N-R Selector Switch…1673
Hoist Control Lever…1674
Raising The Dump Body…1674
Lowering The Dump Body…1674
Ash Tray…1674
Lighter…1674
L.H. Window Control Switch…1674
R.H. Window Control Switch…1674
Engine Shutdown Switch…1674
Override/Fault Reset Switch…1675
Retard Speed Control (RSC) Switch…1675
Retard Speed Control (RSC) Adjust Dial…1675
PSC Download Port…1676
Engine Diagnostics Download Port…1676
TCI Download Port…1676
Passenger Seat…1676
Engine Control System…1676
Modular Mining System…1676
Payload Meter And Download Connector…1676
OPERATOR COMFORT…1677
OPERATOR SEAT…1677
Adjustment…1677
Seat Removal…1677
Seat Installation…1677
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…1678
Defroster Vent Control Switch…1678
Outside/Inside Air Control Switch…1678
Heater Control Switch…1678
Temperature Control Knob…1678
Fan Control Knob…1678
Heater/Air Conditioner Selector Switch…1678
Heater/Air Conditioner Selector Vents…1678
INSTRUMENT PANEL AND INDICATOR LIGHTS…1680
CONTROL SYMBOLS…1680
INSTRUMENT PANEL…1680
PANEL GAUGES, INDICATORS, AND CONTROLS…1682
Key Switch…1682
Starting…1682
Engine Shutdown Switch With 5 Minute Idle Timer Delay…1682
Fog Lights (Optional)…1683
Ladder Light Switch…1683
Manual Backup Switch…1683
Panel Illumination Lights…1683
Cab/Air Conditioner Vents…1683
Rotating Beacon Light Switch (Optional)…1683
Heated Mirror Switch (Optional)…1683
Wheel Brake Lock Control…1684
Parking Brake Control…1684
Tachometer…1684
Right Turn Signal Indicator …1685
High Beam Indicator…1685
Left Turn Signal Indicator…1685
Speedometer/Payload Meter Display…1685
Voltmeter…1685
Engine Oil Pressure Gauge…1685
Water Temperature Gauge…1685
Fuel Gauge…1685
AC Drive System Temperature Gauge…1686
Hourmeter…1686
Hydraulic Oil Temperature Gauge…1686
Rest Switch…1686
Light Switch…1687
Windshield Wiper And Washer…1687
Panel Light And DImmer…1687
Payload Meter Switch…1687
OVERHEAD STATUS/WARNING INDICATORS…1688
STATUS/WARNING INDICATOR LIGHT SYMBOLS…1689
Hazard Warning Lights…1695
Lamp Test Switch…1695
Link-On Warning Light…1695
LUBRICATION AND SERVICE…1696
930E SERVICE CAPACITIES…1696
HYDRAULIC TANK SERVICE…1696
Adding Oil…1696
WHEEL MOTOR SERVICE…1696
COOLANT LEVEL CHECK…1697
RADIATOR FILLING PROCEDURE…1697
RESERVE ENGINE OIL SYSTEM (OPTIONAL)…1697
Reserve Oil Tank Filling Procedure (Remote Fill)…1697
LUBRICATION CHART…1698
10 HOUR (DAILY) INSPECTION…1699
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1702
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1703
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1704
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1707
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1708
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1709
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…1709
AUTOMATIC LUBRICATION SYSTEM…1710
GENERAL DESCRIPTION…1710
SYSTEM COMPONENTS…1712
SYSTEM OPERATION…1713
Normal Operation…1713
Pressure Failure Detection Circuits…1714
GENERAL INSTRUCTIONS…1715
Required Lubricant For System…1715
System Priming…1715
Filter Assembly…1715
LUBRICANT PUMP…1716
Pump Housing Oil Level…1716
Pump Pressure Control…1716
Pressure Control Valve Adjustment…1716
INJECTOR OPERATION…1717
INJECTORS (SL-1 SERIES "H")…1718
Injector Specifications…1718
Injector Adjustment…1718
SYSTEM CHECKOUT…1719
Lubrication Cycle Timer Check…1719
Lubrication Cycle Timer Adjustment…1719
SYSTEM TROUBLESHOOTING CHART…1720
PREVENTATIVE MAINTENANCE PROCEDURES…1723
Daily Lubrication System Inspection…1723
250 Hour Inspection…1723
1000 Hour Inspection…1723
MAJOR COMPONENT DESCRIPTION…1724
PAYLOAD METER III TM…1728
INDEX…1728
OPERATION SECTION…1730
Introduction…1730
Data Summary…1730
Data Gathering…1730
COMPONENT DESCRIPTION…1731
System Diagram…1731
Suspension Pressure Sensors…1731
Inclinometer…1731
Operator Display…1731
Operator Switch…1732
Speed Input…1732
Body-Up Switch…1732
Brake Lock Switch…1732
Payload Meter…1732
Communications Ports…1732
Keyswitch Input…1733
Payload Meter Power…1733
Load Lights…1733
Wiring and Termination…1734
TCI Outputs…1734
OPERATOR’S DISPLAY AND SWITCH…1735
Reading the Speedometer…1735
Reading the Load Display…1735
Using the Operator ID…1735
Using the Load and Ton Counter…1735
Total Ton Counter…1735
Total Load Counter…1736
Clearing the Counters…1736
Viewing Live Sensor Data…1736
Other Display Messages…1736
PAYLOAD OPERATION & CALCULATION…1737
Description of Haul Cycle States…1737
Haul Cycle Description…1737
Load Calculation…1738
Carry Back…1738
Measurement Accuracy…1738
SOURCES FOR PAYLOAD ERROR…1738
Payload Error…1738
Loading Conditions…1739
Pressure Sensors…1739
Swingloads…1739
Speed and Distance…1739
HAUL CYCLE DATA…1739
Haul Cycle Data…1740
Haul Cycle Warning Flags…1741
A: Continuous Loading…1741
B: Loading to Dumping Transition…1741
C: No Final Load…1741
D: Maneuvering to Dumping Transition…1741
E: Average Load or Tare Used…1741
F: Final Zone to Dumping Transition…1741
H: False Body Up…1741
I: Body Up Signal Failed…1741
J: Speed Sensor Failed…1741
K: New Tare Not Calculated…1741
L: Incomplete Haul Cycle…1741
M: Haul Cycle Too Long…1742
N: Sensor Input Error…1742
Alarm Records…1742
Frame Torque Data…1742
Sprung Weight Data…1743
Maximum Speed Data…1743
PC SOFTWARE OVERVIEW…1743
PC Overview…1743
System Configuration…1743
Installing the PLMIII Software…1743
DOWNLOADING DATA…1744
PLMIII SYSTEM CONFIGURATION…1745
Starting Communications…1745
Displayed Payload Units…1745
Time Units…1745
Connection Menu…1745
Connecting to the Payload Meter…1746
Configure the Payload Meter…1746
Setting the Date and Time…1746
Setting the Truck Type…1747
Setting the Gauge Display Units…1747
Setting the Frame Serial Number…1747
Setting the Truck Number…1747
Setting the Komatsu Distributor…1747
Setting the Komatsu Customer…1747
Clean Truck Tare…1748
Inclinometer Calibration…1748
DATA ANALYSIS…1749
Sorting on Truck Unit Number…1749
Creating a Query…1749
Sorting on Truck Type…1749
Sorting on Date Range…1750
Sorting on Time Range…1750
Payload Detail Screen…1751
Creating Reports…1751
Summary – one page report…1752
Detailed – multi-page report…1752
Creating Graphs…1753
Exporting Data…1753
CSV Export…1753
Compressed…1754
To export data in ZIP format:…1755
Importing Data…1755
Deleting Haul Cycle Records…1755
Viewing Alarms…1756
Deleting Alarm Records…1756
RADIO, AM / FM STEREO CASSETTE…1758
SETTING THE TIME…1758
GENERAL RECEIVER FUNCTIONS…1758
Turning The Power On And Off…1758
Display…1758
Setting The Default Display…1759
Adjusting Display Brightness…1759
OPERATING THE RADIO…1759
BAND…1759
TUNE/SEEK…1759
Manual Tuning…1759
SEEK Mode…1759
SCAN…1759
AUTO…1759
ADJUSTING THE RECEIVER SETTINGS…1760
PROGRAMMING PRESET STATIONS…1760
OPERATION OF THE WEATHERBAND (U.S.)…1760
SATELLITE RADIO…1761
Operating Satellite Radio…1761
Program Type Search (PTY)…1761
CASSETTE PLAYER…1762
Playing A Cassette…1762
Cassette Functions…1762
PROGRAMMABLE EJECT DEFAULT…1762
Bad Tape Detect…1763
CASSETTE PLAYER CLEANING…1763
CEAM012000 – Dump Truck 930E-2 Operation & Maintenance Manual…1766
COVER…1766
SECTION 10 – INTRODUCTION…1772
FOREWORD…1772
ALERTS PAGE…1773
TABLE OF CONTENTS…1774
TRUCK MODEL ILLUSTRATION…1781
ABOUT THIS MANUAL…1782
SECTION 12 – STANDARD CHARTS AND TABLES…1784
SECTION 20 – SAFETY…1790
Safety Rules…1790
Safety Features…1790
Clothing And Personal Items…1790
Unauthorized Modification…1790
Leaving The Operator’s Seat…1791
Mounting And Dismounting…1791
Fire Prevention For Fuel And Oil…1791
Precautions With High Temperature Fluids…1792
Asbestos Dust Hazard Prevention…1792
Prevention Of Injury By Work Equipment…1792
Fire Extinguisher And First Aid Kit…1792
Precautions When Using ROPS…1793
Precautions For Attachments…1793
PRECAUTIONS DURING OPERATION…1794
Safety Is Thinking Ahead…1794
Safety At The Worksite…1794
Fire Prevention…1794
Preparing For Operation…1794
Ventilation In Enclosed Areas…1794
In Operator’s Cab – Before Starting The Engine…1795
Mirrors, Windows, And Lights…1795
OPERATING THE MACHINE…1795
When Starting The Engine…1795
Truck Operation – General…1795
Check When Traveling In Reverse…1796
Traveling…1796
Traveling On Slopes…1797
Ensure Good Visibility…1797
Operate Carefully On Snow…1797
Avoid Damage To Dump Body…1797
Driving Near High Voltage Cables…1797
When Dumping…1798
Working On Loose Ground…1798
When Loading…1798
Parking The Machine…1798
TOWING…1798
WORKING NEAR BATTERIES…1799
Battery Hazard Prevention…1799
Starting With Booster Cables…1799
PRECAUTIONS FOR MAINTENANCE…1800
BEFORE PERFORMING MAINTENANCE…1800
Warning Tag…1800
Proper Tools…1800
Stopping The Engine Before Service…1800
Securing The Dump Body…1800
DURING MAINTENANCE…1801
Personnel…1801
Attachments…1801
Working Under The Machine…1801
Keep The Machine Clean…1801
Rules To Follow When Adding Fuel Or Oil…1801
Radiator Water Level…1802
Use Of Lighting…1802
Precautions With The Battery…1802
Handling High Pressure Hoses…1802
Precautions With High Pressure Oil…1802
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1803
Rotating Fan And Belts…1803
Waste Materials…1803
TIRES…1804
Handling Tires…1804
Storing Tires After Removal…1804
ADDITIONAL JOB SITE RULES…1805
WHEN REPAIRS ARE NECESSARY…1806
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1807
Preliminary Procedures Before Welding or Performing Maintenance…1807
Normal Engine Shutdown Procedure…1807
Engine Shutdown Procedure Before Welding or Performing Maintenance…1808
SECTION 22 – WARNINGS AND CAUTIONS…1810
SECTION 30 – OPERATING INSTRUCTIONS…1820
PREPARING FOR OPERATION…1820
Safety Is Thinking Ahead…1820
At The Truck – Ground Level Walk Around Inspection…1820
Cold Weather Starting…1824
AFTER ENGINE HAS STARTED…1824
MACHINE OPERATION SAFETY PRECAUTIONS…1825
MACHINE OPERATION ON THE HAUL ROAD…1825
STARTING ON A GRADE WITH A LOADED TRUCK…1826
PASSING…1826
LOADING…1826
DUMPING…1827
Raising The Dump Body…1827
Lowering The Dump Body…1827
TOWING…1829
SAFE PARKING PROCEDURES…1829
NORMAL ENGINE SHUTDOWN PROCEDURE…1829
DELAYED ENGINE SHUTDOWN PROCEDURE…1830
SUDDEN LOSS OF ENGINE POWER…1831
RESERVE ENGINE OIL SYSTEM (Optional)…1832
SECTION 32 – OPERATOR CAB AND CONTROLS…1834
STEERING WHEEL AND CONTROLS…1835
Horn Button…1835
Telescope Lock Ring…1835
Tilt Wheel Lever…1835
Turn Signal/Headlight Dimmer…1835
DYNAMIC RETARDING…1835
Retarder Control Lever…1836
Dynamic Retarder/Service Brake Pedal…1836
Accelerator (Throttle) Pedal…1836
Starting on a Grade With a Loaded Truck…1836
GRADE/SPEED RETARD CHART…1837
INSTRUMENT PANEL…1838
OVERHEAD PANEL AND DISPLAYS…1838
CENTER CONSOLE…1839
F-N-R Selector Switch…1839
Hoist Control Lever…1840
Raising The Dump Body…1840
Lowering The Dump Body:…1840
Ash Tray…1840
Lighter…1840
L.H. Window Control Switch…1840
R.H. Window Control Switch…1840
Engine Shutdown Switch…1840
Override/Fault Reset Switch…1841
Retard Speed Control (RSC) Switch…1841
Retard Speed Control (RSC) Adjust Dial…1841
PSC Download Port…1842
Engine Diagnostics Download Port…1842
TCI Download Port…1842
Passenger Seat…1842
Engine Control System…1842
Modular Mining System…1842
Payload Meter And Download Connector…1842
OPERATOR COMFORT…1843
OPERATOR SEAT…1843
Adjustment…1843
HEATER / AIR CONDITIONER COMPART MENT AND CONTROLS…1844
Defroster Vent Control Switch…1844
Outside/Inside Air Control Switch…1844
Heater Control Switch…1844
Temperature Control Knob…1844
Fan Control Knob…1844
Heater/Air Conditioner Selector Switch…1844
Heater/Air Conditioner Vents…1844
INSTRUMENT PANEL AND INDICATOR LIGHTS…1846
CONTROL SYMBOLS…1846
INSTRUMENT PANEL…1846
PANEL GAUGES, INDICATORS, AND CONTROLS…1848
Key Switch…1848
Starting…1848
Engine Shutdown Switch with 5 Minute Idle Timer Delay…1848
Fog Lights (Optional)…1849
Ladder Light Switch…1849
Manual Backup Switch…1849
Panel Illumination Lights…1849
Cab/Air Conditioner Vents…1849
Rotating Beacon Light Switch (Optional)…1849
Heated Mirror Switch (Optional)…1849
Wheel Brake Lock Control…1850
Parking Brake Control…1850
Tachometer…1850
Right Turn Signal Indicator…1851
High Beam Indicator…1851
Left Turn Signal Indicator…1851
Speedometer/Payload Meter Display…1851
Voltmeter…1851
Engine Oil Pressure Gauge…1851
Water Temperature Gauge…1851
Fuel Gauge…1851
AC Drive System Temperature Gauge…1852
Hourmeter…1852
Hydraulic Oil Temperature Gauge…1852
Rest Switch…1852
Light Switch…1853
Windshield Wiper and Washer…1853
Panel Light Dimmer…1853
Payload Meter Switch…1853
OVERHEAD STATUS / WARNING INDICATORS…1854
STATUS / WARNING INDICATOR LIGHT SYMBOLS…1855
Hazard Warning Lights…1861
Lamp Test Switch…1861
Link-On Warning Light…1861
SECTION 40 – LUBRICATION AND SERVICE…1862
930E SERVICE CAPACITIES…1862
HYDRAULIC TANK SERVICE…1862
Adding Oil…1862
WHEEL MOTOR SERVICE…1862
COOLANT LEVEL CHECK…1863
RADIATOR FILLING PROCEDURE…1863
RESERVE ENGINE OIL SYSTEM (Optional)…1863
Reserve Oil Tank Filling Procedure (Remote fill)…1863
LUBRICATION CHART…1864
10 HOUR (DAILY) INSPECTION…1865
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1868
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1869
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1870
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1873
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1874
2500 HOUR MAINTENANCE CHECKS…1875
5000 HOUR MAINTENANCE CHECKS…1875
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…1876
GENERAL DESCRIPTION…1876
SYSTEM COMPONENTS…1878
SYSTEM OPERATION…1879
Normal Operation…1879
Pressure Failure Detection Circuits…1880
GENERAL INSTRUCTIONS…1881
Required Lubricant For System…1881
System Priming…1881
Filter Assembly…1881
LUBRICANT PUMP…1882
Pump Housing Oil Level…1882
Pump Pressure Control…1882
Pressure Control Valve Adjustment…1882
INJECTOR OPERATION…1883
INJECTORS (SL-1 Series “H”))…1884
Injector Specifications…1884
Injector Adjustment…1884
SYSTEM CHECKOUT…1885
Lubrication Cycle Timer Check…1885
Lubrication Cycle Timer Adjustment…1885
SYSTEM TROUBLESHOOTING CHART…1886
PREVENTATIVE MAINTENANCE PROCEDURES…1889
Daily Lubrication System Inspection…1889
250 Hour Inspection…1889
1000 Hour Inspection…1889
SECTION 50 – MAJOR COMPONENT DESCRIPTION…1890
SECTION 60 – PAYLOAD METER III™ – INDEX…1894
OPERATION SECTION…1896
Introduction…1896
Data Summary…1896
Data Gathering…1896
COMPONENT DESCRIPTION…1897
System Diagram…1897
Suspension Pressure Sensors…1897
Inclinometer…1897
Operator Display…1897
Operator Switch…1898
Speed Input…1898
Body-Up Switch…1898
Brake Lock Switch…1898
Payload Meter…1898
Communications Ports…1898
Keyswitch Input…1899
Payload Meter Power…1899
Load Lights…1899
Wiring and Termination…1900
TCI Outputs…1900
OPERATOR’S DISPLAY AND SWITCH…1901
Reading the Speedometer…1901
Reading the Load Display…1901
Using the Operator ID…1901
Using the Load and Ton Counter…1901
Total Ton Counter…1901
Total Load Counter…1902
Clearing the Counters…1902
Viewing Live Sensor Data…1902
Other Display Messages…1902
PAYLOAD OPERATION & CALCULATION…1903
Description of Haul Cycle States…1903
Haul Cycle Description…1903
Load Calculation…1904
Carry Back…1904
Measurement Accuracy…1904
SOURCES FOR PAYLOAD ERROR…1904
Payload Error…1904
Loading Conditions…1905
Pressure Sensors…1905
Swingloads…1905
Speed and Distance…1905
HAUL CYCLE DATA…1905
Haul Cycle Data…1906
Haul Cycle Warning Flags…1907
A: Continuous Loading…1907
B: Loading to Dumping Transition…1907
C: No Final Load…1907
D: Maneuvering to Dumping Transition…1907
E: Average Load or Tare Used…1907
F: Final Zone to Dumping Transition…1907
H: False Body Up…1907
I: Body Up Signal Failed…1907
J: Speed Sensor Failed…1907
K: New Tare Not Calculated…1907
L: Incomplete Haul Cycle…1907
M: Haul Cycle Too Long…1908
N: Sensor Input Error…1908
Alarm Records…1908
Frame Torque Data…1908
Sprung Weight Data…1909
Maximum Speed Data…1909
PC SOFTWARE OVERVIEW…1909
PC Overview…1909
System Configuration…1909
Installing the PLMIII Software…1909
DOWNLOADING DATA…1910
PLMIII SYSTEM CONFIGURATION…1911
Starting Communications…1911
Displayed Payload Units…1911
Time Units…1911
Connection Menu…1911
Connecting to the Payload Meter…1912
Configure the Payload Meter…1912
Setting the Date and Time…1912
Setting the Truck Type…1913
Setting the Gauge Display Units…1913
Setting the Frame Serial Number…1913
Setting the Truck Number…1913
Setting the Komatsu Distributor…1913
Setting the Komatsu Customer…1913
Clean Truck Tare…1914
Inclinometer Calibration…1914
DATA ANALYSIS…1915
Sorting on Truck Unit Number…1915
Creating a Query…1915
Sorting on Truck Type…1915
Sorting on Date Range…1916
Sorting on Time Range…1916
Payload Detail Screen…1917
Creating Reports…1917
Summary – one page report…1918
Detailed – multi-page report…1918
Creating Graphs…1919
Exporting Data…1919
CSV Export…1919
Compressed…1920
To export data in ZIP format:…1921
Importing Data…1921
Deleting Haul Cycle Records…1921
Viewing Alarms…1922
Deleting Alarm Records…1922
SECTION 70 – RADIO, AM / FM STEREO CASSETTE…1924
SETTING THE TIME…1924
GENERAL RECEIVER FUNCTIONS…1924
Turning The Power On And Off…1924
Display…1924
Setting The Default Display…1925
Adjusting Display Brightness…1925
OPERATING THE RADIO…1925
BAND…1925
TUNE/SEEK…1925
Manual Tuning…1925
SEEK Mode…1925
SCAN…1925
AUTO…1925
PROGRAMMING PRESET STATIONS…1926
OPERATION OF THE WEATHERBAND (U.S.)…1926
ADJUSTING THE RECEIVER SETTINGS…1926
PROGRAMMABLE EJECT DEFAULT…1927
CASSETTE PLAYER…1927
Playing A Cassette…1927
Cassette Functions…1927
Bad Tape Detect…1928
CASSETTE PLAYER CLEANING…1928
CEAM012100 – Dump Truck 930E-2 Operation & Maintenance Manual…1931
COVER…1931
SECTION 10 – INTRODUCTION …1936
FOREWORD…1936
ALERTS PAGE…1937
TABLE OF CONTENTS…1938
TRUCK MODEL ILLUSTRATION…1945
ABOUT THIS MANUAL…1946
SECTION 12 – STANDARD CHARTS AND TABLES…1948
SECTION 20 – SAFETY…1954
Safety Rules…1954
Safety Features…1954
Clothing And Personal Items…1954
Unauthorized Modification…1954
Leaving The Operator’s Seat…1955
Mounting And Dismounting…1955
Fire Prevention For Fuel And Oil…1955
Precautions With High Temperature Fluids…1956
Asbestos Dust Hazard Prevention…1956
Prevention Of Injury By Work Equipment…1956
Fire Extinguisher And First Aid Kit…1956
Precautions When Using ROPS…1957
Precautions For Attachments…1957
PRECAUTIONS DURING OPERATION…1958
Safety Is Thinking Ahead…1958
Safety At The Worksite…1958
Fire Prevention…1958
Preparing For Operation…1958
Ventilation In Enclosed Areas…1958
In Operator’s Cab – Before Starting The Engine…1959
Mirrors, Windows, And Lights…1959
OPERATING THE MACHINE…1959
When Starting The Engine…1959
Truck Operation – General…1959
Check When Traveling In Reverse…1960
Traveling…1960
Traveling On Slopes…1961
Ensure Good Visibility…1961
Operate Carefully On Snow…1961
Avoid Damage To Dump Body…1961
Driving Near High Voltage Cables…1961
When Dumping…1962
Working On Loose Ground…1962
When Loading…1962
Parking The Machine…1962
TOWING…1962
WORKING NEAR BATTERIES…1963
Battery Hazard Prevention…1963
Starting With Booster Cables…1963
PRECAUTIONS FOR MAINTENANCE…1964
BEFORE PERFORMING MAINTENANCE…1964
Warning Tag…1964
Proper Tools…1964
Stopping The Engine Before Service…1964
Securing The Dump Body…1964
DURING MAINTENANCE…1965
Personnel…1965
Attachments…1965
Working Under The Machine…1965
Keep The Machine Clean…1965
Rules To Follow When Adding Fuel Or Oil…1965
Radiator Water Level…1966
Use Of Lighting…1966
Precautions With The Battery…1966
Handling High Pressure Hoses…1966
Precautions With High Pressure Oil…1966
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1967
Rotating Fan And Belts…1967
Waste Materials…1967
TIRES…1968
Handling Tires…1968
Storing Tires After Removal…1968
ADDITIONAL JOB SITE RULES…1969
WHEN REPAIRS ARE NECESSARY…1970
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…1971
Preliminary Procedures Before Welding or Performing Maintenance…1971
Normal Engine Shutdown Procedure…1971
Engine Shutdown Procedure Before Welding or Performing Maintenance…1972
SECTION 22 – WARNINGS AND CAUTIONS…1974
SECTION 30 – OPERATING INSTRUCTIONS…1984
PREPARING FOR OPERATION…1984
Safety Is Thinking Ahead…1984
At The Truck – Ground Level Walk Around Inspection…1984
ENGINE START-UP SAFETY PRACTICES…1987
Cold Weather Starting…1988
AFTER ENGINE HAS STARTED…1988
MACHINE OPERATION SAFETY PRECAUTIONS…1989
MACHINE OPERATION ON THE HAUL ROAD…1989
STARTING ON A GRADE WITH A LOADED TRUCK…1990
PASSING…1990
LOADING…1990
DUMPING…1991
Raising The Dump Body…1991
Lowering The Dump Body…1991
TOWING…1993
SAFE PARKING PROCEDURES…1993
NORMAL ENGINE SHUTDOWN PROCEDURE…1993
DELAYED ENGINE SHUTDOWN PROCEDURE…1994
SUDDEN LOSS OF ENGINE POWER…1995
RESERVE ENGINE OIL SYSTEM (Optional)…1996
SECTION 32 – OPERATOR CAB AND CONTROLS…1998
STEERING WHEEL AND CONTROLS…1999
Horn Button…1999
Telescope Lock Ring…1999
Tilt Wheel Lever…1999
Turn Signal/Headlight Dimmer…1999
DYNAMIC RETARDING…1999
Retarder Control Lever…2000
Dynamic Retarder/Service Brake Pedal…2000
Accelerator (Throttle) Pedal…2000
Starting on a Grade With a Loaded Truck…2000
GRADE/SPEED RETARD CHART…2001
INSTRUMENT PANEL…2002
OVERHEAD PANEL AND DISPLAYS…2002
CENTER CONSOLE…2003
F-N-R Selector Switch…2003
Hoist Control Lever…2004
Raising The Dump Body…2004
Lowering The Dump Body:…2004
Ash Tray…2004
Lighter…2004
L.H. Window Control Switch…2004
R.H. Window Control Switch…2004
Engine Shutdown Switch…2004
Override/Fault Reset Switch…2005
Retard Speed Control (RSC) Switch…2005
Retard Speed Control (RSC) Adjust Dial…2005
PSC Download Port…2006
Engine Diagnostics Download Port…2006
TCI Download Port…2006
Passenger Seat…2006
Engine Control System…2006
Modular Mining System…2006
Payload Meter And Download Connector…2006
OPERATOR COMFORT…2007
OPERATOR SEAT…2007
Adjustment…2007
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2008
Heater/Air Conditioner Vents…2008
Defroster Control Switch…2008
Heat Control Switch…2008
Temperature Control Knob…2008
Fan Control Knob…2008
Heater/Air Conditioner Selector Switch…2008
INSTRUMENT PANEL AND INDICATOR LIGHTS…2010
CONTROL SYMBOLS…2010
INSTRUMENT PANEL…2010
PANEL GAUGES, INDICATORS, AND CONTROLS…2012
Key Switch…2012
Starting…2012
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2012
Fog Lights (Optional)…2013
Ladder Light Switch…2013
Manual Backup Switch…2013
Panel Illumination Lights…2013
Cab/Air Conditioner Vents…2013
Rotating Beacon Light Switch (Optional)…2013
Heated Mirror Switch (Optional)…2013
Wheel Brake Lock Control…2014
Parking Brake Control…2014
Tachometer…2014
Right Turn Signal Indicator…2015
High Beam Indicator…2015
Left Turn Signal Indicator…2015
Speedometer/Payload Meter Display…2015
Voltmeter…2015
Engine Oil Pressure Gauge…2015
Water Temperature Gauge…2015
Fuel Gauge…2015
AC Drive System Temperature Gauge…2016
Hourmeter…2016
Hydraulic Oil Temperature Gauge…2016
Rest Switch…2016
Light Switch…2017
Windshield Wiper and Washer…2017
Panel Light Dimmer…2017
Payload Meter Switch…2017
OVERHEAD STATUS / WARNING INDICATORS…2018
STATUS / WARNING INDICATOR LIGHT SYMBOLS…2019
Hazard Warning Lights…2025
Lamp Test Switch…2025
Link-On Warning Light…2025
SECTION 40 – LUBRICATION AND SERVICE…2026
930E SERVICE CAPACITIES…2026
HYDRAULIC TANK SERVICE…2026
Adding Oil…2026
WHEEL MOTOR SERVICE…2026
COOLANT LEVEL CHECK…2027
RADIATOR FILLING PROCEDURE…2027
RESERVE ENGINE OIL SYSTEM (Optional)…2027
Reserve Oil Tank Filling Procedure (Remote fill)…2027
LUBRICATION CHART…2028
10 HOUR (DAILY) INSPECTION…2029
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2032
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2033
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2034
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2037
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2038
2500 HOUR MAINTENANCE CHECKS…2039
5000 HOUR MAINTENANCE CHECKS…2039
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…2040
GENERAL DESCRIPTION…2040
SYSTEM COMPONENTS…2042
SYSTEM OPERATION…2043
Normal Operation…2043
Pressure Failure Detection Circuits…2044
GENERAL INSTRUCTIONS…2045
Required Lubricant For System…2045
System Priming…2045
Filter Assembly…2045
LUBRICANT PUMP…2046
Pump Housing Oil Level…2046
Pump Pressure Control…2046
Pressure Control Valve Adjustment…2046
INJECTOR OPERATION…2047
INJECTORS (SL-1 Series “H”))…2048
Injector Specifications…2048
Injector Adjustment…2048
SYSTEM CHECKOUT…2049
Lubrication Cycle Timer Check…2049
Lubrication Cycle Timer Adjustment…2049
SYSTEM TROUBLESHOOTING CHART…2050
PREVENTATIVE MAINTENANCE PROCEDURES…2053
Daily Lubrication System Inspection…2053
250 Hour Inspection…2053
1000 Hour Inspection…2053
SECTION 50 – MAJOR COMPONENT DESCRIPTION…2054
SECTION 60 – PAYLOAD METER III – INDEX…2058
OPERATION SECTION…2060
Introduction…2060
Data Summary…2060
Data Gathering…2060
COMPONENT DESCRIPTION…2061
System Diagram…2061
Suspension Pressure Sensors…2061
Inclinometer…2061
Operator Display…2061
Operator Switch…2062
Speed Input…2062
Body-Up Switch…2062
Brake Lock Switch…2062
Payload Meter…2062
Communications Ports…2062
Keyswitch Input…2063
Payload Meter Power…2063
Load Lights…2063
Wiring and Termination…2064
TCI Outputs…2064
OPERATOR’S DISPLAY AND SWITCH…2065
Reading the Speedometer…2065
Reading the Load Display…2065
Using the Operator ID…2065
Using the Load and Ton Counter…2065
Total Ton Counter…2065
Total Load Counter…2066
Clearing the Counters…2066
Viewing Live Sensor Data…2066
Other Display Messages…2066
PAYLOAD OPERATION & CALCULATION…2067
Description of Haul Cycle States…2067
Haul Cycle Description…2067
Load Calculation…2068
Carry Back…2068
Measurement Accuracy…2068
SOURCES FOR PAYLOAD ERROR…2068
Payload Error…2068
Loading Conditions…2069
Pressure Sensors…2069
Swingloads…2069
Speed and Distance…2069
HAUL CYCLE DATA…2069
Haul Cycle Data…2070
Haul Cycle Warning Flags…2071
A: Continuous Loading…2071
B: Loading to Dumping Transition…2071
C: No Final Load…2071
D: Maneuvering to Dumping Transition…2071
E: Average Load or Tare Used…2071
F: Final Zone to Dumping Transition…2071
H: False Body Up…2071
I: Body Up Signal Failed…2071
J: Speed Sensor Failed…2071
K: New Tare Not Calculated…2071
L: Incomplete Haul Cycle…2071
M: Haul Cycle Too Long…2072
N: Sensor Input Error…2072
Alarm Records…2072
Frame Torque Data…2072
Sprung Weight Data…2073
Maximum Speed Data…2073
PC SOFTWARE OVERVIEW…2073
PC Overview…2073
System Configuration…2073
Installing the PLMIII Software…2073
DOWNLOADING DATA…2074
PLMIII SYSTEM CONFIGURATION…2075
Starting Communications…2075
Displayed Payload Units…2075
Time Units…2075
Connection Menu…2075
Connecting to the Payload Meter…2076
Configure the Payload Meter…2076
Setting the Date and Time…2076
Setting the Truck Type…2077
Setting the Gauge Display Units…2077
Setting the Frame Serial Number…2077
Setting the Truck Number…2077
Setting the Komatsu Distributor…2077
Setting the Komatsu Customer…2077
Clean Truck Tare…2078
Inclinometer Calibration…2078
DATA ANALYSIS…2079
Sorting on Truck Unit Number…2079
Creating a Query…2079
Sorting on Truck Type…2079
Sorting on Date Range…2080
Sorting on Time Range…2080
Payload Detail Screen…2081
Creating Reports…2081
Summary – one page report…2082
Detailed – multi-page report…2082
Creating Graphs…2083
Exporting Data…2083
CSV Export…2083
Compressed…2084
To export data in ZIP format:…2085
Importing Data…2085
Deleting Haul Cycle Records…2085
Viewing Alarms…2086
Deleting Alarm Records…2086
SECTION 70 – RADIO, AM / FM STEREO CASSETTE…2088
SETTING THE TIME…2088
GENERAL RECEIVER FUNCTIONS…2088
Turning The Power On And Off…2088
Display…2088
Setting The Default Display…2089
Adjusting Display Brightness…2089
OPERATING THE RADIO…2089
BAND…2089
TUNE/SEEK…2089
Manual Tuning…2089
SEEK Mode…2089
SCAN…2089
AUTO…2089
ADJUSTING THE RECEIVER SETTINGS…2090
PROGRAMMING PRESET STATIONS…2090
OPERATION OF THE WEATHERBAND (U.S.)…2090
SATELLITE RADIO…2091
Operating Satellite Radio…2091
Program Type Search (PTY)…2091
CASSETTE PLAYER…2092
Playing A Cassette…2092
Cassette Functions…2092
PROGRAMMABLE EJECT DEFAULT…2092
Bad Tape Detect…2093
CASSETTE PLAYER CLEANING…2093
CEAM013500 – Dump Truck 930E-3 Operation & Maintenance Manual…2095
COVER…2095
INTRODUCTION…2101
FOREWORD…2101
ALERTS PAGE…2102
TABLE OF CONTENTS…2103
TRUCK MODEL ILLUSTRATION…2110
ABOUT THIS MANUAL…2111
STANDARD CHARTS AND TABLES…2113
SAFETY…2119
SAFETY…2119
Safety Rules…2119
Safety Features…2119
Clothing And Personal Items…2119
Unauthorized Modification…2119
Leaving The Operator’s Seat…2120
Mounting And Dismounting…2120
Fire Prevention For Fuel And Oil…2120
Precautions With High Temperature Fluids…2121
Asbestos Dust Hazard Prevention…2121
Prevention Of Injury By Work Equipment…2121
Fire Extinguisher And First Aid Kit…2121
Precautions When Using ROPS…2122
Precautions For Attachments…2122
Precautions For Starting Machine…2122
PRECAUTIONS DURING OPERATION…2123
Safety Is Thinking Ahead…2123
Safety At The Worksite…2123
Fire Prevention…2123
Preparing For Operation…2123
Ventilation In Enclosed Areas…2123
In Operator’s Cab – Before Starting The Engine…2124
Mirrors, Windows, And Lights…2124
OPERATING THE MACHINE…2124
When Starting The Engine…2124
Truck Operation – General…2124
Check When Traveling In Reverse…2125
Traveling…2125
Traveling On Slopes…2126
Ensure Good Visibility…2126
Operate Carefully On Snow…2126
Avoid Damage To Dump Body…2126
Driving Near High Voltage Cables…2126
When Dumping…2127
Working On Loose Ground…2127
When Loading…2127
Parking The Machine…2127
TOWING…2127
WORKING NEAR BATTERIES…2128
Battery Hazard Prevention…2128
Starting With Booster Cables…2128
PRECAUTIONS FOR MAINTENANCE…2129
BEFORE PERFORMING MAINTENANCE…2129
Warning Tag…2129
Proper Tools…2129
Stopping The Engine Before Service…2129
Securing The Dump Body…2129
DURING MAINTENANCE…2130
Personnel…2130
Attachments…2130
Working Under The Machine…2130
Keep The Machine Clean…2130
Rules To Follow When Adding Fuel Or Oil…2130
Radiator Water Level…2131
Use Of Lighting…2131
Precautions With The Battery…2131
Handling High Pressure Hoses…2131
Precautions With High Pressure Oil…2131
Precautions When Performing Maintenance Near High Temperature Or High Pressure…2132
Rotating Fan And Belts…2132
Waste Materials…2132
TIRES…2133
Handling Tires…2133
Storing Tires After Removal…2133
ADDITIONAL JOB SITE RULES…2134
WHEN REPAIRS ARE NECESSARY…2135
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…2136
Preliminary Procedures Before Welding or Performing Maintenance…2136
Normal Engine Shutdown Procedure…2136
Engine Shutdown Procedure Before Welding or Performing Maintenance…2137
WARNINGS AND CAUTIONS…2139
OPERATION…2149
OPERATING INSTRUCTIONS…2149
PREPARING FOR OPERATION…2149
Safety Is Thinking Ahead…2149
At The Truck – Ground Level Walk Around Inspection…2149
ENGINE START-UP SAFETY PRACTICES…2152
Cold Weather Starting…2153
AFTER ENGINE HAS STARTED…2153
MACHINE OPERATION SAFETY PRECAUTIONS…2154
MACHINE OPERATION ON THE HAUL ROAD…2154
STARTING ON A GRADE WITH A LOADED TRUCK…2155
PASSING…2155
LOADING…2155
DUMPING…2156
Raising The Dump Body…2156
Lowering The Dump Body…2156
TOWING…2158
SAFE PARKING PROCEDURES…2158
NORMAL ENGINE SHUTDOWN PROCEDURE…2158
DELAYED ENGINE SHUTDOWN PROCEDURE…2159
SUDDEN LOSS OF ENGINE POWER…2160
RESERVE ENGINE OIL SYSTEM (Optional)…2161
OPERATOR CAB AND CONTROLS…2163
STEERING WHEEL AND CONTROLS…2164
Horn Button…2164
Telescope Lock Ring…2164
Tilt Wheel Lever…2164
Turn Signal/Headlight Dimmer…2164
DYNAMIC RETARDING…2164
Retarder Control Lever…2165
Dynamic Retarder/Service Brake Pedal…2165
Accelerator (Throttle) Pedal…2165
Starting on a Grade With a Loaded Truck…2165
GRADE/SPEED RETARD CHART…2166
INSTRUMENT PANEL…2167
OVERHEAD PANEL AND DISPLAYS…2167
CENTER CONSOLE…2168
F-N-R Selector Switch…2168
Hoist Control Lever…2169
Raising The Dump Body…2169
Lowering The Dump Body:…2169
Ash Tray…2169
Lighter…2169
L.H. Window Control Switch…2169
R.H. Window Control Switch…2169
Engine Shutdown Switch…2169
Override/Fault Reset Switch…2170
Retard Speed Control (RSC) Switch…2170
Retard Speed Control (RSC) Adjust Dial…2170
Data Store Button…2171
Engine Control System…2171
Service Engine Light (Blue)…2171
Engine Diagnostic Download Port…2171
Payload Meter…2171
TCI Download Port…2171
Modular Mining System (Optional)…2171
PSC Download Port…2171
Payload Meter And Download Connector…2171
OPERATOR COMFORT…2172
OPERATOR SEAT…2172
Adjustment…2172
Seat Removal…2172
Seat Installation…2172
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2173
Heater/Air Conditioner Vents…2173
Defroster Control Switch…2173
Heat Control Switch…2173
Temperature Control Knob…2173
Fan Control Knob…2173
Heater/Air Conditioner Selector Switch…2173
INSTRUMENT PANEL AND INDICATOR LIGHTS…2175
CONTROL SYMBOLS…2175
INSTRUMENT PANEL…2175
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7)…2177
Key Switch…2177
Starting…2177
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2177
Fog Lights (Optional)…2178
Ladder Light Switch…2178
Manual Backup Switch…2178
Panel Illumination Lights…2178
Cab/Air Conditioner Vents…2178
Rotating Beacon Light Switch (Optional)…2178
Heated Mirror Switch (Optional)…2178
Wheel Brake Lock Control…2179
Parking Brake Control…2179
Tachometer…2179
Right Turn Signal Indicator…2180
High Beam Indicator…2180
Left Turn Signal Indicator…2180
Speedometer/Payload Meter Display…2180
Voltmeter…2180
Engine Oil Pressure Gauge…2180
Water Temperature Gauge…2180
Fuel Gauge…2180
AC Drive System Temperature Gauge…2181
Hourmeter…2181
Hydraulic Oil Temperature Gauge…2181
Rest Switch…2181
Light Switch…2182
Windshield Wiper and Washer…2182
Panel Light Dimmer…2182
Payload Meter Switch…2182
OVERHEAD STATUS / WARNING INDICATORS…2183
STATUS / WARNING INDICATOR LIGHT SYMBOLS…2184
Hazard Warning Lights…2190
Lamp Test Switch…2190
Link-On Warning Light…2190
MAINTENANCE…2191
LUBRICATION AND SERVICE…2191
930E SERVICE CAPACITIES…2191
HYDRAULIC TANK SERVICE…2191
Adding Oil…2191
WHEEL MOTOR SERVICE…2191
COOLANT LEVEL CHECK…2192
RADIATOR FILLING PROCEDURE…2192
RESERVE ENGINE OIL SYSTEM (Optional)…2192
Reserve Oil Tank Filling Procedure (Remote fill)…2192
LUBRICATION CHART…2193
10 HOUR (DAILY) INSPECTION…2194
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2197
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2198
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2199
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2202
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2203
2500 HOUR MAINTENANCE CHECKS…2204
5000 HOUR MAINTENANCE CHECKS…2204
AUTOMATIC LUBRICATION SYSTEM…2205
GENERAL DESCRIPTION…2205
SYSTEM COMPONENTS…2207
System Operation…2208
Normal Operation…2208
Pressure Failure Detection Circuits…2209
GENERAL INSTRUCTIONS…2210
Lubricant Required For System…2210
System Priming…2210
Filter Assembly…2210
LUBRICANT PUMP…2211
Pump Housing Oil Level…2211
Pump Pressure Control…2211
Pressure Control Valve Adjustment…2211
INJECTORS (SL-1 Series "H")…2212
Injector Specifications…2212
Injector Adjustment…2212
INJECTOR OPERATION…2213
SYSTEM CHECKOUT…2214
Lubrication Cycle Timer Check…2214
Lubrication Cycle Timer Adjustment…2214
SYSTEM TROUBLESHOOTING CHART…2215
PREVENTATIVE MAINTENANCE PROCEDURES…2217
Daily Lubrication System Inspection…2217
250 Hour Inspection…2217
1000 Hour Inspection…2217
MAJOR COMPONENT DESCRIPTION…2219
OPTIONAL EQUIPMENT…2223
PAYLOAD METER III…2223
OPERATION SECTION…2225
Introduction…2225
Data Summary…2225
Data Gathering…2225
COMPONENT DESCRIPTION…2226
System Diagram…2226
Suspension Pressure Sensors…2226
Inclinometer…2226
Operator Display…2226
Operator Switch…2227
Speed Input…2227
Body-Up Switch…2227
Brake Lock Switch…2227
Payload Meter…2227
Communications Ports…2227
Keyswitch Input…2228
Payload Meter Power…2228
Load Lights…2228
Wiring and Termination…2229
TCI Outputs…2229
OPERATOR’S DISPLAY AND SWITCH…2230
Reading the Speedometer…2230
Reading the Load Display…2230
Using the Operator ID…2230
Using the Load and Ton Counter…2230
Total Ton Counter…2230
Total Load Counter…2231
Clearing the Counters…2231
Viewing Live Sensor Data…2231
Other Display Messages…2231
PAYLOAD OPERATION & CALCULATION…2232
Description of Haul Cycle States…2232
Haul Cycle Description…2232
Load Calculation…2233
Carry Back…2233
Measurement Accuracy…2233
SOURCES FOR PAYLOAD ERROR…2233
Payload Error…2233
Loading Conditions…2234
Pressure Sensors…2234
Swingloads…2234
Speed and Distance…2234
HAUL CYCLE DATA…2234
Haul Cycle Data…2235
Haul Cycle Warning Flags…2236
A: Continuous Loading…2236
B: Loading to Dumping Transition…2236
C: No Final Load…2236
D: Maneuvering to Dumping Transition…2236
E: Average Load or Tare Used…2236
F: Final Zone to Dumping Transition…2236
H: False Body Up…2236
I: Body Up Signal Failed…2236
J: Speed Sensor Failed…2236
K: New Tare Not Calculated…2236
L: Incomplete Haul Cycle…2236
M: Haul Cycle Too Long…2237
N: Sensor Input Error…2237
Alarm Records…2237
Frame Torque Data…2237
Sprung Weight Data…2238
Maximum Speed Data…2238
PC SOFTWARE OVERVIEW…2238
PC Overview…2238
System Configuration…2238
Installing the PLMIII Software…2238
DOWNLOADING DATA…2239
PLMIII SYSTEM CONFIGURATION…2240
Starting Communications…2240
Displayed Payload Units…2240
Time Units…2240
Connection Menu…2240
Connecting to the Payload Meter…2241
Configure the Payload Meter…2241
Setting the Date and Time…2241
Setting the Truck Type…2242
Setting the Gauge Display Units…2242
Setting the Frame Serial Number…2242
Setting the Truck Number…2242
Setting the Komatsu Distributor…2242
Setting the Komatsu Customer…2242
Clean Truck Tare…2243
Inclinometer Calibration…2243
DATA ANALYSIS…2244
Sorting on Truck Unit Number…2244
Creating a Query…2244
Sorting on Truck Type…2244
Sorting on Date Range…2245
Sorting on Time Range…2245
Payload Detail Screen…2246
Creating Reports…2246
Summary – one page report…2247
Detailed – multi-page report…2247
Creating Graphs…2248
Exporting Data…2248
CSV Export…2248
Compressed…2249
To export data in ZIP format:…2250
Importing Data…2250
Deleting Haul Cycle Records…2250
Viewing Alarms…2251
Deleting Alarm Records…2251
RADIO, AM / FM STEREO CASSETTE…2253
SETTING THE TIME…2253
GENERAL RECEIVER FUNCTIONS…2253
Turning The Power On And Off…2253
Display…2253
Setting The Default Display…2254
Adjusting Display Brightness…2254
OPERATING THE RADIO…2254
BAND…2254
TUNE/SEEK…2254
Manual Tuning…2254
SEEK Mode…2254
SCAN…2254
AUTO…2254
ADJUSTING THE RECEIVER SETTINGS…2255
PROGRAMMING PRESET STATIONS…2255
OPERATION OF THE WEATHERBAND (U.S.)…2255
SATELLITE RADIO…2256
Operating Satellite Radio…2256
Program Type Search (PTY)…2256
CASSETTE PLAYER…2257
Playing A Cassette…2257
Cassette Functions…2257
PROGRAMMABLE EJECT DEFAULT…2257
Bad Tape Detect…2258
CASSETTE PLAYER CLEANING…2258
CEAM014001 – Dump Truck 930E-3SE Operation & Maintenance Manual…2261
COVER…2261
INTRODUCTION…2267
FOREWORD…2267
ALERTS PAGE…2268
TRUCK MODEL ILLUSTRATION…2276
ABOUT THIS MANUAL…2277
TABLE OF CONTENTS…2269
STANDARD CHARTS AND TABLES…2279
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2279
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Capscrews (SAE)…2280
STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & Class 10 Nuts…2280
GENERAL SAFETY…2285
Safety Rules…2285
Truck Safety Features…2285
Clothing And Personal Items…2285
Unauthorized Modification…2285
Leaving The Operator’s Seat…2285
Mounting And Dismounting…2285
Fire Extinguishers And First Aid Kits…2286
Precautions For High Temperature Fluids…2286
Asbestos Dust Hazard Prevention…2286
Fire Prevention For Fuel And Oil…2286
ROPS Precautions…2287
Preventing Injury From Work Equipment…2287
Precautions For Optional Attachments…2287
Precautions When Starting The Machine…2287
PRECAUTIONS FOR TRUCK OPERATION…2288
Safety Is Thinking Ahead…2288
Safety At The Worksite…2288
Fire Prevention…2288
Preparing For Operation…2288
Ventilation For Enclosed Areas…2288
Mirrors, Windows, And Lights…2288
In The Operator’s Cab – Before Starting The Engine…2289
OPERATING THE MACHINE…2289
Starting The Engine…2289
Truck Operation – General…2289
Traveling In The Truck…2290
Precautions When Traveling In Reverse…2290
Traveling On Slopes…2290
Ensuring Good Visibility…2291
Operating On Snow…2291
Avoid Damage To The Dump Body…2291
Driving Near High Voltage Cables…2291
When Loading The Truck…2291
When Dumping…2291
Working On Loose Ground…2291
Parking The Machine…2292
TOWING…2292
WORKING NEAR BATTERIES…2292
Jump Starting With Booster Cables…2292
PRECAUTIONS FOR MAINTENANCE…2293
BEFORE PERFORMING MAINTENANCE…2293
Stopping The Engine Before Service…2293
Warning Tag…2293
Proper Tools…2293
Securing The Dump Body…2293
DURING MAINTENANCE…2294
Personnel…2294
Attachments…2294
Working Under The Machine…2294
Keeping The Machine Clean…2294
Rules To Follow When Adding Fuel Or Oil…2294
Radiator Coolant Level…2294
Use Of Lighting…2294
Precautions With The Battery…2295
Handling High Pressure Hoses…2295
Precautions With High Pressure Oil…2295
Maintenance Near High Temperatures And High Pressures…2295
Rotating Fan And Belts…2295
Waste Materials…2295
TIRES…2296
Handling Tires…2296
Storing Tires After Removal…2296
ADDITIONAL JOB SITE RULES…2297
WHEN REPAIRS ARE NECESSARY…2298
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…2299
Preliminary Procedures before Welding or Performing Maintenance…2299
Normal Engine Shutdown Procedure…2299
Engine Shutdown Procedure before Welding or Performing Maintenance…2299
WARNINGS AND CAUTIONS…2303
TRUCK OPERATION…2313
PREPARING FOR OPERATION…2313
Safety Is Thinking Ahead…2313
WALK AROUND INSPECTION…2313
ENGINE START-UP SAFETY PRACTICES…2317
AFTER STARTING THE ENGINE…2318
Additional Guidelines…2318
MACHINE OPERATION SAFETY PRECAUTIONS…2318
MACHINE OPERATION ON THE HAUL ROAD…2319
STARTING ON A GRADE WITH A LOADED TRUCK…2320
PASSING…2320
LOADING…2320
DUMPING…2320
Raising The Dump Body…2320
Lowering The Dump Body…2321
TOWING…2322
SAFE PARKING PROCEDURES…2323
NORMAL ENGINE SHUTDOWN PROCEDURE…2323
DELAYED ENGINE SHUTDOWN PROCEDURE…2323
SUDDEN LOSS OF ENGINE POWER…2324
DISABLED TRUCK DUMPING PROCEDURE…2325
Hookup…2325
Raising the Body…2325
Lowering the Body…2325
RESERVE ENGINE OIL SYSTEM (Optional)…2326
OPERATOR CAB AND CONTROLS…2327
STEERING WHEEL AND CONTROLS…2328
Horn Button…2328
Tilt / Telescope Lever…2328
Turn Signal/Headlight Dimmer…2328
DYNAMIC RETARDING…2328
Retarder Control Lever…2329
Dynamic Retarder/Service Brake Pedal…2329
Accelerator (Throttle) Pedal…2329
Starting on a Grade With a Loaded Truck…2329
GRADE/SPEED RETARD CHART…2330
INSTRUMENT PANEL…2331
OVERHEAD PANEL AND DISPLAYS…2331
CENTER CONSOLE…2332
F-N-R Selector Switch…2332
Hoist Control Lever…2333
Raising The Dump Body…2333
Lowering The Dump Body:…2333
Ash Tray…2333
Lighter…2333
L.H. Window Control Switch…2333
R.H. Window Control Switch…2333
Engine Shutdown Switch…2333
Override/Fault Reset Switch…2334
Retard Speed Control (RSC) Switch…2334
Retard Speed Control (RSC) Adjust Dial…2334
Data Store Button…2335
Engine Control System…2335
Service Engine Light (Blue)…2335
Engine Diagnostic Download Port…2335
Payload Meter…2335
TCI Download Port…2335
Modular Mining System (Optional)…2335
PSC Download Port…2335
Payload Meter And Download Connector…2335
OPERATOR COMFORT…2336
OPERATOR SEAT…2336
Adjustment…2336
Seat Removal…2336
Seat Installation…2336
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2337
Heater/Air Conditioner Vents…2337
Defroster Control Switch…2337
Heat Control Switch…2337
Temperature Control Knob…2337
Fan Control Knob…2337
Heater/Air Conditioner Selector Switch…2337
INSTRUMENT PANEL AND INDICATOR LIGHTS…2339
CONTROL SYMBOLS…2339
INSTRUMENT PANEL…2339
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7)…2341
Key Switch…2341
Starting…2341
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2341
Fog Lights (Optional)…2342
Ladder Light Switch…2342
Manual Backup Switch…2342
Panel Illumination Lights…2342
Cab/Air Conditioner Vents…2342
Rotating Beacon Light Switch (Optional)…2342
Heated Mirror Switch (Optional)…2342
Wheel Brake Lock Control…2343
Parking Brake Control…2343
Tachometer…2343
Right Turn Signal Indicator…2344
High Beam Indicator…2344
Left Turn Signal Indicator…2344
Speedometer/Payload Meter Display…2344
Voltmeter…2344
Engine Oil Pressure Gauge…2344
Water Temperature Gauge…2344
Fuel Gauge…2344
AC Drive System Temperature Gauge…2345
Hourmeter…2345
Hydraulic Oil Temperature Gauge…2345
Rest Switch…2345
Light Switch…2346
Windshield Wiper and Washer…2346
Panel Light Dimmer…2346
Payload Meter Switch…2346
OVERHEAD STATUS / WARNING INDICATORS…2347
STATUS / WARNING INDICATOR LIGHT SYMBOLS…2348
Hazard Warning Lights…2354
Lamp Test Switch…2354
Link-On Warning Light…2354
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2355
Operation…2355
Interface Module…2356
Basic Precautions…2356
FUSE BLOCKS…2357
CIRCUIT BREAKERS…2357
LUBRICATION AND SERVICE…2359
930E SERVICE CAPACITIES…2359
HYDRAULIC TANK SERVICE…2359
Adding Oil…2359
WHEEL MOTOR SERVICE…2359
COOLANT LEVEL CHECK…2360
RADIATOR FILLING PROCEDURE…2360
RESERVE ENGINE OIL SYSTEM (Optional)…2360
Reserve Oil Tank Filling Procedure (Remote fill)…2360
LUBRICATION CHART…2361
10 HOUR (DAILY) INSPECTION…2362
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2365
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2366
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2367
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2370
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2371
5000 HOUR MAINTENANCE CHECKS…2372
AUTOMATIC LUBRICATION SYSTEM…2373
GENERAL DESCRIPTION…2373
SYSTEM COMPONENTS…2375
SYSTEM OPERATION…2376
Normal Operation…2376
Pressure Failure Detection Circuits…2377
GENERAL INSTRUCTIONS…2378
Required Lubricant For System…2378
System Priming…2378
Filter Assembly…2378
LUBRICANT PUMP…2379
Pump Housing Oil Level…2379
Pump Pressure Control…2379
Pressure Control Valve Adjustment…2379
INJECTORS (SL-1 Series “H”)…2380
Injector Specifications…2380
Injector Adjustment…2380
INJECTOR OPERATION…2381
SYSTEM CHECKOUT…2382
Lubrication Cycle Timer Check…2382
Lubrication Cycle Timer Adjustment…2382
PREVENTIVE MAINTENANCE PROCEDURES…2383
Daily Lubrication System Inspection…2383
250 Hour Inspection…2383
1000 Hour Inspection…2383
SYSTEM TROUBLESHOOTING CHART…2384
MAJOR COMPONENT DESCRIPTION…2387
PAYLOAD METER III™…2391
INDEX…2391
Introduction…2393
Data Summary…2393
Data Gathering…2393
COMPONENT DESCRIPTION…2394
System Diagram…2394
Suspension Pressure Sensors…2394
Inclinometer…2394
Operator Display…2394
Operator Switch…2395
Speed Input…2395
Body-Up Switch…2395
Brake Lock Switch…2395
Payload Meter…2395
Communications Ports…2395
Keyswitch Input…2396
Payload Meter Power…2396
Load Lights…2396
Wiring and Termination…2397
TCI Outputs…2397
OPERATOR’S DISPLAY AND SWITCH…2398
Reading the Speedometer…2398
Reading the Load Display…2398
Using the Operator ID…2398
Using the Load and Ton Counter…2398
Total Ton Counter…2398
Total Load Counter…2399
Clearing the Counters…2399
Viewing Live Sensor Data…2399
Other Display Messages…2399
PAYLOAD OPERATION & CALCULATION…2400
Description of Haul Cycle States…2400
Haul Cycle Description…2400
Load Calculation…2401
Carry Back…2401
Measurement Accuracy…2401
SOURCES FOR PAYLOAD ERROR…2401
Payload Error…2401
Loading Conditions…2402
Pressure Sensors…2402
Swingloads…2402
Speed and Distance…2402
HAUL CYCLE DATA…2402
Haul Cycle Data…2403
Haul Cycle Warning Flags…2404
M: Haul Cycle Too Long…2405
N: Sensor Input Error…2405
Frame Torque Data…2405
Sprung Weight Data…2405
Maximum Speed Data…2405
Alarm Records…2405
Fault Code Data…2406
PC SOFTWARE OVERVIEW…2407
PC Overview…2407
System Configuration…2407
Installing the PLMIII Software…2407
DOWNLOADING DATA…2408
PLM III SYSTEM CONFIGURATION…2409
Starting Communications…2409
Displayed Payload Units…2409
Time Units…2409
Connection Menu…2409
Connecting to the Payload Meter…2410
Configure the Payload Meter…2410
Setting the Date and Time…2410
Setting the Truck Type…2411
Setting the Gauge Display Units…2411
Setting the Frame Serial Number…2411
Setting the Truck Number…2411
Setting the Komatsu Distributor…2411
Setting the Komatsu Customer…2411
Clean Truck Tare…2412
Inclinometer Calibration…2412
DATA ANALYSIS…2413
Creating a Query…2413
Sorting on Truck Unit Number…2413
Sorting on Truck Type…2413
Sorting on Date Range…2414
Sorting on Time Range…2414
Payload Detail Screen…2415
Creating Reports…2415
Summary – one page report…2416
Detailed – multi-page report…2416
Creating Graphs…2417
Exporting Data…2417
CSV Export…2417
Compressed…2418
Importing Data…2419
Deleting Haul Cycle Records…2419
Viewing Alarms…2420
Deleting Alarm Records…2420
RADIO / CASSETTE PLAYER…2423
GENERAL RECEIVER FUNCTIONS…2423
Turning The Power On And Off…2423
Display…2423
Setting The Default Display…2423
Adjusting Display Brightness…2423
SETTING THE TIME…2424
OPERATING THE RADIO…2424
BAND…2424
TUNE/SEEK…2424
Manual Tuning…2424
SEEK Mode…2424
SCAN…2424
AUTO…2424
ADJUSTING THE RECEIVER SETTINGS…2425
PROGRAMMING PRESET STATIONS…2425
OPERATION OF THE WEATHERBAND (U.S.)…2425
SATELLITE RADIO…2426
Operating Satellite Radio…2426
Program Type Search (PTY)…2426
CASSETTE PLAYER…2427
Playing A Cassette…2427
Cassette Functions…2427
Progrommable Eject Default…2427
Bad Tape Detect…2428
Cleaning The Cassette Player…2428
CEAM014600 – Dump Truck 930E-3 Operation & Maintenance Manual…2429
COVER…2429
SECTION 10 – INTRODUCTION…2434
FOREWORD…2434
ALERTS PAGE…2435
TRUCK MODEL ILLUSTRATION…2443
ABOUT THIS MANUAL…2444
TABLE OF CONTENTS…2436
SECTION 12 – STANDARD CHARTS AND TABLES…2446
SECTION 20 – SAFETY…2452
SAFETY…2452
Safety Rules…2452
Safety Features…2452
Clothing And Personal Items…2452
Unauthorized Modification…2452
Leaving The Operator’s Seat…2453
Mounting And Dismounting…2453
Fire Prevention For Fuel And Oil…2453
Precautions With High Temperature Fluids…2454
Asbestos Dust Hazard Prevention…2454
Prevention Of Injury By Work Equipment…2454
Fire Extinguisher And First Aid Kit…2454
Precautions When Using ROPS…2455
Precautions For Attachments…2455
Precautions For Starting Machine…2455
PRECAUTIONS DURING OPERATION…2456
Safety Is Thinking Ahead…2456
Safety At The Worksite…2456
Fire Prevention…2456
Preparing For Operation…2456
Ventilation In Enclosed Areas…2456
In Operator’s Cab – Before Starting The Engine…2457
Mirrors, Windows, And Lights…2457
OPERATING THE MACHINE…2457
When Starting The Engine…2457
Truck Operation – General…2457
Check When Traveling In Reverse…2458
Traveling…2458
Traveling On Slopes…2459
Ensure Good Visibility…2459
Operate Carefully On Snow…2459
Avoid Damage To Dump Body…2459
Driving Near High Voltage Cables…2459
When Dumping…2460
Working On Loose Ground…2460
When Loading…2460
Parking The Machine…2460
TOWING…2460
WORKING NEAR BATTERIES…2461
Battery Hazard Prevention…2461
Starting With Booster Cables…2461
PRECAUTIONS FOR MAINTENANCE…2462
BEFORE PERFORMING MAINTENANCE…2462
Warning Tag…2462
Proper Tools…2462
Stopping The Engine Before Service…2462
Securing The Dump Body…2462
DURING MAINTENANCE…2463
Personnel…2463
Attachments…2463
Working Under The Machine…2463
Keep The Machine Clean…2463
Rules To Follow When Adding Fuel Or Oil…2463
Radiator Water Level…2464
Use Of Lighting…2464
Precautions With The Battery…2464
Handling High Pressure Hoses…2464
Precautions With High Pressure Oil…2464
Precautions When Performing Maintenance Near High Temperature Or High Pressure…2465
Rotating Fan And Belts…2465
Waste Materials…2465
TIRES…2466
Handling Tires…2466
Storing Tires After Removal…2466
ADDITIONAL JOB SITE RULES…2467
WHEN REPAIRS ARE NECESSARY…2468
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…2469
Preliminary Procedures Before Welding or Performing Maintenance…2469
Normal Engine Shutdown Procedure…2469
Engine Shutdown Procedure Before Welding or Performing Maintenance…2470
SECTION 22 – WARNINGS AND CAUTIONS…2472
SECTION 30 – OPERATING INSTRUCTIONS…2482
PREPARING FOR OPERATION…2482
Safety Is Thinking Ahead…2482
At The Truck – Ground Level Walk Around Inspection…2482
ENGINE START-UP SAFETY PRACTICES…2485
Cold Weather Starting…2486
AFTER ENGINE HAS STARTED…2486
MACHINE OPERATION SAFETY PRECAUTIONS…2487
MACHINE OPERATION ON THE HAUL ROAD…2487
STARTING ON A GRADE WITH A LOADED TRUCK…2488
PASSING…2488
LOADING…2488
DUMPING…2489
Raising The Dump Body…2489
Lowering The Dump Body…2489
TOWING…2491
SAFE PARKING PROCEDURES…2491
NORMAL ENGINE SHUTDOWN PROCEDURE…2491
DELAYED ENGINE SHUTDOWN PROCEDURE…2492
SUDDEN LOSS OF ENGINE POWER…2493
DISABLED TRUCK DUMPING PROCEDURE…2494
Hookup…2494
DUMPING PROCEDURE…2494
Raising the Body…2494
Lowering the Body…2494
RESERVE ENGINE OIL SYSTEM (Optional)…2495
SECTION 32 – OPERATOR CAB AND CONTROLS…2496
STEERING WHEEL AND CONTROLS…2497
Horn Button…2497
Telescope Lock Ring…2497
Tilt Wheel Lever…2497
Multi-Function Turn Signal Switch…2497
DYNAMIC RETARDING…2498
Retarder Control Lever…2498
Dynamic Retarder/Service Brake Pedal…2498
Accelerator (Throttle) Pedal…2499
Starting on a Grade With a Loaded Truck…2499
GRADE/SPEED RETARD CHART…2499
INSTRUMENT PANEL…2501
OVERHEAD PANEL AND DISPLAYS…2501
CENTER CONSOLE…2502
F-N-R Selector Switch…2502
Hoist Control Lever…2503
Raising The Dump Body…2503
Lowering The Dump Body:…2503
Ash Tray…2503
Lighter…2503
L.H. Window Control Switch…2503
R.H. Window Control Switch…2503
Engine Shutdown Switch…2503
Override/Fault Reset Switch…2504
Retard Speed Control (RSC) Switch…2504
Retard Speed Control (RSC) Adjust Dial…2504
Data Store Button…2505
Engine Control System…2505
Service Engine Light…2505
Engine Diagnostic Download Port…2505
Payload Meter Port…2505
TCI Download Port…2505
Modular Mining System (Optional)…2505
PSC Download Port…2505
Payload Meter And Download Connector…2505
OPERATOR COMFORT…2506
OPERATOR SEAT…2506
Adjustment…2506
Seat Removal…2506
Seat Installation…2506
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2507
Heater/Air Conditioner Vents…2507
Defroster Control Switch…2507
Heat Control Switch…2507
Temperature Control Knob…2507
Fan Control Knob…2507
Heater/Air Conditioner Selector Switch…2507
INSTRUMENT PANEL AND INDICATOR LIGHTS…2508
CONTROL SYMBOLS…2508
INSTRUMENT PANEL…2508
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 32-7)…2510
Key Switch…2510
Starting…2510
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2510
Fog Lights (Optional)…2511
Ladder Light Switch…2511
Manual Backup Switch…2511
Panel Illumination Lights…2511
Cab/Air Conditioner Vents…2511
Rotating Beacon Light Switch (Optional)…2511
Heated Mirror Switch (Optional)…2511
Wheel Brake Lock Control…2512
Parking Brake Control…2512
Tachometer…2512
Right Turn Signal Indicator…2513
High Beam Indicator…2513
Left Turn Signal Indicator…2513
Speedometer/Payload Meter Display…2513
Voltmeter…2513
Engine Oil Pressure Gauge…2513
Water Temperature Gauge…2513
Fuel Gauge…2513
AC Drive System Temperature Gauge…2514
Hourmeter…2514
Hydraulic Oil Temperature Gauge…2514
Rest Switch…2515
Light Switch…2515
Panel Light Dimmer…2515
Payload Meter Switch…2515
OVERHEAD STATUS / WARNING INDICATORS…2516
STATUS / WARNING INDICATOR LIGHT SYMBOLS…2517
Hazard Warning Lights…2523
Lamp Test Switch…2523
Link-On Warning Light…2523
FUSE BLOCKS…2524
CIRCUIT BREAKERS…2524
SECTION 40 – LUBRICATION AND SERVICE…2526
930E SERVICE CAPACITIES…2526
HYDRAULIC TANK SERVICE…2526
Adding Oil…2526
WHEEL MOTOR SERVICE…2526
COOLANT LEVEL CHECK…2527
RADIATOR FILLING PROCEDURE…2527
RESERVE ENGINE OIL SYSTEM (Optional)…2527
Reserve Oil Tank Filling Procedure (Remote fill)…2527
LUBRICATION CHART…2528
10 HOUR (DAILY) INSPECTION…2529
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2532
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2533
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2534
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2537
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2538
2500 HOUR MAINTENANCE CHECKS…2539
5000 HOUR MAINTENANCE CHECKS…2539
SECTION 42 – AUTOMATIC LUBRICATION SYSTEM…2540
GENERAL DESCRIPTION…2540
SYSTEM COMPONENTS…2542
Filter…2542
Hydraulic Motor and Pump…2542
Grease Reservoir…2542
Pressure Reducing Valve…2542
Flow Control Valve…2542
Solenoid Valve…2542
Vent Valve…2542
Lubrication Cycle Timer…2542
Time Delay Module…2542
Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])…2542
Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])…2542
Pressure Gauge…2542
Injectors…2542
SYSTEM OPERATION…2543
Pressure Failure Detection Circuits…2544
GENERAL INSTRUCTIONS…2545
Required Lubricant For System…2545
System Priming…2545
Filter Assembly…2545
LUBRICANT PUMP…2546
Pump Housing Oil Level…2546
Pump Pressure Control…2546
Pressure Control Valve Adjustment…2546
INJECTORS (SL-1 Series “H”))…2547
Injector Specifications…2547
Injector Adjustment…2547
INJECTOR OPERATION…2548
SYSTEM CHECKOUT…2549
Lubrication Cycle Timer Check…2549
Lubrication Cycle Timer Adjustment…2549
SYSTEM TROUBLESHOOTING CHART…2550
PREVENTATIVE MAINTENANCE PROCEDURES…2552
Daily Lubrication System Inspection…2552
250 Hour Inspection…2552
1000 Hour Inspection…2552
SECTION 50 – MAJOR COMPONENT DESCRIPTION…2554
SECTION 60 – PAYLOAD METER III INDEX…2558
OPERATION SECTION…2560
Introduction…2560
Data Summary…2560
Data Gathering…2560
COMPONENT DESCRIPTION…2561
System Diagram…2561
Suspension Pressure Sensors…2561
Inclinometer…2561
Operator Display…2561
Operator Switch…2562
Speed Input…2562
Body-Up Switch…2562
Brake Lock Switch…2562
Payload Meter…2562
Communications Ports…2562
Keyswitch Input…2563
Payload Meter Power…2563
Load Lights…2563
Wiring and Termination…2564
TCI Outputs…2564
OPERATOR’S DISPLAY AND SWITCH…2565
Reading the Speedometer…2565
Reading the Load Display…2565
Using the Operator ID…2565
Using the Load and Ton Counter…2565
Total Ton Counter…2565
Total Load Counter…2566
Clearing the Counters…2566
Viewing Live Sensor Data…2566
Other Display Messages…2566
PAYLOAD OPERATION & CALCULATION…2567
Description of Haul Cycle States…2567
Haul Cycle Description…2567
Load Calculation…2568
Carry Back…2568
Measurement Accuracy…2568
SOURCES FOR PAYLOAD ERROR…2568
Payload Error…2568
Loading Conditions…2569
Pressure Sensors…2569
Swingloads…2569
Speed and Distance…2569
HAUL CYCLE DATA…2569
Haul Cycle Data…2570
Haul Cycle Warning Flags…2571
A: Continuous Loading…2571
B: Loading to Dumping Transition…2571
C: No Final Load…2571
D: Maneuvering to Dumping Transition…2571
E: Average Load or Tare Used…2571
F: Final Zone to Dumping Transition…2571
H: False Body Up…2571
I: Body Up Signal Failed…2571
J: Speed Sensor Failed…2571
K: New Tare Not Calculated…2571
L: Incomplete Haul Cycle…2571
M: Haul Cycle Too Long…2572
N: Sensor Input Error…2572
Alarm Records…2572
Frame Torque Data…2572
Sprung Weight Data…2573
Maximum Speed Data…2573
PC SOFTWARE OVERVIEW…2573
PC Overview…2573
System Configuration…2573
Installing the PLMIII Software…2573
DOWNLOADING DATA…2574
PLMIII SYSTEM CONFIGURATION…2575
Starting Communications…2575
Displayed Payload Units…2575
Time Units…2575
Connection Menu…2575
Connecting to the Payload Meter…2576
Configure the Payload Meter…2576
Setting the Date and Time…2576
Setting the Truck Type…2577
Setting the Gauge Display Units…2577
Setting the Frame Serial Number…2577
Setting the Truck Number…2577
Setting the Komatsu Distributor…2577
Setting the Komatsu Customer…2577
Clean Truck Tare…2578
Inclinometer Calibration…2578
DATA ANALYSIS…2579
Sorting on Truck Unit Number…2579
Creating a Query…2579
Sorting on Truck Type…2579
Sorting on Date Range…2580
Sorting on Time Range…2580
Payload Detail Screen…2581
Creating Reports…2581
Summary – one page report…2582
Detailed – multi-page report…2582
Creating Graphs…2583
Exporting Data…2583
CSV Export…2583
Compressed…2584
To export data in ZIP format:…2585
Importing Data…2585
Deleting Haul Cycle Records…2585
Viewing Alarms…2586
Deleting Alarm Records…2586
SECTION 70 – RADIO, AM / FM STEREO CASSETTE…2588
SETTING THE TIME…2588
GENERAL RECEIVER FUNCTIONS…2588
Turning The Power On And Off…2588
Display…2588
Setting The Default Display…2589
Adjusting Display Brightness…2589
OPERATING THE RADIO…2589
BAND…2589
TUNE/SEEK…2589
Manual Tuning…2589
SEEK Mode…2589
SCAN…2589
AUTO…2589
ADJUSTING THE RECEIVER SETTINGS…2590
PROGRAMMING PRESET STATIONS…2590
OPERATION OF THE WEATHERBAND (U.S.)…2590
SATELLITE RADIO…2591
Operating Satellite Radio…2591
Program Type Search (PTY)…2591
CASSETTE PLAYER…2592
Playing A Cassette…2592
Cassette Functions…2592
PROGRAMMABLE EJECT DEFAULT…2592
Bad Tape Detect…2593
CASSETTE PLAYER CLEANING…2593
CEAM015901 – Dump Truck 930E-3 Operation & Maintenance Manual…2595
COVER…2595
INTRODUCTION…2601
FOREWORD…2601
TRUCK MODEL ILLUSTRATION…2602
ABOUT THIS MANUAL…2603
ALERTS PAGE…2604
TABLE OF CONTENTS…2605
STANDARD CHARTS AND TABLES…2613
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2613
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2614
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2614
GENERAL SAFETY…2619
Safety Rules…2619
Truck Safety Features…2619
Clothing And Personal Items…2619
Unauthorized Modification…2619
Leaving The Operator’s Seat…2619
Mounting And Dismounting…2619
Fire Extinguishers And First Aid Kits…2620
Precautions For High Temperature Fluids…2620
Asbestos Dust Hazard Prevention…2620
Fire Prevention For Fuel And Oil…2620
ROPS Precautions…2621
Preventing Injury From Work Equipment…2621
Precautions For Optional Attachments…2621
Precautions When Starting The Machine…2621
PRECAUTIONS FOR TRUCK OPERATION…2622
Safety Is Thinking Ahead…2622
Safety At The Worksite…2622
Fire Prevention…2622
Preparing For Operation…2622
Ventilation For Enclosed Areas…2622
Mirrors, Windows, And Lights…2622
In The Operator’s Cab – Before Starting The Engine…2623
OPERATING THE MACHINE…2623
Starting The Engine…2623
Truck Operation – General…2623
Traveling In The Truck…2624
Precautions When Traveling In Reverse…2624
Traveling On Slopes…2624
Ensuring Good Visibility…2625
Operating On Snow…2625
Avoid Damage To The Dump Body…2625
Driving Near High Voltage Cables…2625
When Loading The Truck…2625
When Dumping…2625
Working On Loose Ground…2625
Parking The Machine…2626
TOWING…2626
WORKING NEAR BATTERIES…2626
Jump Starting With Booster Cables…2626
PRECAUTIONS FOR MAINTENANCE…2627
BEFORE PERFORMING MAINTENANCE…2627
Stopping The Engine Before Service…2627
Warning Tag…2627
Proper Tools…2627
Securing The Dump Body…2627
DURING MAINTENANCE…2628
Personnel…2628
Attachments…2628
Working Under The Machine…2628
Keeping The Machine Clean…2628
Rules To Follow When Adding Fuel Or Oil…2628
Radiator Coolant Level…2628
Use Of Lighting…2628
Precautions With The Battery…2629
Handling High Pressure Hoses…2629
Precautions With High Pressure Oil…2629
Maintenance Near High Temperatures And High Pressures…2629
Rotating Fan And Belts…2629
Waste Materials…2629
TIRES…2630
Handling Tires…2630
Storing Tires After Removal…2630
ADDITIONAL JOB SITE RULES…2631
WHEN REPAIRS ARE NECESSARY…2632
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…2633
Preliminary Procedures before Welding or Performing Maintenance…2633
Normal Engine Shutdown Procedure…2633
Engine Shutdown Procedure before Welding or Performing Maintenance…2633
WARNINGS AND CAUTIONS…2637
TRUCK OPERATION…2647
PREPARING FOR OPERATION…2647
Safety Is Thinking Ahead…2647
WALK AROUND INSPECTION…2647
ENGINE START-UP SAFETY PRACTICES…2650
AFTER STARTING THE ENGINE…2651
Additional Guidelines…2651
EMERGENCY STEERING SYSTEM…2652
Operation…2652
Pre-Operation Testing…2652
MACHINE OPERATION SAFETY PRECAUTIONS…2653
MACHINE OPERATION ON THE HAUL ROAD…2654
STARTING ON A GRADE WITH A LOADED TRUCK…2654
PASSING…2654
LOADING…2655
DUMPING…2655
Raising The Dump Body…2655
Lowering The Dump Body…2656
TOWING…2657
SAFE PARKING PROCEDURES…2657
NORMAL ENGINE SHUTDOWN PROCEDURE…2658
DELAYED ENGINE SHUTDOWN PROCEDURE…2658
SUDDEN LOSS OF ENGINE POWER…2659
DISABLED TRUCK DUMPING PROCEDURE…2660
Hookup…2660
Raising the Body…2660
Lowering the Body…2660
RESERVE ENGINE OIL SYSTEM (Optional)…2661
OPERATOR CAB AND CONTROLS…2663
STEERING WHEEL AND CONTROLS…2664
Horn Button…2664
Tilt / Telescope Lever…2664
Multi-Function Turn Signal Switch…2664
DYNAMIC RETARDING…2665
Retarder Control Lever…2665
Dynamic Retarder/Service Brake Pedal…2665
Throttle/Accelerator Pedal…2666
Starting on a Grade With a Loaded Truck…2666
GRADE/SPEED RETARD CHART…2666
OVERHEAD PANEL AND DISPLAYS…2668
CENTER CONSOLE…2669
F-N-R Selector Switch…2669
Hoist Control Lever…2670
Raising The Dump Body…2670
Lowering The Dump Body…2670
Ash Tray…2670
Lighter…2670
L.H. Window Control Switch…2670
R.H. Window Control Switch…2670
Engine Shutdown Switch…2670
Override/Fault Reset Switch…2671
Retard Speed Control (RSC) Switch…2671
Retard Speed Control (RSC) Adjust Dial…2671
Data Store Button…2672
Engine Control System…2672
Service Engine Light…2672
Engine Diagnostic Download Port…2672
Payload Meter Port…2672
TCI Download Port…2672
Modular Mining System (Optional)…2672
PSC Download Port…2672
Payload Meter And Download Connector…2672
OPERATOR’S SEAT…2673
Adjustment…2673
Seat Removal…2673
Seat Installation…2673
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2674
Heater/Air Conditioner Vents…2674
Defroster Control Switch…2674
Heat Control Switch…2674
Temperature Control Knob…2674
Fan Control Knob…2674
Heater/Air Conditioner Selector Switch…2674
INSTRUMENT PANEL…2675
Control Symbols…2675
Key Switch…2677
Starting…2677
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2677
Fog Lights (Optional)…2678
Ladder Light Switch…2678
Manual Backup Switch…2678
Panel Illumination Lights…2678
Cab/Air Conditioner Vents…2678
Rotating Beacon Light Switch (Optional)…2678
Heated Mirror Switch (Optional)…2678
Wheel Brake Lock Control…2679
Parking Brake Control…2679
Tachometer…2679
Right Turn Signal Indicator…2680
High Beam Indicator…2680
Left Turn Signal Indicator…2680
Speedometer/Payload Meter Display…2680
Voltmeter…2680
Engine Oil Pressure Gauge…2680
Water Temperature Gauge…2680
Fuel Gauge…2680
AC Drive System Temperature Gauge…2681
Hourmeter…2681
Hydraulic Oil Temperature Gauge…2681
Rest Switch…2682
Light Switch…2682
Panel Light Dimmer…2682
Payload Meter Switch…2682
OVERHEAD STATUS / WARNING INDICATORS…2683
Status / Warning Indicator Light Symbols…2684
Hazard Warning Lights…2690
Lamp Test Switch…2690
Link-On Warning Light…2690
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2691
Operation…2691
Interface Module…2692
Basic Precautions…2692
FUSE BLOCKS…2693
CIRCUIT BREAKERS…2693
LUBRICATION AND SERVICE…2695
GENERAL…2695
930E SERVICE CAPACITIES…2695
HYDRAULIC TANK SERVICE…2695
Adding Hydraulic Oil…2695
WHEEL MOTOR SERVICE…2695
COOLING SYSTEM SERVICE…2696
Radiator Filling Procedure…2696
RESERVE ENGINE OIL SYSTEM…2696
Reserve Oil Tank Filling Procedure (Remote Fill)…2696
LUBRICATION CHART…2697
10 HOUR (DAILY) INSPECTIONS…2698
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2700
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2700
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2700
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2703
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2704
5000 HOUR MAINTENANCE CHECKS…2704
AUTOMATIC LUBRICATION SYSTEM…2705
GENERAL DESCRIPTION…2705
SYSTEM COMPONENTS…2707
Filter…2707
Hydraulic Motor and Pump…2707
Grease Reservoir…2707
Pressure Reducing Valve…2707
Flow Control Valve…2707
Solenoid Valve…2707
Vent Valve…2707
Lubrication Cycle Timer…2707
Time Delay Module…2707
Pump Cutoff Pressure Switch…2707
Grease Pressure Failure Switch…2707
Pressure Gauge…2707
Injectors…2707
SYSTEM OPERATION…2708
Normal Operation…2708
Pressure Failure Detection Circuits…2709
System Priming…2710
Filter Assembly…2710
LUBRICANT PUMP…2711
Pump Housing Oil Level…2711
Pump Pressure Control…2711
Pressure Control Valve Adjustment…2711
INJECTORS (SL-1 Series “H”))…2712
Injector Specifications…2712
Injector Adjustment…2712
INJECTOR OPERATION…2713
SYSTEM CHECKOUT…2714
Lubrication Cycle Timer Check…2714
Lubrication Cycle Timer Adjustment…2714
PREVENTIVE MAINTENANCE PROCEDURES…2715
Daily Lubrication System Inspection…2715
250 Hour Inspection…2715
1000 Hour Inspection…2715
SYSTEM TROUBLESHOOTING CHART…2716
COMPONENTS & SPECIFICATIONS…2719
MAJOR COMPONENT DESCRIPTIONS…2719
Truck And Engine…2719
Alternator (GE-GTA41)…2719
AC Induction Traction Motorized Wheels…2719
Suspension…2719
Operator's Cab…2719
Power Steering…2719
Dynamic Retarding…2719
Brake System…2719
SPECIFICATIONS…2721
ENGINE…2721
AC ELECTRIC DRIVE SYSTEM…2721
DYNAMIC RETARDING…2721
BATTERY ELECTRIC SYSTEM…2721
SERVICE CAPACITIES…2721
HYDRAULIC SYSTEMS…2721
SERVICE BRAKES…2721
STEERING…2721
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…2722
TIRES…2722
WEIGHT DISTRIBUTION…2722
Loaded Vehicle…2722
PAYLOAD METER III™…2723
INDEX…2723
Introduction…2725
Data Summary…2725
Data Gathering…2725
COMPONENT DESCRIPTION…2726
System Diagram…2726
Suspension Pressure Sensors…2726
Inclinometer…2726
Operator Display…2726
Operator Switch…2727
Speed Input…2727
Body-Up Switch…2727
Brake Lock Switch…2727
Payload Meter…2727
Communications Ports…2727
Key Switch Input…2728
Payload Meter Power…2728
Load Lights…2728
Wiring and Termination…2729
TCI Outputs…2729
OPERATOR’S DISPLAY AND SWITCH…2730
Reading the Speedometer…2730
Reading the Load Display…2730
Using the Operator ID…2730
Using the Load and Ton Counter…2730
Total Ton Counter…2730
Total Load Counter…2731
Clearing the Counters…2731
Viewing Live Sensor Data…2731
Other Display Messages…2731
PAYLOAD OPERATION & CALCULATION…2732
Haul Cycle States…2732
Haul Cycle Description…2732
Load Calculation…2733
Carry Back…2733
Measurement Accuracy…2733
SOURCES FOR PAYLOAD ERROR…2733
Payload Error…2733
Loading Conditions…2734
Pressure Sensors…2734
Swingloads…2734
Speed and Distance…2734
HAUL CYCLE DATA…2734
Haul Cycle Data…2735
Haul Cycle Warning Flags…2736
Frame Torque Data…2737
Sprung Weight Data…2737
Maximum Speed Data…2737
Alarm Records…2737
Fault Code Data…2738
PC SOFTWARE OVERVIEW…2739
PC Overview…2739
System Configuration…2739
Installing the PLMIII Software…2739
DOWNLOADING DATA…2740
PLM III SYSTEM CONFIGURATION…2741
Starting Communications…2741
Displayed Payload Units…2741
Time Units…2741
Connection Menu…2741
Connecting to the Payload Meter…2742
Configure the Payload Meter…2742
Setting the Date and Time…2742
Setting the Truck Type…2743
Setting the Gauge Display Units…2743
Setting the Frame Serial Number…2743
Setting the Truck Number…2743
Setting the Komatsu Distributor…2743
Setting the Komatsu Customer…2743
Clean Truck Tare…2744
Inclinometer Calibration…2744
DATA ANALYSIS…2745
Creating a Query…2745
Sorting on Truck Unit Number…2745
Sorting on Truck Type…2745
Sorting on Date Range…2746
Sorting on Time Range…2746
Payload Detail Screen…2747
Creating Reports…2747
Summary – one page report…2748
Detailed – multi-page report…2748
Creating Graphs…2749
Exporting Data…2749
CSV Export…2749
Compressed…2750
Importing Data…2751
Deleting Haul Cycle Records…2751
Viewing Alarms…2752
Deleting Alarm Records…2752
RADIO / CASSETTE PLAYER…2755
GENERAL RECEIVER FUNCTIONS…2755
Turning The Power On And Off…2755
Display…2755
Setting The Default Display…2755
Adjusting Display Brightness…2755
SETTING THE TIME…2756
OPERATING THE RADIO…2756
BAND…2756
TUNE/SEEK…2756
Manual Tuning…2756
SEEK Mode…2756
SCAN…2756
AUTO…2756
ADJUSTING THE RECEIVER SETTINGS…2757
PROGRAMMING PRESET STATIONS…2757
OPERATION OF THE WEATHERBAND (U.S.)…2757
SATELLITE RADIO…2758
Operating Satellite Radio…2758
Program Type Search (PTY)…2758
CASSETTE PLAYER…2759
Playing A Cassette…2759
Cassette Functions…2759
Programmable Eject Default…2759
Bad Tape Detect…2760
Cleaning The Cassette Player…2760
CEAM016000 – Dump Truck 930E-3SE Operation & Maintenance Manual…2765
COVER…2765
FOREWORD…2771
ALERTS PAGE…2772
TRUCK MODEL ILLUSTRATION…2780
ABOUT THIS MANUAL…2781
TABLE OF CONTENTS…2773
STANDARD CHARTS AND TABLES…2783
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2783
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Capscrews (SAE)…2784
STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & Class 10 Nuts…2784
GENERAL SAFETY…2789
Safety Rules…2789
Truck Safety Features…2789
Clothing And Personal Items…2789
Unauthorized Modification…2789
Leaving The Operator’s Seat…2789
Mounting And Dismounting…2789
Fire Extinguishers And First Aid Kits…2790
Precautions For High Temperature Fluids…2790
Asbestos Dust Hazard Prevention…2790
Fire Prevention For Fuel And Oil…2790
ROPS Precautions…2791
Preventing Injury From Work Equipment…2791
Precautions For Optional Attachments…2791
Precautions When Starting The Machine…2791
PRECAUTIONS FOR TRUCK OPERATION…2792
Safety Is Thinking Ahead…2792
Safety At The Worksite…2792
Fire Prevention…2792
Preparing For Operation…2792
Ventilation For Enclosed Areas…2792
Mirrors, Windows, And Lights…2792
In The Operator’s Cab – Before Starting The Engine…2793
OPERATING THE MACHINE…2793
Starting The Engine…2793
Truck Operation – General…2793
Traveling In The Truck…2794
Precautions When Traveling In Reverse…2794
Traveling On Slopes…2794
Ensuring Good Visibility…2795
Operating On Snow…2795
Avoid Damage To The Dump Body…2795
Driving Near High Voltage Cables…2795
When Loading The Truck…2795
When Dumping…2795
Working On Loose Ground…2795
Parking The Machine…2796
TOWING…2796
WORKING NEAR BATTERIES…2796
Jump Starting With Booster Cables…2796
PRECAUTIONS FOR MAINTENANCE…2797
BEFORE PERFORMING MAINTENANCE…2797
Stopping The Engine Before Service…2797
Warning Tag…2797
Proper Tools…2797
Securing The Dump Body…2797
DURING MAINTENANCE…2798
Personnel…2798
Attachments…2798
Working Under The Machine…2798
Keeping The Machine Clean…2798
Rules To Follow When Adding Fuel Or Oil…2798
Radiator Coolant Level…2798
Use Of Lighting…2798
Precautions With The Battery…2799
Handling High Pressure Hoses…2799
Precautions With High Pressure Oil…2799
Maintenance Near High Temperatures And High Pressures…2799
Rotating Fan And Belts…2799
Waste Materials…2799
TIRES…2800
Handling Tires…2800
Storing Tires After Removal…2800
ADDITIONAL JOB SITE RULES…2801
WHEN REPAIRS ARE NECESSARY…2802
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…2803
Preliminary Procedures before Welding or Performing Maintenance…2803
Normal Engine Shutdown Procedure…2803
Engine Shutdown Procedure before Welding or Performing Maintenance…2803
WARNINGS AND CAUTIONS…2807
TRUCK OPERATION…2817
PREPARING FOR OPERATION…2817
Safety Is Thinking Ahead…2817
WALK AROUND INSPECTION…2817
ENGINE START-UP SAFETY PRACTICES…2821
AFTER STARTING THE ENGINE…2822
Additional Guidelines…2822
MACHINE OPERATION SAFETY PRECAUTIONS…2822
MACHINE OPERATION ON THE HAUL ROAD…2823
STARTING ON A GRADE WITH A LOADED TRUCK…2824
PASSING…2824
LOADING…2824
DUMPING…2824
Raising The Dump Body…2824
Lowering The Dump Body…2825
TOWING…2826
SAFE PARKING PROCEDURES…2827
NORMAL ENGINE SHUTDOWN PROCEDURE…2827
DELAYED ENGINE SHUTDOWN PROCEDURE…2827
SUDDEN LOSS OF ENGINE POWER…2828
DISABLED TRUCK DUMPING PROCEDURE…2829
Hookup…2829
Raising the Body…2829
Lowering the Body…2829
RESERVE ENGINE OIL SYSTEM (Optional)…2830
OPERATOR CAB AND CONTROLS…2831
STEERING WHEEL AND CONTROLS…2832
Horn Button…2832
Tilt / Telescope Lever…2832
Multi-Function Turn Signal Switch…2832
DYNAMIC RETARDING…2833
Retarder Control Lever…2833
Dynamic Retarder/Service Brake Pedal…2833
Throttle/Accelerator Pedal…2834
Starting on a Grade With a Loaded Truck…2834
GRADE/SPEED RETARD CHART…2834
OVERHEAD PANEL AND DISPLAYS…2836
CENTER CONSOLE…2837
F-N-R Selector Switch…2837
Hoist Control Lever…2838
Raising The Dump Body…2838
Lowering The Dump Body…2838
Ash Tray…2838
Lighter…2838
L.H. Window Control Switch…2838
R.H. Window Control Switch…2838
Engine Shutdown Switch…2838
Override/Fault Reset Switch…2839
Retard Speed Control (RSC) Switch…2839
Retard Speed Control (RSC) Adjust Dial…2839
Data Store Button…2840
Engine Control System…2840
Service Engine Light…2840
Engine Diagnostic Download Port…2840
Payload Meter Port…2840
TCI Download Port…2840
Modular Mining System (Optional)…2840
PSC Download Port…2840
Payload Meter And Download Connector…2840
OPERATOR’S SEAT…2841
Adjustment…2841
Seat Removal…2841
Seat Installation…2841
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2842
Heater/Air Conditioner Vents…2842
Defroster Control Switch…2842
Heat Control Switch…2842
Temperature Control Knob…2842
Fan Control Knob…2842
Heater/Air Conditioner Selector Switch…2842
INSTRUMENT PANEL…2843
Control Symbols…2843
Key Switch…2845
Starting…2845
Engine Shutdown Switch with 5 Minute Idle Timer Delay…2845
Fog Lights (Optional)…2846
Ladder Light Switch…2846
Manual Backup Switch…2846
Panel Illumination Lights…2846
Cab/Air Conditioner Vents…2846
Rotating Beacon Light Switch (Optional)…2846
Heated Mirror Switch (Optional)…2846
Wheel Brake Lock Control…2847
Parking Brake Control…2847
Tachometer…2847
Right Turn Signal Indicator…2848
High Beam Indicator…2848
Left Turn Signal Indicator…2848
Speedometer/Payload Meter Display…2848
Voltmeter…2848
Engine Oil Pressure Gauge…2848
Water Temperature Gauge…2848
Fuel Gauge…2848
AC Drive System Temperature Gauge…2849
Hourmeter…2849
Hydraulic Oil Temperature Gauge…2849
Rest Switch…2850
Light Switch…2850
Panel Light Dimmer…2850
Payload Meter Switch…2850
OVERHEAD STATUS / WARNING INDICATORS…2851
Status / Warning Indicator Light Symbols…2852
Hazard Warning Lights…2858
Lamp Test Switch…2858
Link-On Warning Light…2858
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2859
Operation…2859
Interface Module…2860
Basic Precautions…2860
FUSE BLOCKS…2861
CIRCUIT BREAKERS…2861
LUBRICATION AND SERVICE…2863
930E SERVICE CAPACITIES…2863
HYDRAULIC TANK SERVICE…2863
Adding Oil…2863
WHEEL MOTOR SERVICE…2863
COOLANT LEVEL CHECK…2864
RADIATOR FILLING PROCEDURE…2864
RESERVE ENGINE OIL SYSTEM (Optional)…2864
Reserve Oil Tank Filling Procedure (Remote fill)…2864
LUBRICATION CHART…2865
10 HOUR (DAILY) INSPECTION…2866
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2869
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2870
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2871
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2874
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2875
5000 HOUR MAINTENANCE CHECKS…2876
AUTOMATIC LUBRICATION SYSTEM…2877
GENERAL DESCRIPTION…2877
SYSTEM COMPONENTS…2879
SYSTEM OPERATION…2880
Normal Operation…2880
Pressure Failure Detection Circuits…2881
GENERAL INSTRUCTIONS…2882
Required Lubricant For System…2882
System Priming…2882
Filter Assembly…2882
LUBRICANT PUMP…2883
Pump Housing Oil Level…2883
Pump Pressure Control…2883
Pressure Control Valve Adjustment…2883
INJECTORS (SL-1 Series “H”)…2884
Injector Specifications…2884
Injector Adjustment…2884
INJECTOR OPERATION…2885
SYSTEM CHECKOUT…2886
Lubrication Cycle Timer Check…2886
Lubrication Cycle Timer Adjustment…2886
PREVENTIVE MAINTENANCE PROCEDURES…2887
Daily Lubrication System Inspection…2887
250 Hour Inspection…2887
1000 Hour Inspection…2887
SYSTEM TROUBLESHOOTING CHART…2888
MAJOR COMPONENT DESCRIPTION…2891
PAYLOAD METER III™…2895
INDEX…2895
Introduction…2897
Data Summary…2897
Data Gathering…2897
COMPONENT DESCRIPTION…2898
System Diagram…2898
Suspension Pressure Sensors…2898
Inclinometer…2898
Operator Display…2898
Operator Switch…2899
Speed Input…2899
Body-Up Switch…2899
Brake Lock Switch…2899
Payload Meter…2899
Communications Ports…2899
Keyswitch Input…2900
Payload Meter Power…2900
Load Lights…2900
Wiring and Termination…2901
TCI Outputs…2901
OPERATOR’S DISPLAY AND SWITCH…2902
Reading the Speedometer…2902
Reading the Load Display…2902
Using the Operator ID…2902
Using the Load and Ton Counter…2902
Total Ton Counter…2902
Total Load Counter…2903
Clearing the Counters…2903
Viewing Live Sensor Data…2903
Other Display Messages…2903
PAYLOAD OPERATION & CALCULATION…2904
Description of Haul Cycle States…2904
Haul Cycle Description…2904
Load Calculation…2905
Carry Back…2905
Measurement Accuracy…2905
SOURCES FOR PAYLOAD ERROR…2905
Payload Error…2905
Loading Conditions…2906
Pressure Sensors…2906
Swingloads…2906
Speed and Distance…2906
HAUL CYCLE DATA…2906
Haul Cycle Data…2907
Haul Cycle Warning Flags…2908
M: Haul Cycle Too Long…2909
N: Sensor Input Error…2909
Frame Torque Data…2909
Sprung Weight Data…2909
Maximum Speed Data…2909
Alarm Records…2909
Fault Code Data…2910
PC SOFTWARE OVERVIEW…2911
PC Overview…2911
System Configuration…2911
Installing the PLMIII Software…2911
DOWNLOADING DATA…2912
PLM III SYSTEM CONFIGURATION…2913
Starting Communications…2913
Displayed Payload Units…2913
Time Units…2913
Connection Menu…2913
Connecting to the Payload Meter…2914
Configure the Payload Meter…2914
Setting the Date and Time…2914
Setting the Truck Type…2915
Setting the Gauge Display Units…2915
Setting the Frame Serial Number…2915
Setting the Truck Number…2915
Setting the Komatsu Distributor…2915
Setting the Komatsu Customer…2915
Clean Truck Tare…2916
Inclinometer Calibration…2916
DATA ANALYSIS…2917
Creating a Query…2917
Sorting on Truck Unit Number…2917
Sorting on Truck Type…2917
Sorting on Date Range…2918
Sorting on Time Range…2918
Payload Detail Screen…2919
Creating Reports…2919
Summary – one page report…2920
Detailed – multi-page report…2920
Creating Graphs…2921
Exporting Data…2921
CSV Export…2921
Compressed…2922
Importing Data…2923
Deleting Haul Cycle Records…2923
Viewing Alarms…2924
Deleting Alarm Records…2924
RADIO / CASSETTE PLAYER…2927
GENERAL RECEIVER FUNCTIONS…2927
Turning The Power On And Off…2927
Display…2927
Setting The Default Display…2927
Adjusting Display Brightness…2927
SETTING THE TIME…2928
OPERATING THE RADIO…2928
BAND…2928
TUNE/SEEK…2928
Manual Tuning…2928
SEEK Mode…2928
SCAN…2928
AUTO…2928
ADJUSTING THE RECEIVER SETTINGS…2929
PROGRAMMING PRESET STATIONS…2929
OPERATION OF THE WEATHERBAND (U.S.)…2929
SATELLITE RADIO…2930
Operating Satellite Radio…2930
Program Type Search (PTY)…2930
CASSETTE PLAYER…2931
Playing A Cassette…2931
Cassette Functions…2931
Progrommable Eject Default…2931
Bad Tape Detect…2932
Cleaning The Cassette Player…2932
CEAM017906 – Dump Truck 930E-4 Operation & Maintenance Manual…2935
COVER…2935
INTRODUCTION…2939
FOREWORD…2939
TRUCK MODEL ILLUSTRATION…2940
ABOUT THIS MANUAL…2941
ALERTS PAGE…2942
TABLE OF CONTENTS…2943
TORQUE TABLES AND CONVERSION CHARTS…2953
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2954
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2954
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…2955
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…2956
SAFETY…2963
GENERAL…2963
Safety Rules…2963
Safety Features…2963
Fire Extinguisher And First Aid Kit…2963
Clothing And Personal Items…2963
Leaving The Operator’s Seat…2964
Mounting And Dismounting…2964
Fire Prevention For Fuel And Oil…2964
Precautions With High Temperature Fluids…2965
Asbestos Dust Hazard Prevention…2965
Prevention Of Injury By Work Equipment…2965
Unauthorized Modification…2965
ROPS Precautions…2965
Precautions For Attachments…2966
Precautions For Starting The Truck…2966
PRECAUTIONS BEFORE OPERATION…2966
Safety At The Worksite…2966
Fire Prevention…2967
Ventilation In Enclosed Areas…2967
Preparing For Operation…2967
Mirrors, Windows And Lights…2967
In The Operator Cab (Before Starting The Engine)…2967
Seat Belts…2967
OPERATING THE TRUCK…2968
When Starting The Engine…2968
General Truck Operation…2968
Ensuring Good Visibility…2968
Traveling…2969
Traveling In Reverse…2969
Traveling On Slopes…2969
Operating On Snow Or Ice…2969
Avoid Damage To The Dump Body…2969
Driving Near High Voltage Cables…2970
Working On Loose Ground…2970
When Dumping…2970
When Loading…2970
Parking The Truck…2970
Towing…2970
WORKING NEAR BATTERIES…2971
Battery Hazard Prevention…2971
Starting With Booster Cables…2971
BEFORE PERFORMING MAINTENANCE…2972
Stopping The Engine…2972
Warning Tag…2972
Proper Tools…2972
Securing The Dump Body…2972
WHILE PERFORMING MAINTENANCE…2973
Keep The Truck Clean…2973
Attachments…2973
Working Under The Truck…2973
Rotating Fan And Belts…2973
Waste Materials…2973
Adding Fuel Or Oil…2974
Radiator Coolant Level…2974
Use Of Lighting…2974
Precautions With The Battery…2974
Handling High Pressure Hoses…2974
Precautions With High Pressure Oil…2974
Performing Maintenance Near High Temperature Or High Pressure…2974
TIRES…2975
Handling Tires…2975
Storing Tires After Removal…2975
WHEN REPAIRS ARE NECESSARY…2976
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…2977
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…2977
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…2977
CAPACITOR DISCHARGE SYSTEM…2979
Necessary Tools…2979
Warnings And Cautions…2980
Manual DC Link Capacitor Discharge Procedure…2981
Failure of the Discharge System…2983
Manual Discharge of Capacitors…2984
Short Isolated Capacitor Terminals…2986
ADDITIONAL JOB SITE RULES…2988
WARNINGS AND CAUTIONS…2989
GRADE/SPEED CHART…2989
KEY SWITCH…2989
ROPS/FOPS…2989
BATTERIES…2990
CAPACITORS…2990
CRUSHING HAZARD…2991
CYLINDER PRESSURE…2991
FILLING THE HYDRAULIC TANK…2992
HYDRAULIC OIL PRESSURE…2992
HOT OIL SPRAY…2993
WHEEL MOTOR OIL LEVEL…2993
HOT EXHAUST…2993
RADIATOR…2993
EMERGENCY LADDER…2993
ACCUMULATOR DRAIN VALVES…2993
EMERGENCY DUMP PROCEDURE…2994
EMERGENCY TOWING PROCEDURE…2994
WELDING…2994
EMERGENCY SHUTDOWN…2994
INFORMATION DISPLAY…2995
WIRELESS SIGNALS…2995
HIGH VOLTAGE…2995
LIFTING INSTRUCTIONS…2996
PRODUCT IDENTIFICATION PLATE…2997
LUBRICATION CHART…2998
OPERATING INSTRUCTIONS…2999
PREPARING FOR OPERATION…2999
WALK AROUND INSPECTION…2999
ENGINE START-UP…3003
AFTER ENGINE START-UP…3004
EMERGENCY STEERING SYSTEM…3004
Operation…3004
Pre-Operation Testing…3004
MACHINE OPERATION SAFETY PRECAUTIONS…3005
OPERATING ON THE HAUL ROAD…3006
STARTING ON A GRADE WITH A LOADED TRUCK…3007
PASSING…3007
LOADING…3007
Overload Speed Limit Function…3007
DUMPING…3008
Raising The Dump Body…3008
Lowering The Dump Body (When dumping on flat ground):…3009
Lowering The Dump Body (When dumping over a berm or into a crusher):…3009
TOWING…3010
SAFE PARKING PROCEDURES…3010
NORMAL ENGINE SHUTDOWN PROCEDURE…3011
SUDDEN LOSS OF ENGINE POWER…3011
FUEL DEPLETION…3012
DISABLED TRUCK DUMPING PROCEDURE…3012
Hookup…3012
Raising the Body…3013
Lowering the Body…3013
RESERVE ENGINE OIL SYSTEM…3014
Operation…3014
Changing Oil…3014
OPERATOR CAB AND CONTROLS…3015
STEERING WHEEL AND CONTROLS…3016
Horn Button…3016
Tilt / Telescope Lever…3016
Multi-Function Turn Signal Switch…3016
DYNAMIC RETARDING…3017
Retarder Lever…3017
Brake/Retarder Pedal…3017
Throttle/Accelerator Pedal…3017
GRADE/SPEED CHART…3018
OVERHEAD PANEL AND DISPLAYS…3019
CENTER CONSOLE…3020
Directional Control Lever…3020
Override/Fault Reset Switch…3021
Engine Shutdown Switch…3021
Window Control Switches…3021
Hoist Control Lever…3021
Retard Speed Control (RSC) Adjustment Dial…3022
Retard Speed Control (RSC) Switch…3022
Data Store Button…3023
KOMTRAX Plus Snapshot In Progress Light…3023
Link Energized Light…3023
Service Engine Light…3023
12V Auxiliary Power Outlets…3023
DIAGNOSTIC PORTS…3023
KOMTRAX Plus Diagnostic Port…3023
Interface Module (IM) Diagnostic Port…3023
Payload Meter Diagnostic Port…3023
Truck Control Interface (TCI) Diagnostic Port…3023
Propulsion System Controller (PSC) Diagnostic Port…3023
Engine Diagnostic Port (CENSE)…3023
Engine Diagnostic Port (QUANTUM)…3023
OPERATOR’S SEAT…3024
Seat Belts…3024
Adjustment…3024
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…3025
Fan Speed Control Knob…3025
Temperature Control Knob…3025
Air Flow Directional Knob…3025
Heater/Air Conditioner Vents…3025
INSTRUMENT PANEL…3026
Control Symbols…3026
Key Switch…3028
Engine Shutdown Timer Switch – 5 Minute Idle Delay…3028
Air Conditioner Compressor Switch…3028
Rotating Beacon Switch (optional)…3028
Heated Mirrors Switch (optional)…3028
AC Drive System Rest Switch…3029
Wheel Brake Lock Switch…3029
Hazard Warning Light Switch…3029
Heater/Air Conditioner Vents…3029
Engine Oil Pressure Gauge…3030
Right Turn Signal Indicator…3030
Digital Tachometer…3030
High Beam Indicator…3030
Speedometer/Payload Meter Display…3030
Left Turn Signal Indicator…3030
Coolant Temperature Gauge…3030
Lamp Check Switch…3030
Light Switch (3-Way)…3030
Ladder Light Switch…3031
Backup Light Switch…3031
Fog Light Switch…3031
Payload Meter Switch…3031
Panel Illumination Light Dimmer Switch…3031
Hydraulic Oil Temperature Gauge…3031
Engine Hourmeter…3031
Fuel Gauge…3031
OVERHEAD STATUS / WARNING INDICATORS…3032
A1. High Brake Oil Temperature…3033
B1. Low Steering Pressure…3033
C1. Low Accumulator Precharge Pressure…3034
D1. Not used…3034
E1. Low Brake Pressure…3034
A2. Low Hydraulic Tank Level…3034
B2. Low Automatic Lubrication System Pressure…3034
C2. Circuit Breaker Tripped…3034
D2. Hydraulic Oil Filter Monitor…3034
E2. Low Fuel…3035
A3. Parking Brake…3035
B3. Service Brake…3035
C3. Body Up…3035
D3. Dynamic Retarding…3035
E3. Stop Engine…3035
A4. Cranking Motor Failure…3035
B4. Backup Lights…3035
C4. Engine Shutdown Timer – 5 Minute Idle…3036
D4. Retard Speed Control (RSC) Indicator…3036
E4. Check Engine…3036
A5. No Power…3036
B5. Propulsion System Warning…3036
C5. Propulsion System Temperature…3036
D5. System/Component Failure…3036
E5. Battery Charging System Failure…3036
A6. No Propel…3037
B6. Propel System At Rest…3037
C6. Propel System Not Ready…3037
D6. Reduced Propulsion…3037
E6. Retard At Continuous Level…3037
REAR AXLE LIGHT BAR…3038
Backup Lights…3038
Retard Lights…3038
Brake Light…3038
Backup Alarm…3038
KOMTRAX PLUS…3039
Operation…3039
Interface Module…3041
Basic Precautions…3041
KOMATSU WIRELESS BRIDGE (Optional)…3042
General Information…3042
Communication Setup…3042
Switching to the KWB_SETUP Network…3042
Setting the Computer Subnet Mask and IP Address…3043
Properties…3043
Setting Up the KWB…3044
Adding Encryption…3044
Final Computer Settings…3044
Data Downloading…3045
Resetting the KWB…3045
KWB Lights…3045
FUSES AND CIRCUIT BREAKERS…3046
LUBRICATION AND SERVICE…3049
GENERAL…3049
SERVICE CAPACITIES…3049
HYDRAULIC TANK SERVICE…3049
Adding Oil…3049
COOLING SYSTEM SERVICE…3050
Radiator Filling Procedure…3050
Coolant Specifications…3050
Unacceptable Practices…3050
WHEEL MOTOR SERVICE…3050
RESERVE OIL TANK SERVICE…3051
Filling the Reserve Oil Tank (Remote Fill)…3051
Inline Screen…3051
QUICK FILL SERVICE CENTER…3052
LUBRICATION CHART…3053
10 HOUR (DAILY) INSPECTIONS…3054
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3056
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3056
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3056
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3059
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…3061
5000 HOUR MAINTENANCE CHECKS…3061
AUTOMATIC LUBRICATION SYSTEM…3063
GENERAL DESCRIPTION…3063
SYSTEM COMPONENTS…3065
Filter…3065
Hydraulic Motor and Pump…3065
Grease Reservoir…3065
Pressure Reducing Valve…3065
Flow Control Valve…3065
Solenoid Valve…3065
Vent Valve…3065
Lubrication Cycle Timer…3065
Over Pressure Cut Off Switch…3065
Grease Pressure Failure Switch…3065
Injectors…3065
Relief Valve (unloader valve)…3065
SYSTEM OPERATION…3066
Normal Operation…3066
GENERAL INSTRUCTIONS…3067
Lubricant Required For System…3067
System Priming…3067
Filter Assembly…3067
LUBRICANT PUMP…3068
Pump Housing Oil Level…3068
Pump Pressure Control…3068
INJECTORS (SL-1 Series “H”)…3069
Injector Specifications…3069
Injector Adjustment…3069
Injector Operation…3070
PREVENTIVE MAINTENANCE PROCEDURES…3071
Daily Lubrication System Inspection…3071
250 Hour Inspection…3071
1000 Hour Inspection…3071
SYSTEM CHECKOUT…3072
Lubrication Controller Check…3072
Lubrication Controller Components…3072
Lubrication Controller Adjustment…3072
SYSTEM TROUBLESHOOTING CHART…3074
COMPONENTS & SPECIFICATIONS…3077
MAJOR COMPONENT DESCRIPTIONS…3077
Truck And Engine…3077
Main Alternator…3077
AC Induction Traction Motorized Wheels…3077
Suspension…3077
Operator's Cab…3077
Power Steering…3077
Dynamic Retarding…3077
Brake System…3077
SPECIFICATIONS…3079
ENGINE…3079
AC ELECTRIC DRIVE SYSTEM…3079
DYNAMIC RETARDING…3079
BATTERY ELECTRIC SYSTEM…3079
SERVICE CAPACITIES…3079
HYDRAULIC SYSTEMS…3080
SERVICE BRAKES…3080
STEERING…3080
TIRES…3080
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…3080
WEIGHT DISTRIBUTION…3081
PAYLOAD METER III…3083
RADIO / CASSETTE PLAYER…3113
GENERAL RECEIVER FUNCTIONS…3113
Turning The Power On And Off…3113
Display…3113
Setting The Default Display…3113
Adjusting Display Brightness…3113
SETTING THE TIME…3114
OPERATING THE RADIO…3114
BAND…3114
TUNE/SEEK…3114
Manual Tuning…3114
SEEK Mode…3114
SCAN…3114
AUTO…3114
ADJUSTING THE RECEIVER SETTINGS…3115
PROGRAMMING PRESET STATIONS…3115
OPERATION OF THE WEATHERBAND (U.S.)…3115
SATELLITE RADIO…3116
Operating Satellite Radio…3116
Program Type Search (PTY)…3116
CASSETTE PLAYER…3117
Playing A Cassette…3117
Cassette Functions…3117
Programmable Eject Default…3117
Bad Tape Detect…3118
Cleaning The Cassette Player…3118
AM/FM RADIO / CD PLAYER…3119
GENERAL RADIO RECEIVER FUNCTIONS…3119
Turning On the Power…3119
One-Hour Timer…3119
Display…3120
Setting a Default Display…3120
Adjusting the Brightness of the Display…3120
Auxiliary Mode…3120
Adjusting the Receiver Settings…3120
USING THE CLOCK…3121
Setting the Clock…3121
USING THE ALARM…3121
Setting the Alarm…3121
Turning the Alarm Off…3121
Activating Snooze…3121
Setting Alarm Volume…3121
USING THE RADIO…3122
Finding a Station…3122
Setting the Presets…3122
USING THE WEATHERBAND…3123
USING THE COMPACT DISC PLAYER…3123
Playing a Compact Disc…3123
Button Functions…3123
PLAYING AN MP3 DISC…3124
MP3 Format Compatibility…3124
Root Directory…3124
Empty Directory or Folder…3124
No Folder…3124
File Name Display…3124
Pre-Programmed Playlists…3125
Playing MP3 Files…3125
Button Functions…3125
TROUBLESHOOTING…3126
CEAM019403 – Dump Truck 930E-4SE Operation & Maintenance Manual…3129
COVER…3129
INTRODUCTION…3133
FOREWORD…3133
TRUCK MODEL ILLUSTRATION…3134
ABOUT THIS MANUAL…3135
ALERTS PAGE…3136
TABLE OF CONTENTS…3137
TORQUE TABLES AND CONVERSION CHARTS…3147
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3148
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3148
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3149
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3150
SAFETY…3157
GENERAL…3157
Safety Rules…3157
Safety Features…3157
Fire Extinguisher And First Aid Kit…3157
Clothing And Personal Items…3157
Leaving The Operator’s Seat…3158
Mounting And Dismounting…3158
Fire Prevention For Fuel And Oil…3158
Precautions With High Temperature Fluids…3159
Asbestos Dust Hazard Prevention…3159
Prevention Of Injury By Work Equipment…3159
Unauthorized Modification…3159
ROPS Precautions…3159
Precautions For Attachments…3160
Precautions For Starting The Truck…3160
PRECAUTIONS BEFORE OPERATION…3160
Safety At The Worksite…3160
Fire Prevention…3161
Ventilation In Enclosed Areas…3161
Preparing For Operation…3161
Mirrors, Windows And Lights…3161
In The Operator Cab (Before Starting The Engine)…3161
Seat Belts…3161
OPERATING THE TRUCK…3162
When Starting The Engine…3162
General Truck Operation…3162
Ensuring Good Visibility…3162
Traveling…3163
Traveling In Reverse…3163
Traveling On Slopes…3163
Operating On Snow Or Ice…3163
Avoid Damage To The Dump Body…3163
Driving Near High Voltage Cables…3164
Working On Loose Ground…3164
When Dumping…3164
When Loading…3164
Parking The Truck…3164
Towing…3164
WORKING NEAR BATTERIES…3165
Battery Hazard Prevention…3165
Starting With Booster Cables…3165
BEFORE PERFORMING MAINTENANCE…3166
Stopping The Engine…3166
Warning Tag…3166
Proper Tools…3166
Securing The Dump Body…3166
WHILE PERFORMING MAINTENANCE…3167
Keep The Truck Clean…3167
Attachments…3167
Working Under The Truck…3167
Rotating Fan And Belts…3167
Waste Materials…3167
Adding Fuel Or Oil…3168
Radiator Coolant Level…3168
Use Of Lighting…3168
Precautions With The Battery…3168
Handling High Pressure Hoses…3168
Precautions With High Pressure Oil…3168
Performing Maintenance Near High Temperature Or High Pressure…3168
TIRES…3169
Handling Tires…3169
Storing Tires After Removal…3169
WHEN REPAIRS ARE NECESSARY…3170
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…3171
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…3171
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…3171
CAPACITOR DISCHARGE SYSTEM…3173
Necessary Tools…3173
Warnings And Cautions…3174
Manual DC Link Capacitor Discharge Procedure…3175
Failure of the Discharge System…3177
Manual Discharge of Capacitors…3178
Short Isolated Capacitor Terminals…3180
ADDITIONAL JOB SITE RULES…3182
WARNINGS AND CAUTIONS…3183
GRADE/SPEED CHART…3183
KEY SWITCH…3183
ROPS/FOPS…3183
BATTERIES…3184
CAPACITORS…3184
CRUSHING HAZARD…3185
CYLINDER PRESSURE…3185
FILLING THE HYDRAULIC TANK…3186
HYDRAULIC OIL PRESSURE…3186
HOT OIL SPRAY…3187
WHEEL MOTOR OIL LEVEL…3187
HOT EXHAUST…3187
RADIATOR…3187
EMERGENCY LADDER…3187
ACCUMULATOR DRAIN VALVES…3187
EMERGENCY DUMP PROCEDURE…3188
EMERGENCY TOWING PROCEDURE…3188
WELDING…3188
EMERGENCY SHUTDOWN…3188
INFORMATION DISPLAY…3189
WIRELESS SIGNALS…3189
HIGH VOLTAGE…3189
LIFTING INSTRUCTIONS…3190
PRODUCT IDENTIFICATION PLATE…3191
LUBRICATION CHART…3192
OPERATING INSTRUCTIONS…3193
PREPARING FOR OPERATION…3193
WALK AROUND INSPECTION…3193
ENGINE START-UP…3197
AFTER ENGINE START-UP…3198
PRE-SHIFT BRAKE CHECK (if equipped)…3198
Events…3198
OPERATION…3199
Description…3199
Brake Test Exit Criteria…3199
PERFORMING THE BRAKE TESTS…3200
Setup…3200
Service Brake Test…3200
Parking Brake Test…3201
Retard System Test…3202
EMERGENCY STEERING SYSTEM…3202
Operation…3202
Pre-Operation Testing…3202
MACHINE OPERATION SAFETY PRECAUTIONS…3203
OPERATING ON THE HAUL ROAD…3204
STARTING ON A GRADE WITH A LOADED TRUCK…3205
PASSING…3205
LOADING…3205
Overload Speed Limit Function…3205
DUMPING…3206
Raising The Dump Body…3206
Lowering The Dump Body (When dumping on flat ground)…3207
Lowering The Dump Body (When dumping over a berm or into a crusher)…3207
TOWING…3208
Special Wiring Harness…3208
SAFE PARKING PROCEDURES…3211
NORMAL ENGINE SHUTDOWN PROCEDURE…3211
SUDDEN LOSS OF ENGINE POWER…3212
FUEL DEPLETION…3212
DISABLED TRUCK DUMPING PROCEDURE…3213
Hookup…3213
Raising the Body…3213
Lowering the Body…3213
RESERVE ENGINE OIL SYSTEM…3214
Operation…3214
Changing Oil…3214
OPERATOR CAB AND CONTROLS…3215
STEERING WHEEL AND CONTROLS…3216
Horn Button…3216
Tilt / Telescope Lever…3216
Multi-Function Turn Signal Switch…3216
DYNAMIC RETARDING…3217
Retarder Lever…3217
Brake/Retarder Pedal…3217
Throttle/Accelerator Pedal…3217
GRADE/SPEED CHART…3218
OVERHEAD PANEL AND DISPLAYS…3219
CENTER CONSOLE…3220
Directional Control Lever…3220
Override/Fault Reset Switch…3221
Engine Shutdown Switch…3221
Window Control Switches…3221
Hoist Control Lever…3221
Retard Speed Control (RSC) Adjustment Dial…3222
Retard Speed Control (RSC) Switch…3222
Data Store Button…3223
KOMTRAX Plus Snapshot In Progress Light…3223
Link Energized Light…3223
Service Engine Light…3223
12V Auxiliary Power Outlets…3223
DIAGNOSTIC PORTS…3223
KOMTRAX Plus Diagnostic Port…3223
Interface Module (IM) Diagnostic Port…3223
Payload Meter Diagnostic Port…3223
Truck Control Interface (TCI) Diagnostic Port…3223
Propulsion System Controller (PSC) Diagnostic Port…3223
Engine Diagnostic Port (CENSE)…3223
Engine Diagnostic Port (QUANTUM)…3223
OPERATOR’S SEAT…3224
Seat Belts…3224
Adjustment…3224
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…3225
Fan Control Knob…3225
Temperature Control Knob…3225
Directional Control Knob…3225
Heater Vents…3225
INSTRUMENT PANEL…3226
Control Symbols…3226
Key Switch…3228
Air Conditioner Compressor Switch…3228
Rotating Beacon Switch (optional)…3228
Heated Mirrors Switch (optional)…3228
AC Drive System Rest Switch…3228
Wheel Brake Lock Switch…3229
Hazard Warning Lights…3229
Heater/Air Conditioner Vents…3229
Engine Oil Pressure Gauge…3229
Right Turn Signal Indicator…3229
Digital Tachometer…3229
High Beam Indicator…3229
Speedometer/Payload Meter Display…3229
Left Turn Signal Indicator…3230
Coolant Temperature Gauge…3230
Lamp Check Switch…3230
Light Switch (3-Way)…3230
Ladder Light Switch…3230
Backup Light Switch…3230
Fog Light Switch…3231
Payload Meter Switch…3231
Panel Illumination Light Dimmer Switch…3231
Hydraulic Oil Temperature Gauge…3231
Engine Hourmeter…3231
Fuel Gauge…3231
OVERHEAD STATUS / WARNING INDICATORS…3232
A1. High Brake Oil Temperature…3233
B1. Low Steering Pressure…3233
C1. Low Accumulator Precharge Pressure…3234
D1. Not used…3234
E1. Low Brake Pressure…3234
A2. Low Hydraulic Tank Level…3234
B2. Low Automatic Lubrication System Pressure…3234
C2. Circuit Breaker Tripped…3234
D2. Hydraulic Oil Filter Monitor…3234
E2. Low Fuel…3235
A3. Parking Brake…3235
B3. Service Brake…3235
C3. Body Up…3235
D3. Dynamic Retarding…3235
E3. Stop Engine…3235
A4. Cranking Motor Failure…3236
B4. Backup Lights…3236
C4. Engine Shutdown Timer…3236
D4. Retard Speed Control (RSC) Indicator…3236
E4. Check Engine…3236
A5. No Power…3236
B5. Propulsion System Warning…3236
C5. Propulsion System Temperature…3236
D5. System/Component Failure…3237
A6. No Propel…3237
B6. Propulsion System At Rest…3237
C6. Propulsion System Not Ready…3237
D6. Reduced Propulsion…3237
E6. Retard At Continuous Level…3237
REAR AXLE LIGHT BAR…3238
Backup Lights…3238
Retard Lights…3238
Brake Light…3238
Backup Alarm…3238
KOMTRAX PLUS…3239
Operation…3239
Interface Module…3241
Basic Precautions…3241
KOMATSU WIRELESS BRIDGE (Optional)…3242
General Information…3242
Communication Setup…3242
Switching to the KWB_SETUP Network…3242
Setting the Computer Subnet Mask and IP Address…3243
Properties…3243
Setting Up the KWB…3244
Adding Encryption…3244
Final Computer Settings…3244
Data Downloading…3245
Resetting the KWB…3245
KWB Lights…3245
FUSES AND CIRCUIT BREAKERS…3246
LUBRICATION AND SERVICE…3249
GENERAL…3249
SERVICE CAPACITIES…3249
HYDRAULIC TANK SERVICE…3249
Adding Oil…3249
COOLING SYSTEM SERVICE…3250
Radiator Filling Procedure…3250
Coolant Specifications…3250
Unacceptable Practices…3250
WHEEL MOTOR SERVICE…3250
RESERVE OIL TANK SERVICE…3251
Filling the Reserve Oil Tank (Remote Fill)…3251
Inline Screen…3251
QUICK FILL SERVICE CENTER…3252
LUBRICATION CHART…3253
10 HOUR (DAILY) INSPECTIONS…3254
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3256
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3256
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3256
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3259
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…3261
5000 HOUR MAINTENANCE CHECKS…3261
AUTOMATIC LUBRICATION SYSTEM…3263
GENERAL DESCRIPTION…3263
SYSTEM COMPONENTS…3265
Filter…3265
Hydraulic Motor and Pump…3265
Grease Reservoir…3265
Pressure Reducing Valve…3265
Flow Control Valve…3265
Solenoid Valve…3265
Vent Valve…3265
Lubrication Cycle Timer…3265
Over Pressure Cut Off Switch…3265
Grease Pressure Failure Switch…3265
Injectors…3265
Relief Valve (unloader valve)…3265
SYSTEM OPERATION…3266
Normal Operation…3266
GENERAL INSTRUCTIONS…3267
Lubricant Required For System…3267
System Priming…3267
Filter Assembly…3267
LUBRICANT PUMP…3268
Pump Housing Oil Level…3268
Pump Pressure Control…3268
INJECTORS (SL-1 Series “H”)…3269
Injector Specifications…3269
Injector Adjustment…3269
Injector Operation…3270
PREVENTIVE MAINTENANCE PROCEDURES…3271
Daily Lubrication System Inspection…3271
250 Hour Inspection…3271
1000 Hour Inspection…3271
SYSTEM CHECKOUT…3272
Lubrication Controller Check…3272
Lubrication Controller Components…3272
Lubrication Controller Adjustment…3272
SYSTEM TROUBLESHOOTING CHART…3274
COMPONENTS & SPECIFICATIONS…3277
MAJOR COMPONENT DESCRIPTIONS…3277
Truck And Engine…3277
Main Alternator…3277
AC Induction Traction Motorized Wheels…3277
Suspension…3277
Operator's Cab…3277
Power Steering…3277
Dynamic Retarding…3277
Brake System…3277
SPECIFICATIONS…3279
ENGINE…3279
AC ELECTRIC DRIVE SYSTEM…3279
DYNAMIC RETARDING…3279
BATTERY ELECTRIC SYSTEM…3279
SERVICE CAPACITIES…3279
HYDRAULIC SYSTEMS…3280
SERVICE BRAKES…3280
STEERING…3280
TIRES…3280
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…3280
WEIGHT DISTRIBUTION…3281
PAYLOAD METER III…3283
AM/FM RADIO / CD PLAYER…3313
GENERAL RADIO RECEIVER FUNCTIONS…3313
Turning On the Power…3313
One-Hour Timer…3313
Display…3314
Setting a Default Display…3314
Adjusting the Brightness of the Display…3314
Auxiliary Mode…3314
Adjusting the Receiver Settings…3314
USING THE CLOCK…3315
Setting the Clock…3315
USING THE ALARM…3315
Setting the Alarm…3315
Turning the Alarm Off…3315
Activating Snooze…3315
Setting Alarm Volume…3315
USING THE RADIO…3316
Finding a Station…3316
Setting the Presets…3316
USING THE WEATHERBAND…3317
USING THE COMPACT DISC PLAYER…3317
Playing a Compact Disc…3317
Button Functions…3317
PLAYING AN MP3 DISC…3318
MP3 Format Compatibility…3318
Root Directory…3318
Empty Directory or Folder…3318
No Folder…3318
File Name Display…3318
Pre-Programmed Playlists…3319
Playing MP3 Files…3319
Button Functions…3319
TROUBLESHOOTING…3320
CEAM019604 – Dump Truck 930E-4 Operation & Maintenance Manual…3323
COVER…3323
INTRODUCTION…3327
FOREWORD…3327
TRUCK MODEL ILLUSTRATION…3328
ABOUT THIS MANUAL…3329
ALERTS PAGE…3330
TABLE OF CONTENTS…3331
TORQUE TABLES AND CONVERSION CHARTS…3341
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3342
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3342
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3343
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3344
SAFETY…3351
GENERAL…3351
Safety Rules…3351
Safety Features…3351
Fire Extinguisher And First Aid Kit…3351
Clothing And Personal Items…3351
Leaving The Operator’s Seat…3352
Mounting And Dismounting…3352
Fire Prevention For Fuel And Oil…3352
Precautions With High Temperature Fluids…3353
Asbestos Dust Hazard Prevention…3353
Prevention Of Injury By Work Equipment…3353
Unauthorized Modification…3353
ROPS Precautions…3353
Precautions For Attachments…3354
Precautions For Starting The Truck…3354
PRECAUTIONS BEFORE OPERATION…3354
Safety At The Worksite…3354
Fire Prevention…3355
Ventilation In Enclosed Areas…3355
Preparing For Operation…3355
Mirrors, Windows And Lights…3355
In The Operator Cab (Before Starting The Engine)…3355
Seat Belts…3355
OPERATING THE TRUCK…3356
When Starting The Engine…3356
General Truck Operation…3356
Ensuring Good Visibility…3356
Traveling…3357
Traveling In Reverse…3357
Traveling On Slopes…3357
Operating On Snow Or Ice…3357
Avoid Damage To The Dump Body…3357
Driving Near High Voltage Cables…3358
Working On Loose Ground…3358
When Dumping…3358
When Loading…3358
Parking The Truck…3358
Towing…3358
WORKING NEAR BATTERIES…3359
Battery Hazard Prevention…3359
Starting With Booster Cables…3359
BEFORE PERFORMING MAINTENANCE…3360
Stopping The Engine…3360
Warning Tag…3360
Proper Tools…3360
Securing The Dump Body…3360
WHILE PERFORMING MAINTENANCE…3361
Keep The Truck Clean…3361
Attachments…3361
Working Under The Truck…3361
Rotating Fan And Belts…3361
Waste Materials…3361
Adding Fuel Or Oil…3362
Radiator Coolant Level…3362
Use Of Lighting…3362
Precautions With The Battery…3362
Handling High Pressure Hoses…3362
Precautions With High Pressure Oil…3362
Performing Maintenance Near High Temperature Or High Pressure…3362
TIRES…3363
Handling Tires…3363
Storing Tires After Removal…3363
WHEN REPAIRS ARE NECESSARY…3364
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…3365
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…3365
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…3365
CAPACITOR DISCHARGE SYSTEM…3367
Necessary Tools…3367
Warnings And Cautions…3368
Manual DC Link Capacitor Discharge Procedure…3369
Failure of the Discharge System…3371
Manual Discharge of Capacitors…3372
Short Isolated Capacitor Terminals…3374
ADDITIONAL JOB SITE RULES…3376
WARNINGS AND CAUTIONS…3377
GRADE/SPEED CHART…3377
KEY SWITCH…3377
ROPS/FOPS…3377
BATTERIES…3378
CAPACITORS…3378
CRUSHING HAZARD…3379
CYLINDER PRESSURE…3379
FILLING THE HYDRAULIC TANK…3380
HYDRAULIC OIL PRESSURE…3380
HOT OIL SPRAY…3381
WHEEL MOTOR OIL LEVEL…3381
HOT EXHAUST…3381
RADIATOR…3381
EMERGENCY LADDER…3381
ACCUMULATOR DRAIN VALVES…3381
EMERGENCY DUMP PROCEDURE…3382
EMERGENCY TOWING PROCEDURE…3382
WELDING…3382
EMERGENCY SHUTDOWN…3382
INFORMATION DISPLAY…3383
WIRELESS SIGNALS…3383
HIGH VOLTAGE…3383
LIFTING INSTRUCTIONS…3384
PRODUCT IDENTIFICATION PLATE…3385
LUBRICATION CHART…3386
OPERATING INSTRUCTIONS…3387
PREPARING FOR OPERATION…3387
WALK AROUND INSPECTION…3387
ENGINE START-UP…3391
AFTER ENGINE START-UP…3392
PRE-SHIFT BRAKE CHECK (if equipped)…3392
Events…3392
OPERATION…3393
Description…3393
Brake Test Exit Criteria…3393
PERFORMING THE BRAKE TESTS…3394
Setup…3394
Service Brake Test…3394
Parking Brake Test…3395
Retard System Test…3396
EMERGENCY STEERING SYSTEM…3396
Operation…3396
Pre-Operation Testing…3396
MACHINE OPERATION SAFETY PRECAUTIONS…3397
OPERATING ON THE HAUL ROAD…3398
STARTING ON A GRADE WITH A LOADED TRUCK…3399
PASSING…3399
LOADING…3399
Overload Speed Limit Function…3399
DUMPING…3400
Raising The Dump Body…3400
Lowering The Dump Body (When dumping on flat ground)…3401
Lowering The Dump Body (When dumping over a berm or into a crusher)…3401
TOWING…3402
Special Wiring Harness…3402
SAFE PARKING PROCEDURES…3405
NORMAL ENGINE SHUTDOWN PROCEDURE…3405
SUDDEN LOSS OF ENGINE POWER…3406
FUEL DEPLETION…3406
DISABLED TRUCK DUMPING PROCEDURE…3407
Hookup…3407
Raising the Body…3407
Lowering the Body…3407
RESERVE ENGINE OIL SYSTEM…3408
Operation…3408
Changing Oil…3408
OPERATOR CAB AND CONTROLS…3409
STEERING WHEEL AND CONTROLS…3410
Horn Button…3410
Tilt / Telescope Lever…3410
Multi-Function Turn Signal Switch…3410
DYNAMIC RETARDING…3411
Retarder Lever…3411
Brake/Retarder Pedal…3411
Throttle/Accelerator Pedal…3411
GRADE/SPEED CHART…3412
OVERHEAD PANEL AND DISPLAYS…3413
CENTER CONSOLE…3414
Directional Control Lever…3414
Override/Fault Reset Switch…3415
Engine Shutdown Switch…3415
Window Control Switches…3415
Hoist Control Lever…3415
Retard Speed Control (RSC) Adjustment Dial…3416
Retard Speed Control (RSC) Switch…3416
Data Store Button…3417
KOMTRAX Plus Snapshot In Progress Light…3417
Link Energized Light…3417
Service Engine Light…3417
12V Auxiliary Power Outlets…3417
DIAGNOSTIC PORTS…3417
KOMTRAX Plus Diagnostic Port…3417
Interface Module (IM) Diagnostic Port…3417
Payload Meter Diagnostic Port…3417
Truck Control Interface (TCI) Diagnostic Port…3417
Propulsion System Controller (PSC) Diagnostic Port…3417
Engine Diagnostic Port (CENSE)…3417
Engine Diagnostic Port (QUANTUM)…3417
OPERATOR’S SEAT…3418
Seat Belts…3418
Adjustment…3418
HEATER / AIR CONDITIONER CONTROLS…3419
Fan Speed Control Knob…3419
Temperature Control Knob…3419
Air Flow Directional Knob…3419
Heater/Air Conditioner Vents…3419
INSTRUMENT PANEL…3420
Control Symbols…3420
Key Switch…3422
Air Conditioner Compressor Switch…3422
Rotating Beacon Light Switch (optional)…3422
Heated Mirror Switch (optional)…3422
AC Drive System Rest Switch…3422
Wheel Brake Lock Switch…3423
Hazard Warning Light Switch…3423
Heater/Air Conditioner Vents…3423
Engine Oil Pressure Gauge…3423
Right Turn Signal Indicator…3423
Digital Tachometer…3423
High Beam Indicator…3423
Speedometer/Payload Meter Display…3423
Left Turn Signal Indicator…3424
Coolant Temperature Gauge…3424
Lamp Check Switch…3424
Light Switch (3-Way)…3424
Ladder Light Switch…3424
Backup Light Switch…3424
Fog Light Switch…3425
Payload Meter Switch…3425
Panel Illumination Light Dimmer Switch…3425
Hydraulic Oil Temperature Gauge…3425
Engine Hourmeter…3425
Fuel Gauge…3425
OVERHEAD STATUS / WARNING INDICATORS…3426
A1. High Brake Oil Temperature…3427
B1. Low Steering Pressure…3427
C1. Low Accumulator Precharge Pressure…3428
D1. Not used…3428
E1. Low Brake Pressure…3428
A2. Low Hydraulic Tank Level…3428
B2. Low Automatic Lubrication System Pressure…3428
C2. Circuit Breaker Tripped…3428
D2. Hydraulic Oil Filter Monitor…3429
E2. Low Fuel…3429
A3. Parking Brake…3429
B3. Service Brake…3429
C3. Body Up…3429
D3. Dynamic Retarding…3429
E3. Stop Engine…3429
A4. Cranking Motor Failure…3430
B4. Backup Lights…3430
C4. Engine Shutdown Timer…3430
D4. Retard Speed Control (RSC) Indicator…3430
E4. Check Engine…3430
A5. No Power…3430
B5. Propulsion System Warning…3430
C5. Propulsion System Temperature…3430
D5. System/Component Failure…3431
E5. Battery Charging System Failure…3431
A6. No Propel…3431
B6. Propel System At Rest…3431
C6. Propel System Not Ready…3431
D6. Reduced Propulsion…3431
E6. Retard At Continuous Level…3431
REAR AXLE LIGHT BAR…3432
Backup Lights…3432
Retard Lights…3432
Brake Lights…3432
Backup Alarm…3432
KOMTRAX PLUS…3433
Operation…3433
Interface Module…3435
Basic Precautions…3435
KOMATSU WIRELESS BRIDGE (Optional)…3436
General Information…3436
Communication Setup…3436
Switching to the KWB_SETUP Network…3436
Setting the Computer Subnet Mask and IP Address…3437
Properties…3437
Setting Up the KWB…3438
Adding Encryption…3438
Final Computer Settings…3438
Data Downloading…3439
Resetting the KWB…3439
KWB Lights…3439
FUSES AND CIRCUIT BREAKERS…3440
LUBRICATION AND SERVICE…3443
GENERAL…3443
SERVICE CAPACITIES…3443
HYDRAULIC TANK SERVICE…3443
Adding Oil…3443
COOLING SYSTEM SERVICE…3444
Radiator Filling Procedure…3444
Coolant Specifications…3444
Unacceptable Practices…3444
WHEEL MOTOR SERVICE…3444
RESERVE OIL TANK SERVICE…3445
Filling the Reserve Oil Tank (Remote Fill)…3445
Inline Screen…3445
QUICK FILL SERVICE CENTER…3446
LUBRICATION CHART…3447
10 HOUR (DAILY) INSPECTIONS…3448
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3450
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3450
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3450
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3453
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…3455
5000 HOUR MAINTENANCE CHECKS…3455
AUTOMATIC LUBRICATION SYSTEM…3457
GENERAL DESCRIPTION…3457
SYSTEM COMPONENTS…3459
Filter…3459
Hydraulic Motor and Pump…3459
Grease Reservoir…3459
Pressure Reducing Valve…3459
Flow Control Valve…3459
Solenoid Valve…3459
Vent Valve…3459
Lubrication Cycle Timer…3459
Over Pressure Cut Off Switch…3459
Grease Pressure Failure Switch…3459
Injectors…3459
Relief Valve (unloader valve)…3459
SYSTEM OPERATION…3460
Normal Operation…3460
GENERAL INSTRUCTIONS…3461
Lubricant Required For System…3461
System Priming…3461
Filter Assembly…3461
LUBRICANT PUMP…3462
Pump Housing Oil Level…3462
Pump Pressure Control…3462
INJECTORS (SL-1 Series “H”)…3463
Injector Specifications…3463
Injector Adjustment…3463
Injector Operation…3464
PREVENTIVE MAINTENANCE PROCEDURES…3465
Daily Lubrication System Inspection…3465
250 Hour Inspection…3465
1000 Hour Inspection…3465
SYSTEM CHECKOUT…3466
Lubrication Controller Check…3466
Lubrication Controller Components…3466
Lubrication Controller Adjustment…3466
SYSTEM TROUBLESHOOTING CHART…3468
COMPONENTS & SPECIFICATIONS…3471
MAJOR COMPONENT DESCRIPTIONS…3471
Truck And Engine…3471
Main Alternator…3471
AC Induction Traction Motorized Wheels…3471
Suspension…3471
Operator's Cab…3471
Power Steering…3471
Dynamic Retarding…3471
Brake System…3471
SPECIFICATIONS…3473
ENGINE…3473
AC ELECTRIC DRIVE SYSTEM…3473
DYNAMIC RETARDING…3473
BATTERY ELECTRIC SYSTEM…3473
SERVICE CAPACITIES…3473
HYDRAULIC SYSTEMS…3474
SERVICE BRAKES…3474
STEERING…3474
TIRES…3474
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…3474
WEIGHT DISTRIBUTION…3475
PAYLOAD METER III…3477
AM/FM RADIO / CD PLAYER…3507
GENERAL RADIO RECEIVER FUNCTIONS…3507
Turning On the Power…3507
One-Hour Timer…3507
Display…3508
Setting a Default Display…3508
Adjusting the Brightness of the Display…3508
Auxiliary Mode…3508
Adjusting the Receiver Settings…3508
USING THE CLOCK…3509
Setting the Clock…3509
USING THE ALARM…3509
Setting the Alarm…3509
Turning the Alarm Off…3509
Activating Snooze…3509
Setting Alarm Volume…3509
USING THE RADIO…3510
Finding a Station…3510
Setting the Presets…3510
USING THE WEATHERBAND…3511
USING THE COMPACT DISC PLAYER…3511
Playing a Compact Disc…3511
Button Functions…3511
PLAYING AN MP3 DISC…3512
MP3 Format Compatibility…3512
Root Directory…3512
Empty Directory or Folder…3512
No Folder…3512
File Name Display…3512
Pre-Programmed Playlists…3513
Playing MP3 Files…3513
Button Functions…3513
TROUBLESHOOTING…3514
CEAM020205 – Dump Truck 930E-4 Operation & Maintenance Manual…3517
COVER…3517
INTRODUCTION…3521
FOREWORD…3521
TRUCK MODEL ILLUSTRATION…3522
ABOUT THIS MANUAL…3523
ALERTS PAGE…3524
TABLE OF CONTENTS…3525
TORQUE TABLES AND CONVERSION CHARTS…3535
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3536
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3536
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3537
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3538
SAFETY…3545
GENERAL…3545
Safety Rules…3545
Safety Features…3545
Fire Extinguisher And First Aid Kit…3545
Clothing And Personal Items…3545
Leaving The Operator’s Seat…3546
Mounting And Dismounting…3546
Fire Prevention For Fuel And Oil…3546
Precautions With High Temperature Fluids…3547
Asbestos Dust Hazard Prevention…3547
Prevention Of Injury By Work Equipment…3547
Unauthorized Modification…3547
ROPS Precautions…3547
Precautions For Attachments…3548
Precautions For Starting The Truck…3548
PRECAUTIONS BEFORE OPERATION…3548
Safety At The Worksite…3548
Fire Prevention…3549
Ventilation In Enclosed Areas…3549
Preparing For Operation…3549
Mirrors, Windows And Lights…3549
In The Operator Cab (Before Starting The Engine)…3549
Seat Belts…3549
OPERATING THE TRUCK…3550
When Starting The Engine…3550
General Truck Operation…3550
Ensuring Good Visibility…3550
Traveling…3551
Traveling In Reverse…3551
Traveling On Slopes…3551
Operating On Snow Or Ice…3551
Avoid Damage To The Dump Body…3551
Driving Near High Voltage Cables…3552
Working On Loose Ground…3552
When Dumping…3552
When Loading…3552
Parking The Truck…3552
Towing…3552
WORKING NEAR BATTERIES…3553
Battery Hazard Prevention…3553
Starting With Booster Cables…3553
BEFORE PERFORMING MAINTENANCE…3554
Stopping The Engine…3554
Warning Tag…3554
Proper Tools…3554
Securing The Dump Body…3554
WHILE PERFORMING MAINTENANCE…3555
Keep The Truck Clean…3555
Attachments…3555
Working Under The Truck…3555
Rotating Fan And Belts…3555
Waste Materials…3555
Adding Fuel Or Oil…3556
Radiator Coolant Level…3556
Use Of Lighting…3556
Precautions With The Battery…3556
Handling High Pressure Hoses…3556
Precautions With High Pressure Oil…3556
Performing Maintenance Near High Temperature Or High Pressure…3556
TIRES…3557
Handling Tires…3557
Storing Tires After Removal…3557
WHEN REPAIRS ARE NECESSARY…3558
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…3559
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…3559
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…3559
CAPACITOR DISCHARGE SYSTEM…3561
Necessary Tools…3561
Warnings And Cautions…3562
Manual DC Link Capacitor Discharge Procedure…3563
Failure of the Discharge System…3565
Manual Discharge of Capacitors…3566
Short Isolated Capacitor Terminals…3568
ADDITIONAL JOB SITE RULES…3570
WARNINGS AND CAUTIONS…3571
GRADE/SPEED CHART…3571
KEY SWITCH…3571
ROPS/FOPS…3571
BATTERIES…3572
CAPACITORS…3572
CRUSHING HAZARD…3573
CYLINDER PRESSURE…3573
FILLING THE HYDRAULIC TANK…3574
HYDRAULIC OIL PRESSURE…3574
HOT OIL SPRAY…3575
WHEEL MOTOR OIL LEVEL…3575
HOT EXHAUST…3575
RADIATOR…3575
EMERGENCY LADDER…3575
ACCUMULATOR DRAIN VALVES…3575
EMERGENCY DUMP PROCEDURE…3576
EMERGENCY TOWING PROCEDURE…3576
WELDING…3576
EMERGENCY SHUTDOWN…3576
INFORMATION DISPLAY…3577
WIRELESS SIGNALS…3577
HIGH VOLTAGE…3577
LIFTING INSTRUCTIONS…3578
PRODUCT IDENTIFICATION PLATE…3579
LUBRICATION CHART…3580
OPERATING INSTRUCTIONS…3581
PREPARING FOR OPERATION…3581
WALK AROUND INSPECTION…3581
ENGINE START-UP…3585
AFTER ENGINE START-UP…3586
PRE-SHIFT BRAKE CHECK (if equipped)…3586
Events…3586
OPERATION…3587
Description…3587
Brake Test Exit Criteria…3587
PERFORMING THE BRAKE TESTS…3588
Setup…3588
Service Brake Test…3588
Parking Brake Test…3589
Retard System Test…3590
EMERGENCY STEERING SYSTEM…3590
Operation…3590
Pre-Operation Testing…3590
MACHINE OPERATION SAFETY PRECAUTIONS…3591
OPERATING ON THE HAUL ROAD…3592
STARTING ON A GRADE WITH A LOADED TRUCK…3593
PASSING…3593
LOADING…3593
Overload Speed Limit Function…3593
DUMPING…3594
Raising The Dump Body…3594
Lowering The Dump Body (When dumping on flat ground)…3595
Lowering The Dump Body (When dumping over a berm or into a crusher)…3595
TOWING…3596
Special Wiring Harness…3596
SAFE PARKING PROCEDURES…3599
NORMAL ENGINE SHUTDOWN PROCEDURE…3599
SUDDEN LOSS OF ENGINE POWER…3600
FUEL DEPLETION…3600
DISABLED TRUCK DUMPING PROCEDURE…3601
Hookup…3601
Raising the Body…3601
Lowering the Body…3601
RESERVE ENGINE OIL SYSTEM…3602
Operation…3602
Changing Oil…3602
OPERATOR CAB AND CONTROLS…3603
STEERING WHEEL AND CONTROLS…3604
Horn Button…3604
Tilt / Telescope Lever…3604
Multi-Function Turn Signal Switch…3604
DYNAMIC RETARDING…3605
Retarder Lever…3605
Brake/Retarder Pedal…3605
Throttle/Accelerator Pedal…3605
GRADE/SPEED CHART…3606
OVERHEAD PANEL AND DISPLAYS…3607
CENTER CONSOLE…3608
Directional Control Lever…3608
Override/Fault Reset Switch…3609
Engine Shutdown Switch…3609
Window Control Switches…3609
Hoist Control Lever…3609
Retard Speed Control (RSC) Adjustment Dial…3610
Retard Speed Control (RSC) Switch…3610
Data Store Button…3611
KOMTRAX Plus Snapshot In Progress Light…3611
Link Energized Light…3611
Service Engine Light…3611
12V Auxiliary Power Outlets…3611
DIAGNOSTIC PORTS…3611
KOMTRAX Plus Diagnostic Port…3611
Interface Module (IM) Diagnostic Port…3611
Payload Meter Diagnostic Port…3611
Truck Control Interface (TCI) Diagnostic Port…3611
Propulsion System Controller (PSC) Diagnostic Port…3611
Engine Diagnostic Port (CENSE)…3611
Engine Diagnostic Port (QUANTUM)…3611
OPERATOR’S SEAT…3612
Seat Belts…3612
Adjustment…3612
HEATER / AIR CONDITIONER CONTROLS…3613
Fan Speed Control Knob…3613
Temperature Control Knob…3613
Air Flow Directional Knob…3613
Heater/Air Conditioner Vents…3613
INSTRUMENT PANEL…3614
Control Symbols…3614
Key Switch…3616
Rotating Beacon Light Switch (optional)…3616
Heated Mirror Switch (optional)…3616
AC Drive System Rest Switch…3616
Wheel Brake Lock Switch…3617
Hazard Warning Light Switch…3617
Heater/Air Conditioner Vents…3617
Engine Oil Pressure Gauge…3617
Right Turn Signal Indicator…3617
Digital Tachometer…3617
High Beam Indicator…3617
Speedometer/Payload Meter Display…3617
Left Turn Signal Indicator…3618
Coolant Temperature Gauge…3618
Lamp Check Switch…3618
Light Switch (3-Way)…3618
Ladder Light Switch…3618
Backup Light Switch…3618
Fog Light Switch…3619
Payload Meter Switch…3619
Panel Illumination Light Dimmer Switch…3619
Hydraulic Oil Temperature Gauge…3619
Engine Hourmeter…3619
Fuel Gauge…3619
OVERHEAD STATUS / WARNING INDICATORS…3620
A1. High Brake Oil Temperature…3621
B1. Low Steering Pressure…3621
C1. Low Accumulator Precharge Pressure…3622
D1. Not used…3622
E1. Low Brake Pressure…3622
A2. Low Hydraulic Tank Level…3622
B2. Low Automatic Lubrication System Pressure…3622
C2. Circuit Breaker Tripped…3622
D2. Hydraulic Oil Filter Monitor…3623
E2. Low Fuel…3623
A3. Parking Brake…3623
B3. Service Brake…3623
C3. Body Up…3623
D3. Dynamic Retarding…3623
E3. Stop Engine…3623
A4. Cranking Motor Failure…3624
B4. Backup Lights…3624
C4. Engine Shutdown Timer…3624
D4. Retard Speed Control (RSC) Indicator…3624
E4. Check Engine…3624
A5. No Power…3624
B5. Propulsion System Warning…3624
C5. Propulsion System Temperature…3624
D5. System/Component Failure…3625
E5. Battery Charging System Failure…3625
A6. No Propel…3625
B6. Propel System At Rest…3625
C6. Propel System Not Ready…3625
D6. Reduced Propulsion…3625
E6. Retard At Continuous Level…3625
REAR AXLE LIGHT BAR…3626
Backup Lights…3626
Retard Lights…3626
Brake Lights…3626
Backup Alarm…3626
KOMTRAX PLUS…3627
Operation…3627
Interface Module…3629
Basic Precautions…3629
KOMATSU WIRELESS BRIDGE (Optional)…3630
General Information…3630
Communication Setup…3630
Switching to the KWB_SETUP Network…3630
Setting the Computer Subnet Mask and IP Address…3631
Properties…3631
Setting Up the KWB…3632
Adding Encryption…3632
Final Computer Settings…3632
Data Downloading…3633
Resetting the KWB…3633
KWB Lights…3633
FUSES AND CIRCUIT BREAKERS…3634
LUBRICATION AND SERVICE…3637
GENERAL…3637
SERVICE CAPACITIES…3637
HYDRAULIC TANK SERVICE…3637
Adding Oil…3637
COOLING SYSTEM SERVICE…3638
Radiator Filling Procedure…3638
Coolant Specifications…3638
Unacceptable Practices…3638
WHEEL MOTOR SERVICE…3638
RESERVE OIL TANK SERVICE…3639
Filling the Reserve Oil Tank (Remote Fill)…3639
Inline Screen…3639
QUICK FILL SERVICE CENTER…3640
LUBRICATION CHART…3641
10 HOUR (DAILY) INSPECTIONS…3642
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3644
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3644
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3644
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3647
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…3649
5000 HOUR MAINTENANCE CHECKS…3649
AUTOMATIC LUBRICATION SYSTEM…3651
GENERAL DESCRIPTION…3651
SYSTEM COMPONENTS…3653
Filter…3653
Hydraulic Motor and Pump…3653
Grease Reservoir…3653
Pressure Reducing Valve…3653
Flow Control Valve…3653
Solenoid Valve…3653
Vent Valve…3653
Lubrication Cycle Timer…3653
Over Pressure Cut Off Switch…3653
Grease Pressure Failure Switch…3653
Injectors…3653
Relief Valve (unloader valve)…3653
SYSTEM OPERATION…3654
Normal Operation…3654
GENERAL INSTRUCTIONS…3655
Lubricant Required For System…3655
System Priming…3655
Filter Assembly…3655
LUBRICANT PUMP…3656
Pump Housing Oil Level…3656
Pump Pressure Control…3656
INJECTORS (SL-1 Series “H”)…3657
Injector Specifications…3657
Injector Adjustment…3657
Injector Operation…3658
PREVENTIVE MAINTENANCE PROCEDURES…3659
Daily Lubrication System Inspection…3659
250 Hour Inspection…3659
1000 Hour Inspection…3659
SYSTEM CHECKOUT…3660
Lubrication Controller Check…3660
Lubrication Controller Components…3660
Lubrication Controller Adjustment…3660
SYSTEM TROUBLESHOOTING CHART…3662
COMPONENTS & SPECIFICATIONS…3665
MAJOR COMPONENT DESCRIPTIONS…3665
Truck And Engine…3665
Main Alternator…3665
AC Induction Traction Motorized Wheels…3665
Suspension…3665
Operator's Cab…3665
Power Steering…3665
Dynamic Retarding…3665
Brake System…3665
SPECIFICATIONS…3667
ENGINE…3667
AC ELECTRIC DRIVE SYSTEM…3667
DYNAMIC RETARDING…3667
BATTERY ELECTRIC SYSTEM…3667
SERVICE CAPACITIES…3667
HYDRAULIC SYSTEMS…3668
SERVICE BRAKES…3668
STEERING…3668
TIRES…3668
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…3668
WEIGHT DISTRIBUTION…3669
PAYLOAD METER III…3671
AM/FM RADIO / CD PLAYER…3701
GENERAL RADIO RECEIVER FUNCTIONS…3701
Turning On the Power…3701
One-Hour Timer…3701
Display…3702
Setting a Default Display…3702
Adjusting the Brightness of the Display…3702
Auxiliary Mode…3702
Adjusting the Receiver Settings…3702
USING THE CLOCK…3703
Setting the Clock…3703
USING THE ALARM…3703
Setting the Alarm…3703
Turning the Alarm Off…3703
Activating Snooze…3703
Setting Alarm Volume…3703
USING THE RADIO…3704
Finding a Station…3704
Setting the Presets…3704
USING THE WEATHERBAND…3705
USING THE COMPACT DISC PLAYER…3705
Playing a Compact Disc…3705
Button Functions…3705
PLAYING AN MP3 DISC…3706
MP3 Format Compatibility…3706
Root Directory…3706
Empty Directory or Folder…3706
No Folder…3706
File Name Display…3706
Pre-Programmed Playlists…3707
Playing MP3 Files…3707
Button Functions…3707
TROUBLESHOOTING…3708
CEAM020305 – Dump Truck 930E-4 Operation & Maintenance Manual…3711
COVER…3711
INTRODUCTION…3715
FOREWORD…3715
TRUCK MODEL ILLUSTRATION…3716
ABOUT THIS MANUAL…3717
ALERTS PAGE…3718
TABLE OF CONTENTS…3719
TORQUE TABLES AND CONVERSION CHARTS…3729
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3730
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3730
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3731
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3732
SAFETY…3739
GENERAL…3739
Safety Rules…3739
Safety Features…3739
Fire Extinguisher And First Aid Kit…3739
Clothing And Personal Items…3739
Leaving The Operator’s Seat…3740
Mounting And Dismounting…3740
Fire Prevention For Fuel And Oil…3740
Precautions With High Temperature Fluids…3741
Asbestos Dust Hazard Prevention…3741
Prevention Of Injury By Work Equipment…3741
Unauthorized Modification…3741
ROPS Precautions…3741
Precautions For Attachments…3742
Precautions For Starting The Truck…3742
PRECAUTIONS BEFORE OPERATION…3742
Safety At The Worksite…3742
Fire Prevention…3743
Ventilation In Enclosed Areas…3743
Preparing For Operation…3743
Mirrors, Windows And Lights…3743
In The Operator Cab (Before Starting The Engine)…3743
Seat Belts…3743
OPERATING THE TRUCK…3744
When Starting The Engine…3744
General Truck Operation…3744
Ensuring Good Visibility…3744
Traveling…3745
Traveling In Reverse…3745
Traveling On Slopes…3745
Operating On Snow Or Ice…3745
Avoid Damage To The Dump Body…3745
Driving Near High Voltage Cables…3746
Working On Loose Ground…3746
When Dumping…3746
When Loading…3746
Parking The Truck…3746
Towing…3746
WORKING NEAR BATTERIES…3747
Battery Hazard Prevention…3747
Starting With Booster Cables…3747
BEFORE PERFORMING MAINTENANCE…3748
Stopping The Engine…3748
Warning Tag…3748
Proper Tools…3748
Securing The Dump Body…3748
WHILE PERFORMING MAINTENANCE…3749
Keep The Truck Clean…3749
Attachments…3749
Working Under The Truck…3749
Rotating Fan And Belts…3749
Waste Materials…3749
Adding Fuel Or Oil…3750
Radiator Coolant Level…3750
Use Of Lighting…3750
Precautions With The Battery…3750
Handling High Pressure Hoses…3750
Precautions With High Pressure Oil…3750
Performing Maintenance Near High Temperature Or High Pressure…3750
TIRES…3751
Handling Tires…3751
Storing Tires After Removal…3751
WHEN REPAIRS ARE NECESSARY…3752
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…3753
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…3753
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…3753
CAPACITOR DISCHARGE SYSTEM…3755
Necessary Tools…3755
Warnings And Cautions…3756
Manual DC Link Capacitor Discharge Procedure…3757
Failure of the Discharge System…3759
Manual Discharge of Capacitors…3760
Short Isolated Capacitor Terminals…3762
ADDITIONAL JOB SITE RULES…3764
WARNINGS AND CAUTIONS…3765
GRADE/SPEED CHART…3765
KEY SWITCH…3765
ROPS/FOPS…3765
BATTERIES…3766
CAPACITORS…3766
CRUSHING HAZARD…3767
CYLINDER PRESSURE…3767
FILLING THE HYDRAULIC TANK…3768
HYDRAULIC OIL PRESSURE…3768
HOT OIL SPRAY…3769
WHEEL MOTOR OIL LEVEL…3769
HOT EXHAUST…3769
RADIATOR…3769
EMERGENCY LADDER…3769
ACCUMULATOR DRAIN VALVES…3769
EMERGENCY DUMP PROCEDURE…3770
EMERGENCY TOWING PROCEDURE…3770
WELDING…3770
EMERGENCY SHUTDOWN…3770
INFORMATION DISPLAY…3771
WIRELESS SIGNALS…3771
HIGH VOLTAGE…3771
LIFTING INSTRUCTIONS…3772
PRODUCT IDENTIFICATION PLATE…3773
LUBRICATION CHART…3774
OPERATING INSTRUCTIONS…3775
PREPARING FOR OPERATION…3775
WALK AROUND INSPECTION…3775
ENGINE START-UP…3779
AFTER ENGINE START-UP…3780
PRE-SHIFT BRAKE CHECK (if equipped)…3780
Events…3780
OPERATION…3781
Description…3781
Brake Test Exit Criteria…3781
PERFORMING THE BRAKE TESTS…3782
Setup…3782
Service Brake Test…3782
Parking Brake Test…3783
Retard System Test…3784
EMERGENCY STEERING SYSTEM…3784
Operation…3784
Pre-Operation Testing…3784
MACHINE OPERATION SAFETY PRECAUTIONS…3785
OPERATING ON THE HAUL ROAD…3786
STARTING ON A GRADE WITH A LOADED TRUCK…3787
PASSING…3787
LOADING…3787
Overload Speed Limit Function…3787
DUMPING…3788
Raising The Dump Body…3788
Lowering The Dump Body (When dumping on flat ground)…3789
Lowering The Dump Body (When dumping over a berm or into a crusher)…3789
TOWING…3790
Special Wiring Harness…3790
SAFE PARKING PROCEDURES…3793
NORMAL ENGINE SHUTDOWN PROCEDURE…3793
SUDDEN LOSS OF ENGINE POWER…3794
FUEL DEPLETION…3794
DISABLED TRUCK DUMPING PROCEDURE…3795
Hookup…3795
Raising the Body…3795
Lowering the Body…3795
RESERVE ENGINE OIL SYSTEM…3796
Operation…3796
Changing Oil…3796
OPERATOR CAB AND CONTROLS…3797
STEERING WHEEL AND CONTROLS…3798
Horn Button…3798
Tilt / Telescope Lever…3798
Multi-Function Turn Signal Switch…3798
DYNAMIC RETARDING…3799
Retarder Lever…3799
Brake/Retarder Pedal…3799
Throttle/Accelerator Pedal…3799
GRADE/SPEED CHART…3800
OVERHEAD PANEL AND DISPLAYS…3801
CENTER CONSOLE…3802
Directional Control Lever…3802
Override/Fault Reset Switch…3803
Engine Shutdown Switch…3803
Window Control Switches…3803
Hoist Control Lever…3803
Retard Speed Control (RSC) Adjustment Dial…3804
Retard Speed Control (RSC) Switch…3804
Data Store Button…3805
KOMTRAX Plus Snapshot In Progress Light…3805
Link Energized Light…3805
Service Engine Light…3805
12V Auxiliary Power Outlets…3805
DIAGNOSTIC PORTS…3805
KOMTRAX Plus Diagnostic Port…3805
Interface Module (IM) Diagnostic Port…3805
Payload Meter Diagnostic Port…3805
Truck Control Interface (TCI) Diagnostic Port…3805
Propulsion System Controller (PSC) Diagnostic Port…3805
Engine Diagnostic Port (CENSE)…3805
Engine Diagnostic Port (QUANTUM)…3805
OPERATOR’S SEAT…3806
Seat Belts…3806
Adjustment…3806
HEATER / AIR CONDITIONER CONTROLS…3807
Fan Speed Control Knob…3807
Temperature Control Knob…3807
Air Flow Directional Knob…3807
Heater/Air Conditioner Vents…3807
INSTRUMENT PANEL…3808
Control Symbols…3808
Key Switch…3810
Rotating Beacon Light Switch (optional)…3810
Heated Mirror Switch (optional)…3810
AC Drive System Rest Switch…3810
Wheel Brake Lock Switch…3811
Hazard Warning Light Switch…3811
Heater/Air Conditioner Vents…3811
Engine Oil Pressure Gauge…3811
Right Turn Signal Indicator…3811
Digital Tachometer…3811
High Beam Indicator…3811
Speedometer/Payload Meter Display…3811
Left Turn Signal Indicator…3812
Coolant Temperature Gauge…3812
Lamp Check Switch…3812
Light Switch (3-Way)…3812
Ladder Light Switch…3812
Backup Light Switch…3812
Fog Light Switch…3813
Payload Meter Switch…3813
Panel Illumination Light Dimmer Switch…3813
Hydraulic Oil Temperature Gauge…3813
Engine Hourmeter…3813
Fuel Gauge…3813
OVERHEAD STATUS / WARNING INDICATORS…3814
A1. High Brake Oil Temperature…3815
B1. Low Steering Pressure…3815
C1. Low Accumulator Precharge Pressure…3816
D1. Not used…3816
E1. Low Brake Pressure…3816
A2. Low Hydraulic Tank Level…3816
B2. Low Automatic Lubrication System Pressure…3816
C2. Circuit Breaker Tripped…3816
D2. Hydraulic Oil Filter Monitor…3817
E2. Low Fuel…3817
A3. Parking Brake…3817
B3. Service Brake…3817
C3. Body Up…3817
D3. Dynamic Retarding…3817
E3. Stop Engine…3817
A4. Cranking Motor Failure…3818
B4. Backup Lights…3818
C4. Engine Shutdown Timer…3818
D4. Retard Speed Control (RSC) Indicator…3818
E4. Check Engine…3818
A5. No Power…3818
B5. Propulsion System Warning…3818
C5. Propulsion System Temperature…3818
D5. System/Component Failure…3819
E5. Battery Charging System Failure…3819
A6. No Propel…3819
B6. Propel System At Rest…3819
C6. Propel System Not Ready…3819
D6. Reduced Propulsion…3819
E6. Retard At Continuous Level…3819
REAR AXLE LIGHT BAR…3820
Backup Lights…3820
Retard Lights…3820
Brake Lights…3820
Backup Alarm…3820
KOMTRAX PLUS…3821
Operation…3821
Interface Module…3823
Basic Precautions…3823
KOMATSU WIRELESS BRIDGE (Optional)…3824
General Information…3824
Communication Setup…3824
Switching to the KWB_SETUP Network…3824
Setting the Computer Subnet Mask and IP Address…3825
Properties…3825
Setting Up the KWB…3826
Adding Encryption…3826
Final Computer Settings…3826
Data Downloading…3827
Resetting the KWB…3827
KWB Lights…3827
FUSES AND CIRCUIT BREAKERS…3828
LUBRICATION AND SERVICE…3831
GENERAL…3831
SERVICE CAPACITIES…3831
HYDRAULIC TANK SERVICE…3831
Adding Oil…3831
COOLING SYSTEM SERVICE…3832
Radiator Filling Procedure…3832
Coolant Specifications…3832
Unacceptable Practices…3832
WHEEL MOTOR SERVICE…3832
RESERVE OIL TANK SERVICE…3833
Filling the Reserve Oil Tank (Remote Fill)…3833
Inline Screen…3833
QUICK FILL SERVICE CENTER…3834
LUBRICATION CHART…3835
10 HOUR (DAILY) INSPECTIONS…3836
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3839
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3839
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3839
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3842
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…3844
5000 HOUR MAINTENANCE CHECKS…3844
AUTOMATIC LUBRICATION SYSTEM…3845
GENERAL DESCRIPTION…3845
SYSTEM COMPONENTS…3847
Filter…3847
Hydraulic Motor and Pump…3847
Grease Reservoir…3847
Pressure Reducing Valve…3847
Flow Control Valve…3847
Solenoid Valve…3847
Vent Valve…3847
Lubrication Cycle Timer…3847
Over Pressure Cut Off Switch…3847
Grease Pressure Failure Switch…3847
Injectors…3847
Relief Valve (unloader valve)…3847
SYSTEM OPERATION…3848
Normal Operation…3848
GENERAL INSTRUCTIONS…3849
Lubricant Required For System…3849
System Priming…3849
Filter Assembly…3849
LUBRICANT PUMP…3850
Pump Housing Oil Level…3850
Pump Pressure Control…3850
INJECTORS (SL-1 Series “H”)…3851
Injector Specifications…3851
Injector Adjustment…3851
Injector Operation…3852
PREVENTIVE MAINTENANCE PROCEDURES…3853
Daily Lubrication System Inspection…3853
250 Hour Inspection…3853
1000 Hour Inspection…3853
SYSTEM CHECKOUT…3854
Lubrication Controller Check…3854
Lubrication Controller Components…3854
Lubrication Controller Adjustment…3854
SYSTEM TROUBLESHOOTING CHART…3856
COMPONENTS & SPECIFICATIONS…3859
MAJOR COMPONENT DESCRIPTIONS…3859
Truck And Engine…3859
Main Alternator…3859
AC Induction Traction Motorized Wheels…3859
Suspension…3859
Operator's Cab…3859
Power Steering…3859
Dynamic Retarding…3859
Brake System…3859
SPECIFICATIONS…3861
ENGINE…3861
AC ELECTRIC DRIVE SYSTEM…3861
DYNAMIC RETARDING…3861
BATTERY ELECTRIC SYSTEM…3861
SERVICE CAPACITIES…3861
HYDRAULIC SYSTEMS…3862
SERVICE BRAKES…3862
STEERING…3862
TIRES…3862
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…3862
WEIGHT DISTRIBUTION…3863
PAYLOAD METER III…3865
AM/FM RADIO / CD PLAYER…3895
GENERAL RADIO RECEIVER FUNCTIONS…3895
Turning On the Power…3895
One-Hour Timer…3895
Display…3896
Setting a Default Display…3896
Adjusting the Brightness of the Display…3896
Auxiliary Mode…3896
Adjusting the Receiver Settings…3896
USING THE CLOCK…3897
Setting the Clock…3897
USING THE ALARM…3897
Setting the Alarm…3897
Turning the Alarm Off…3897
Activating Snooze…3897
Setting Alarm Volume…3897
USING THE RADIO…3898
Finding a Station…3898
Setting the Presets…3898
USING THE WEATHERBAND…3899
USING THE COMPACT DISC PLAYER…3899
Playing a Compact Disc…3899
Button Functions…3899
PLAYING AN MP3 DISC…3900
MP3 Format Compatibility…3900
Root Directory…3900
Empty Directory or Folder…3900
No Folder…3900
File Name Display…3900
Pre-Programmed Playlists…3901
Playing MP3 Files…3901
Button Functions…3901
TROUBLESHOOTING…3902
CEAM020504 – Dump Truck 930E-4SE Operation & Maintenance Manual…3905
COVER…3905
INTRODUCTION…3909
FOREWORD…3909
TRUCK MODEL ILLUSTRATION…3910
ABOUT THIS MANUAL…3911
ALERTS PAGE…3912
TABLE OF CONTENTS…3913
TORQUE TABLES AND CONVERSION CHARTS…3923
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3924
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3924
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3925
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3926
SAFETY…3933
GENERAL…3933
Safety Rules…3933
Safety Features…3933
Fire Extinguisher And First Aid Kit…3933
Clothing And Personal Items…3933
Leaving The Operator’s Seat…3934
Mounting And Dismounting…3934
Fire Prevention For Fuel And Oil…3934
Precautions With High Temperature Fluids…3935
Asbestos Dust Hazard Prevention…3935
Prevention Of Injury By Work Equipment…3935
Unauthorized Modification…3935
ROPS Precautions…3935
Precautions For Attachments…3936
Precautions For Starting The Truck…3936
PRECAUTIONS BEFORE OPERATION…3936
Safety At The Worksite…3936
Fire Prevention…3937
Ventilation In Enclosed Areas…3937
Preparing For Operation…3937
Mirrors, Windows And Lights…3937
In The Operator Cab (Before Starting The Engine)…3937
Seat Belts…3937
OPERATING THE TRUCK…3938
When Starting The Engine…3938
General Truck Operation…3938
Ensuring Good Visibility…3938
Traveling…3939
Traveling In Reverse…3939
Traveling On Slopes…3939
Operating On Snow Or Ice…3939
Avoid Damage To The Dump Body…3939
Driving Near High Voltage Cables…3940
Working On Loose Ground…3940
When Dumping…3940
When Loading…3940
Parking The Truck…3940
Towing…3940
WORKING NEAR BATTERIES…3941
Battery Hazard Prevention…3941
Starting With Booster Cables…3941
BEFORE PERFORMING MAINTENANCE…3942
Stopping The Engine…3942
Warning Tag…3942
Proper Tools…3942
Securing The Dump Body…3942
WHILE PERFORMING MAINTENANCE…3943
Keep The Truck Clean…3943
Attachments…3943
Working Under The Truck…3943
Rotating Fan And Belts…3943
Waste Materials…3943
Adding Fuel Or Oil…3944
Radiator Coolant Level…3944
Use Of Lighting…3944
Precautions With The Battery…3944
Handling High Pressure Hoses…3944
Precautions With High Pressure Oil…3944
Performing Maintenance Near High Temperature Or High Pressure…3944
TIRES…3945
Handling Tires…3945
Storing Tires After Removal…3945
WHEN REPAIRS ARE NECESSARY…3946
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…3947
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…3947
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…3947
CAPACITOR DISCHARGE SYSTEM…3949
Necessary Tools…3949
Warnings And Cautions…3950
Manual DC Link Capacitor Discharge Procedure…3951
Failure of the Discharge System…3953
Manual Discharge of Capacitors…3954
Short Isolated Capacitor Terminals…3956
ADDITIONAL JOB SITE RULES…3958
WARNINGS AND CAUTIONS…3959
GRADE/SPEED CHART…3959
KEY SWITCH…3959
ROPS/FOPS…3959
BATTERIES…3960
CAPACITORS…3960
CRUSHING HAZARD…3961
CYLINDER PRESSURE…3961
FILLING THE HYDRAULIC TANK…3962
HYDRAULIC OIL PRESSURE…3962
HOT OIL SPRAY…3963
WHEEL MOTOR OIL LEVEL…3963
HOT EXHAUST…3963
RADIATOR…3963
EMERGENCY LADDER…3963
ACCUMULATOR DRAIN VALVES…3963
EMERGENCY DUMP PROCEDURE…3964
EMERGENCY TOWING PROCEDURE…3964
WELDING…3964
EMERGENCY SHUTDOWN…3964
INFORMATION DISPLAY…3965
WIRELESS SIGNALS…3965
HIGH VOLTAGE…3965
LIFTING INSTRUCTIONS…3966
PRODUCT IDENTIFICATION PLATE…3967
LUBRICATION CHART…3968
OPERATING INSTRUCTIONS…3969
PREPARING FOR OPERATION…3969
WALK AROUND INSPECTION…3969
ENGINE START-UP…3973
AFTER ENGINE START-UP…3974
PRE-SHIFT BRAKE CHECK (if equipped)…3974
Events…3974
OPERATION…3975
Description…3975
Brake Test Exit Criteria…3975
PERFORMING THE BRAKE TESTS…3976
Setup…3976
Service Brake Test…3976
Parking Brake Test…3977
Retard System Test…3978
EMERGENCY STEERING SYSTEM…3978
Operation…3978
Pre-Operation Testing…3978
MACHINE OPERATION SAFETY PRECAUTIONS…3979
OPERATING ON THE HAUL ROAD…3980
STARTING ON A GRADE WITH A LOADED TRUCK…3981
PASSING…3981
LOADING…3981
Overload Speed Limit Function…3981
DUMPING…3982
Raising The Dump Body…3982
Lowering The Dump Body (When dumping on flat ground)…3983
Lowering The Dump Body (When dumping over a berm or into a crusher)…3983
TOWING…3984
Special Wiring Harness…3984
SAFE PARKING PROCEDURES…3987
NORMAL ENGINE SHUTDOWN PROCEDURE…3987
SUDDEN LOSS OF ENGINE POWER…3988
FUEL DEPLETION…3988
DISABLED TRUCK DUMPING PROCEDURE…3989
Hookup…3989
Raising the Body…3989
Lowering the Body…3989
RESERVE ENGINE OIL SYSTEM…3990
Operation…3990
Changing Oil…3990
OPERATOR CAB AND CONTROLS…3991
STEERING WHEEL AND CONTROLS…3992
Horn Button…3992
Tilt / Telescope Lever…3992
Multi-Function Turn Signal Switch…3992
DYNAMIC RETARDING…3993
Retarder Lever…3993
Brake/Retarder Pedal…3993
Throttle/Accelerator Pedal…3993
GRADE/SPEED CHART…3994
OVERHEAD PANEL AND DISPLAYS…3995
CENTER CONSOLE…3996
Directional Control Lever…3996
Override/Fault Reset Switch…3997
Engine Shutdown Switch…3997
Window Control Switches…3997
Hoist Control Lever…3997
Retard Speed Control (RSC) Adjustment Dial…3998
Retard Speed Control (RSC) Switch…3998
Data Store Button…3999
KOMTRAX Plus Snapshot In Progress Light…3999
Link Energized Light…3999
Service Engine Light…3999
12V Auxiliary Power Outlets…3999
DIAGNOSTIC PORTS…3999
KOMTRAX Plus Diagnostic Port…3999
Interface Module (IM) Diagnostic Port…3999
Payload Meter Diagnostic Port…3999
Truck Control Interface (TCI) Diagnostic Port…3999
Propulsion System Controller (PSC) Diagnostic Port…3999
Engine Diagnostic Port (CENSE)…3999
Engine Diagnostic Port (QUANTUM)…3999
OPERATOR’S SEAT (S/N A30727-A30741)…4000
Seat Belts…4000
Adjustment…4000
OPERATOR’S SEAT (S/N A30749 & Up)…4001
Seat Belts…4001
Adjustment…4001
PASSENGER SEAT…4002
Seat Belts…4002
Adjustment…4002
HEATER / AIR CONDITIONER CONTROLS…4003
Fan Speed Control Knob…4003
Temperature Control Knob…4003
Air Flow Directional Knob…4003
Heater/Air Conditioner Vents…4003
INSTRUMENT PANEL…4004
Control Symbols…4004
Key Switch…4006
Rotating Beacon Light Switch (optional)…4006
Heated Mirror Switch (optional)…4006
AC Drive System Rest Switch…4006
Wheel Brake Lock Switch…4007
Hazard Warning Light Switch…4007
Heater/Air Conditioner Vents…4007
Engine Oil Pressure Gauge…4007
Right Turn Signal Indicator…4007
Digital Tachometer…4007
High Beam Indicator…4007
Speedometer/Payload Meter Display…4007
Left Turn Signal Indicator…4008
Coolant Temperature Gauge…4008
Lamp Check Switch…4008
Light Switch (3-Way)…4008
Ladder Light Switch…4008
Backup Light Switch…4008
Fog Light Switch…4009
Payload Meter Switch…4009
Panel Illumination Light Dimmer Switch…4009
Hydraulic Oil Temperature Gauge…4009
Engine Hourmeter…4009
Fuel Gauge…4009
OVERHEAD STATUS / WARNING INDICATORS…4010
A1. High Brake Oil Temperature…4011
B1. Low Steering Pressure…4011
C1. Low Accumulator Precharge Pressure…4012
D1. Not used…4012
E1. Low Brake Pressure…4012
A2. Low Hydraulic Tank Level…4012
B2. Low Automatic Lubrication System Pressure…4012
C2. Circuit Breaker Tripped…4012
D2. Hydraulic Oil Filter Monitor…4012
E2. Low Fuel…4013
A3. Parking Brake…4013
B3. Service Brake…4013
C3. Body Up…4013
D3. Dynamic Retarding…4013
E3. Stop Engine…4013
A4. Cranking Motor Failure…4014
B4. Backup Lights…4014
C4. Engine Shutdown Timer…4014
D4. Retard Speed Control (RSC) Indicator…4014
E4. Check Engine…4014
A5. No Power…4014
B5. Propulsion System Warning…4014
C5. Propulsion System Temperature…4014
D5. System/Component Failure…4015
E5. Battery Charging System Failure…4015
A6. No Propel…4015
B6. Propulsion System At Rest…4015
C6. Propulsion System Not Ready…4015
D6. Reduced Propulsion…4015
E6. Retard At Continuous Level…4015
REAR AXLE LIGHT BAR…4016
Backup Lights…4016
Retard Lights…4016
Brake Light…4016
Backup Alarm…4016
KOMTRAX PLUS…4017
Operation…4017
Interface Module…4019
Basic Precautions…4019
KOMATSU WIRELESS BRIDGE (Optional)…4020
General Information…4020
Communication Setup…4020
Switching to the KWB_SETUP Network…4020
Setting the Computer Subnet Mask and IP Address…4021
Properties…4021
Setting Up the KWB…4022
Adding Encryption…4022
Final Computer Settings…4022
Data Downloading…4023
Resetting the KWB…4023
KWB Lights…4023
FUSES AND CIRCUIT BREAKERS…4024
LUBRICATION AND SERVICE…4028
GENERAL…4028
SERVICE CAPACITIES…4028
HYDRAULIC TANK SERVICE…4028
Adding Oil…4028
COOLING SYSTEM SERVICE…4029
Radiator Filling Procedure…4029
Coolant Specifications…4029
Unacceptable Practices…4029
WHEEL MOTOR SERVICE…4029
RESERVE OIL TANK SERVICE…4030
Filling the Reserve Oil Tank (Remote Fill)…4030
Inline Screen…4030
QUICK FILL SERVICE CENTER…4031
LUBRICATION CHART…4032
10 HOUR (DAILY) INSPECTIONS…4033
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…4035
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…4035
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…4035
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…4038
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…4040
5000 HOUR MAINTENANCE CHECKS…4040
AUTOMATIC LUBRICATION SYSTEM…4042
GENERAL DESCRIPTION…4042
SYSTEM COMPONENTS…4044
Filter…4044
Hydraulic Motor and Pump…4044
Grease Reservoir…4044
Pressure Reducing Valve…4044
Flow Control Valve…4044
Solenoid Valve…4044
Vent Valve…4044
Lubrication Cycle Timer…4044
Over Pressure Cut Off Switch…4044
Grease Pressure Failure Switch…4044
Injectors…4044
Relief Valve (unloader valve)…4044
SYSTEM OPERATION…4045
Normal Operation…4045
GENERAL INSTRUCTIONS…4046
Lubricant Required For System…4046
System Priming…4046
Filter Assembly…4046
LUBRICANT PUMP…4047
Pump Housing Oil Level…4047
Pump Pressure Control…4047
INJECTORS (SL-1 Series “H”)…4048
Injector Specifications…4048
Injector Adjustment…4048
Injector Operation…4049
PREVENTIVE MAINTENANCE PROCEDURES…4050
Daily Lubrication System Inspection…4050
250 Hour Inspection…4050
1000 Hour Inspection…4050
SYSTEM CHECKOUT…4051
Lubrication Controller Check…4051
Lubrication Controller Components…4051
Lubrication Controller Adjustment…4051
SYSTEM TROUBLESHOOTING CHART…4053
COMPONENTS & SPECIFICATIONS…4056
MAJOR COMPONENT DESCRIPTIONS…4056
Truck And Engine…4056
Main Alternator…4056
AC Induction Traction Motorized Wheels…4056
Suspension…4056
Operator's Cab…4056
Power Steering…4056
Dynamic Retarding…4056
Brake System…4056
SPECIFICATIONS…4058
ENGINE…4058
AC ELECTRIC DRIVE SYSTEM…4058
DYNAMIC RETARDING…4058
BATTERY ELECTRIC SYSTEM…4058
SERVICE CAPACITIES…4058
HYDRAULIC SYSTEMS…4059
SERVICE BRAKES…4059
STEERING…4059
TIRES…4059
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…4059
WEIGHT DISTRIBUTION…4060
PAYLOAD METER III…4062
AM/FM RADIO / CD PLAYER…4092
GENERAL RADIO RECEIVER FUNCTIONS…4092
Turning On the Power…4092
One-Hour Timer…4092
Display…4093
Setting a Default Display…4093
Adjusting the Brightness of the Display…4093
Auxiliary Mode…4093
Adjusting the Receiver Settings…4093
USING THE CLOCK…4094
Setting the Clock…4094
USING THE ALARM…4094
Setting the Alarm…4094
Turning the Alarm Off…4094
Activating Snooze…4094
Setting Alarm Volume…4094
USING THE RADIO…4095
Finding a Station…4095
Setting the Presets…4095
USING THE WEATHERBAND…4096
USING THE COMPACT DISC PLAYER…4096
Playing a Compact Disc…4096
Button Functions…4096
PLAYING AN MP3 DISC…4097
MP3 Format Compatibility…4097
Root Directory…4097
Empty Directory or Folder…4097
No Folder…4097
File Name Display…4097
Pre-Programmed Playlists…4098
Playing MP3 Files…4098
Button Functions…4098
TROUBLESHOOTING…4099
CEAM021005 – Dump Truck 930E-4 Operation & Maintenance Manual…4102
COVER…4102
INTRODUCTION…4106
FOREWORD…4106
TRUCK MODEL ILLUSTRATION…4107
ABOUT THIS MANUAL…4108
ALERTS PAGE…4109
TABLE OF CONTENTS…4110
TORQUE TABLES AND CONVERSION CHARTS…4120
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…4121
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…4121
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…4122
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…4123
SAFETY…4130
GENERAL…4130
Safety Rules…4130
Safety Features…4130
Fire Extinguisher And First Aid Kit…4130
Clothing And Personal Items…4130
Leaving The Operator’s Seat…4131
Mounting And Dismounting…4131
Fire Prevention For Fuel And Oil…4131
Precautions With High Temperature Fluids…4132
Asbestos Dust Hazard Prevention…4132
Prevention Of Injury By Work Equipment…4132
Unauthorized Modification…4132
ROPS Precautions…4132
Precautions For Attachments…4133
Precautions For Starting The Truck…4133
PRECAUTIONS BEFORE OPERATION…4133
Safety At The Worksite…4133
Fire Prevention…4134
Ventilation In Enclosed Areas…4134
Preparing For Operation…4134
Mirrors, Windows And Lights…4134
In The Operator Cab (Before Starting The Engine)…4134
Seat Belts…4134
OPERATING THE TRUCK…4135
When Starting The Engine…4135
General Truck Operation…4135
Ensuring Good Visibility…4135
Traveling…4136
Traveling In Reverse…4136
Traveling On Slopes…4136
Operating On Snow Or Ice…4136
Avoid Damage To The Dump Body…4136
Driving Near High Voltage Cables…4137
Working On Loose Ground…4137
When Dumping…4137
When Loading…4137
Parking The Truck…4137
Towing…4137
WORKING NEAR BATTERIES…4138
Battery Hazard Prevention…4138
Starting With Booster Cables…4138
BEFORE PERFORMING MAINTENANCE…4139
Stopping The Engine…4139
Warning Tag…4139
Proper Tools…4139
Securing The Dump Body…4139
WHILE PERFORMING MAINTENANCE…4140
Keep The Truck Clean…4140
Attachments…4140
Working Under The Truck…4140
Rotating Fan And Belts…4140
Waste Materials…4140
Adding Fuel Or Oil…4141
Radiator Coolant Level…4141
Use Of Lighting…4141
Precautions With The Battery…4141
Handling High Pressure Hoses…4141
Precautions With High Pressure Oil…4141
Performing Maintenance Near High Temperature Or High Pressure…4141
TIRES…4142
Handling Tires…4142
Storing Tires After Removal…4142
WHEN REPAIRS ARE NECESSARY…4143
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…4144
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…4144
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…4144
CAPACITOR DISCHARGE SYSTEM…4146
Necessary Tools…4146
Warnings And Cautions…4147
Manual DC Link Capacitor Discharge Procedure…4148
Failure of the Discharge System…4150
Manual Discharge of Capacitors…4151
Short Isolated Capacitor Terminals…4153
ADDITIONAL JOB SITE RULES…4155
WARNINGS AND CAUTIONS…4156
GRADE/SPEED CHART…4156
KEY SWITCH…4156
ROPS/FOPS…4156
BATTERIES…4157
CAPACITORS…4157
CRUSHING HAZARD…4158
CYLINDER PRESSURE…4158
FILLING THE HYDRAULIC TANK…4159
HYDRAULIC OIL PRESSURE…4159
HOT OIL SPRAY…4160
WHEEL MOTOR OIL LEVEL…4160
HOT EXHAUST…4160
RADIATOR…4160
EMERGENCY LADDER…4160
ACCUMULATOR DRAIN VALVES…4160
EMERGENCY DUMP PROCEDURE…4161
EMERGENCY TOWING PROCEDURE…4161
WELDING…4161
EMERGENCY SHUTDOWN…4161
INFORMATION DISPLAY…4162
WIRELESS SIGNALS…4162
HIGH VOLTAGE…4162
LIFTING INSTRUCTIONS…4163
PRODUCT IDENTIFICATION PLATE…4164
LUBRICATION CHART…4165
OPERATING INSTRUCTIONS…4166
PREPARING FOR OPERATION…4166
WALK AROUND INSPECTION…4166
ENGINE START-UP…4170
AFTER ENGINE START-UP…4171
PRE-SHIFT BRAKE CHECK (if equipped)…4171
Events…4171
OPERATION…4172
Description…4172
Brake Test Exit Criteria…4172
PERFORMING THE BRAKE TESTS…4173
Setup…4173
Service Brake Test…4173
Parking Brake Test…4174
Retard System Test…4175
EMERGENCY STEERING SYSTEM…4175
Operation…4175
Pre-Operation Testing…4175
MACHINE OPERATION SAFETY PRECAUTIONS…4176
OPERATING ON THE HAUL ROAD…4177
STARTING ON A GRADE WITH A LOADED TRUCK…4178
PASSING…4178
LOADING…4178
Overload Speed Limit Function…4178
DUMPING…4179
Raising The Dump Body…4179
Lowering The Dump Body (When dumping on flat ground)…4180
Lowering The Dump Body (When dumping over a berm or into a crusher)…4180
TOWING…4181
Special Wiring Harness…4181
SAFE PARKING PROCEDURES…4184
NORMAL ENGINE SHUTDOWN PROCEDURE…4184
SUDDEN LOSS OF ENGINE POWER…4185
FUEL DEPLETION…4185
DISABLED TRUCK DUMPING PROCEDURE…4186
Hookup…4186
Raising the Body…4186
Lowering the Body…4186
RESERVE ENGINE OIL SYSTEM…4187
Operation…4187
Changing Oil…4187
OPERATOR CAB AND CONTROLS…4188
STEERING WHEEL AND CONTROLS…4189
Horn Button…4189
Tilt / Telescope Lever…4189
Multi-Function Turn Signal Switch…4189
DYNAMIC RETARDING…4190
Retarder Lever…4190
Brake/Retarder Pedal…4190
Throttle/Accelerator Pedal…4190
GRADE/SPEED CHART…4191
OVERHEAD PANEL AND DISPLAYS…4192
CENTER CONSOLE…4193
Directional Control Lever…4193
Override/Fault Reset Switch…4194
Engine Shutdown Switch…4194
Window Control Switches…4194
Hoist Control Lever…4194
Retard Speed Control (RSC) Adjustment Dial…4195
Retard Speed Control (RSC) Switch…4195
Data Store Button…4196
KOMTRAX Plus Snapshot In Progress Light…4196
Link Energized Light…4196
Service Engine Light…4196
12V Auxiliary Power Outlets…4196
DIAGNOSTIC PORTS…4196
KOMTRAX Plus Diagnostic Port…4196
Interface Module (IM) Diagnostic Port…4196
Payload Meter Diagnostic Port…4196
Truck Control Interface (TCI) Diagnostic Port…4196
Propulsion System Controller (PSC) Diagnostic Port…4196
Engine Diagnostic Port (CENSE)…4196
Engine Diagnostic Port (QUANTUM)…4196
OPERATOR’S SEAT…4197
Seat Belts…4197
Adjustment…4197
PASSENGER SEAT…4198
Seat Belts…4198
Adjustment…4198
HEATER / AIR CONDITIONER CONTROLS…4199
Fan Speed Control Knob…4199
Temperature Control Knob…4199
Air Flow Directional Knob…4199
Heater/Air Conditioner Vents…4199
INSTRUMENT PANEL…4200
Control Symbols…4200
Key Switch…4202
Rotating Beacon Light Switch (optional)…4202
Heated Mirror Switch (optional)…4202
AC Drive System Rest Switch…4202
Wheel Brake Lock Switch…4203
Hazard Warning Light Switch…4203
Heater/Air Conditioner Vents…4203
Engine Oil Pressure Gauge…4203
Right Turn Signal Indicator…4203
Digital Tachometer…4203
High Beam Indicator…4203
Speedometer/Payload Meter Display…4203
Left Turn Signal Indicator…4204
Coolant Temperature Gauge…4204
Lamp Check Switch…4204
Light Switch (3-Way)…4204
Ladder Light Switch…4204
Backup Light Switch…4204
Fog Light Switch…4205
Payload Meter Switch…4205
Panel Illumination Light Dimmer Switch…4205
Hydraulic Oil Temperature Gauge…4205
Engine Hourmeter…4205
Fuel Gauge…4205
OVERHEAD STATUS / WARNING INDICATORS…4206
A1. High Brake Oil Temperature…4207
B1. Low Steering Pressure…4207
C1. Low Accumulator Precharge Pressure…4208
D1. Not used…4208
E1. Low Brake Pressure…4208
A2. Low Hydraulic Tank Level…4208
B2. Low Automatic Lubrication System Pressure…4208
C2. Circuit Breaker Tripped…4208
D2. Hydraulic Oil Filter Monitor…4209
E2. Low Fuel…4209
A3. Parking Brake…4209
B3. Service Brake…4209
C3. Body Up…4209
D3. Dynamic Retarding…4209
E3. Stop Engine…4210
A4. Cranking Motor Failure…4210
B4. Backup Lights…4210
C4. Engine Shutdown Timer…4210
D4. Retard Speed Control (RSC) Indicator…4210
E4. Check Engine…4210
A5. No Power…4211
B5. Propulsion System Warning…4211
C5. Propulsion System Temperature…4211
D5. System/Component Failure…4211
E5. Battery Charging System Failure…4211
A6. No Propel…4211
B6. Propel System At Rest…4211
C6. Propel System Not Ready…4212
D6. Reduced Propulsion…4212
E6. Retard At Continuous Level…4212
D7. Brake Test Light…4212
E7. Maintenance Monitor…4212
8. Brake Test Switch…4212
REAR AXLE LIGHT BAR…4213
Backup Lights…4213
Retard Lights…4213
Brake Lights…4213
Backup Alarm…4213
KOMTRAX PLUS…4214
Operation…4214
Interface Module…4216
Basic Precautions…4216
KOMATSU WIRELESS BRIDGE (Optional)…4217
General Information…4217
Communication Setup…4217
Switching to the KWB_SETUP Network…4217
Setting the Computer Subnet Mask and IP Address…4218
Properties…4218
Setting Up the KWB…4219
Adding Encryption…4219
Final Computer Settings…4219
Data Downloading…4220
Resetting the KWB…4220
KWB Lights…4220
FUSES AND CIRCUIT BREAKERS…4221
LUBRICATION AND SERVICE…4226
GENERAL…4226
SERVICE CAPACITIES…4226
HYDRAULIC TANK SERVICE…4226
Adding Oil…4226
COOLING SYSTEM SERVICE…4227
Radiator Filling Procedure…4227
Coolant Specifications…4227
Unacceptable Practices…4227
WHEEL MOTOR SERVICE…4227
RESERVE OIL TANK SERVICE…4228
Filling the Reserve Oil Tank (Remote Fill)…4228
Inline Screen…4228
QUICK FILL SERVICE CENTER…4229
LUBRICATION CHART…4230
10 HOUR (DAILY) INSPECTIONS…4231
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…4233
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…4233
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…4233
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…4236
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…4238
5000 HOUR MAINTENANCE CHECKS…4238
AUTOMATIC LUBRICATION SYSTEM…4240
GENERAL DESCRIPTION…4240
SYSTEM COMPONENTS…4242
Filter…4242
Hydraulic Motor and Pump…4242
Grease Reservoir…4242
Pressure Reducing Valve…4242
Flow Control Valve…4242
Solenoid Valve…4242
Vent Valve…4242
Lubrication Cycle Timer…4242
Over Pressure Cut Off Switch…4242
Grease Pressure Failure Switch…4242
Injectors…4242
Relief Valve (unloader valve)…4242
SYSTEM OPERATION…4243
Normal Operation…4243
GENERAL INSTRUCTIONS…4244
Lubricant Required For System…4244
System Priming…4244
Filter Assembly…4244
LUBRICANT PUMP…4245
Pump Housing Oil Level…4245
Pump Pressure Control…4245
INJECTORS (SL-1 Series “H”)…4246
Injector Specifications…4246
Injector Adjustment…4246
Injector Operation…4247
PREVENTIVE MAINTENANCE PROCEDURES…4248
Daily Lubrication System Inspection…4248
250 Hour Inspection…4248
1000 Hour Inspection…4248
SYSTEM CHECKOUT…4249
Lubrication Controller Check…4249
Lubrication Controller Components…4249
Lubrication Controller Adjustment…4249
SYSTEM TROUBLESHOOTING CHART…4251
COMPONENTS & SPECIFICATIONS…4254
MAJOR COMPONENT DESCRIPTIONS…4254
Truck And Engine…4254
Main Alternator…4254
AC Induction Traction Motorized Wheels…4254
Suspension…4254
Operator's Cab…4254
Power Steering…4254
Dynamic Retarding…4254
Brake System…4254
SPECIFICATIONS…4256
ENGINE…4256
AC ELECTRIC DRIVE SYSTEM…4256
DYNAMIC RETARDING…4256
BATTERY ELECTRIC SYSTEM…4256
SERVICE CAPACITIES…4256
HYDRAULIC SYSTEMS…4257
SERVICE BRAKES…4257
STEERING…4257
TIRES…4257
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…4257
WEIGHT DISTRIBUTION…4258
PAYLOAD METER III…4260
AM/FM RADIO / CD PLAYER…4290
GENERAL RADIO RECEIVER FUNCTIONS…4290
Turning On the Power…4290
One-Hour Timer…4290
Display…4291
Setting a Default Display…4291
Adjusting the Brightness of the Display…4291
Auxiliary Mode…4291
Adjusting the Receiver Settings…4291
USING THE CLOCK…4292
Setting the Clock…4292
USING THE ALARM…4292
Setting the Alarm…4292
Turning the Alarm Off…4292
Activating Snooze…4292
Setting Alarm Volume…4292
USING THE RADIO…4293
Finding a Station…4293
Setting the Presets…4293
USING THE WEATHERBAND…4294
USING THE COMPACT DISC PLAYER…4294
Playing a Compact Disc…4294
Button Functions…4294
PLAYING AN MP3 DISC…4295
MP3 Format Compatibility…4295
Root Directory…4295
Empty Directory or Folder…4295
No Folder…4295
File Name Display…4295
Pre-Programmed Playlists…4296
Playing MP3 Files…4296
Button Functions…4296
TROUBLESHOOTING…4297
CEAM021304 – Dump Truck 930E-4SE Operation & Maintenance Manual…4300
COVER…4300
INTRODUCTION…4304
FOREWORD…4304
TRUCK MODEL ILLUSTRATION…4305
ABOUT THIS MANUAL…4306
ALERTS PAGE…4307
TABLE OF CONTENTS…4308
TORQUE TABLES AND CONVERSION CHARTS…4318
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…4319
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…4319
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…4320
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…4321
SAFETY…4328
GENERAL…4328
Safety Rules…4328
Safety Features…4328
Fire Extinguisher And First Aid Kit…4328
Clothing And Personal Items…4328
Leaving The Operator’s Seat…4329
Mounting And Dismounting…4329
Fire Prevention For Fuel And Oil…4329
Precautions With High Temperature Fluids…4330
Asbestos Dust Hazard Prevention…4330
Prevention Of Injury By Work Equipment…4330
Unauthorized Modification…4330
ROPS Precautions…4330
Precautions For Attachments…4331
Precautions For Starting The Truck…4331
PRECAUTIONS BEFORE OPERATION…4331
Safety At The Worksite…4331
Fire Prevention…4332
Ventilation In Enclosed Areas…4332
Preparing For Operation…4332
Mirrors, Windows And Lights…4332
In The Operator Cab (Before Starting The Engine)…4332
Seat Belts…4332
OPERATING THE TRUCK…4333
When Starting The Engine…4333
General Truck Operation…4333
Ensuring Good Visibility…4333
Traveling…4334
Traveling In Reverse…4334
Traveling On Slopes…4334
Operating On Snow Or Ice…4334
Avoid Damage To The Dump Body…4334
Driving Near High Voltage Cables…4335
Working On Loose Ground…4335
When Dumping…4335
When Loading…4335
Parking The Truck…4335
Towing…4335
WORKING NEAR BATTERIES…4336
Battery Hazard Prevention…4336
Starting With Booster Cables…4336
BEFORE PERFORMING MAINTENANCE…4337
Stopping The Engine…4337
Warning Tag…4337
Proper Tools…4337
Securing The Dump Body…4337
WHILE PERFORMING MAINTENANCE…4338
Keep The Truck Clean…4338
Attachments…4338
Working Under The Truck…4338
Rotating Fan And Belts…4338
Waste Materials…4338
Adding Fuel Or Oil…4339
Radiator Coolant Level…4339
Use Of Lighting…4339
Precautions With The Battery…4339
Handling High Pressure Hoses…4339
Precautions With High Pressure Oil…4339
Performing Maintenance Near High Temperature Or High Pressure…4339
TIRES…4340
Handling Tires…4340
Storing Tires After Removal…4340
WHEN REPAIRS ARE NECESSARY…4341
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…4342
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…4342
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…4342
CAPACITOR DISCHARGE SYSTEM…4344
Necessary Tools…4344
Warnings And Cautions…4345
Manual DC Link Capacitor Discharge Procedure…4346
Failure of the Discharge System…4348
Manual Discharge of Capacitors…4349
Short Isolated Capacitor Terminals…4351
ADDITIONAL JOB SITE RULES…4353
WARNINGS AND CAUTIONS…4354
GRADE/SPEED CHART…4354
KEY SWITCH…4354
ROPS/FOPS…4354
BATTERIES…4355
CAPACITORS…4355
CRUSHING HAZARD…4356
CYLINDER PRESSURE…4356
FILLING THE HYDRAULIC TANK…4357
HYDRAULIC OIL PRESSURE…4357
HOT OIL SPRAY…4358
WHEEL MOTOR OIL LEVEL…4358
HOT EXHAUST…4358
RADIATOR…4358
EMERGENCY LADDER…4358
ACCUMULATOR DRAIN VALVES…4358
EMERGENCY DUMP PROCEDURE…4359
EMERGENCY TOWING PROCEDURE…4359
WELDING…4359
EMERGENCY SHUTDOWN…4359
INFORMATION DISPLAY…4360
WIRELESS SIGNALS…4360
HIGH VOLTAGE…4360
LIFTING INSTRUCTIONS…4361
PRODUCT IDENTIFICATION PLATE…4362
LUBRICATION CHART…4363
OPERATING INSTRUCTIONS…4364
PREPARING FOR OPERATION…4364
WALK AROUND INSPECTION…4364
ENGINE START-UP…4368
AFTER ENGINE START-UP…4369
PRE-SHIFT BRAKE CHECK (if equipped)…4369
Events…4369
OPERATION…4370
Description…4370
Brake Test Exit Criteria…4370
PERFORMING THE BRAKE TESTS…4371
Setup…4371
Service Brake Test…4371
Parking Brake Test…4372
Retard System Test…4373
EMERGENCY STEERING SYSTEM…4373
Operation…4373
Pre-Operation Testing…4373
MACHINE OPERATION SAFETY PRECAUTIONS…4374
OPERATING ON THE HAUL ROAD…4375
STARTING ON A GRADE WITH A LOADED TRUCK…4376
PASSING…4376
LOADING…4376
Overload Speed Limit Function…4376
DUMPING…4377
Raising The Dump Body…4377
Lowering The Dump Body (When dumping on flat ground)…4378
Lowering The Dump Body (When dumping over a berm or into a crusher)…4378
TOWING…4379
Special Wiring Harness…4379
SAFE PARKING PROCEDURES…4382
NORMAL ENGINE SHUTDOWN PROCEDURE…4382
SUDDEN LOSS OF ENGINE POWER…4383
FUEL DEPLETION…4383
DISABLED TRUCK DUMPING PROCEDURE…4384
Hookup…4384
Raising the Body…4384
Lowering the Body…4384
RESERVE ENGINE OIL SYSTEM…4385
Operation…4385
Changing Oil…4385
OPERATOR CAB AND CONTROLS…4386
STEERING WHEEL AND CONTROLS…4387
Horn Button…4387
Tilt / Telescope Lever…4387
Multi-Function Turn Signal Switch…4387
DYNAMIC RETARDING…4388
Retarder Lever…4388
Brake/Retarder Pedal…4388
Throttle/Accelerator Pedal…4388
GRADE/SPEED CHART…4389
OVERHEAD PANEL AND DISPLAYS…4390
CENTER CONSOLE…4391
Directional Control Lever…4391
Override/Fault Reset Switch…4392
Engine Shutdown Switch…4392
Window Control Switches…4392
Hoist Control Lever…4392
Retard Speed Control (RSC) Adjustment Dial…4393
Retard Speed Control (RSC) Switch…4393
Data Store Button…4394
KOMTRAX Plus Snapshot In Progress Light…4394
Link Energized Light…4394
Service Engine Light…4394
12V Auxiliary Power Outlets…4394
DIAGNOSTIC PORTS…4394
KOMTRAX Plus Diagnostic Port…4394
Interface Module (IM) Diagnostic Port…4394
Payload Meter Diagnostic Port…4394
Truck Control Interface (TCI) Diagnostic Port…4394
Propulsion System Controller (PSC) Diagnostic Port…4394
Engine Diagnostic Port (CENSE)…4394
Engine Diagnostic Port (QUANTUM)…4394
OPERATOR’S SEAT…4395
Seat Belts…4395
Adjustment…4395
PASSENGER SEAT…4396
Seat Belts…4396
Adjustment…4396
HEATER / AIR CONDITIONER CONTROLS…4397
Fan Speed Control Knob…4397
Temperature Control Knob…4397
Air Flow Directional Knob…4397
Heater/Air Conditioner Vents…4397
INSTRUMENT PANEL…4398
Control Symbols…4398
Key Switch…4400
Rotating Beacon Light Switch (optional)…4400
Heated Mirror Switch (optional)…4400
AC Drive System Rest Switch…4400
Wheel Brake Lock Switch…4401
Hazard Warning Light Switch…4401
Heater/Air Conditioner Vents…4401
Engine Oil Pressure Gauge…4401
Right Turn Signal Indicator…4401
Digital Tachometer…4401
High Beam Indicator…4401
Speedometer/Payload Meter Display…4401
Left Turn Signal Indicator…4402
Coolant Temperature Gauge…4402
Lamp Check Switch…4402
Light Switch (3-Way)…4402
Ladder Light Switch…4402
Backup Light Switch…4402
Fog Light Switch…4403
Payload Meter Switch…4403
Panel Illumination Light Dimmer Switch…4403
Hydraulic Oil Temperature Gauge…4403
Engine Hourmeter…4403
Fuel Gauge…4403
OVERHEAD STATUS / WARNING INDICATORS…4404
A1. High Brake Oil Temperature…4405
B1. Low Steering Pressure…4405
C1. Low Accumulator Precharge Pressure…4406
D1. Not used…4406
E1. Low Brake Pressure…4406
A2. Low Hydraulic Tank Level…4406
B2. Low Automatic Lubrication System Pressure…4406
C2. Circuit Breaker Tripped…4406
D2. Hydraulic Oil Filter Monitor…4407
E2. Low Fuel…4407
A3. Parking Brake…4407
B3. Service Brake…4407
C3. Body Up…4407
D3. Dynamic Retarding…4407
E3. Stop Engine…4408
A4. Cranking Motor Failure…4408
B4. Backup Lights…4408
C4. Engine Shutdown Timer…4408
D4. Retard Speed Control (RSC) Indicator…4408
E4. Check Engine…4408
A5. No Power…4409
B5. Propulsion System Warning…4409
C5. Propulsion System Temperature…4409
D5. System/Component Failure…4409
A6. No Propel…4409
B6. Propel System At Rest…4409
C6. Propel System Not Ready…4410
D6. Reduced Propulsion…4410
E6. Retard At Continuous Level…4410
D7. Brake Test Light…4410
E7. Maintenance Monitor…4410
8. Brake Test Switch…4410
REAR AXLE LIGHT BAR…4411
Backup Lights…4411
Retard Lights…4411
Brake Light…4411
Backup Alarm…4411
KOMTRAX PLUS…4412
Operation…4412
Interface Module…4414
Basic Precautions…4414
KOMATSU WIRELESS BRIDGE (Optional)…4415
General Information…4415
Communication Setup…4415
Switching to the KWB_SETUP Network…4415
Setting the Computer Subnet Mask and IP Address…4416
Properties…4416
Setting Up the KWB…4417
Adding Encryption…4417
Final Computer Settings…4417
Data Downloading…4418
Resetting the KWB…4418
KWB Lights…4418
FUSES AND CIRCUIT BREAKERS…4419
LUBRICATION AND SERVICE…4424
GENERAL…4424
SERVICE CAPACITIES…4424
HYDRAULIC TANK SERVICE…4424
Adding Oil…4424
COOLING SYSTEM SERVICE…4425
Radiator Filling Procedure…4425
Coolant Specifications…4425
Unacceptable Practices…4425
WHEEL MOTOR SERVICE…4425
RESERVE OIL TANK SERVICE…4426
Filling the Reserve Oil Tank (Remote Fill)…4426
Inline Screen…4426
QUICK FILL SERVICE CENTER…4427
LUBRICATION CHART…4428
10 HOUR (DAILY) INSPECTIONS…4429
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…4431
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…4431
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…4431
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…4434
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…4436
5000 HOUR MAINTENANCE CHECKS…4436
AUTOMATIC LUBRICATION SYSTEM…4438
GENERAL DESCRIPTION…4438
SYSTEM COMPONENTS…4440
Filter…4440
Hydraulic Motor and Pump…4440
Grease Reservoir…4440
Pressure Reducing Valve…4440
Flow Control Valve…4440
Solenoid Valve…4440
Vent Valve…4440
Lubrication Cycle Timer…4440
Over Pressure Cut Off Switch…4440
Grease Pressure Failure Switch…4440
Injectors…4440
Relief Valve (unloader valve)…4440
SYSTEM OPERATION…4441
Normal Operation…4441
GENERAL INSTRUCTIONS…4442
Lubricant Required For System…4442
System Priming…4442
Filter Assembly…4442
LUBRICANT PUMP…4443
Pump Housing Oil Level…4443
Pump Pressure Control…4443
INJECTORS (SL-1 Series “H”)…4444
Injector Specifications…4444
Injector Adjustment…4444
Injector Operation…4445
PREVENTIVE MAINTENANCE PROCEDURES…4446
Daily Lubrication System Inspection…4446
250 Hour Inspection…4446
1000 Hour Inspection…4446
SYSTEM CHECKOUT…4447
Lubrication Controller Check…4447
Lubrication Controller Components…4447
Lubrication Controller Adjustment…4447
SYSTEM TROUBLESHOOTING CHART…4449
COMPONENTS & SPECIFICATIONS…4452
MAJOR COMPONENT DESCRIPTIONS…4452
Truck And Engine…4452
Main Alternator…4452
AC Induction Traction Motorized Wheels…4452
Suspension…4452
Operator's Cab…4452
Power Steering…4452
Dynamic Retarding…4452
Brake System…4452
SPECIFICATIONS…4454
ENGINE…4454
AC ELECTRIC DRIVE SYSTEM…4454
DYNAMIC RETARDING…4454
BATTERY ELECTRIC SYSTEM…4454
SERVICE CAPACITIES…4454
HYDRAULIC SYSTEMS…4455
SERVICE BRAKES…4455
STEERING…4455
TIRES…4455
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…4455
WEIGHT DISTRIBUTION…4456
PAYLOAD METER III…4458
AM/FM RADIO / CD PLAYER…4488
GENERAL RADIO RECEIVER FUNCTIONS…4488
Turning On the Power…4488
One-Hour Timer…4488
Display…4489
Setting a Default Display…4489
Adjusting the Brightness of the Display…4489
Auxiliary Mode…4489
Adjusting the Receiver Settings…4489
USING THE CLOCK…4490
Setting the Clock…4490
USING THE ALARM…4490
Setting the Alarm…4490
Turning the Alarm Off…4490
Activating Snooze…4490
Setting Alarm Volume…4490
USING THE RADIO…4491
Finding a Station…4491
Setting the Presets…4491
USING THE WEATHERBAND…4492
USING THE COMPACT DISC PLAYER…4492
Playing a Compact Disc…4492
Button Functions…4492
PLAYING AN MP3 DISC…4493
MP3 Format Compatibility…4493
Root Directory…4493
Empty Directory or Folder…4493
No Folder…4493
File Name Display…4493
Pre-Programmed Playlists…4494
Playing MP3 Files…4494
Button Functions…4494
TROUBLESHOOTING…4495
CEAM021405 – Dump Truck 930E-4 Operation & Maintenance Manual…4498
COVER…4498
INTRODUCTION…4502
FOREWORD…4502
TRUCK MODEL ILLUSTRATION…4503
ABOUT THIS MANUAL…4504
ALERTS PAGE…4505
TABLE OF CONTENTS…4506
TORQUE TABLES AND CONVERSION CHARTS…4516
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…4517
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…4517
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…4518
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…4519
SAFETY…4526
GENERAL…4526
Safety Rules…4526
Safety Features…4526
Fire Extinguisher And First Aid Kit…4526
Clothing And Personal Items…4526
Leaving The Operator’s Seat…4527
Mounting And Dismounting…4527
Fire Prevention For Fuel And Oil…4527
Precautions With High Temperature Fluids…4528
Asbestos Dust Hazard Prevention…4528
Prevention Of Injury By Work Equipment…4528
Unauthorized Modification…4528
ROPS Precautions…4528
Precautions For Attachments…4529
Precautions For Starting The Truck…4529
PRECAUTIONS BEFORE OPERATION…4529
Safety At The Worksite…4529
Fire Prevention…4530
Ventilation In Enclosed Areas…4530
Preparing For Operation…4530
Mirrors, Windows And Lights…4530
In The Operator Cab (Before Starting The Engine)…4530
Seat Belts…4530
OPERATING THE TRUCK…4531
When Starting The Engine…4531
General Truck Operation…4531
Ensuring Good Visibility…4531
Traveling…4532
Traveling In Reverse…4532
Traveling On Slopes…4532
Operating On Snow Or Ice…4532
Avoid Damage To The Dump Body…4532
Driving Near High Voltage Cables…4533
Working On Loose Ground…4533
When Dumping…4533
When Loading…4533
Parking The Truck…4533
Towing…4533
WORKING NEAR BATTERIES…4534
Battery Hazard Prevention…4534
Starting With Booster Cables…4534
BEFORE PERFORMING MAINTENANCE…4535
Stopping The Engine…4535
Warning Tag…4535
Proper Tools…4535
Securing The Dump Body…4535
WHILE PERFORMING MAINTENANCE…4536
Keep The Truck Clean…4536
Attachments…4536
Working Under The Truck…4536
Rotating Fan And Belts…4536
Waste Materials…4536
Adding Fuel Or Oil…4537
Radiator Coolant Level…4537
Use Of Lighting…4537
Precautions With The Battery…4537
Handling High Pressure Hoses…4537
Precautions With High Pressure Oil…4537
Performing Maintenance Near High Temperature Or High Pressure…4537
TIRES…4538
Handling Tires…4538
Storing Tires After Removal…4538
WHEN REPAIRS ARE NECESSARY…4539
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…4540
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…4540
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…4540
CAPACITOR DISCHARGE SYSTEM…4542
Necessary Tools…4542
Warnings And Cautions…4543
Manual DC Link Capacitor Discharge Procedure…4544
Failure of the Discharge System…4546
Manual Discharge of Capacitors…4547
Short Isolated Capacitor Terminals…4549
ADDITIONAL JOB SITE RULES…4551
WARNINGS AND CAUTIONS…4552
GRADE/SPEED CHART…4552
KEY SWITCH…4552
ROPS/FOPS…4552
BATTERIES…4553
CAPACITORS…4553
CRUSHING HAZARD…4554
CYLINDER PRESSURE…4554
FILLING THE HYDRAULIC TANK…4555
HYDRAULIC OIL PRESSURE…4555
HOT OIL SPRAY…4556
WHEEL MOTOR OIL LEVEL…4556
HOT EXHAUST…4556
RADIATOR…4556
EMERGENCY LADDER…4556
ACCUMULATOR DRAIN VALVES…4556
EMERGENCY DUMP PROCEDURE…4557
EMERGENCY TOWING PROCEDURE…4557
WELDING…4557
EMERGENCY SHUTDOWN…4557
INFORMATION DISPLAY…4558
WIRELESS SIGNALS…4558
HIGH VOLTAGE…4558
LIFTING INSTRUCTIONS…4559
PRODUCT IDENTIFICATION PLATE…4560
LUBRICATION CHART…4561
OPERATING INSTRUCTIONS…4562
PREPARING FOR OPERATION…4562
WALK AROUND INSPECTION…4562
ENGINE START-UP…4566
AFTER ENGINE START-UP…4567
PRE-SHIFT BRAKE CHECK (if equipped)…4567
Events…4567
OPERATION…4568
Description…4568
Brake Test Exit Criteria…4568
PERFORMING THE BRAKE TESTS…4569
Setup…4569
Service Brake Test…4569
Parking Brake Test…4570
Retard System Test…4571
EMERGENCY STEERING SYSTEM…4571
Operation…4571
Pre-Operation Testing…4571
MACHINE OPERATION SAFETY PRECAUTIONS…4572
OPERATING ON THE HAUL ROAD…4573
STARTING ON A GRADE WITH A LOADED TRUCK…4574
PASSING…4574
LOADING…4574
Overload Speed Limit Function…4574
DUMPING…4575
Raising The Dump Body…4575
Lowering The Dump Body (When dumping on flat ground)…4576
Lowering The Dump Body (When dumping over a berm or into a crusher)…4576
TOWING…4577
Special Wiring Harness…4577
SAFE PARKING PROCEDURES…4580
NORMAL ENGINE SHUTDOWN PROCEDURE…4580
SUDDEN LOSS OF ENGINE POWER…4581
FUEL DEPLETION…4581
DISABLED TRUCK DUMPING PROCEDURE…4582
Hookup…4582
Raising the Body…4582
Lowering the Body…4582
RESERVE ENGINE OIL SYSTEM…4583
Operation…4583
Changing Oil…4583
OPERATOR CAB AND CONTROLS…4584
STEERING WHEEL AND CONTROLS…4585
Horn Button…4585
Tilt / Telescope Lever…4585
Multi-Function Turn Signal Switch…4585
DYNAMIC RETARDING…4586
Retarder Lever…4586
Brake/Retarder Pedal…4586
Throttle/Accelerator Pedal…4586
GRADE/SPEED CHART…4587
OVERHEAD PANEL AND DISPLAYS…4588
CENTER CONSOLE…4589
Directional Control Lever…4589
Override/Fault Reset Switch…4590
Engine Shutdown Switch…4590
Window Control Switches…4590
Hoist Control Lever…4590
Retard Speed Control (RSC) Adjustment Dial…4591
Retard Speed Control (RSC) Switch…4591
Data Store Button…4592
KOMTRAX Plus Snapshot In Progress Light…4592
Link Energized Light…4592
Service Engine Light…4592
12V Auxiliary Power Outlets…4592
DIAGNOSTIC PORTS…4592
KOMTRAX Plus Diagnostic Port…4592
Interface Module (IM) Diagnostic Port…4592
Payload Meter Diagnostic Port…4592
Truck Control Interface (TCI) Diagnostic Port…4592
Propulsion System Controller (PSC) Diagnostic Port…4592
Engine Diagnostic Port (CENSE)…4592
Engine Diagnostic Port (QUANTUM)…4592
OPERATOR’S SEAT…4593
Seat Belts…4593
Adjustment…4593
PASSENGER SEAT…4594
Seat Belts…4594
Adjustment…4594
HEATER / AIR CONDITIONER CONTROLS…4595
Fan Speed Control Knob…4595
Temperature Control Knob…4595
Air Flow Directional Knob…4595
Heater/Air Conditioner Vents…4595
INSTRUMENT PANEL…4596
Control Symbols…4596
Key Switch…4598
Rotating Beacon Light Switch (optional)…4598
Heated Mirror Switch (optional)…4598
AC Drive System Rest Switch…4598
Wheel Brake Lock Switch…4599
Hazard Warning Light Switch…4599
Heater/Air Conditioner Vents…4599
Engine Oil Pressure Gauge…4599
Right Turn Signal Indicator…4599
Digital Tachometer…4599
High Beam Indicator…4599
Speedometer/Payload Meter Display…4599
Left Turn Signal Indicator…4600
Coolant Temperature Gauge…4600
Lamp Check Switch…4600
Light Switch (3-Way)…4600
Ladder Light Switch…4600
Backup Light Switch…4600
Fog Light Switch…4601
Payload Meter Switch…4601
Panel Illumination Light Dimmer Switch…4601
Hydraulic Oil Temperature Gauge…4601
Engine Hourmeter…4601
Fuel Gauge…4601
OVERHEAD STATUS / WARNING INDICATORS…4602
A1. High Brake Oil Temperature…4603
B1. Low Steering Pressure…4603
C1. Low Accumulator Precharge Pressure…4604
D1. Not used…4604
E1. Low Brake Pressure…4604
A2. Low Hydraulic Tank Level…4604
B2. Low Automatic Lubrication System Pressure…4604
C2. Circuit Breaker Tripped…4604
D2. Hydraulic Oil Filter Monitor…4605
E2. Low Fuel…4605
A3. Parking Brake…4605
B3. Service Brake…4605
C3. Body Up…4605
D3. Dynamic Retarding…4605
E3. Stop Engine…4606
A4. Cranking Motor Failure…4606
B4. Backup Lights…4606
C4. Engine Shutdown Timer…4606
D4. Retard Speed Control (RSC) Indicator…4606
E4. Check Engine…4606
A5. No Power…4607
B5. Propulsion System Warning…4607
C5. Propulsion System Temperature…4607
D5. System/Component Failure…4607
E5. Battery Charging System Failure…4607
A6. No Propel…4607
B6. Propel System At Rest…4607
C6. Propel System Not Ready…4608
D6. Reduced Propulsion…4608
E6. Retard At Continuous Level…4608
D7. Brake Test Light…4608
E7. Maintenance Monitor…4608
8. Brake Test Switch…4608
REAR AXLE LIGHT BAR…4609
Backup Lights…4609
Retard Lights…4609
Brake Lights…4609
Backup Alarm…4609
KOMTRAX PLUS…4610
Operation…4610
Interface Module…4612
Basic Precautions…4612
KOMATSU WIRELESS BRIDGE (Optional)…4613
General Information…4613
Communication Setup…4613
Switching to the KWB_SETUP Network…4613
Setting the Computer Subnet Mask and IP Address…4614
Properties…4614
Setting Up the KWB…4615
Adding Encryption…4615
Final Computer Settings…4615
Data Downloading…4616
Resetting the KWB…4616
KWB Lights…4616
FUSES AND CIRCUIT BREAKERS…4617
LUBRICATION AND SERVICE…4622
GENERAL…4622
SERVICE CAPACITIES…4622
HYDRAULIC TANK SERVICE…4622
Adding Oil…4622
COOLING SYSTEM SERVICE…4623
Radiator Filling Procedure…4623
Coolant Specifications…4623
Unacceptable Practices…4623
WHEEL MOTOR SERVICE…4623
RESERVE OIL TANK SERVICE…4624
Filling the Reserve Oil Tank (Remote Fill)…4624
Inline Screen…4624
QUICK FILL SERVICE CENTER…4625
LUBRICATION CHART…4626
10 HOUR (DAILY) INSPECTIONS…4627
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…4630
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…4630
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…4630
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…4633
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…4635
5000 HOUR MAINTENANCE CHECKS…4635
AUTOMATIC LUBRICATION SYSTEM…4636
GENERAL DESCRIPTION…4636
SYSTEM COMPONENTS…4638
Filter…4638
Hydraulic Motor and Pump…4638
Grease Reservoir…4638
Pressure Reducing Valve…4638
Flow Control Valve…4638
Solenoid Valve…4638
Vent Valve…4638
Lubrication Cycle Timer…4638
Over Pressure Cut Off Switch…4638
Grease Pressure Failure Switch…4638
Injectors…4638
Relief Valve (unloader valve)…4638
SYSTEM OPERATION…4639
Normal Operation…4639
GENERAL INSTRUCTIONS…4640
Lubricant Required For System…4640
System Priming…4640
Filter Assembly…4640
LUBRICANT PUMP…4641
Pump Housing Oil Level…4641
Pump Pressure Control…4641
INJECTORS (SL-1 Series “H”)…4642
Injector Specifications…4642
Injector Adjustment…4642
Injector Operation…4643
PREVENTIVE MAINTENANCE PROCEDURES…4644
Daily Lubrication System Inspection…4644
250 Hour Inspection…4644
1000 Hour Inspection…4644
SYSTEM CHECKOUT…4645
Lubrication Controller Check…4645
Lubrication Controller Components…4645
Lubrication Controller Adjustment…4645
SYSTEM TROUBLESHOOTING CHART…4647
COMPONENTS & SPECIFICATIONS…4650
MAJOR COMPONENT DESCRIPTIONS…4650
Truck And Engine…4650
Main Alternator…4650
AC Induction Traction Motorized Wheels…4650
Suspension…4650
Operator's Cab…4650
Power Steering…4650
Dynamic Retarding…4650
Brake System…4650
SPECIFICATIONS…4652
ENGINE…4652
AC ELECTRIC DRIVE SYSTEM…4652
DYNAMIC RETARDING…4652
BATTERY ELECTRIC SYSTEM…4652
SERVICE CAPACITIES…4652
HYDRAULIC SYSTEMS…4653
SERVICE BRAKES…4653
STEERING…4653
TIRES…4653
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…4653
WEIGHT DISTRIBUTION…4654
PAYLOAD METER III…4656
AM/FM RADIO / CD PLAYER…4686
GENERAL RADIO RECEIVER FUNCTIONS…4686
Turning On the Power…4686
One-Hour Timer…4686
Display…4687
Setting a Default Display…4687
Adjusting the Brightness of the Display…4687
Auxiliary Mode…4687
Adjusting the Receiver Settings…4687
USING THE CLOCK…4688
Setting the Clock…4688
USING THE ALARM…4688
Setting the Alarm…4688
Turning the Alarm Off…4688
Activating Snooze…4688
Setting Alarm Volume…4688
USING THE RADIO…4689
Finding a Station…4689
Setting the Presets…4689
USING THE WEATHERBAND…4690
USING THE COMPACT DISC PLAYER…4690
Playing a Compact Disc…4690
Button Functions…4690
PLAYING AN MP3 DISC…4691
MP3 Format Compatibility…4691
Root Directory…4691
Empty Directory or Folder…4691
No Folder…4691
File Name Display…4691
Pre-Programmed Playlists…4692
Playing MP3 Files…4692
Button Functions…4692
TROUBLESHOOTING…4693
CEAM022602 – Dump Truck 930E-4 Operation & Maintenance Manual…4696
COVER…4696
INTRODUCTION…4700
FOREWORD…4700
TRUCK MODEL ILLUSTRATION…4701
ABOUT THIS MANUAL…4702
ALERTS PAGE…4703
TABLE OF CONTENTS…4704
TORQUE TABLES AND CONVERSION CHARTS…4714
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…4715
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…4715
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…4716
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…4717
SAFETY…4724
GENERAL…4724
Safety Rules…4724
Safety Features…4724
Fire Extinguisher And First Aid Kit…4724
Clothing And Personal Items…4724
Leaving The Operator’s Seat…4725
Mounting And Dismounting…4725
Fire Prevention For Fuel And Oil…4725
Precautions With High Temperature Fluids…4726
Asbestos Dust Hazard Prevention…4726
Prevention Of Injury By Work Equipment…4726
Unauthorized Modification…4726
ROPS Precautions…4726
Precautions For Attachments…4727
Precautions For Starting The Truck…4727
PRECAUTIONS BEFORE OPERATION…4727
Safety At The Worksite…4727
Fire Prevention…4728
Ventilation In Enclosed Areas…4728
Preparing For Operation…4728
Mirrors, Windows And Lights…4728
In The Operator Cab (Before Starting The Engine)…4728
Seat Belts…4728
OPERATING THE TRUCK…4729
When Starting The Engine…4729
General Truck Operation…4729
Ensuring Good Visibility…4729
Traveling…4730
Traveling In Reverse…4730
Traveling On Slopes…4730
Operating On Snow Or Ice…4730
Avoid Damage To The Dump Body…4730
Driving Near High Voltage Cables…4731
Working On Loose Ground…4731
When Dumping…4731
When Loading…4731
Parking The Truck…4731
Towing…4731
WORKING NEAR BATTERIES…4732
Battery Hazard Prevention…4732
Starting With Booster Cables…4732
BEFORE PERFORMING MAINTENANCE…4733
Stopping The Engine…4733
Warning Tag…4733
Proper Tools…4733
Securing The Dump Body…4733
WHILE PERFORMING MAINTENANCE…4734
Keep The Truck Clean…4734
Attachments…4734
Working Under The Truck…4734
Rotating Fan And Belts…4734
Waste Materials…4734
Adding Fuel Or Oil…4735
Radiator Coolant Level…4735
Use Of Lighting…4735
Precautions With The Battery…4735
Handling High Pressure Hoses…4735
Precautions With High Pressure Oil…4735
Performing Maintenance Near High Temperature Or High Pressure…4735
TIRES…4736
Handling Tires…4736
Storing Tires After Removal…4736
WHEN REPAIRS ARE NECESSARY…4737
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…4738
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…4738
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…4738
CAPACITOR DISCHARGE SYSTEM…4740
Necessary Tools…4740
Warnings And Cautions…4741
Manual DC Link Capacitor Discharge Procedure…4742
Failure of the Discharge System…4744
Manual Discharge of Capacitors…4745
Short Isolated Capacitor Terminals…4747
ADDITIONAL JOB SITE RULES…4749
WARNINGS AND CAUTIONS…4750
GRADE/SPEED CHART…4750
KEY SWITCH…4750
ROPS/FOPS…4750
BATTERIES…4751
CAPACITORS…4751
CRUSHING HAZARD…4752
CYLINDER PRESSURE…4752
FILLING THE HYDRAULIC TANK…4753
HYDRAULIC OIL PRESSURE…4753
HOT OIL SPRAY…4754
WHEEL MOTOR OIL LEVEL…4754
HOT EXHAUST…4754
RADIATOR…4754
EMERGENCY LADDER…4754
ACCUMULATOR DRAIN VALVES…4754
EMERGENCY DUMP PROCEDURE…4755
EMERGENCY TOWING PROCEDURE…4755
WELDING…4755
EMERGENCY SHUTDOWN…4755
INFORMATION DISPLAY…4756
WIRELESS SIGNALS…4756
HIGH VOLTAGE…4756
LIFTING INSTRUCTIONS…4757
PRODUCT IDENTIFICATION PLATE…4758
LUBRICATION CHART…4759
OPERATING INSTRUCTIONS…4760
PREPARING FOR OPERATION…4760
WALK AROUND INSPECTION…4760
ENGINE START-UP…4764
AFTER ENGINE START-UP…4765
PRE-SHIFT BRAKE CHECK (if equipped)…4765
Events…4765
OPERATION…4766
Description…4766
Brake Test Exit Criteria…4766
PERFORMING THE BRAKE TESTS…4767
Setup…4767
Service Brake Test…4767
Parking Brake Test…4768
Retard System Test…4769
EMERGENCY STEERING SYSTEM…4769
Operation…4769
Pre-Operation Testing…4769
MACHINE OPERATION SAFETY PRECAUTIONS…4770
OPERATING ON THE HAUL ROAD…4771
STARTING ON A GRADE WITH A LOADED TRUCK…4772
PASSING…4772
LOADING…4772
Overload Speed Limit Function…4772
DUMPING…4773
Raising The Dump Body…4773
Lowering The Dump Body (When dumping on flat ground)…4774
Lowering The Dump Body (When dumping over a berm or into a crusher)…4774
TOWING…4775
Special Wiring Harness…4775
SAFE PARKING PROCEDURES…4778
NORMAL ENGINE SHUTDOWN PROCEDURE…4778
SUDDEN LOSS OF ENGINE POWER…4779
FUEL DEPLETION…4779
DISABLED TRUCK DUMPING PROCEDURE…4780
Hookup…4780
Raising the Body…4780
Lowering the Body…4780
RESERVE ENGINE OIL SYSTEM…4781
Operation…4781
Changing Oil…4781
OPERATOR CAB AND CONTROLS…4782
STEERING WHEEL AND CONTROLS…4783
Horn Button…4783
Tilt / Telescope Lever…4783
Multi-Function Turn Signal Switch…4783
DYNAMIC RETARDING…4784
Retarder Lever…4784
Brake/Retarder Pedal…4784
Throttle/Accelerator Pedal…4784
GRADE/SPEED CHART…4785
OVERHEAD PANEL AND DISPLAYS…4786
CENTER CONSOLE…4787
Directional Control Lever…4787
Override/Fault Reset Switch…4788
Engine Shutdown Switch…4788
Window Control Switches…4788
Hoist Control Lever…4788
Retard Speed Control (RSC) Adjustment Dial…4789
Retard Speed Control (RSC) Switch…4789
Data Store Button…4790
KOMTRAX Plus Snapshot In Progress Light…4790
Link Energized Light…4790
Service Engine Light…4790
12V Auxiliary Power Outlets…4790
DIAGNOSTIC PORTS…4790
KOMTRAX Plus Diagnostic Port…4790
Interface Module (IM) Diagnostic Port…4790
Payload Meter Diagnostic Port…4790
Truck Control Interface (TCI) Diagnostic Port…4790
Propulsion System Controller (PSC) Diagnostic Port…4790
Engine Diagnostic Port (CENSE)…4790
Engine Diagnostic Port (QUANTUM)…4790
OPERATOR’S SEAT…4791
Seat Belts…4791
Adjustment…4791
PASSENGER SEAT…4792
Seat Belts…4792
Adjustment…4792
HEATER / AIR CONDITIONER CONTROLS…4793
Fan Speed Control Knob…4793
Temperature Control Knob…4793
Air Flow Directional Knob…4793
Heater/Air Conditioner Vents…4793
INSTRUMENT PANEL…4794
Control Symbols…4794
Key Switch…4796
Rotating Beacon Light Switch (optional)…4796
Heated Mirror Switch (optional)…4796
AC Drive System Rest Switch…4796
Wheel Brake Lock Switch…4797
Hazard Warning Light Switch…4797
Heater/Air Conditioner Vents…4797
Engine Oil Pressure Gauge…4797
Right Turn Signal Indicator…4797
Digital Tachometer…4797
High Beam Indicator…4797
Speedometer/Payload Meter Display…4797
Left Turn Signal Indicator…4798
Coolant Temperature Gauge…4798
Lamp Check Switch…4798
Light Switch (3-Way)…4798
Ladder Light Switch…4798
Backup Light Switch…4798
Fog Light Switch…4799
Payload Meter Switch…4799
Panel Illumination Light Dimmer Switch…4799
Hydraulic Oil Temperature Gauge…4799
Engine Hourmeter…4799
Fuel Gauge…4799
OVERHEAD STATUS / WARNING INDICATORS…4800
A1. High Brake Oil Temperature…4801
B1. Low Steering Pressure…4801
C1. Low Accumulator Precharge Pressure…4802
D1. Not used…4802
E1. Low Brake Pressure…4802
A2. Low Hydraulic Tank Level…4802
B2. Low Automatic Lubrication System Pressure…4802
C2. Circuit Breaker Tripped…4802
D2. Hydraulic Oil Filter Monitor…4803
E2. Low Fuel…4803
A3. Parking Brake…4803
B3. Service Brake…4803
C3. Body Up…4803
D3. Dynamic Retarding…4803
E3. Stop Engine…4804
A4. Cranking Motor Failure…4804
B4. Backup Lights…4804
C4. Engine Shutdown Timer…4804
D4. Retard Speed Control (RSC) Indicator…4804
E4. Check Engine…4804
A5. No Power…4805
B5. Propulsion System Warning…4805
C5. Propulsion System Temperature…4805
D5. System/Component Failure…4805
E5. Battery Charging System Failure…4805
A6. No Propel…4805
B6. Propel System At Rest…4805
C6. Propel System Not Ready…4806
D6. Reduced Propulsion…4806
E6. Retard At Continuous Level…4806
D7. Brake Test Light…4806
E7. Maintenance Monitor…4806
8. Brake Test Switch…4806
REAR AXLE LIGHT BAR…4807
Backup Lights…4807
Retard Lights…4807
Brake Lights…4807
Backup Alarm…4807
KOMTRAX PLUS…4808
Operation…4808
Interface Module…4810
Basic Precautions…4810
KOMATSU WIRELESS BRIDGE (Optional)…4811
General Information…4811
Communication Setup…4811
Switching to the KWB_SETUP Network…4811
Setting the Computer Subnet Mask and IP Address…4812
Properties…4812
Setting Up the KWB…4813
Adding Encryption…4813
Final Computer Settings…4813
Data Downloading…4814
Resetting the KWB…4814
KWB Lights…4814
FUSES AND CIRCUIT BREAKERS…4815
LUBRICATION AND SERVICE…4820
GENERAL…4820
SERVICE CAPACITIES…4820
HYDRAULIC TANK SERVICE…4820
Adding Oil…4820
COOLING SYSTEM SERVICE…4821
Radiator Filling Procedure…4821
Coolant Specifications…4821
Unacceptable Practices…4821
WHEEL MOTOR SERVICE…4821
RESERVE OIL TANK SERVICE…4822
Filling the Reserve Oil Tank (Remote Fill)…4822
Inline Screen…4822
QUICK FILL SERVICE CENTER…4823
LUBRICATION CHART…4824
10 HOUR (DAILY) INSPECTIONS…4825
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…4828
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…4828
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…4828
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…4831
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…4833
5000 HOUR MAINTENANCE CHECKS…4833
AUTOMATIC LUBRICATION SYSTEM…4834
GENERAL DESCRIPTION…4834
SYSTEM COMPONENTS…4836
Filter…4836
Hydraulic Motor and Pump…4836
Grease Reservoir…4836
Pressure Reducing Valve…4836
Flow Control Valve…4836
Solenoid Valve…4836
Vent Valve…4836
Lubrication Cycle Timer…4836
Over Pressure Cut Off Switch…4836
Grease Pressure Failure Switch…4836
Injectors…4836
Relief Valve (unloader valve)…4836
SYSTEM OPERATION…4837
Normal Operation…4837
GENERAL INSTRUCTIONS…4838
Lubricant Required For System…4838
System Priming…4838
Filter Assembly…4838
LUBRICANT PUMP…4839
Pump Housing Oil Level…4839
Pump Pressure Control…4839
INJECTORS (SL-1 Series “H”)…4840
Injector Specifications…4840
Injector Adjustment…4840
Injector Operation…4841
PREVENTIVE MAINTENANCE PROCEDURES…4842
Daily Lubrication System Inspection…4842
250 Hour Inspection…4842
1000 Hour Inspection…4842
SYSTEM CHECKOUT…4843
Lubrication Controller Check…4843
Lubrication Controller Components…4843
Lubrication Controller Adjustment…4843
SYSTEM TROUBLESHOOTING CHART…4845
COMPONENTS & SPECIFICATIONS…4848
MAJOR COMPONENT DESCRIPTIONS…4848
Truck And Engine…4848
Main Alternator…4848
AC Induction Traction Motorized Wheels…4848
Suspension…4848
Operator's Cab…4848
Power Steering…4848
Dynamic Retarding…4848
Brake System…4848
SPECIFICATIONS…4850
ENGINE…4850
AC ELECTRIC DRIVE SYSTEM…4850
DYNAMIC RETARDING…4850
BATTERY ELECTRIC SYSTEM…4850
SERVICE CAPACITIES…4850
HYDRAULIC SYSTEMS…4851
SERVICE BRAKES…4851
STEERING…4851
TIRES…4851
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…4851
WEIGHT DISTRIBUTION…4852
PAYLOAD METER III…4854
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…4884
OPERATING INSTRUCTIONS…4884
GENERAL RADIO RECEIVER FUNCTIONS…4884
Turning On the Power…4884
One-Hour Timer…4884
Adjusting the Volume…4885
Display…4885
Radio Mode Displays…4885
CD Mode Displays…4885
MP3/USB/iPod Mode Displays…4885
AUX Input Displays…4886
CLOCK/ALARM Button…4886
Front Auxiliary Mode…4886
Rear Auxiliary Mode…4886
Adjusting the Receiver Audio Settings…4886
Adjusting the Receiver Menu Settings…4887
USING THE RADIO…4888
Finding a Station…4888
Setting the Presets…4888
USING THE CLOCK…4889
Setting the Clock…4889
USING THE ALARM…4889
Setting the Alarm…4889
Turning the Alarm Off…4890
Activating Snooze…4890
USING THE WEATHERBAND (USA Only)…4890
USING THE COMPACT DISC PLAYER/USB…4891
Playing A Compact Disc…4891
Button Functions…4891
PLAYING AN MP3 DISC/USB…4892
Root Directory…4892
Empty Directory or Folder…4892
No Folder…4892
File Name Display…4892
PLAYING MP3 FILES…4892
Button Functions…4892
USING AN iPOD®…4893
Playing an iPod…4893
Button Functions…4893
OPERATING TIPS…4894
Tips About The Audio System…4894
Understanding Radio Reception…4894
Care of The Compact Discs…4894
TROUBLESHOOTING…4895
CEAM022701 – Dump Truck 930E-4SE Operation & Maintenance Manual…4898
COVER…4898
INTRODUCTION…4902
FOREWORD…4902
TRUCK MODEL ILLUSTRATION…4903
ABOUT THIS MANUAL…4904
ALERTS PAGE…4905
TABLE OF CONTENTS…4906
TORQUE TABLES AND CONVERSION CHARTS…4916
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…4917
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…4917
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…4918
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…4919
SAFETY…4926
GENERAL…4926
Safety Rules…4926
Safety Features…4926
Fire Extinguisher And First Aid Kit…4926
Clothing And Personal Items…4926
Leaving The Operator’s Seat…4927
Mounting And Dismounting…4927
Fire Prevention For Fuel And Oil…4927
Precautions With High Temperature Fluids…4928
Asbestos Dust Hazard Prevention…4928
Prevention Of Injury By Work Equipment…4928
Unauthorized Modification…4928
ROPS Precautions…4928
Precautions For Attachments…4929
Precautions For Starting The Truck…4929
PRECAUTIONS BEFORE OPERATION…4929
Safety At The Worksite…4929
Fire Prevention…4930
Ventilation In Enclosed Areas…4930
Preparing For Operation…4930
Mirrors, Windows And Lights…4930
In The Operator Cab (Before Starting The Engine)…4930
Seat Belts…4930
OPERATING THE TRUCK…4931
When Starting The Engine…4931
General Truck Operation…4931
Ensuring Good Visibility…4931
Traveling…4932
Traveling In Reverse…4932
Traveling On Slopes…4932
Operating On Snow Or Ice…4932
Avoid Damage To The Dump Body…4932
Driving Near High Voltage Cables…4933
Working On Loose Ground…4933
When Dumping…4933
When Loading…4933
Parking The Truck…4933
Towing…4933
WORKING NEAR BATTERIES…4934
Battery Hazard Prevention…4934
Starting With Booster Cables…4934
BEFORE PERFORMING MAINTENANCE…4935
Stopping The Engine…4935
Warning Tag…4935
Proper Tools…4935
Securing The Dump Body…4935
WHILE PERFORMING MAINTENANCE…4936
Keep The Truck Clean…4936
Attachments…4936
Working Under The Truck…4936
Rotating Fan And Belts…4936
Waste Materials…4936
Adding Fuel Or Oil…4937
Radiator Coolant Level…4937
Use Of Lighting…4937
Precautions With The Battery…4937
Handling High Pressure Hoses…4937
Precautions With High Pressure Oil…4937
Performing Maintenance Near High Temperature Or High Pressure…4937
TIRES…4938
Handling Tires…4938
Storing Tires After Removal…4938
WHEN REPAIRS ARE NECESSARY…4939
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…4940
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…4940
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…4940
CAPACITOR DISCHARGE SYSTEM…4942
Necessary Tools…4942
Warnings And Cautions…4943
Manual DC Link Capacitor Discharge Procedure…4944
Failure of the Discharge System…4946
Manual Discharge of Capacitors…4947
Short Isolated Capacitor Terminals…4949
ADDITIONAL JOB SITE RULES…4951
WARNINGS AND CAUTIONS…4952
GRADE/SPEED CHART…4952
KEY SWITCH…4952
ROPS/FOPS…4952
BATTERIES…4953
CAPACITORS…4953
CRUSHING HAZARD…4954
CYLINDER PRESSURE…4954
FILLING THE HYDRAULIC TANK…4955
HYDRAULIC OIL PRESSURE…4955
HOT OIL SPRAY…4956
WHEEL MOTOR OIL LEVEL…4956
HOT EXHAUST…4956
RADIATOR…4956
EMERGENCY LADDER…4956
ACCUMULATOR DRAIN VALVES…4956
EMERGENCY DUMP PROCEDURE…4957
EMERGENCY TOWING PROCEDURE…4957
WELDING…4957
EMERGENCY SHUTDOWN…4957
INFORMATION DISPLAY…4958
WIRELESS SIGNALS…4958
HIGH VOLTAGE…4958
LIFTING INSTRUCTIONS…4959
PRODUCT IDENTIFICATION PLATE…4960
LUBRICATION CHART…4961
OPERATING INSTRUCTIONS…4962
PREPARING FOR OPERATION…4962
WALK AROUND INSPECTION…4962
ENGINE START-UP…4966
AFTER ENGINE START-UP…4967
PRE-SHIFT BRAKE CHECK (if equipped)…4967
Events…4967
OPERATION…4968
Description…4968
Brake Test Exit Criteria…4968
PERFORMING THE BRAKE TESTS…4969
Setup…4969
Service Brake Test…4969
Parking Brake Test…4970
Retard System Test…4971
EMERGENCY STEERING SYSTEM…4971
Operation…4971
Pre-Operation Testing…4971
MACHINE OPERATION SAFETY PRECAUTIONS…4972
OPERATING ON THE HAUL ROAD…4973
STARTING ON A GRADE WITH A LOADED TRUCK…4974
PASSING…4974
LOADING…4974
Overload Speed Limit Function…4974
DUMPING…4975
Raising The Dump Body…4975
Lowering The Dump Body (When dumping on flat ground)…4976
Lowering The Dump Body (When dumping over a berm or into a crusher)…4976
TOWING…4977
Special Wiring Harness…4977
SAFE PARKING PROCEDURES…4980
NORMAL ENGINE SHUTDOWN PROCEDURE…4980
SUDDEN LOSS OF ENGINE POWER…4981
FUEL DEPLETION…4981
DISABLED TRUCK DUMPING PROCEDURE…4982
Hookup…4982
Raising the Body…4982
Lowering the Body…4982
RESERVE ENGINE OIL SYSTEM…4983
Operation…4983
Changing Oil…4983
OPERATOR CAB AND CONTROLS…4984
STEERING WHEEL AND CONTROLS…4985
Horn Button…4985
Tilt / Telescope Lever…4985
Multi-Function Turn Signal Switch…4985
DYNAMIC RETARDING…4986
Retarder Lever…4986
Brake/Retarder Pedal…4986
Throttle/Accelerator Pedal…4986
GRADE/SPEED CHART…4987
OVERHEAD PANEL AND DISPLAYS…4988
CENTER CONSOLE…4989
Directional Control Lever…4989
Override/Fault Reset Switch…4990
Engine Shutdown Switch…4990
Window Control Switches…4990
Hoist Control Lever…4990
Retard Speed Control (RSC) Adjustment Dial…4991
Retard Speed Control (RSC) Switch…4991
Data Store Button…4992
KOMTRAX Plus Snapshot In Progress Light…4992
Link Energized Light…4992
Service Engine Light…4992
12V Auxiliary Power Outlets…4992
DIAGNOSTIC PORTS…4992
KOMTRAX Plus Diagnostic Port…4992
Interface Module (IM) Diagnostic Port…4992
Payload Meter Diagnostic Port…4992
Truck Control Interface (TCI) Diagnostic Port…4992
Propulsion System Controller (PSC) Diagnostic Port…4992
Engine Diagnostic Port (CENSE)…4992
Engine Diagnostic Port (QUANTUM)…4992
OPERATOR’S SEAT…4993
Seat Belts…4993
Adjustment…4993
PASSENGER SEAT…4994
Seat Belts…4994
Adjustment…4994
HEATER / AIR CONDITIONER CONTROLS…4995
Fan Speed Control Knob…4995
Temperature Control Knob…4995
Air Flow Directional Knob…4995
Heater/Air Conditioner Vents…4995
INSTRUMENT PANEL…4996
Control Symbols…4996
Key Switch…4998
Rotating Beacon Light Switch (optional)…4998
Heated Mirror Switch (optional)…4998
AC Drive System Rest Switch…4998
Wheel Brake Lock Switch…4999
Hazard Warning Light Switch…4999
Heater/Air Conditioner Vents…4999
Engine Oil Pressure Gauge…4999
Right Turn Signal Indicator…4999
Digital Tachometer…4999
High Beam Indicator…4999
Speedometer/Payload Meter Display…4999
Left Turn Signal Indicator…5000
Coolant Temperature Gauge…5000
Lamp Check Switch…5000
Light Switch (3-Way)…5000
Ladder Light Switch…5000
Backup Light Switch…5000
Fog Light Switch…5001
Payload Meter Switch…5001
Panel Illumination Light Dimmer Switch…5001
Hydraulic Oil Temperature Gauge…5001
Engine Hourmeter…5001
Fuel Gauge…5001
OVERHEAD STATUS / WARNING INDICATORS…5002
A1. High Brake Oil Temperature…5003
B1. Low Steering Pressure…5003
C1. Low Accumulator Precharge Pressure…5004
D1. Not used…5004
E1. Low Brake Pressure…5004
A2. Low Hydraulic Tank Level…5004
B2. Low Automatic Lubrication System Pressure…5004
C2. Circuit Breaker Tripped…5004
D2. Hydraulic Oil Filter Monitor…5005
E2. Low Fuel…5005
A3. Parking Brake…5005
B3. Service Brake…5005
C3. Body Up…5005
D3. Dynamic Retarding…5005
E3. Stop Engine…5006
A4. Cranking Motor Failure…5006
B4. Backup Lights…5006
C4. Engine Shutdown Timer…5006
D4. Retard Speed Control (RSC) Indicator…5006
E4. Check Engine…5006
A5. No Power…5007
B5. Propulsion System Warning…5007
C5. Propulsion System Temperature…5007
D5. System/Component Failure…5007
A6. No Propel…5007
B6. Propel System At Rest…5007
C6. Propel System Not Ready…5008
D6. Reduced Propulsion…5008
E6. Retard At Continuous Level…5008
D7. Brake Test Light…5008
E7. Maintenance Monitor…5008
8. Brake Test Switch…5008
REAR AXLE LIGHT BAR…5009
Backup Lights…5009
Retard Lights…5009
Brake Light…5009
Backup Alarm…5009
KOMTRAX PLUS…5010
Operation…5010
Interface Module…5012
Basic Precautions…5012
KOMATSU WIRELESS BRIDGE (Optional)…5013
General Information…5013
Communication Setup…5013
Switching to the KWB_SETUP Network…5013
Setting the Computer Subnet Mask and IP Address…5014
Properties…5014
Setting Up the KWB…5015
Adding Encryption…5015
Final Computer Settings…5015
Data Downloading…5016
Resetting the KWB…5016
KWB Lights…5016
FUSES AND CIRCUIT BREAKERS…5017
LUBRICATION AND SERVICE…5022
GENERAL…5022
SERVICE CAPACITIES…5022
HYDRAULIC TANK SERVICE…5022
Adding Oil…5022
COOLING SYSTEM SERVICE…5023
Radiator Filling Procedure…5023
Coolant Specifications…5023
Unacceptable Practices…5023
WHEEL MOTOR SERVICE…5023
RESERVE OIL TANK SERVICE…5024
Filling the Reserve Oil Tank (Remote Fill)…5024
Inline Screen…5024
QUICK FILL SERVICE CENTER…5025
LUBRICATION CHART…5026
10 HOUR (DAILY) INSPECTIONS…5027
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…5029
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…5029
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…5029
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…5032
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…5034
5000 HOUR MAINTENANCE CHECKS…5034
AUTOMATIC LUBRICATION SYSTEM…5036
GENERAL DESCRIPTION…5036
SYSTEM COMPONENTS…5038
Filter…5038
Hydraulic Motor and Pump…5038
Grease Reservoir…5038
Pressure Reducing Valve…5038
Flow Control Valve…5038
Solenoid Valve…5038
Vent Valve…5038
Lubrication Cycle Timer…5038
Over Pressure Cut Off Switch…5038
Grease Pressure Failure Switch…5038
Injectors…5038
Relief Valve (unloader valve)…5038
SYSTEM OPERATION…5039
Normal Operation…5039
GENERAL INSTRUCTIONS…5040
Lubricant Required For System…5040
System Priming…5040
Filter Assembly…5040
LUBRICANT PUMP…5041
Pump Housing Oil Level…5041
Pump Pressure Control…5041
INJECTORS (SL-1 Series “H”)…5042
Injector Specifications…5042
Injector Adjustment…5042
Injector Operation…5043
PREVENTIVE MAINTENANCE PROCEDURES…5044
Daily Lubrication System Inspection…5044
250 Hour Inspection…5044
1000 Hour Inspection…5044
SYSTEM CHECKOUT…5045
Lubrication Controller Check…5045
Lubrication Controller Components…5045
Lubrication Controller Adjustment…5045
SYSTEM TROUBLESHOOTING CHART…5047
COMPONENTS & SPECIFICATIONS…5050
MAJOR COMPONENT DESCRIPTIONS…5050
Truck And Engine…5050
Main Alternator…5050
AC Induction Traction Motorized Wheels…5050
Suspension…5050
Operator's Cab…5050
Power Steering…5050
Dynamic Retarding…5050
Brake System…5050
SPECIFICATIONS…5052
ENGINE…5052
AC ELECTRIC DRIVE SYSTEM…5052
DYNAMIC RETARDING…5052
BATTERY ELECTRIC SYSTEM…5052
SERVICE CAPACITIES…5052
HYDRAULIC SYSTEMS…5053
SERVICE BRAKES…5053
STEERING…5053
TIRES…5053
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…5053
WEIGHT DISTRIBUTION…5054
PAYLOAD METER III…5056
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…5086
OPERATING INSTRUCTIONS…5086
GENERAL RADIO RECEIVER FUNCTIONS…5086
Turning On the Power…5086
One-Hour Timer…5086
Adjusting the Volume…5087
Display…5087
Radio Mode Displays…5087
CD Mode Displays…5087
MP3/USB/iPod Mode Displays…5087
AUX Input Displays…5088
CLOCK/ALARM Button…5088
Front Auxiliary Mode…5088
Rear Auxiliary Mode…5088
Adjusting the Receiver Audio Settings…5088
Adjusting the Receiver Menu Settings…5089
USING THE RADIO…5090
Finding a Station…5090
Setting the Presets…5090
USING THE CLOCK…5091
Setting the Clock…5091
USING THE ALARM…5091
Setting the Alarm…5091
Turning the Alarm Off…5092
Activating Snooze…5092
USING THE WEATHERBAND (USA Only)…5092
USING THE COMPACT DISC PLAYER/USB…5093
Playing A Compact Disc…5093
Button Functions…5093
PLAYING AN MP3 DISC/USB…5094
Root Directory…5094
Empty Directory or Folder…5094
No Folder…5094
File Name Display…5094
PLAYING MP3 FILES…5094
Button Functions…5094
USING AN iPOD®…5095
Playing an iPod…5095
Button Functions…5095
OPERATING TIPS…5096
Tips About The Audio System…5096
Understanding Radio Reception…5096
Care of The Compact Discs…5096
TROUBLESHOOTING…5097
CEAM024203 – Dump Truck 930E-4 Operation & Maintenance Manual…5100
1 INTRODUCTION…5113
FOREWORD…5113
ABOUT THIS MANUAL…5114
WARNINGS…5115
CALIFORNIA PROPOSITION 65 WARNINGS…5115
ALERTS…5116
TRUCK MODEL ILLUSTRATION…5117
NON-OEM PARTS IN CRITICAL SYSTEMS…5118
2 STANDARD CHARTS AND TABLES…5121
GENERAL INFORMATION…5121
EFFECT OF SPECIAL LUBRICANTS…5121
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…5121
STANDARD TIGHTENING TORQUES…5122
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…5122
SAE GRADE 5 AND GRADE 8 CAP SCREWS…5123
SAE GRADE 9 CAP SCREWS…5124
T-BOLT CLAMPS…5124
SPLIT FLANGE CLAMPS…5125
FLARED TUBE AND HOSE FITTINGS…5125
JIC 37° SWIVEL NUTS…5126
PIPE THREAD FITTINGS…5127
O-RING BOSS FITTINGS…5128
O-RING FACE SEAL FITTINGS…5129
CONVERSION MULTIPLIERS…5130
METRIC TO ENGLISH…5130
ENGLISH TO METRIC…5131
TEMPERATURE CONVERSIONS…5132
3 GENERAL SAFETY…5135
GENERAL SAFETY…5135
Safety Rules…5135
Truck Safety Features…5135
Clothing And Personal Items…5135
Unauthorized Modification…5135
Leaving The Operator’s Seat…5135
Mounting And Dismounting…5135
Fire Extinguishers And First Aid Kits…5136
Precautions For High Temperature Fluids…5136
Asbestos Dust Hazard Prevention…5136
Fire Prevention…5136
ROPS Precautions…5136
Preventing Injury From Work Equipment…5137
Precautions For Optional Attachments…5137
Precautions When Starting The Machine…5137
PRECAUTIONS FOR TRUCK OPERATION…5138
Safety Is Thinking Ahead…5138
Safety At The Worksite…5138
Preparing For Operation…5138
Ventilation For Enclosed Areas…5138
Mirrors, Windows, And Lights…5138
Before Starting The Engine…5138
Seat Belts…5138
Emergency Egress Ladders…5139
OPERATING THE MACHINE…5140
General Information…5140
Starting The Engine…5140
Traveling In The Machine…5140
Traveling In Reverse…5140
Traveling On Slopes…5141
Traveling On Snow…5141
Traveling Near High Voltage Cables…5141
Traveling On Loose Ground…5141
Ensuring Good Visibility…5141
Avoid Damage To The Dump Body…5141
Safe Parking Of The Machine…5141
Loading The Machine…5142
Dumping The Machine…5142
Towing The Machine…5142
EXTERIOR LIGHTING…5143
Fog Lights…5143
Headlights…5143
Brake Light…5143
Retard Light…5144
Clearance/Turn Signal Lights…5144
Backup Lights…5145
Retard Lights…5145
Brake Lights…5145
Backup Alarm…5145
HID Backup Light…5145
PRECAUTIONS FOR MAINTENANCE…5146
BEFORE PERFORMING MAINTENANCE…5146
Securing The Dump Body…5146
DURING MAINTENANCE…5147
Warning Tag…5147
Proper Tools…5147
Attachments…5147
Working Under The Machine…5147
Keeping The Machine Clean…5147
Adding Fuel Or Oil To The Machine…5147
Radiator Coolant Level…5148
Use of Lighting…5148
Handling High Pressure Hoses…5148
Precautions With High Pressure Oil…5148
Maintenance Near High Temperatures and High Pressures…5148
Rotating Fan and Belts…5148
Waste Materials…5148
Use of Tie-Off Anchor During Maintenance…5149
Handling Tires…5149
Tire Maintenance…5149
Storing Tires After Removal…5150
Battery Hazard Prevention…5150
Jump Starting With Booster Cables…5151
Jump Starting With Receptacles…5151
WHEN REPAIRS ARE NECESSARY…5152
Observe The Following Precautions…5152
SPECIAL PRECAUTIONS…5153
Preliminary Procedures Before Welding or Performing Maintenance…5153
Engine Shutdown Procedure Before Welding or Performing Maintenan…5153
Discharging Control Cabinet Capacitors…5154
4 WARNING AND CAUTIONS…5157
GENERAL INFORMATION…5157
PIN PLATE…5157
GRADE SPEED CHART…5158
MACHINE SAFETY…5158
KEY SWITCH…5160
OIL FILL AND CHECK…5161
HIGH PRESSURES…5162
BATTERY AND ENGINE SHUTDOWN…5164
HIGH VOLTAGE…5166
WELDING…5167
LIFTING POINTS…5168
EMERGENCY DUMPING…5169
ROPS/FOPS…5169
TOWING…5169
LUBRICATION CHART…5170
5 OPERATING INSTRUCTIONS…5173
PREPARING FOR OPERATION…5173
Safety Is Thinking Ahead…5173
Walk Around Inspection…5173
RETRACTABLE LADDER SYSTEM (If Equipped)…5177
GENERAL INFORMATION…5177
LADDER SYSTEM DESCRIPTION…5177
LADDER SYSTEM OPERATION…5177
In-Cab Control Panel…5178
Ground Level Control Box…5180
Emergency Down Valve…5180
PRE-SHIFT BRAKE TEST…5181
OPERATION…5181
Service Brake Test…5182
Parking Brake Test…5182
Retard System Test…5183
Brake Test Exit Criteria…5183
TRUCK OPERATION…5184
ENGINE START-UP SAFETY…5184
After Engine Has Started…5184
MACHINE OPERATION SAFETY PRECAUTIONS…5185
Machine Operation on the Haul Road…5186
Starting on a Grade With a Loaded Truck…5186
Retarding on a Grade…5186
Passing…5187
Loading…5187
Overload Speed Limit Function…5188
Dumping…5188
Lowering the Dump Body (When Dumping on Flat Ground)…5189
Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush…5189
SUDDEN LOSS OF ENGINE POWER…5190
EMERGENCY STEERING SYSTEM…5190
Operation…5190
Pre-Operation Testing…5190
Additional Guidelines…5191
FUEL DEPLETION…5191
SAFE PARKING PROCEDURES…5192
NORMAL ENGINE SHUTDOWN PROCEDURE…5192
DISABLED TRUCK CONNECTORS…5194
GENERAL INFORMATION…5194
HOIST SYSTEM…5194
Hookup…5194
Dumping Procedure…5194
TOWING…5196
SPECIAL WIRING HARNESS…5196
TOWING PROCEDURE…5196
PAYLOAD METER III SYSTEM…5199
GENERAL INFORMATION…5199
Data Summary…5199
Data Gathering…5199
COMPONENT DESCRIPTION…5199
Operator Display…5199
Operator Switch…5199
Brake Lock Switch…5199
Payload Meter Module…5200
Communications Ports…5200
Load Lights…5200
OPERATORS DISPLAY AND SWITCH…5200
Reading the Load Display…5200
Setting the Operator ID…5201
Load and Ton Counter…5201
Viewing Live Sensor Data…5201
Other Display Messages…5201
HAUL CYCLE WARNING FLAGS…5202
Haul Cycle Data…5202
Haul Cycle Warning Flags…5203
PC SOFTWARE OVERVIEW…5205
SYSTEM CONFIGURATION…5205
Connecting to the Payload Meter…5205
Displayed Payload Units…5206
Connection Menu…5206
Configure the Payload Meter…5206
Setting the Date and Time…5206
Setting the Truck Type and Serial Number…5207
Setting the Gauge Display Units…5207
Setting the Carryback Alarm Threshold…5207
Setting the Truck Number…5208
Setting the Komatsu Distributor…5208
Setting the Komatsu Customer…5208
Clean Truck Tare Calibration…5208
Inclinometer Calibration…5209
DOWNLOADING PAYLOAD DATA…5209
UPLOADING DATA…5210
DATA ANALYSIS…5211
Creating a Query…5211
Payload Detail Screen…5212
Creating Reports…5212
Creating Graphs…5212
Exporting Data…5213
Importing Data…5213
Deleting Haul Cycle Records…5213
Viewing Alarms…5214
Deleting Alarm Records…5214
Patent Acknowledgment…5214
AUTOMATIC LUBRICATION SYSTEM…5215
GENERAL INFORMATION…5215
COMPONENT DESCRIPTION…5215
Filter…5216
Hydraulic Motor and Pump…5216
Grease Reservoir…5216
Pressure Reducing Valve…5216
Flow Control Valve…5216
Solenoid Valve…5217
Vent Valve…5217
Lubrication Cycle Timer…5217
Pressure Cut Off Switch…5217
Injectors…5219
Grease Pressure Failure Switch…5219
Relief Valve (unloader valve)…5219
SYSTEM OPERATION…5219
Filling The Reservoir…5219
Priming The Automatic Lubrication System…5220
PREVENTIVE MAINTENANCE PROCEDURES…5220
Daily Lubrication System Inspection…5220
250 Hour Inspection…5221
1000 Hour Inspection…5221
SYSTEM CHECKOUT…5221
General Checks…5221
Lubrication Controller Components…5222
RESERVE ENGINE OIL SYSTEM (If Equipped)…5223
Operation…5223
Changing Oil…5223
6 OPERATOR CAB AND CONTROLS…5227
CAB INTERIOR…5227
STEERING WHEEL AND CONTROLS…5228
Horn Button…5228
Tilt / Telescope Lever…5228
Multi-Function Turn Signal Switch…5228
Turn Signal Operation…5228
High Beam Headlight Operation…5228
Windshield Wiper Operation…5228
PEDALS AND RETARDER LEVER…5229
DYNAMIC RETARDING…5229
RETARDER LEVER…5229
BRAKE/RETARDER PEDAL…5229
ACCELERATOR PEDAL…5229
OVERHEAD PANEL AND DISPLAYS…5230
RADIO SPEAKERS…5230
WARNING ALARM BUZZER…5230
CAB RADIO…5230
WARNING LIGHT DIMMER CONTROL…5230
STATUS/WARNING INDICATOR LIGHT PANEL…5230
AIR CLEANER VACUUM GAUGES…5230
WINDSHIELD WIPERS…5230
CAMERA MONITOR (OPTIONAL)…5230
CENTER CONSOLE…5231
DIRECTIONAL CONTROL LEVER…5231
OVERRIDE/FAULT RESET SWITCH…5231
ENGINE STOP SWITCH…5232
WINDOW CONTROL SWITCHES…5232
HOIST CONTROL LEVER…5232
Raising The Dump Body…5232
Lowering The Dump Body…5232
RETARD SPEED CONTROL (RSC) ADJUST DIAL…5232
RETARD SPEED CONTROL (RSC) SWITCH…5233
DATA STORE BUTTON…5233
KOMTRAX PLUS SNAPSHOT IN PROGRESS LIGHT…5233
LINK ENERGIZED LIGHT…5233
SERVICE ENGINE LIGHT…5233
12V AUXILIARY POWER OUTLETS…5233
FIRE SUPPRESSION CONTROL OUTLET…5233
COMMUNICATION RADIO OULET…5233
DIAGNOSTIC PORTS…5234
KOMTRAX Plus …5234
INTERFACE MODULE (IM)…5234
PAYLOAD METER…5234
TRUCK CONTROL INTERFACE (TCI)…5234
PROPULSION SYSTEM CONTROLLER (PSC)…5234
ENGINE (CENSE)…5234
ENGINE (QUANTUM)…5234
OPERATOR SEAT (Standard)…5235
SEAT BELTS…5235
ADJUSTMENT…5235
PASSENGER SEAT (Standard)…5237
SEAT BELTS…5237
ADJUSTMENT…5237
OPERATOR SEAT (Optional)…5238
SEAT BELTS…5238
ADJUSTMENT…5238
PASSENGER SEAT (Optional)…5239
SEAT BELTS…5239
ADJUSTMENT…5239
HEATER / AIR CONDITIONER CONTROLS…5241
Fan Speed Control Knob…5241
Temperature Control Knob…5241
Air Flow Directional Knob…5241
Heater/Air Conditioner Vents…5241
INSTRUMENT PANEL …5242
CONTROL SYMBOLS…5242
Key Switch…5243
Grid Dryer (Optional)…5243
Camera System (Optional)…5244
Rotating Beacon Light Switch (Optional)…5244
Heated Mirror Switch (Optional)…5244
Rest Switch…5244
Wheel Brake Lock Control Switch…5245
Hazard Warning Light Switch…5245
Cab/Air Conditioner Vents…5245
Engine Oil Pressure Gauge…5245
Right Turn Signal Indicator…5246
Tachometer…5246
High Beam Indicator…5246
Speedometer/Payload Meter Display…5246
Left Turn Signal Indicator…5246
Coolant Temperature Gauge…5246
Lamp Test Switch…5246
Light Switch…5246
Ladder Light Switch…5247
Manual Backup Switch…5247
Fog Light Switch…5247
Payload Meter Switch…5247
Panel Light Dimmer…5247
Hydraulic Oil Temperature Gauge…5247
Hourmeter…5248
Fuel Level Gauge…5248
OVERHEAD STATUS/WARNING INDICATOR…5249
STATUS / WARNING INDICATOR LIGHT SYMBOLS…5250
High Hydraulic Oil Temperature…5250
Low Steering Pressure…5250
Low Accumulator Precharge Pressure…5251
Low Brake Pressure…5251
Low Hydraulic Tank Level…5251
Automatic Lubrication System Pressure…5251
Circuit Breaker Tripped…5251
Hydraulic Oil Filter Monitor…5251
Low Fuel…5252
Parking Brake…5252
Service Brake…5252
Body Up…5252
Dynamic Retarding…5252
Stop Engine…5252
Cranking Motor Failure…5253
Manual Backup Lights…5253
Engine Shutdown Timer…5253
Retard Speed Control (RSC) Indicator…5253
Check Engine…5253
No Power…5253
Propulsion System Warning…5254
Propulsion System Temperature…5254
System/Component Failure…5254
Battery Charging System Failure…5254
No Propel…5254
Propel System at Rest…5254
Propel System Not Ready…5254
Reduced Propulsion…5255
Retard at Continuous Level…5255
Brake Test Light (If Equipped)…5255
Maintenance Monitor…5255
Brake Test Switch (If Equipped)…5255
KOMTRAX Plus…5256
KOMTRAX Plus OPERATION…5256
Basic Precautions…5256
Interface Module…5257
DOWNLOADING KOMTRAX Plus DATA…5258
GENERAL INFORMATION…5258
KOMTRAX Plus DOWNLOADING PROCEDURE…5258
Location of Downloaded Files…5258
UPLOADING KOMTRAX Plus DATA…5259
ORBCOMM…5260
KOMATSU WIRELESS BRIDGE (Optional)…5261
General Information…5261
Communication Setup…5261
Switching to the KWB_SETUP Network…5261
Setting the Computer Subnet Mask and IP Address…5262
Setting Up the KWB…5262
Adding Encryption…5263
Final Computer Settings…5263
Downloading Data…5263
Resetting the KWB…5264
FUSES AND CIRCUIT BREAKERS…5265
FUSE BLOCK #1…5265
FUSE BLOCK #2…5266
FUSE BLOCK #3…5266
FUSE BLOCK #4…5267
FUSE HOLDERS…5267
CIRCUIT BREAKERS…5267
7 LUBRICATION AND SERVICE…5269
GENERAL INFORMATION…5269
HYDRAULIC SYSTEM SERVICE…5269
Hydraulic Tank…5269
Hydraulic Filters…5270
Hydraulic Pump Drive Shaft…5270
WHEEL MOTOR SERVICE…5270
COOLANT LEVEL SERVICE…5270
Radiator Filling Procedure…5271
Coolant Specifications…5271
Unacceptable Practices…5271
RESERVE ENGINE OIL SERVICE…5271
Reserve Oil Tank Filling Procedure (Remote Fill)…5272
Inline Screen…5272
CAB AIR FILTER SERVICE…5272
FUEL SYSTEM SERVICE…5273
Fuel Tank Cleaning…5273
Fuel Filter Service…5273
INTAKE AIR CLEANER SERVICE…5274
QUICK FILL SERVICE CENTER…5275
LUBRICATION CHART…5276
EVERY 10 HOUR (DAILY) MAINTENANCE…5277
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5279
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5280
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…5281
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…5283
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…5285
EVERY 5000 HOUR MAINTENANCE…5286
8 SPECIFICATIONS…5289
MAJOR COMPONENT DESCRIPTION…5289
Truck and Engine…5289
Traction Alternator…5289
Main Control Cabinet…5289
AC Induction Traction Motorized Wheels…5289
Suspension…5289
Operator's Cab…5289
Power Steering…5289
Dynamic Retarding Grid…5289
Brake System…5289
SPECIFICATIONS…5290
Engine…5290
AC Electric Drive System…5290
Dynamic Retarding…5290
Battery Electric System…5290
Service Capacities…5290
Hydraulic Systems…5290
Service Brakes…5290
Steering…5290
Standard Dump Body Capacities and Dimensions…5290
Tires…5290
Weight Distribution…5291
Overall Truck Dimensions…5291
9 RADIO…5293
RADIO OPERATION…5293
GENERAL RADIO RECEIVER FUNCTIONS…5293
Turning On the Power…5293
One-Hour Timer…5294
Finding a Station…5294
Setting the Presets…5294
Adjusting the Receiver Audio Settings…5294
Display…5295
Adjusting the Receiver Menu Settings…5295
Front Auxiliary Mode…5296
Rear Auxiliary Mode…5296
CLOCK…5297
Clock/Alarm Button…5297
Setting the Clock…5297
Setting the Alarm…5297
Turning the Alarm Off…5298
Activating Snooze…5298
CD PLAYER…5299
Playing a Compact Disc…5299
Playing an MP3 DISC…5299
CD Mode Displays…5299
Button Functions…5299
MP3 PLAYER…5301
Playing MP3 Files…5301
MP3 Mode Displays…5301
Button Functions…5302
iPod®…5303
Playing an iPod®…5303
iPod® Mode Displays…5303
Button Functions…5303
WEATHERBAND (USA Only)…5305
TROUBLESHOOTING…5306
Tips About the Audio System…5306
Understanding Radio Reception…5306
Care of the Compact Discs…5306
CEAM024302 – Dump Truck 930E-4 Operation & Maintenance Manual…5307
COVER…5307
INTRODUCTION…5311
FOREWORD…5311
TRUCK MODEL ILLUSTRATION…5312
ABOUT THIS MANUAL…5313
ALERTS PAGE…5314
TABLE OF CONTENTS…5315
TORQUE TABLES AND CONVERSION CHARTS…5325
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…5326
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…5326
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…5327
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…5328
SAFETY…5335
GENERAL…5335
Safety Rules…5335
Safety Features…5335
Fire Extinguisher And First Aid Kit…5335
Clothing And Personal Items…5335
Leaving The Operator’s Seat…5336
Mounting And Dismounting…5336
Fire Prevention For Fuel And Oil…5336
Precautions With High Temperature Fluids…5337
Asbestos Dust Hazard Prevention…5337
Prevention Of Injury By Work Equipment…5337
Unauthorized Modification…5337
ROPS Precautions…5337
Precautions For Attachments…5338
Precautions For Starting The Truck…5338
PRECAUTIONS BEFORE OPERATION…5338
Safety At The Worksite…5338
Fire Prevention…5339
Ventilation In Enclosed Areas…5339
Preparing For Operation…5339
Mirrors, Windows And Lights…5339
In The Operator Cab (Before Starting The Engine)…5339
Seat Belts…5339
OPERATING THE TRUCK…5340
When Starting The Engine…5340
General Truck Operation…5340
Ensuring Good Visibility…5340
Traveling…5341
Traveling In Reverse…5341
Traveling On Slopes…5341
Operating On Snow Or Ice…5341
Avoid Damage To The Dump Body…5341
Driving Near High Voltage Cables…5342
Working On Loose Ground…5342
When Dumping…5342
When Loading…5342
Parking The Truck…5342
Towing…5342
WORKING NEAR BATTERIES…5343
Battery Hazard Prevention…5343
Starting With Booster Cables…5343
BEFORE PERFORMING MAINTENANCE…5344
Stopping The Engine…5344
Warning Tag…5344
Proper Tools…5344
Securing The Dump Body…5344
WHILE PERFORMING MAINTENANCE…5345
Keep The Truck Clean…5345
Attachments…5345
Working Under The Truck…5345
Rotating Fan And Belts…5345
Waste Materials…5345
Adding Fuel Or Oil…5346
Radiator Coolant Level…5346
Use Of Lighting…5346
Precautions With The Battery…5346
Handling High Pressure Hoses…5346
Precautions With High Pressure Oil…5346
Performing Maintenance Near High Temperature Or High Pressure…5346
TIRES…5347
Handling Tires…5347
Storing Tires After Removal…5347
WHEN REPAIRS ARE NECESSARY…5348
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS…5349
PRELIMINARY PROCEDURES BEFORE WELDING OR PERFORMING MAINTENANCE…5349
ENGINE SHUTDOWN PROCEDURE BEFORE WELDING OR PERFORMING MAINTENANCE…5349
CAPACITOR DISCHARGE SYSTEM…5351
Necessary Tools…5351
Warnings And Cautions…5352
Manual DC Link Capacitor Discharge Procedure…5353
Failure of the Discharge System…5355
Manual Discharge of Capacitors…5356
Short Isolated Capacitor Terminals…5358
ADDITIONAL JOB SITE RULES…5360
WARNINGS AND CAUTIONS…5361
GRADE/SPEED CHART…5361
KEY SWITCH…5361
ROPS/FOPS…5361
BATTERIES…5362
CAPACITORS…5362
CRUSHING HAZARD…5363
CYLINDER PRESSURE…5363
FILLING THE HYDRAULIC TANK…5364
HYDRAULIC OIL PRESSURE…5364
HOT OIL SPRAY…5365
WHEEL MOTOR OIL LEVEL…5365
HOT EXHAUST…5365
RADIATOR…5365
EMERGENCY LADDER…5365
ACCUMULATOR DRAIN VALVES…5365
EMERGENCY DUMP PROCEDURE…5366
EMERGENCY TOWING PROCEDURE…5366
WELDING…5366
EMERGENCY SHUTDOWN…5366
INFORMATION DISPLAY…5367
WIRELESS SIGNALS…5367
HIGH VOLTAGE…5367
LIFTING INSTRUCTIONS…5368
PRODUCT IDENTIFICATION PLATE…5369
LUBRICATION CHART…5370
OPERATING INSTRUCTIONS…5371
PREPARING FOR OPERATION…5371
WALK AROUND INSPECTION…5371
RETRACTABLE LADDER SYSTEM (Optional)…5375
Description…5375
Normal Operation…5375
General Safety…5375
IN-CAB CONTROL PANEL…5376
Digital Display Screen…5376
Command Buttons…5376
USING THE IN-CAB CONTROL PANEL…5377
Raising the Ladder…5378
Lowering the Ladder…5378
USING THE GROUND LEVEL CONTROL BOX…5379
Raising the Ladder…5379
Lowering the Ladder…5379
EMERGENCY OPERATION…5379
ENGINE START-UP…5380
AFTER ENGINE START-UP…5381
PRE-SHIFT BRAKE CHECK…5381
Events…5381
OPERATION…5382
Description…5382
Brake Test Exit Criteria…5382
PERFORMING THE BRAKE TESTS…5383
Setup…5383
Service Brake Test…5383
Parking Brake Test…5384
Retard System Test…5385
EMERGENCY STEERING SYSTEM…5385
Operation…5385
Pre-Operation Testing…5385
MACHINE OPERATION SAFETY PRECAUTIONS…5386
OPERATING ON THE HAUL ROAD…5387
STARTING ON A GRADE WITH A LOADED TRUCK…5388
PASSING…5388
LOADING…5388
Overload Speed Limit Function…5388
DUMPING…5389
Raising The Dump Body…5389
Lowering The Dump Body (When dumping on flat ground)…5390
Lowering The Dump Body (When dumping over a berm or into a crusher)…5390
TOWING…5391
Special Wiring Harness…5391
SAFE PARKING PROCEDURES…5394
NORMAL ENGINE SHUTDOWN PROCEDURE…5394
SUDDEN LOSS OF ENGINE POWER…5395
FUEL DEPLETION…5395
DISABLED TRUCK DUMPING PROCEDURE…5396
Hookup…5396
Raising the Body…5396
Lowering the Body…5396
RESERVE ENGINE OIL SYSTEM…5397
Operation…5397
Changing Oil…5397
OPERATOR CAB AND CONTROLS…5399
STEERING WHEEL AND CONTROLS…5400
Horn Button…5400
Tilt / Telescope Lever…5400
Multi-Function Turn Signal Switch…5400
DYNAMIC RETARDING…5401
Retarder Lever…5401
Brake/Retarder Pedal…5401
Throttle/Accelerator Pedal…5401
GRADE/SPEED CHART…5402
OVERHEAD PANEL AND DISPLAYS…5403
CENTER CONSOLE…5404
Directional Control Lever…5404
Override/Fault Reset Switch…5405
Engine Shutdown Switch…5405
Window Control Switches…5405
Hoist Control Lever…5405
Retard Speed Control (RSC) Adjustment Dial…5406
Retard Speed Control (RSC) Switch…5406
Data Store Button…5407
KOMTRAX Plus Snapshot In Progress Light…5407
Link Energized Light…5407
Service Engine Light…5407
12V Auxiliary Power Outlets…5407
Fire Suppression Control Outlet…5407
Communication Radio Outlet…5407
DIAGNOSTIC PORTS…5407
KOMTRAX Plus Diagnostic Port…5407
Interface Module (IM) Diagnostic Port…5407
Payload Meter Diagnostic Port…5407
Truck Control Interface (TCI) Diagnostic Port…5407
Propulsion System Controller (PSC) Diagnostic Port…5407
Engine Diagnostic Port (CENSE)…5407
Engine Diagnostic Port (QUANTUM)…5407
OPERATOR’S SEAT (STANDARD SEAT)…5408
Seat Belts…5408
Adjustment…5408
PASSENGER SEAT (STANDARD SEAT)…5409
Seat Belts…5409
Adjustment…5409
OPERATOR’S SEAT (OPTIONAL SEAT)…5410
Seat Belts…5410
Adjustment…5410
PASSENGER SEAT (OPTIONAL SEAT)…5411
Seat Belts…5411
Adjustment…5411
HEATER / AIR CONDITIONER CONTROLS…5412
Fan Speed Control Knob…5412
Temperature Control Knob…5412
Air Flow Directional Knob…5412
Heater/Air Conditioner Vents…5412
INSTRUMENT PANEL…5413
Control Symbols…5413
Key Switch…5415
Rotating Beacon Light Switch (optional)…5415
Heated Mirror Switch (optional)…5415
AC Drive System Rest Switch…5415
Wheel Brake Lock Switch…5416
Hazard Warning Light Switch…5416
Heater/Air Conditioner Vents…5416
Engine Oil Pressure Gauge…5416
Right Turn Signal Indicator…5416
Digital Tachometer…5416
High Beam Indicator…5416
Speedometer/Payload Meter Display…5416
Left Turn Signal Indicator…5417
Coolant Temperature Gauge…5417
Lamp Check Switch…5417
Light Switch (3-Way)…5417
Ladder Light Switch…5417
Backup Light Switch…5417
Fog Light Switch…5418
Payload Meter Switch…5418
Panel Illumination Light Dimmer Switch…5418
Hydraulic Oil Temperature Gauge…5418
Engine Hourmeter…5418
Fuel Gauge…5418
OVERHEAD STATUS / WARNING INDICATORS…5419
A1. High Brake Oil Temperature…5420
B1. Low Steering Pressure…5420
C1. Low Accumulator Precharge Pressure…5421
D1. Not used…5421
E1. Low Brake Pressure…5421
A2. Low Hydraulic Tank Level…5421
B2. Low Automatic Lubrication System Pressure…5421
C2. Circuit Breaker Tripped…5421
D2. Hydraulic Oil Filter Monitor…5422
E2. Low Fuel…5422
A3. Parking Brake…5422
B3. Service Brake…5422
C3. Body Up…5422
D3. Dynamic Retarding…5422
E3. Stop Engine…5423
A4. Cranking Motor Failure…5423
B4. Backup Lights…5423
C4. Engine Shutdown Timer…5423
D4. Retard Speed Control (RSC) Indicator…5423
E4. Check Engine…5423
A5. No Power…5424
B5. Propulsion System Warning…5424
C5. Propulsion System Temperature…5424
D5. System/Component Failure…5424
A6. No Propel…5424
B6. Propel System At Rest…5424
C6. Propel System Not Ready…5425
D6. Reduced Propulsion…5425
E6. Retard At Continuous Level…5425
D7. Brake Test Light…5425
E7. Maintenance Monitor…5425
8. Brake Test Switch…5425
REAR AXLE LIGHT BAR…5426
Backup Lights…5426
Retard Lights…5426
Brake Lights…5426
Backup Alarm…5426
KOMTRAX PLUS…5427
Operation…5427
Interface Module…5429
Basic Precautions…5429
KOMATSU WIRELESS BRIDGE (Optional)…5430
General Information…5430
Communication Setup…5430
Switching to the KWB_SETUP Network…5430
Setting the Computer Subnet Mask and IP Address…5431
Properties…5431
Setting Up the KWB…5432
Adding Encryption…5432
Final Computer Settings…5432
Data Downloading…5433
Resetting the KWB…5433
KWB Lights…5433
FUSES AND CIRCUIT BREAKERS…5434
LUBRICATION AND SERVICE…5439
GENERAL…5439
SERVICE CAPACITIES…5439
HYDRAULIC TANK SERVICE…5439
Adding Oil…5439
COOLING SYSTEM SERVICE…5440
Radiator Filling Procedure…5440
Coolant Specifications…5440
Unacceptable Practices…5440
WHEEL MOTOR SERVICE…5440
RESERVE OIL TANK SERVICE…5441
Filling the Reserve Oil Tank (Remote Fill)…5441
Inline Screen…5441
QUICK FILL SERVICE CENTER…5442
LUBRICATION CHART…5443
10 HOUR (DAILY) INSPECTIONS…5444
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…5447
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…5447
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…5447
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…5450
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…5452
5000 HOUR MAINTENANCE CHECKS…5452
AUTOMATIC LUBRICATION SYSTEM…5453
GENERAL DESCRIPTION…5453
SYSTEM COMPONENTS…5455
Filter…5455
Hydraulic Motor and Pump…5455
Grease Reservoir…5455
Pressure Reducing Valve…5455
Flow Control Valve…5455
Solenoid Valve…5455
Vent Valve…5455
Lubrication Cycle Timer…5455
Over Pressure Cut Off Switch…5455
Grease Pressure Failure Switch…5455
Injectors…5455
Relief Valve (unloader valve)…5455
SYSTEM OPERATION…5456
Normal Operation…5456
GENERAL INSTRUCTIONS…5457
Lubricant Required For System…5457
System Priming…5457
Filter Assembly…5457
LUBRICANT PUMP…5458
Pump Housing Oil Level…5458
Pump Pressure Control…5458
INJECTORS (SL-1 Series “H”)…5459
Injector Specifications…5459
Injector Adjustment…5459
INJECTOR OPERATION…5460
PREVENTIVE MAINTENANCE PROCEDURES…5461
Daily Lubrication System Inspection…5461
250 Hour Inspection…5461
1000 Hour Inspection…5461
SYSTEM CHECKOUT…5462
Lubrication Controller Check…5462
Lubrication Controller Components…5462
Lubrication Controller Adjustment…5462
SYSTEM TROUBLESHOOTING CHART…5464
COMPONENTS & SPECIFICATIONS…5467
MAJOR COMPONENT DESCRIPTIONS…5467
Truck And Engine…5467
Main Alternator…5467
AC Induction Traction Motorized Wheels…5467
Suspension…5467
Operator's Cab…5467
Power Steering…5467
Dynamic Retarding…5467
Brake System…5467
SPECIFICATIONS…5469
ENGINE…5469
AC ELECTRIC DRIVE SYSTEM…5469
DYNAMIC RETARDING…5469
BATTERY ELECTRIC SYSTEM…5469
SERVICE CAPACITIES…5469
HYDRAULIC SYSTEMS…5470
SERVICE BRAKES…5470
STEERING…5470
TIRES…5470
STANDARD DUMP BODY CAPACITIES AND DIMENSIONS…5470
WEIGHT DISTRIBUTION…5471
PAYLOAD METER III…5473
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…5503
OPERATING INSTRUCTIONS…5503
GENERAL RADIO RECEIVER FUNCTIONS…5503
Turning On the Power…5503
One-Hour Timer…5503
Adjusting the Volume…5504
Display…5504
Radio Mode Displays…5504
CD Mode Displays…5504
MP3/USB/iPod Mode Displays…5504
AUX Input Displays…5505
CLOCK/ALARM Button…5505
Front Auxiliary Mode…5505
Rear Auxiliary Mode…5505
Adjusting the Receiver Audio Settings…5505
Adjusting the Receiver Menu Settings…5506
USING THE RADIO…5507
Finding a Station…5507
Setting the Presets…5507
USING THE CLOCK…5508
Setting the Clock…5508
USING THE ALARM…5508
Setting the Alarm…5508
Turning the Alarm Off…5509
Activating Snooze…5509
USING THE WEATHERBAND (USA Only)…5509
USING THE COMPACT DISC PLAYER/USB…5510
Playing A Compact Disc…5510
Button Functions…5510
PLAYING AN MP3 DISC/USB…5511
Root Directory…5511
Empty Directory or Folder…5511
No Folder…5511
File Name Display…5511
PLAYING MP3 FILES…5511
Button Functions…5511
USING AN iPOD®…5512
Playing an iPod…5512
Button Functions…5512
OPERATING TIPS…5513
Tips About The Audio System…5513
Understanding Radio Reception…5513
Care of The Compact Discs…5513
TROUBLESHOOTING…5514
CEAM024503 – Dump Truck 930E-4SE Operation & Maintenance Manual…5517
1 INTRODUCTION…5530
FOREWORD…5530
ABOUT THIS MANUAL…5531
WARNINGS…5532
CALIFORNIA PROPOSITION 65 WARNINGS…5532
ALERTS…5533
TRUCK MODEL ILLUSTRATION…5534
NON-OEM PARTS IN CRITICAL SYSTEMS…5535
2 STANDARD CHARTS AND TABLES…5538
GENERAL INFORMATION…5538
EFFECT OF SPECIAL LUBRICANTS…5538
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…5538
STANDARD TIGHTENING TORQUES…5539
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…5539
SAE GRADE 5 AND GRADE 8 CAP SCREWS…5540
SAE GRADE 9 CAP SCREWS…5541
T-BOLT CLAMPS…5541
SPLIT FLANGE CLAMPS…5542
FLARED TUBE AND HOSE FITTINGS…5542
JIC 37° SWIVEL NUTS…5543
PIPE THREAD FITTINGS…5544
O-RING BOSS FITTINGS…5545
O-RING FACE SEAL FITTINGS…5546
CONVERSION MULTIPLIERS…5547
METRIC TO ENGLISH…5547
ENGLISH TO METRIC…5548
TEMPERATURE CONVERSIONS…5549
3 GENERAL SAFETY…5552
GENERAL SAFETY…5552
Safety Rules…5552
Truck Safety Features…5552
Clothing And Personal Items…5552
Unauthorized Modification…5552
Leaving The Operator’s Seat…5552
Mounting And Dismounting…5552
Fire Extinguishers And First Aid Kits…5553
Precautions For High Temperature Fluids…5553
Asbestos Dust Hazard Prevention…5553
Fire Prevention…5553
ROPS Precautions…5553
Preventing Injury From Work Equipment…5554
Precautions For Optional Attachments…5554
Precautions When Starting The Machine…5554
PRECAUTIONS FOR TRUCK OPERATION…5555
Safety Is Thinking Ahead…5555
Safety At The Worksite…5555
Preparing For Operation…5555
Ventilation For Enclosed Areas…5555
Mirrors, Windows, And Lights…5555
Before Starting The Engine…5555
Seat Belts…5555
Emergency Egress Ladders…5556
OPERATING THE MACHINE…5557
General Information…5557
Starting The Engine…5557
Traveling In The Machine…5557
Traveling In Reverse…5557
Traveling On Slopes…5558
Traveling On Snow…5558
Traveling Near High Voltage Cables…5558
Traveling On Loose Ground…5558
Ensuring Good Visibility…5558
Avoid Damage To The Dump Body…5558
Safe Parking Of The Machine…5558
Loading The Machine…5559
Dumping The Machine…5559
Towing The Machine…5559
EXTERIOR LIGHTING…5560
Fog Lights…5560
Headlights…5560
Brake Light…5560
Retard Light…5560
Clearance/Turn Signal Lights…5560
Backup Lights…5561
Retard Lights…5561
Brake Lights…5561
Backup Alarm…5561
HID Backup Light…5561
PRECAUTIONS FOR MAINTENANCE…5562
BEFORE PERFORMING MAINTENANCE…5562
Securing The Dump Body…5562
DURING MAINTENANCE…5563
Warning Tag…5563
Proper Tools…5563
Attachments…5563
Working Under The Machine…5563
Keeping The Machine Clean…5563
Adding Fuel Or Oil To The Machine…5563
Radiator Coolant Level…5564
Use of Lighting…5564
Handling High Pressure Hoses…5564
Precautions With High Pressure Oil…5564
Maintenance Near High Temperatures and High Pressures…5564
Rotating Fan and Belts…5564
Waste Materials…5564
Use of Tie-Off Anchor During Maintenance…5565
Handling Tires…5565
Tire Maintenance…5565
Storing Tires After Removal…5566
BATTERY HAZARD PREVENTION…5566
Jump Starting With Booster Cables…5567
Jump Starting With Receptacles…5567
WHEN REPAIRS ARE NECESSARY…5568
Observe The Following Precautions…5568
SPECIAL PRECAUTIONS…5569
Preliminary Procedures Before Welding or Performing Maintenance…5569
Engine Shutdown Procedure Before Welding or Performing Maintenan…5569
Discharging Control Cabinet Capacitors…5570
4 WARNING AND CAUTIONS…5572
GENERAL INFORMATION…5572
PIN PLATE…5572
GRADE SPEED CHART…5573
MACHINE SAFETY…5573
KEY SWITCH…5575
OIL FILL AND CHECK…5575
HIGH PRESSURES…5576
BATTERY AND ENGINE SHUTDOWN…5579
HIGH VOLTAGE…5580
WELDING…5582
LIFTING POINTS…5582
EMERGENCY DUMPING…5583
ROPS/FOPS…5584
TOWING…5584
LUBRICATION CHART…5584
5 OPERATING INSTRUCTIONS…5586
PREPARING FOR OPERATION…5586
Safety Is Thinking Ahead…5586
Walk Around Inspection…5586
RETRACTABLE LADDER SYSTEM (If Equipped)…5590
GENERAL INFORMATION…5590
LADDER SYSTEM DESCRIPTION…5590
LADDER SYSTEM OPERATION…5590
In-Cab Control Panel…5591
Ground Level Control Box…5593
Emergency Down Valve…5593
PRE-SHIFT BRAKE TEST…5594
OPERATION…5594
Service Brake Test…5595
Parking Brake Test…5595
Retard System Test…5596
Brake Test Exit Criteria…5596
TRUCK OPERATION…5597
ENGINE START-UP SAFETY…5597
After Engine Has Started…5597
MACHINE OPERATION SAFETY PRECAUTIONS…5598
Machine Operation on the Haul Road…5599
Starting on a Grade With a Loaded Truck…5599
Retarding on a Grade…5599
Passing…5600
Loading…5600
Overload Speed Limit Function…5600
Dumping…5601
Lowering the Dump Body (When Dumping on Flat Ground)…5602
Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush…5602
SUDDEN LOSS OF ENGINE POWER…5603
EMERGENCY STEERING SYSTEM…5603
Operation…5603
Pre-Operation Testing…5603
Additional Guidelines…5604
FUEL DEPLETION…5604
SAFE PARKING PROCEDURES…5605
NORMAL ENGINE SHUTDOWN PROCEDURE…5605
DISABLED TRUCK CONNECTORS…5606
GENERAL INFORMATION…5606
HOIST SYSTEM…5606
Hookup…5606
Dumping Procedure…5606
TOWING…5608
SPECIAL WIRING HARNESS…5608
TOWING PROCEDURE…5608
PAYLOAD METER III SYSTEM…5610
GENERAL INFORMATION…5610
Data Summary…5610
Data Gathering…5610
COMPONENT DESCRIPTION…5610
Operator Display…5610
Operator Switch…5610
Brake Lock Switch…5610
Payload Meter Module…5611
Communications Ports…5611
Load Lights…5611
OPERATORS DISPLAY AND SWITCH…5611
Reading the Load Display…5611
Setting the Operator ID…5612
Load and Ton Counter…5612
Viewing Live Sensor Data…5612
Other Display Messages…5612
HAUL CYCLE WARNING FLAGS…5613
Haul Cycle Data…5613
Haul Cycle Warning Flags…5614
PC SOFTWARE OVERVIEW…5616
SYSTEM CONFIGURATION…5616
Connecting to the Payload Meter…5616
Displayed Payload Units…5617
Connection Menu…5617
Configure the Payload Meter…5617
Setting the Date and Time…5617
Setting the Truck Type and Serial Number…5618
Setting the Gauge Display Units…5618
Setting the Carryback Alarm Threshold…5618
Setting the Truck Number…5619
Setting the Komatsu Distributor…5619
Setting the Komatsu Customer…5619
Clean Truck Tare Calibration…5619
Inclinometer Calibration…5620
DOWNLOADING PAYLOAD DATA…5620
UPLOADING DATA…5621
DATA ANALYSIS…5622
Creating a Query…5622
Payload Detail Screen…5623
Creating Reports…5623
Creating Graphs…5623
Exporting Data…5624
Importing Data…5624
Deleting Haul Cycle Records…5624
Viewing Alarms…5625
Deleting Alarm Records…5625
Patent Acknowledgment…5625
AUTOMATIC LUBRICATION SYSTEM…5626
GENERAL INFORMATION…5626
COMPONENT DESCRIPTION…5626
Filter…5627
Hydraulic Motor and Pump…5627
Grease Reservoir…5627
Pressure Reducing Valve…5627
Flow Control Valve…5627
Solenoid Valve…5628
Vent Valve…5628
Lubrication Cycle Timer…5628
Pressure Cut Off Switch…5628
Injectors…5629
Grease Pressure Failure Switch…5630
Relief Valve (unloader valve)…5630
SYSTEM OPERATION…5630
Filling The Reservoir…5630
Priming The Automatic Lubrication System…5631
PREVENTIVE MAINTENANCE PROCEDURES…5631
Daily Lubrication System Inspection…5631
250 Hour Inspection…5632
1000 Hour Inspection…5632
SYSTEM CHECKOUT…5633
General Checks…5633
Lubrication Controller Components…5633
RESERVE ENGINE OIL SYSTEM (If Equipped)…5634
Operation…5634
Changing Oil…5634
6 OPERATOR CAB AND CONTROLS…5636
CAB INTERIOR…5636
STEERING WHEEL AND CONTROLS…5637
Horn Button…5637
Tilt / Telescope Lever…5637
Multi-Function Turn Signal Switch…5637
Turn Signal Operation…5637
High Beam Headlight Operation…5637
Windshield Wiper Operation…5637
PEDALS AND RETARDER LEVER…5638
DYNAMIC RETARDING…5638
RETARDER LEVER…5638
BRAKE/RETARDER PEDAL…5638
ACCELERATOR PEDAL…5638
OVERHEAD PANEL AND DISPLAYS…5640
RADIO SPEAKERS…5640
WARNING ALARM BUZZER…5640
CAB RADIO…5640
WARNING LIGHT DIMMER CONTROL…5640
STATUS/WARNING INDICATOR LIGHT PANEL…5640
AIR CLEANER VACUUM GAUGES…5640
WINDSHIELD WIPERS…5640
CENTER CONSOLE…5641
DIRECTIONAL CONTROL LEVER…5641
OVERRIDE/FAULT RESET SWITCH…5641
ENGINE STOP SWITCH…5642
WINDOW CONTROL SWITCHES…5642
HOIST CONTROL LEVER…5642
Raising The Dump Body…5642
Lowering The Dump Body…5642
RETARD SPEED CONTROL (RSC) ADJUST DIAL…5642
RETARD SPEED CONTROL (RSC) SWITCH…5643
DATA STORE BUTTON…5643
KOMTRAX PLUS SNAPSHOT IN PROGRESS LIGHT…5643
LINK ENERGIZED LIGHT…5643
SERVICE ENGINE LIGHT…5643
12V AUXILIARY POWER OUTLETS…5643
FIRE SUPPRESSION CONTROL OUTLET…5643
COMMUNICATION RADIO OUTLET…5643
DIAGNOSTIC PORTS…5644
KOMTRAX Plus …5644
INTERFACE MODULE (IM)…5644
PAYLOAD METER…5644
TRUCK CONTROL INTERFACE (TCI)…5644
PROPULSION SYSTEM CONTROLLER (PSC)…5644
ENGINE (CENSE)…5644
ENGINE (QUANTUM)…5644
OPERATOR SEAT (Standard)…5645
SEAT BELTS…5645
ADJUSTMENT…5645
PASSENGER SEAT (Standard)…5647
SEAT BELTS…5647
ADJUSTMENT…5647
OPERATOR SEAT (Optional)…5648
SEAT BELTS…5648
ADJUSTMENT…5648
PASSENGER SEAT (Optional)…5649
SEAT BELTS…5649
ADJUSTMENT…5649
HEATER / AIR CONDITIONER CONTROLS…5650
Fan Speed Control Knob…5650
Temperature Control Knob…5650
Air Flow Directional Knob…5650
Heater/Air Conditioner Vents…5650
INSTRUMENT PANEL …5651
CONTROL SYMBOLS…5651
Key Switch…5652
Grid Dryer (Optional)…5652
Camera System (Optional)…5653
Rotating Beacon Light Switch (Optional)…5653
Heated Mirror Switch (Optional)…5653
Rest Switch…5653
Wheel Brake Lock Control Switch…5653
Hazard Warning Light Switch…5654
Cab/Air Conditioner Vents…5654
Engine Oil Pressure Gauge…5654
Right Turn Signal Indicator…5654
Tachometer…5654
High Beam Indicator…5654
Speedometer/Payload Meter Display…5654
Left Turn Signal Indicator…5654
Coolant Temperature Gauge…5654
Lamp Test Switch…5655
Light Switch…5655
Ladder Light Switch…5655
Manual Backup Switch…5655
Fog Light Switch…5655
Payload Meter Switch…5655
Panel Light Dimmer…5655
Hydraulic Oil Temperature Gauge…5656
Hourmeter…5656
Fuel Level Gauge…5656
OVERHEAD STATUS/WARNING INDICATOR…5657
STATUS / WARNING INDICATOR LIGHT SYMBOLS…5657
High Hydraulic Oil Temperature…5658
Low Steering Pressure…5658
Low Accumulator Precharge Pressure…5659
Low Brake Pressure…5659
Low Hydraulic Tank Level…5659
Automatic Lubrication System Pressure…5659
Circuit Breaker Tripped…5659
Hydraulic Oil Filter Monitor…5659
Low Fuel…5659
Parking Brake…5660
Service Brake…5660
Body Up…5660
Dynamic Retarding…5660
Stop Engine…5660
Cranking Motor Failure…5661
Manual Backup Lights…5661
Engine Shutdown Timer…5661
Retard Speed Control (RSC) Indicator…5661
Check Engine…5661
No Power…5661
Propulsion System Warning…5661
Propulsion System Temperature…5661
System/Component Failure…5662
Battery Charging System Failure…5662
No Propel…5662
Propel System at Rest…5662
Propel System Not Ready…5662
Reduced Propulsion…5662
Retard at Continuous Level…5662
Brake Test Light (If Equipped)…5663
Maintenance Monitor…5663
Brake Test Switch (If Equipped)…5663
KOMTRAX Plus…5664
KOMTRAX Plus OPERATION…5664
Basic Precautions…5664
Interface Module…5665
DOWNLOADING KOMTRAX Plus DATA…5666
GENERAL INFORMATION…5666
KOMTRAX Plus DOWNLOADING PROCEDURE…5666
Location of Downloaded Files…5666
UPLOADING KOMTRAX Plus DATA…5667
ORBCOMM…5668
KOMATSU WIRELESS BRIDGE (Optional)…5669
General Information…5669
Communication Setup…5669
Switching to the KWB_SETUP Network…5669
Setting the Computer Subnet Mask and IP Address…5670
Setting Up the KWB…5670
Adding Encryption…5671
Final Computer Settings…5671
Downloading Data…5671
Resetting the KWB…5672
FUSES AND CIRCUIT BREAKERS…5673
FUSE BLOCK #1…5673
FUSE BLOCK #2…5674
FUSE BLOCK #3…5674
FUSE BLOCK #4…5675
FUSE HOLDERS…5675
CIRCUIT BREAKERS…5675
7 LUBRICATION AND SERVICE…5678
GENERAL INFORMATION…5678
HYDRAULIC SYSTEM SERVICE…5678
Hydraulic Tank…5678
Hydraulic Filters…5679
Hydraulic Pump Drive Shaft…5679
WHEEL MOTOR SERVICE…5679
COOLANT LEVEL SERVICE…5679
Radiator Filling Procedure…5680
Coolant Specifications…5680
Unacceptable Practices…5680
RESERVE ENGINE OIL SERVICE…5680
Reserve Oil Tank Filling Procedure (Remote Fill)…5681
Inline Screen…5681
CAB AIR FILTER SERVICE…5681
FUEL SYSTEM SERVICE…5682
Fuel Tank Cleaning…5682
Fuel Filter Service…5682
INTAKE AIR CLEANER SERVICE…5683
QUICK FILL SERVICE CENTER…5683
LUBRICATION CHART…5685
EVERY 10 HOUR (DAILY) MAINTENANCE…5686
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5688
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5689
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…5690
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…5692
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…5694
EVERY 5000 HOUR MAINTENANCE…5695
8 SPECIFICATIONS…5698
MAJOR COMPONENT DESCRIPTION…5698
Truck and Engine…5698
Traction Alternator…5698
Main Control Cabinet…5698
AC Induction Traction Motorized Wheels…5698
Suspension…5698
Operator's Cab…5698
Power Steering…5698
Dynamic Retarding Grid…5698
Brake System…5698
SPECIFICATIONS…5699
Engine…5699
AC Electric Drive System…5699
Dynamic Retarding…5699
Battery Electric System…5699
Service Capacities…5699
Hydraulic Systems…5699
Service Brakes…5700
Steering…5700
Standard Dump Body Capacities and Dimensions…5700
Tires…5700
Weight Distribution…5700
Overall Truck Dimensions…5700
9 RADIO…5704
RADIO OPERATION…5704
GENERAL RADIO RECEIVER FUNCTIONS…5704
Turning On the Power…5704
One-Hour Timer…5704
Finding a Station…5704
Setting the Presets…5705
Adjusting the Receiver Audio Settings…5705
Display…5706
Adjusting the Receiver Menu Settings…5706
Front Auxiliary Mode…5706
Rear Auxiliary Mode…5706
CLOCK…5707
Clock/Alarm Button…5707
Setting the Clock…5707
Setting the Alarm…5707
Turning the Alarm Off…5708
Activating Snooze…5708
CD PLAYER…5709
Playing a Compact Disc…5709
Playing an MP3 DISC…5709
CD Mode Displays…5709
Button Functions…5709
MP3 PLAYER…5711
Playing MP3 Files…5711
MP3 Mode Displays…5711
Button Functions…5711
iPod®…5713
Playing an iPod®…5713
iPod® Mode Displays…5713
Button Functions…5713
WEATHERBAND (USA Only)…5715
TROUBLESHOOTING…5716
Tips About the Audio System…5716
Understanding Radio Reception…5716
Care of the Compact Discs…5716
CEAM027800 – Dump Truck 930E-4 Operation & Maintenance Manual…5717
1 INTRODUCTION…5730
FOREWORD…5730
ABOUT THIS MANUAL…5731
WARNINGS…5732
CALIFORNIA PROPOSITION 65 WARNINGS…5732
ALERTS…5733
TRUCK MODEL ILLUSTRATION…5734
NON-OEM PARTS IN CRITICAL SYSTEMS…5735
2 STANDARD CHARTS AND TABLES…5738
GENERAL INFORMATION…5738
EFFECT OF SPECIAL LUBRICANTS…5738
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…5738
STANDARD TIGHTENING TORQUES…5739
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…5739
SAE GRADE 5 AND GRADE 8 CAP SCREWS…5740
SAE GRADE 9 CAP SCREWS…5741
T-BOLT CLAMPS…5741
SPLIT FLANGE CLAMPS…5742
FLARED TUBE AND HOSE FITTINGS…5742
JIC 37° SWIVEL NUTS…5743
PIPE THREAD FITTINGS…5744
O-RING BOSS FITTINGS…5745
O-RING FACE SEAL FITTINGS…5746
CONVERSION MULTIPLIERS…5747
METRIC TO ENGLISH…5747
ENGLISH TO METRIC…5748
TEMPERATURE CONVERSIONS…5749
3 GENERAL SAFETY…5752
GENERAL SAFETY…5752
Safety Rules…5752
Truck Safety Features…5752
Clothing And Personal Items…5752
Unauthorized Modification…5752
Leaving The Operator’s Seat…5752
Mounting And Dismounting…5752
Fire Extinguishers And First Aid Kits…5753
Precautions For High Temperature Fluids…5753
Asbestos Dust Hazard Prevention…5753
Fire Prevention…5753
ROPS Precautions…5753
Preventing Injury From Work Equipment…5754
Precautions For Optional Attachments…5754
Precautions When Starting The Machine…5754
PRECAUTIONS FOR TRUCK OPERATION…5755
Safety Is Thinking Ahead…5755
Safety At The Worksite…5755
Preparing For Operation…5755
Ventilation For Enclosed Areas…5755
Mirrors, Windows, And Lights…5755
Before Starting The Engine…5755
Seat Belts…5755
Emergency Egress Ladders…5756
OPERATING THE MACHINE…5757
General Information…5757
Starting The Engine…5757
Traveling In The Machine…5757
Traveling In Reverse…5757
Traveling On Slopes…5758
Traveling On Snow…5758
Traveling Near High Voltage Cables…5758
Traveling On Loose Ground…5758
Ensuring Good Visibility…5758
Avoid Damage To The Dump Body…5758
Safe Parking Of The Machine…5758
Loading The Machine…5759
Dumping The Machine…5759
Towing The Machine…5759
EXTERIOR LIGHTING…5760
Fog Lights…5760
Headlights…5760
Brake Light…5760
Retard Light…5760
Clearance/Turn Signal Lights…5760
Backup Lights…5761
Retard Lights…5761
Brake Lights…5761
Backup Alarm…5761
HID Backup Light…5761
PRECAUTIONS FOR MAINTENANCE…5762
BEFORE PERFORMING MAINTENANCE…5762
Securing The Dump Body…5762
DURING MAINTENANCE…5763
Warning Tag…5763
Proper Tools…5763
Attachments…5763
Working Under The Machine…5763
Keeping The Machine Clean…5763
Adding Fuel Or Oil To The Machine…5763
Radiator Coolant Level…5764
Use of Lighting…5764
Handling High Pressure Hoses…5764
Precautions With High Pressure Oil…5764
Maintenance Near High Temperatures and High Pressures…5764
Rotating Fan and Belts…5764
Waste Materials…5764
Use of Tie-Off Anchor During Maintenance…5765
Handling Tires…5765
Tire Maintenance…5765
Storing Tires After Removal…5766
BATTERY HAZARD PREVENTION…5766
Jump Starting With Booster Cables…5767
Jump Starting With Receptacles…5767
WHEN REPAIRS ARE NECESSARY…5768
Observe The Following Precautions…5768
SPECIAL PRECAUTIONS…5769
Preliminary Procedures Before Welding or Performing Maintenance…5769
Engine Shutdown Procedure Before Welding or Performing Maintenan…5769
Before welding on the machine, obey the following guidelines:…5769
Discharging Control Cabinet Capacitors…5770
4 WARNING AND CAUTIONS…5772
GENERAL INFORMATION…5772
PIN PLATE…5772
GRADE SPEED CHART…5773
MACHINE SAFETY…5773
KEY SWITCH…5775
OIL FILL AND CHECK…5775
HIGH PRESSURES…5776
BATTERY AND ISOLATION BOX…5779
HIGH VOLTAGE…5781
WELDING…5783
LIFTING POINTS…5784
EMERGENCY DUMPING…5785
AUTOMATIC LUBRICATION FILL…5785
ROPS/FOPS…5786
TOWING…5786
LUBRICATION CHART…5786
5 OPERATING INSTRUCTIONS…5788
PREPARING FOR OPERATION…5788
Safety Is Thinking Ahead…5788
Walk Around Inspection…5788
RETRACTABLE LADDER SYSTEM (If Equipped)…5792
GENERAL INFORMATION…5792
LADDER SYSTEM DESCRIPTION…5792
LADDER SYSTEM OPERATION…5792
In-Cab Control Panel…5793
Ground Level Control Box…5795
Emergency Down Valve…5796
PRE-SHIFT BRAKE TEST…5797
OPERATION…5797
Service Brake Test…5798
Parking Brake Test…5798
Retard System Test…5799
Brake Test Exit Criteria…5799
TRUCK OPERATION…5800
ENGINE START-UP SAFETY…5800
After Engine Has Started…5800
MACHINE OPERATION SAFETY PRECAUTIONS…5801
Machine Operation on the Haul Road…5801
Starting on a Grade With a Loaded Truck…5802
Retarding on a Grade…5802
Passing…5803
Loading…5803
Overload Speed Limit Function…5804
Dumping…5804
Lowering the Dump Body (When Dumping on Flat Ground)…5805
Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush…5805
SUDDEN LOSS OF ENGINE POWER…5806
EMERGENCY STEERING SYSTEM…5806
Operation…5806
Pre-Operation Testing…5807
Additional Guidelines…5807
FUEL DEPLETION…5807
SAFE PARKING PROCEDURES…5808
NORMAL ENGINE SHUTDOWN PROCEDURE…5808
DISABLED TRUCK CONNECTORS…5809
GENERAL INFORMATION…5809
HOIST SYSTEM…5809
Hookup…5809
Dumping Procedure…5809
TOWING…5811
SPECIAL WIRING HARNESS…5811
TOWING PROCEDURE…5811
PAYLOAD METER III SYSTEM…5813
GENERAL INFORMATION…5813
Data Summary…5813
Data Gathering…5813
COMPONENT DESCRIPTION…5813
Operator Display…5813
Operator Switches…5813
Brake Lock Switch…5813
Payload Meter Module…5814
Communications Ports…5814
Load Lights…5814
OPERATOR’S DISPLAY AND SWITCH…5814
Reading the Load Display…5814
Setting the Operator ID…5814
Load and Ton Counter…5815
Viewing Live Sensor Data…5815
Other Display Messages…5815
HAUL CYCLE WARNING FLAGS…5815
Haul Cycle Data…5815
Haul Cycle Warning Flags…5817
PC SOFTWARE OVERVIEW…5818
SYSTEM CONFIGURATION…5819
Connecting to the Payload Meter…5819
Displayed Payload Units…5819
Connection Menu…5820
Configure the Payload Meter…5820
Setting the Date and Time…5820
Setting the Truck Type and Serial Number…5821
Setting the Gauge Display Units…5821
Setting the Carryback Alarm Threshold…5821
Setting the Truck Number…5821
Setting the Komatsu Distributor…5822
Setting the Komatsu Customer…5822
Clean Truck Tare Calibration…5822
Inclinometer Calibration…5823
DOWNLOADING PAYLOAD DATA…5823
UPLOADING DATA…5824
DATA ANALYSIS…5825
Creating a Query…5825
Payload Detail Screen…5825
Creating Reports…5826
Creating Graphs…5826
Exporting Data…5827
Importing Data…5827
Deleting Haul Cycle Records…5827
Viewing Alarms…5828
Deleting Alarm Records…5828
Patent Acknowledgment…5828
AUTOMATIC LUBRICATION SYSTEM…5829
GENERAL INFORMATION…5829
COMPONENT DESCRIPTION…5829
Filter…5830
Hydraulic Motor and Pump…5830
Grease Reservoir…5830
Pressure Reducing Valve…5830
Flow Control Valve…5830
Solenoid Valve…5831
Vent Valve…5831
Interface Module…5831
Pressure Cut Off Switch…5831
Injectors…5832
Grease Pressure Failure Switch…5833
Relief Valve (unloader valve)…5833
SYSTEM OPERATION…5833
Filling The Reservoir…5833
Priming The Automatic Lubrication System…5834
PREVENTIVE MAINTENANCE PROCEDURES…5834
Daily Lubrication System Inspection…5834
250 Hour Inspection…5835
1000 Hour Inspection…5835
SYSTEM CHECKOUT…5835
General Checks…5835
Lubrication Cycle Operation…5836
RESERVE ENGINE OIL SYSTEM…5837
Operation…5837
Changing Oil…5837
6 OPERATOR CAB AND CONTROLS…5840
CAB INTERIOR…5840
STEERING WHEEL AND CONTROLS…5841
Horn Button…5841
Tilt / Telescope Lever…5841
Multi-Function Turn Signal Switch…5841
Turn Signal Operation…5841
High Beam Headlight Operation…5841
Windshield Wiper Operation…5841
PEDALS AND RETARDER LEVER…5842
DYNAMIC RETARDING…5842
RETARDER LEVER…5842
BRAKE/RETARDER PEDAL…5842
ACCELERATOR PEDAL…5842
OVERHEAD PANEL AND DISPLAYS…5843
RADIO SPEAKERS…5843
WARNING ALARM BUZZER…5843
CAB RADIO…5843
AIR CLEANER VACUUM GAUGES…5843
CAMERA MONITOR (OPTIONAL)…5843
CENTER CONSOLE…5844
DIRECTIONAL CONTROL LEVER…5844
OVERRIDE/FAULT RESET SWITCH…5844
ENGINE STOP SWITCH…5844
WINDOW CONTROL SWITCHES…5845
HOIST CONTROL LEVER…5845
Raising The Dump Body…5845
Lowering The Dump Body…5845
RETARD SPEED CONTROL (RSC) ADJUST DIAL…5845
RETARD SPEED CONTROL (RSC) SWITCH…5846
DATA STORE BUTTON…5846
12V AUXILIARY POWER OUTLETS…5846
FIRE SUPPRESSION CONTROL OUTLET…5846
COMMUNICATION RADIO OUTLET…5846
DIAGNOSTIC PORTS…5847
KOMTRAX Plus …5847
INTERFACE MODULE (IM)…5847
PAYLOAD METER…5847
DRIVE SYSTEM OR MODULAR MINING…5847
DRIVE SYSTEM CONTROLLER (DSC)…5847
ENGINE (CENSE)…5847
ENGINE (QUANTUM)…5847
OPERATOR SEAT (Standard)…5848
SEAT BELTS…5848
ADJUSTMENT…5848
PASSENGER SEAT (Standard)…5850
SEAT BELTS…5850
ADJUSTMENT…5850
OPERATOR SEAT (Optional)…5851
SEAT BELTS…5851
ADJUSTMENT…5851
PASSENGER SEAT (Optional)…5852
SEAT BELTS…5852
ADJUSTMENT…5852
HEATER / AIR CONDITIONER CONTROLS…5853
Fan Speed Control Knob…5853
Temperature Control Knob…5853
Air Flow Directional Knob…5853
Heater/Air Conditioner Vents…5853
INSTRUMENT PANEL …5854
CONTROL SYMBOLS…5854
Cab/Air Conditioner Vents…5855
Status Indicator Light Panel…5855
Hydraulic Oil Temperature Gauge…5855
Coolant Temperature Gauge…5855
Speedometer/Digital Display…5855
Fuel Level Gauge…5855
Drive System Temperature Gauge…5855
Hazard Warning Light Switch…5856
Pre-Shift Brake Test Switch…5856
Wheel Brake Lock Control Switch…5856
Rest Switch…5856
Engine Warm Up…5857
Key Switch…5857
Warning Light…5857
Digital Display Contrast Buttons…5857
Turn Signal Indicators…5857
Panel Light Dimmer…5857
Mode Switches…5857
Fog Light Swich…5858
Backup Light Switch…5858
Ladder Light Switch…5858
Headlight/Panel Illumination Light Switch…5858
STATUS INDICATOR LIGHT PANEL…5859
STATUS INDICATOR LIGHT SYMBOLS…5859
Body Up…5859
Parking Brake…5859
Propel System Not Ready…5859
No Propel…5860
Engine Warm Up…5860
Engine Shutdown Delay…5860
Retarding Grid Drier…5860
Wheel Brake Lock…5860
Traction Control…5860
Repair Monitor…5860
Retractable Ladder Down…5860
Snapshot In Progress…5860
Pantograph Energized…5860
Pantograph Up…5861
Service Brake…5861
Dynamic Retarding…5861
No DC Link Voltage…5861
DIGITAL DISPLAY OPERATION…5862
Toggling Through Main Level Screens…5862
Toggling Through Warning Screens…5863
Entering Payload Meter Data…5864
KOMTRAX Plus…5865
KOMTRAX Plus OPERATION…5865
Basic Precautions…5865
Interface Module…5866
DOWNLOADING KOMTRAX Plus DATA…5867
GENERAL INFORMATION…5867
KOMTRAX Plus DOWNLOADING PROCEDURE…5867
Location of Downloaded Files…5868
UPLOADING KOMTRAX Plus DATA…5868
ORBCOMM…5870
KOMATSU WIRELESS BRIDGE (Optional)…5870
General Information…5870
Communication Setup…5871
Switching to the KWB_SETUP Network…5871
Setting the Computer Subnet Mask and IP Address…5871
Setting Up the KWB…5872
Adding Encryption…5872
Final Computer Settings…5873
Downloading Data…5873
Resetting the KWB…5873
FUSES AND CIRCUIT BREAKERS…5875
VEHICLE ELECTRICAL CENTER 89…5875
VEHICLE ELECTRICAL CENTER 90…5877
VEHICLE ELECTRICAL CENTER 91…5879
CIRCUIT BREAKERS…5881
7 LUBRICATION AND SERVICE…5884
GENERAL INFORMATION…5884
HYDRAULIC SYSTEM SERVICE…5884
Hydraulic Tank…5884
Hydraulic Filters…5885
Hydraulic Pump Drive Shaft…5885
WHEEL MOTOR SERVICE…5885
COOLANT LEVEL SERVICE…5885
Radiator Filling Procedure…5886
Coolant Specifications…5886
Unacceptable Practices…5886
RESERVE ENGINE OIL SERVICE…5886
Reserve Oil Tank Filling Procedure (Remote Fill)…5887
Inline Screen…5887
CAB AIR FILTER SERVICE…5887
FUEL SYSTEM SERVICE…5888
Fuel Tank Cleaning…5888
Fuel Filter Service…5888
INTAKE AIR CLEANER SERVICE…5889
QUICK FILL SERVICE CENTER…5890
TIE ROD INSPECTION AND TORQUE PROCEDURE…5890
LUBRICATION CHART…5891
EVERY 10 HOUR (DAILY) MAINTENANCE…5892
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5894
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…5895
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…5896
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…5898
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…5900
EVERY 5000 HOUR MAINTENANCE…5901
8 SPECIFICATIONS…5904
MAJOR COMPONENT DESCRIPTION…5904
Truck and Engine…5904
Traction Alternator…5904
Main Control Cabinet…5904
AC Induction Traction Motorized Wheels…5904
Suspension…5904
Operator's Cab…5904
Power Steering…5904
Dynamic Retarding Grid…5904
Brake System…5904
SPECIFICATIONS…5905
Engine…5905
AC Electric Drive System…5905
Dynamic Retarding…5905
Battery Electric System…5905
Service Capacities…5905
Hydraulic Systems…5905
Service Brakes…5906
Steering…5906
Standard Dump Body Capacities and Dimensions…5906
Tires…5906
Weight Distribution…5906
Overall Truck Dimensions…5906
9 RADIO…5910
RADIO OPERATION…5910
GENERAL RADIO RECEIVER FUNCTIONS…5910
Turning On the Power…5910
One-Hour Timer…5910
Finding a Station…5910
Setting the Presets…5911
Adjusting the Receiver Audio Settings…5911
Display…5912
Adjusting the Receiver Menu Settings…5912
Front Auxiliary Mode…5912
Rear Auxiliary Mode…5912
CLOCK…5913
Clock/Alarm Button…5913
Setting the Clock…5913
Setting the Alarm…5913
Turning the Alarm Off…5914
Activating Snooze…5914
CD PLAYER…5915
Playing a Compact Disc…5915
Playing an MP3 DISC…5915
CD Mode Displays…5915
Button Functions…5915
MP3 PLAYER…5917
Playing MP3 Files…5917
MP3 Mode Displays…5917
Button Functions…5917
iPod®…5919
Playing an iPod®…5919
iPod® Mode Displays…5919
Button Functions…5919
WEATHERBAND (USA Only)…5921
TROUBLESHOOTING…5922
Tips About the Audio System…5922
Understanding Radio Reception…5922
Care of the Compact Discs…5922
CEAW003900 – Dump Truck 930E-3 Field Assembly Manual…5923
COVER…5923
CEAW003900…5923
930E-3…5923
DUMP TRUCK…5923
FOREWARD…5924
TABLE OF CONTENTS…5926
SAFETY RULES, TOOLS & EQUIPMENT…5928
TRUCK COMPONENTS AND SPECIFICATIONS…5938
MAJOR COMPONENT WEIGHTS…5942
FIELD WELDING FOR ASSEMBLY OR REPAIR…5944
RECEIVING & ASSEMBLY PREPARATION…5954
CHASSIS ASSEMBLY…5956
DUMP BODY ASSEMBLY…6028
FINAL ASSEMBLY…6036
FINAL CHECKOUT…6076
APPENDIX…6078
LUBRICATION CHART…6080
SUSPENSION OILING AND CHARGING PROCEDURE…6082
TOE IN ADJUSTMENT PROCEDURE…6090
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE…6092
AIR CONDITIONING CHECKOUT PROCEDURE…6096
AIR CONDITIONING DRIVE BELT ADJUSTMENT PROCEDURE…6097
HYDRAULIC CHECKOUT PROCEDURE…6098
BRAKE CHECKOUT PROCEDURE…6112
VHMS CHECKOUT PROCEDURE…6120
PAYLOAD METER III CHECKOUT PROCEDURE…6136
ELECTRICAL CHECKOUT PROCEDURE …6150
STANDARD TORQUE CHARTS AND CONVERSION TABLES…6238
FIELD ASSEMBLY INSPECTION REPORT…6244
CEAW004001 – Dump Truck 930E-3SE Field Assembly Manual…6250
COVER…6250
FORWARD…6251
TABLE OF CONTENTS…6253
SAFETY RULES, TOOLS & EQUIPMENT…6255
TRUCK COMPONENTS AND SPECIFICATIONS…6265
MAJOR COMPONENT WEIGHTS…6271
FIELD WELDING FOR ASSEMBLY OR REPAIR…6275
RECEIVING & ASSEMBLY PREPARATION…6285
CHASSIS ASSEMBLY…6287
DUMP BODY ASSEMBLY…6361
FINAL ASSEMBLY…6369
FINAL CHECKOUT…6409
APPENDIX…6411
LUBRICATION CHART…6413
SUSPENSION OILING AND CHARGING PROCEDURE…6415
TOE IN ADJUSTMENT PROCEDURE…6423
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE…6425
AIR CONDITIONING CHECKOUT PROCEDURE…6429
AIR CONDITIONING DRIVE BELT ADJUSTMENT PROCEDURE…6430
HYDRAULIC CHECKOUT PROCEDURE…6431
BRAKE CHECKOUT PROCEDURE…6444
VHMS CHECKOUT PROCEDURE…6451
PAYLOAD METER III CHECKOUT PROCEDURE…6466
ELECTRICAL CHECKOUT PROCEDURE…6480
STANDARD TORQUE CHARTS AND CONVERSION TABLES…6567
FIELD ASSEMBLY INSPECTION REPORT…6573
CEAW004600 – Dump Truck 930E-4 Field Assembly Manual…6579
COVER…6579
FOREWARD…6581
TABLE OF CONTENTS…6583
SAFETY RULES, TOOLS AND EQUIPMENT…6585
TRUCK COMPONENTS AND SPECIFICATIONS…6595
MAJOR COMPONENTS AND SPECIFICATIONS…6599
FIELD WELDING FOR ASSEMBLY OR REPAIR…6601
RECEIVING AND ASSEMBLY PREPARATION…6611
CHASSIS ASSEMBLY…6613
DUMP BODY ASSEMBLY…6687
FINAL ASSEMBLY…6695
FINAL CHECK-OUT…6733
APPENDIX…6735
LUBRICATION CHART…6737
SUSPENSION OILING AND CHARGING…6739
TOE IN ADJUSTMENT…6747
AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE…6749
AIR CONDITIONING CHECKOUT PROCEDURE…6753
AIR CONDITIONING DRIVE BELT ADJUSTMENT PROCEDURE…6755
HYDRAULIC CHECKOUT PROCEDURE…6757
BRAKE CHECKOUT…6771
VHMS CHECKOUT PROCEDURE…6779
PAYLOAD METER III CHECKOUT PROCEDURE…6794
ELECTRICAL CHECKOUT PROCEDURE…6808
STANDARD TORQUE CHARTS AND CONVERSION TABLES…6895
FIELD ASSEMBLY INSPECTION REPORT…6901
50 HOUR POST-COMMISSIONING CHECKSHEET…6907
CEAW005000 – Dump Truck 930E-4SE Field Assembly Manual…6915
CEAW006103 – Dump Truck 930E-4 Field Assembly Manual…7219
COVER…7219
FOREWORD…7221
TABLE OF CONTENTS…7223
SAFETY RULES, TOOLS & EQUIPMENT…7225
MAJOR COMPONENTS & SPECIFICATIONS…7235
MAJOR COMPONENT WEIGHTS…7241
FIELD WELDING FOR ASSEMBLY OR REPAIR…7243
RECEIVING & ASSEMBLY PREPARATION…7253
CHASSIS ASSEMBLY…7255
DUMP BODY ASSEMBLY…7327
FINAL ASSEMBLY…7335
FINAL CHECKOUT…7365
APPENDIX…7367
LUBRICATION CHART…7369
SUSPENSION OILING AND CHARGING PROCEDURE…7371
TOE-IN ADJUSTMENT…7379
AUTO LUBE CHECKOUT PROCEDURE…7381
A/C CHECKOUT PROCEDURE…7383
A/C BELT ADJUSTING PROCEDURE…7384
HYDRAULIC SYSTEM CHECKOUT PROCEDURE…7385
BRAKE SYSTEM CHECKOUT PROCEDURE…7405
VHMS CHECKOUT PROCEDURE…7413
PAYLOAD METER CHECKOUT PROCEDURE…7417
ELECTRICAL CHECKOUT PROCEDURE…7431
AMENDMENTS TO ELECTRICAL CHECKOUT PROCEDURE…7519
WEBASTO COOLANT HEATER CHECKOUT PROCEDURE…7523
STANDARD TORQUE CHARTS AND CONVERSION TABLES…7525
FIELD ASSEMBLY INSPECTION REPORT…7531
50 HOUR POST-COMMISSIONING CHECKLIST…7536
CEAW006203 – Dump Truck 930E-4SE Field Assembly Manual…7543
COVER…7543
FOREWORD…7545
TABLE OF CONTENTS…7547
SAFETY RULES, TOOLS & EQUIPMENT…7549
MAJOR COMPONENTS & SPECIFICATIONS…7559
MAJOR COMPONENT WEIGHTS…7565
FIELD WELDING FOR ASSEMBLY OR REPAIR…7567
RECEIVING & ASSEMBLY PREPARATION…7577
CHASSIS ASSEMBLY…7579
DUMP BODY ASSEMBLY…7651
FINAL ASSEMBLY…7659
FINAL CHECKOUT…7689
APPENDIX…7691
LUBRICATION CHART…7693
SUSPENSION OILING AND CHARGING PROCEDURE…7695
TOE-IN ADJUSTMENT…7703
AUTO LUBE CHECKOUT PROCEDURE…7705
A/C CHECKOUT PROCEDURE…7707
A/C BELT ADJUSTING PROCEDURE…7708
HYDRAULIC SYSTEM CHECKOUT PROCEDURE…7709
BRAKE SYSTEM CHECKOUT…7729
VHMS CHECKOUT PROCEDURE…7737
PAYLOAD METER CHECKOUT PROCEDURE…7741
ELECTRICAL CHECKOUT PROCEDURE…7755
AMENDMENTS TO ELECTRICAL CHECKOUT PROCEDURE…7843
CEAW006600 – Dump Truck 930E-4 Field Assembly Manual…7865
FOREWORD…7867
SAFETY RULES, TOOLS & EQUIPMENT…7871
MAJOR COMPONENTS & SPECIFICATIONS…7881
MAJOR COMPONENT WEIGHTS…7887
FIELD WELDING FOR ASSEMBLY OR REPAIR…7889
RECEIVING & ASSEMBLY PREPARATION…7899
CHASSIS ASSEMBLY…7901
DUMP BODY ASSEMBLY…7973
FINAL ASSEMBLY…7981
APPENDIX…8011
CEAW006901 – Dump Truck 930E-4 Field Assembly Manual…8219
COVER…8219
FOREWORD…8221
TABLE OF CONTENTS…8223
SAFETY RULES, TOOLS & EQUIPMENT…8225
MAJOR COMPONENTS & SPECIFICATIONS…8235
MAJOR COMPONENT WEIGHTS…8241
FIELD WELDING FOR ASSEMBLY OR REPAIR…8243
RECEIVING & ASSEMBLY PREPARATION…8253
CHASSIS ASSEMBLY…8255
DUMP BODY ASSEMBLY…8327
FINAL ASSEMBLY…8335
FINAL CHECKOUT…8363
APPENDIX…8365
CEAW007001 – Dump Truck 930E-4SE Field Assembly Manual…8593
COVER…8593
FOREWORD…8595
TABLE OF CONTENTS…8597
SAFETY RULES, TOOLS & EQUIPMENT…8599
MAJOR COMPONENTS & SPECIFICATIONS…8609
MAJOR COMPONENT WEIGHTS…8615
FIELD WELDING FOR ASSEMBLY OR REPAIR…8617
RECEIVING & ASSEMBLY PREPARATION…8627
CHASSIS ASSEMBLY…8629
DUMP BODY ASSEMBLY…8701
FINAL ASSEMBLY…8709
FINAL CHECKOUT…8737
APPENDIX…8739
CEAWD03300 – Dump Truck 930E-2 Field Assembly Manual…8971
COVER…8971
WARNINGS…8972
FOREWORD…8974
TABLE OF CONTENTS…8976
SAFETY RULES DURING ASSEMBLY…8978
TOOLS AND EQUIPMENT FOR ASSEMBLY…8979
MACHINE COMPONENT DESCRIPTION…8984
930E MAJOR COMPONENTS…8985
SPECIFICATIONS…8986
OVERALL TRUCK DIMENSIONS…8988
930E-2 MAJOR COMPONENT WEIGHTS…8990
FIELD WELDING FOR ASSEMBLY OR REPAIR…8994
WELDER QUALIFICATION AND TRAINING…8994
WELD PROCESSES…8994
WELD QUALITY…8995
SPECIAL PRECAUTIONS FOR WELDING ON A 930E TRUCK…9000
RECEIVING…9002
CHASSIS ASSEMBLY…9004
RECOMMENDED ASSEMBLY DATA…9004
WHEN WELDING:…9004
BASIC ASSEMBLY PROCEDURE…9005
ORDER OF ASSEMBLY…9005
930E CHASSIS ASSEMBLY PROCEDURE…9007
BODY ASSEMBLY…9078
FINAL ASSEMBLY…9099
FINAL CHECK-0UT…9136
STANDARD CHARTS AND TABLES…9138
CSAM019400 – Manual de Operación y Mantenimiento 930E-4SE Camion Tolva…9145
DG711 – Dump Truck 930E Operation & Maintenance Manual…9300
COVER…9300
INTRODUCTION…9306
FOREWARD…9306
ALERTS…9307
CONTENTS…9308
TRUCK MODEL ILLUSTRATION…9311
ABOUT THIS MANUAL…9312
STANDARD CHARTS AND TABLES…9314
SAFETY…9320
GENERAL SAFETY…9320
PRECAUTIONS DURING OPERATION…9324
OPERATING MACHINE…9325
TOWING…9328
BATTERY…9329
PRECAUTIONS FOR MAINTENANCE…9330
BEFORE CARRYING OUT MAINTENANCE…9330
DURING MAINTENANCE…9331
TIRES…9334
ADDITIONAL JOB SITE RULES…9335
WHEN REPAIRS ARE NECESSARY…9336
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…9337
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…9340
OPERATION…9350
OPERATING INSTRUCTIONS…9350
PREPARING FOR OPERATION…9350
SAFETY IS THINKING AHEAD…9350
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…9350
ENGINE START-UP SAFETY PRACTICES…9353
AFTER ENGINE HAS STARTED…9354
MACHINE OPERATION SAFETY PRECAUTIONS…9355
MACHINE OPERATION ON THE HAUL ROAD…9355
STARTING ON A GRADE WITH A LOADED TRUCK…9356
PASSING…9356
LOADING…9356
DUMPING…9357
TOWING…9358
SAFE PARKING PROCEDURES…9359
NORMAL ENGINE SHUTDOWN PROCEDURE…9359
DELAYED ENGINE SHUTDOWN PROCEDURE…9360
OPERATOR CAB AND CONTROLS…9362
STEERING WHEEL AND CONTROLS…9363
DYNAMIC RETARDER/SERVER BRAKE PEDAL…9364
ACCELERATOR (THROTTLE) PEDAL…9364
HEATER/AIR CONDITIONER VENTS…9364
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…9365
OVERHEAD PANEL AND DISPLAYS…9366
CENTER CONSOLE CONTROLS AND FEATURES…9368
HOIST CONTROL LEVER…9369
OPERATOR SEAT…9372
INSTRUMENT PANEL AND INDICATOR LIGHTS…9374
CONTROL SYMBOLS…9374
INSTRUMENT PANEL (FIGURE 3-6)…9375
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…9376
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…9382
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…9383
HAZARD WARNING LIGHTS (7)…9389
LAMP TEST SWITCH (8)…9389
LINK-ON WARNINGS LIGHT…9389
MAINTENANCE…9390
LUBRICATION AND SERVICE…9390
SERVICE CAPACITIES…9390
HYDRAULIC TANK SERVICE…9390
COOLANT LEVEL CHECK…9391
RADIATOR FILLING PROCEDURE…9391
COOLING SYSTEM RECOMMENDATIONS…9391
LUBRICATION CHART…9392
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…9393
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…9395
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…9396
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…9397
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9398
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9399
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9400
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9400
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…9402
SYSTEM COMPONENTS…9402
SYSTEM OPERATION…9404
GENERAL INSTRUCTIONS…9405
LUBRICANT REQUIRED…9405
SYSTEM PRIMING…9405
SYSTEM CHECK-OUT…9405
24 VDC SOLID STATE TIMER CHECK…9406
INJECTORS AND ADJUSTMENT…9407
PUMP CYCLE TIMER (FLASHER TIMER)…9409
PRESSURE SWITCH…9409
PRESSURE REDUCER ADJUSTMENT…9411
TROUBLESHOOTING CHART…9412
PREVENTATIVE MAINTENANCE PROCEDURES…9415
SPECIFICATIONS…9416
MAJOR COMPONENT DESCRIPTIONS…9416
SPECIFICATIONS…9418
OPTIONAL EQUIPMENT…9420
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…9420
GENERAL INFORMATION…9422
LIGHTS, SWITHES, AND COMPONENTS…9423
TIPS FOR OPERATION…9424
EXTERNAL DISPLAY LIGHTS…9424
THEORY OF OPERATION…9425
BASIC DESCRIPTION…9425
LINKAGE FACTOR…9425
BRAKE LOCK…9426
SOURCES OF ERROR…9426
TYPICAL DATA FROM SERVICE CHECK MODE…9426
EXAMPLE CALCULATION OF PAYLOAD…9427
CALCULATION OF THE CALIBRATION LOAD…9427
TYPES OF DATA STORED…9428
CYCLE DATA…9428
ENGINE ON/OFF DATA…9429
FAULT CODES AND WARNING DATA…9429
ENGINE OPERATION…9430
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…9430
OTHER DATA…9430
OPERATOR FUNCTIONS…9431
USING THE OPERATOR LOAD COUNTER…9431
DESCRIPTION…9431
VIEWING THE OPERATOR LOAD COUNTER…9431
CLEARING THE OPERATOR LOAD COUNTER…9431
DIMMING THE LIGHTS ONTHE DISPLAY…9431
INITIAL SETUP OF PAYLOAD METER…9432
SWITCH SETTINGS…9432
CHECKING THE OPERATOR CHECK MODE…9432
CHECKING THE SERVICE CHECK MODE…9433
SETTING "UP:00"…9433
SETTING "PL:00"…9433
CHECKING THE Gt SETTING…9433
CHECKING THE INCLINOMETER SETTINGS…9433
CALIBRATING A TRUCK…9434
DISPLAYS AT START-UP…9435
SETUP AND MAINTENANCE…9436
SETTING THE SPEED LIMIT…9436
SETTINGS THE OPTION CODE…9436
SETTING THE MACHINE I.D…9436
SETTING THE OPERATOR I.D…9437
SETTING THE TIME AND DATE…9437
DOWNLOAD OF PAYLOAD FAULT CODES…9437
DISPLAY OF FAULT CODES…9438
CHARTS OF ERROR CODES AND OTHER INFORMATION…9439
SERVICE CHECK MODE…9441
MONITORING INPUT SIGNALS …9441
UP FACTOR – PAYLOAD CALCULATION GAIN…9442
PL MODE – LOAD CALCULATION…9442
FINAL GEAR RATIO SELECTION…9443
BATTERY REPLACEMENT PROCEDURE…9444
REPLACING THE BATTERY…9444
AFTER REPLACING THE BATTERY…9445
SUSPENSION PRESSURE SENSOR…9445
REMOVAL…9445
INSTALLATION…9446
INCLINOMETER…9446
REMOVAL…9446
INSTALLATION…9446
SCOREBOARD…9447
DESCRIPTION…9447
MAKING CONNECTIONS…9447
WIRING DIAGRAM…9448
NORMAL OPERATION OF THE SCOREBOARD…9449
PAYLOAD METER BACK PANEL…9449
CONNECTIONS (AMP PIN IDENTIFICATION)…9450
PAYLOAD CIRCUIT NUMBERS…9451
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…9452
RADIO, AM/FM STERO CASSETTE…9454
DG748 – Dump Truck 930E-2 Operation & Maintenance Manual…9458
COVER…9458
INTRODUCTION…9464
FOREWARD…9464
ALERTS…9465
CONTENTS…9466
TRUCK MODEL ILLUSTRATION…9469
ABOUT THIS MANUAL…9470
STANDARD CHARTS AND TABLES…9472
SAFETY…9478
GENERAL SAFETY…9478
PRECAUTIONS DURING OPERATION…9482
OPERATING MACHINE…9483
TOWING…9486
BATTERY…9487
PRECAUTIONS FOR MAINTENANCE…9488
BEFORE CARRYING OUT MAINTENANCE…9488
DURING MAINTENANCE…9489
TIRES…9492
ADDITIONAL JOB SITE RULES…9493
WHEN REPAIRS ARE NECESSARY…9494
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…9495
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…9498
OPERATION…9508
OPERATING INSTRUCTIONS…9508
PREPARING FOR OPERATION…9508
SAFETY IS THINKING AHEAD…9508
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…9508
ENGINE START-UP SAFETY PRACTICES…9511
AFTER ENGINE HAS STARTED…9512
MACHINE OPERATION SAFETY PRECAUTIONS…9513
MACHINE OPERATION ON THE HAUL ROAD…9513
STARTING ON A GRADE WITH A LOADED TRUCK…9514
PASSING…9514
LOADING…9514
DUMPING…9515
TOWING…9516
SAFE PARKING PROCEDURES…9517
NORMAL ENGINE SHUTDOWN PROCEDURE…9517
DELAYED ENGINE SHUTDOWN PROCEDURE…9518
OPERATOR CAB AND CONTROLS…9520
STEERING WHEEL AND CONTROLS…9521
DYNAMIC RETARDER/SERVER BRAKE PEDAL…9522
ACCELERATOR (THROTTLE) PEDAL…9522
HEATER/AIR CONDITIONER VENTS…9522
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…9523
OVERHEAD PANEL AND DISPLAYS…9524
CENTER CONSOLE CONTROLS AND FEATURES…9526
HOIST CONTROL LEVER…9527
OPERATOR SEAT…9530
INSTRUMENT PANEL AND INDICATOR LIGHTS…9532
CONTROL SYMBOLS…9532
INSTRUMENT PANEL (FIGURE 3-6)…9533
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…9534
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…9540
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…9541
HAZARD WARNING LIGHTS (7)…9547
LAMP TEST SWITCH (8)…9547
LINK-ON WARNINGS LIGHT…9547
MAINTENANCE…9548
LUBRICATION AND SERVICE…9548
SERVICE CAPACITIES…9548
HYDRAULIC TANK SERVICE…9548
COOLANT LEVEL CHECK…9549
RADIATOR FILLING PROCEDURE…9549
COOLING SYSTEM RECOMMENDATIONS…9549
LUBRICATION CHART…9550
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…9551
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…9553
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…9554
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…9555
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9557
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9558
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9559
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9559
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…9560
SYSTEM COMPONENTS…9560
SYSTEM OPERATION…9562
GENERAL INSTRUCTIONS…9563
LUBRICANT REQUIRED…9563
SYSTEM PRIMING…9563
SYSTEM CHECK-OUT…9563
24 VDC SOLID STATE TIMER CHECK…9564
INJECTORS…9565
PUMP CYCLE TIMER (FLASHER TIMER)…9567
PRESSURE SWITCH…9567
PRESSURE REDUCER ADJUSTMENT…9569
TROUBLESHOOTING CHART…9570
PREVENTATIVE MAINTENANCE PROCEDURES…9573
SPECIFICATIONS…9574
MAJOR COMPONENT DESCRIPTIONS…9574
SPECIFICATIONS…9576
OPTIONAL EQUIPMENT…9578
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…9578
GENERAL INFORMATION…9580
LIGHTS, SWITHES, AND COMPONENTS…9581
TIPS FOR OPERATION…9582
EXTERNAL DISPLAY LIGHTS…9582
THEORY OF OPERATION…9583
BASIC DESCRIPTION…9583
LINKAGE FACTOR…9583
BRAKE LOCK…9584
SOURCES OF ERROR…9584
TYPICAL DATA FROM SERVICE CHECK MODE…9584
EXAMPLE CALCULATION OF PAYLOAD…9585
CALCULATION OF THE CALIBRATION LOAD…9585
TYPES OF DATA STORED…9586
CYCLE DATA…9586
ENGINE ON/OFF DATA…9587
FAULT CODES AND WARNING DATA…9587
ENGINE OPERATION…9588
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…9588
OTHER DATA…9588
OPERATOR FUNCTIONS…9589
USING THE OPERATOR LOAD COUNTER…9589
DESCRIPTION…9589
VIEWING THE OPERATOR LOAD COUNTER…9589
CLEARING THE OPERATOR LOAD COUNTER…9589
DIMMING THE LIGHTS ONTHE DISPLAY…9589
INITIAL SETUP OF PAYLOAD METER…9590
SWITCH SETTINGS…9590
CHECKING THE OPERATOR CHECK MODE…9590
CHECKING THE SERVICE CHECK MODE…9591
SETTING "UP:00"…9591
SETTING "PL:00"…9591
CHECKING THE Gt SETTING…9591
CHECKING THE INCLINOMETER SETTINGS…9591
CALIBRATING A TRUCK…9592
DISPLAYS AT START-UP…9593
SETUP AND MAINTENANCE…9594
SETTING THE SPEED LIMIT…9594
SETTINGS THE OPTION CODE…9594
SETTING THE MACHINE I.D…9594
SETTING THE OPERATOR I.D…9595
SETTING THE TIME AND DATE…9595
DOWNLOAD OF PAYLOAD FAULT CODES…9595
DISPLAY OF FAULT CODES…9596
CHARTS OF ERROR CODES AND OTHER INFORMATION…9597
SERVICE CHECK MODE…9599
MONITORING INPUT SIGNALS …9599
UP FACTOR – PAYLOAD CALCULATION GAIN…9600
PL MODE – LOAD CALCULATION…9600
FINAL GEAR RATIO SELECTION…9601
BATTERY REPLACEMENT PROCEDURE…9602
REPLACING THE BATTERY…9602
AFTER REPLACING THE BATTERY…9603
SUSPENSION PRESSURE SENSOR…9603
REMOVAL…9603
INSTALLATION…9604
INCLINOMETER…9604
REMOVAL…9604
INSTALLATION…9604
SCOREBOARD…9605
DESCRIPTION…9605
MAKING CONNECTIONS…9605
WIRING DIAGRAM…9606
NORMAL OPERATION OF THE SCOREBOARD…9607
PAYLOAD METER BACK PANEL…9607
CONNECTIONS (AMP PIN IDENTIFICATION)…9608
PAYLOAD CIRCUIT NUMBERS…9609
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…9610
RADIO, AM/FM STERO CASSETTE…9612
DG750 – Dump Truck 930E-2 Operation & Maintenance Manual…9616
COVER…9616
INTRODUCTION…9622
FOREWARD…9622
ALERTS…9623
CONTENTS…9624
TRUCK MODEL ILLUSTRATION…9627
ABOUT THIS MANUAL…9628
STANDARD CHARTS AND TABLES…9630
SAFETY…9636
GENERAL SAFETY…9636
PRECAUTIONS DURING OPERATION…9640
OPERATING MACHINE…9641
TOWING…9644
BATTERY…9645
PRECAUTIONS FOR MAINTENANCE…9646
BEFORE CARRYING OUT MAINTENANCE…9646
DURING MAINTENANCE…9647
TIRES…9650
ADDITIONAL JOB SITE RULES…9651
WHEN REPAIRS ARE NECESSARY…9652
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…9653
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…9656
OPERATION…9666
OPERATING INSTRUCTIONS…9666
PREPARING FOR OPERATION…9666
SAFETY IS THINKING AHEAD…9666
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…9666
ENGINE START-UP SAFETY PRACTICES…9669
AFTER ENGINE HAS STARTED…9670
MACHINE OPERATION SAFETY PRECAUTIONS…9671
MACHINE OPERATION ON THE HAUL ROAD…9671
STARTING ON A GRADE WITH A LOADED TRUCK…9672
PASSING…9672
LOADING…9672
DUMPING…9673
TOWING…9674
SAFE PARKING PROCEDURES…9675
NORMAL ENGINE SHUTDOWN PROCEDURE…9675
DELAYED ENGINE SHUTDOWN PROCEDURE…9676
OPERATOR CAB AND CONTROLS…9678
STEERING WHEEL AND CONTROLS…9679
DYNAMIC RETARDER/SERVER BRAKE PEDAL…9680
ACCELERATOR (THROTTLE) PEDAL…9680
HEATER/AIR CONDITIONER VENTS…9680
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…9681
OVERHEAD PANEL AND DISPLAYS…9682
CENTER CONSOLE CONTROLS AND FEATURES…9684
HOIST CONTROL LEVER…9685
OPERATOR SEAT…9688
INSTRUMENT PANEL AND INDICATOR LIGHTS…9690
CONTROL SYMBOLS…9690
INSTRUMENT PANEL (FIGURE 3-6)…9691
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-29, FIGURE 3-6)…9692
OVERHEAD STATUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…9698
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…9699
HAZARD WARNING LIGHTS (7)…9705
LAMP TEST SWITCH (8)…9705
LINK-ON WARNINGS LIGHT…9705
MAINTENANCE…9706
LUBRICATION AND SERVICE…9706
SERVICE CAPACITIES…9706
HYDRAULIC TANK SERVICE…9706
COOLANT LEVEL CHECK…9707
RADIATOR FILLING PROCEDURE…9707
COOLING SYSTEM RECOMMENDATIONS…9707
LUBRICATION CHART…9708
10 HOUR (SHIFT) LUBRICATION AND MAINTENANCE CHECKS…9709
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…9711
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…9712
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…9713
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9715
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9716
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…9717
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…9717
LINCOLN AUTOMATIC LUBRICATION SYSTEM (ROTARY PUMP)…9718
SYSTEM COMPONENTS…9718
SYSTEM OPERATION…9720
GENERAL INSTRUCTIONS…9721
LUBRICANT REQUIRED…9721
SYSTEM PRIMING…9721
SYSTEM CHECK-OUT…9721
24 VDC SOLID STATE TIMER CHECK…9722
INJECTORS…9723
PUMP CYCLE TIMER (FLASHER TIMER)…9725
PRESSURE SWITCH…9725
PRESSURE REDUCER ADJUSTMENT…9727
TROUBLESHOOTING CHART…9728
PREVENTATIVE MAINTENANCE PROCEDURES…9731
SPECIFICATIONS…9732
MAJOR COMPONENT DESCRIPTIONS…9732
SPECIFICATIONS…9734
OPTIONAL EQUIPMENT…9736
PAYLOAD METER II (ON BOARD WEIGHING SYSTEM (OBWS) INDEX)…9736
GENERAL INFORMATION…9738
LIGHTS, SWITHES, AND COMPONENTS…9739
TIPS FOR OPERATION…9740
EXTERNAL DISPLAY LIGHTS…9740
THEORY OF OPERATION…9741
BASIC DESCRIPTION…9741
LINKAGE FACTOR…9741
BRAKE LOCK…9742
SOURCES OF ERROR…9742
TYPICAL DATA FROM SERVICE CHECK MODE…9742
EXAMPLE CALCULATION OF PAYLOAD…9743
CALCULATION OF THE CALIBRATION LOAD…9743
TYPES OF DATA STORED…9744
CYCLE DATA…9744
ENGINE ON/OFF DATA…9745
FAULT CODES AND WARNING DATA…9745
ENGINE OPERATION…9746
TOTAL PAYLOAD AND TOTAL NUMBER OF CYCLES…9746
OTHER DATA…9746
OPERATOR FUNCTIONS…9747
USING THE OPERATOR LOAD COUNTER…9747
DESCRIPTION…9747
VIEWING THE OPERATOR LOAD COUNTER…9747
CLEARING THE OPERATOR LOAD COUNTER…9747
DIMMING THE LIGHTS ONTHE DISPLAY…9747
INITIAL SETUP OF PAYLOAD METER…9748
SWITCH SETTINGS…9748
CHECKING THE OPERATOR CHECK MODE…9748
CHECKING THE SERVICE CHECK MODE…9749
SETTING "UP:00"…9749
SETTING "PL:00"…9749
CHECKING THE Gt SETTING…9749
CHECKING THE INCLINOMETER SETTINGS…9749
CALIBRATING A TRUCK…9750
DISPLAYS AT START-UP…9751
SETUP AND MAINTENANCE…9752
SETTING THE SPEED LIMIT…9752
SETTINGS THE OPTION CODE…9752
SETTING THE MACHINE I.D…9752
SETTING THE OPERATOR I.D…9753
SETTING THE TIME AND DATE…9753
DOWNLOAD OF PAYLOAD FAULT CODES…9753
DISPLAY OF FAULT CODES…9754
CHARTS OF ERROR CODES AND OTHER INFORMATION…9755
SERVICE CHECK MODE…9757
MONITORING INPUT SIGNALS …9757
UP FACTOR – PAYLOAD CALCULATION GAIN…9758
PL MODE – LOAD CALCULATION…9758
FINAL GEAR RATIO SELECTION…9759
BATTERY REPLACEMENT PROCEDURE…9760
REPLACING THE BATTERY…9760
AFTER REPLACING THE BATTERY…9761
SUSPENSION PRESSURE SENSOR…9761
REMOVAL…9761
INSTALLATION…9762
INCLINOMETER…9762
REMOVAL…9762
INSTALLATION…9762
SCOREBOARD…9763
DESCRIPTION…9763
MAKING CONNECTIONS…9763
WIRING DIAGRAM…9764
NORMAL OPERATION OF THE SCOREBOARD…9765
PAYLOAD METER BACK PANEL…9765
CONNECTIONS (AMP PIN IDENTIFICATION)…9766
PAYLOAD CIRCUIT NUMBERS…9767
PAYLOAD METER II RE-INITIALIZATION PROCEDURE…9768
RADIO, AM/FM STERO CASSETTE…9770

Komatsu Dump Trucks 930E Operation & Maintenance Manuals

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