PDF Operation & Maintenance Manual Komatsu 930E-2 Dump Truck - 580 KB
This is the complete Operation & Maintenance Manual for the Komatsu 930E-2 haul truck, covering serial number A30292.
It is the primary guide for operators and service personnel, detailing safe operating procedures, controls and instruments, and a full schedule of preventative maintenance tasks.
Adhering to the guidelines in this manual is the best way to ensure the safety, reliability, and longevity of this massive piece of mining equipment.
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--- Page 1 ---
CEAM019604
Operation & Maintenance
Manual
DUMP TRUCK
SERIAL NUMBERS A30601 - A30692
®
--- Page 3 ---
OM1088 8/11 Introduction - Section 10
Page 10-7
TABLE OF CONTENTS (cont.)
WARNINGS AND CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-1
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
PREPARING FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
WALK AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-1
ENGINE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-5
AFTER ENGINE START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6
PRE-SHIFT BRAKE CHECK (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-7
Performing The Brake Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-8
EMERGENCY STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
Pre-Operation Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10
MACHINE OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
OPERATING ON THE HAUL ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-12
STARTING ON A GRADE WITH A LOADED TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13
PASSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13
LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13
Overload Speed Limit Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-13
DUMPING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14
Raising The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-14
Lowering The Dump Body (when dumping on flat ground) . . . . . . . . . . . . . . . . . . . . . . . . . . .30-15
Lowering The Dump Body (when dumping over a berm or into a crusher) . . . . . . . . . . . . . . .30-15
TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-16
Special Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-16
SAFE PARKING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-19
NORMAL ENGINE SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-19
SUDDEN LOSS OF ENGINE POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20
FUEL DEPLETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20
DISABLED TRUCK DUMPING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21
Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21
Raising the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21
Lowering the Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21
RESERVE ENGINE OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-22
Changing Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-22
OPERATOR CAB AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-1
STEERING WHEEL AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Horn Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
Tilt/Telescope Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-2
--- Page 4 ---
OM1200 02/11 Torque Tables And Conversion Charts - Section 12
Page 12-3
STANDARD TIGHTENING TORQUES
For SAE Grade 5 and Grade 8 Cap screws
The following specifications apply to required assem-
• The maximum torque tolerance shall be ±10% of
bly torques for all grade 5 and grade 8 cap screws.
the torque value shown.
• Cap screw threads and seats shall be lubricated
when assembled. • In the following table under Cap Screw Size, the
first number represents the shank diameter (in.).
Unless instructions specifically recommend The second number represents threads per inch.
otherwise, these standard torque values are to
be used with simple lithium base chassis grease Example: 7/16 - 20
(multi-purpose EP NLGI) or a rust- preventive 7/16 = shank diameter (7/16 inch (0.438 inch))
grease (see list, previous page) on the threads.
20 = threads per inch
• Torques are calculated to give a clamping force
of approximately 75% of proof load.
TABLE 2.
Standard Tightening Torque
for SAE Hex Head Cap Screw And Nut Assembly
Cap Torque - Torque - Cap Torque - Torque -
Screw Grade 5 Grade 8 Screw Grade 5 Grade 8
Size N·m ft lb kg·m N·m ft lb kg·m Size N·m ft lb kg·m N·m ft lb kg·m
1/4-20 9.5 7 0.97 13.6 10 1.38 3/4-16 319 235 32.5 454 335 46.3
1/4-28 10.8 8 1.11 14.9 11 1.52 7/8-9 475 350 48.4 678 500 69.2
5/16-18 20.3 15 2.07 28 21 2.90 7/8-14 508 375 51.9 719 530 73.3
5/16-24 22 16 2.21 30 22 3.04 1.0-8 712 525 72.6 1017 750 103.7
3/8-16 34 25 3.46 47 35 4.84 1.0-12 759 560 77.4 1071 790 109.3
3/8-24 41 30 4.15 54 40 5.5 1.0-14 773 570 78.8 1085 800 110.6
7/16-14 54 40 5.5 79 58 8.0 1 1/8-7 881 650 89.9 1424 1050 145
7/16-20 61 45 6.2 84 62 8.57 1 1/8-12 949 700 96.8 1546 1140 158
1/2-13 88 65 9 122 90 12.4 1 1/4-7 1234 910 125.9 2007 1480 205
1/2-20 95 70 9.7 129 95 13.1 1 1/4-12 1322 975 134.8 2142 1580 219
9/16-12 122 90 12.4 169 125 17.3 1 3/8-6 1627 1200 166 2630 1940 268
9/16-18 129 95 13.1 183 135 18.7 1 3/8-12 1776 1310 181 2874 2120 293
5/8-11 169 125 17.3 237 175 24.2 1 1/2-6 2142 1580 219 3471 2560 354
5/8-18 183 135 18.7 258 190 26.2 1 1/2-12 2305 1700 235 3756 2770 383
3/4-10 298 220 30.4 420 310 42.8
1 ft. lb. = 0.138 kg·m = 1.356 N.m
--- Page 5 ---
OM2042 7/11 Safety - Section 20
Page 20-3
Precautions With High Temperature Fluids Prevention Of Injury By Work Equipment
Immediately after truck operation, engine coolant, Never enter or put your hand, arm or any other part of
engine oil, and hydraulic oil are at high temperatures your body between movable parts such as the dump
and are pressurized. If the cap is removed, the fluids body, chassis or cylinders. If the work equipment is
are drained, the filters are replaced, etc., there is operated, clearances will change and may lead to
danger of serious burns. Allow heat and pressure to serious bodily injury or death.
dissipate before performing such tasks and follow
proper procedures as outlined in the service manual.
Unauthorized Modification
Any modification made to this vehicle without
authorization from Komatsu America Corp. can
possibly create hazards.
Before making any modification, consult the
authorized regional Komatsu America Corp.
distributor. Komatsu will not be responsible for any
injury or damage caused by any unauthorized
To prevent hot coolant from spraying: modification.
1. Stop the engine.
2. Wait for the coolant temperature to decrease. ROPS Precautions
3. Depress the pressure release button on the cap
The ROPS is intended to protect the operator if the
to vent cooling system pressure.
truck should roll over. It is designed not only to
4. Turn the radiator cap slowly to release the support the load of the truck, but also to absorb the
pressure before removing. energy of the impact.
To prevent hot engine oil spray: • The Rollover Protection Structure (ROPS) must
be properly installed before the truck is operated.
1. Stop the engine.
• ROPS installed on equipment manufactured and
2. Wait for the oil temperature to cool down. designed by Komatsu America Corp. fulfills all of
3. Turn the cap slowly to release the pressure the regulations and standards for all countries. If
before removing the cap. it is modified or repaired without authorization
from Komatsu, or if it is damaged when the truck
rolls over, the strength of the structure will be
compromised and will not be able to fulfill its
Asbestos Dust Hazard Prevention intended purpose. Optimum strength of the
structure can only be achieved if it is repaired or
Asbestos dust is hazardous to your health when modified as specified by Komatsu.
inhaled. If you handle materials containing asbestos
• When modifying or repairing the ROPS, always
fibers, follow the guidelines below:
consult your nearest Komatsu distributor.
• Never use compressed air for cleaning. • Even with the ROPS installed, the operator must
• Use water for cleaning to control dust. always use the seat belt when operating the
truck.
• Operate the truck or perform tasks with the wind
to your back whenever possible.
• Use an approved respirator when necessary.
--- Page 6 ---
OM2042 7/11 Safety - Section 20
Page 20-13
TIRES
Handling Tires Storing Tires After Removal
If tires are not used under the specified conditions, • As a basic rule, store the tires in a warehouse in
they may overheat and burst, or be cut and burst by which unauthorized persons cannot enter. If the
sharp stones on rough road surfaces. This may lead tires are stored outside, always erect a fence
to serious injury or damage. around the tires and put up “No Entry” signs and
other warning signs that even young children can
To maintain tire safety, always use the specified tires. understand.
Inflate the tires to the specified pressure. An
• Stand the tire on level ground and block it
abnormal level of heat is generated when the inflation
securely so that it cannot roll or fall over.
pressure is too low.
• If the tire falls over, flee the area quickly. The tires
The tire inflation pressure and permissible speeds for dump trucks are extremely heavy. Never
are general values. The actual values may differ attempt to hold or support the tire. Attempting to
depending on the type of tire and the condition under hold or support a tire may lead to serious injury.
which they are used. For details, please consult the
tire manufacturer.
When tires become hot, a flammable gas is produced
and may ignite. It is particularly dangerous if the tires
become overheated while the tires are pressurized. If
the gas generated inside the tire ignites, the internal
pressure will suddenly rise and the tire will explode,
resulting in danger to personnel in the area.
Explosions differ from punctures or tire bursts
because the destructive force is extremely large.
Therefore, the following operations are strictly
prohibited when the tire is pressurized:
• Welding the rim
• Welding near the wheel or tire
• Smoking or creating open flames
If the proper procedure for performing maintenance
or replacement of the wheel or tire is not used, the
wheel or tire may burst and cause serious injury or
damage. When performing such maintenance,
consult your authorized regional Komatsu distributor
or the tire manufacturer.
--- Page 7 ---
OM2042 7/11 Safety - Section 20
Page 20-23
4. Measure voltage on all capacitors as described
in Failure of the Discharge System on page 30-
21. Discharge any capacitors that show voltage.
5. If all capacitors read discharged, verify that the
meter is functioning correctly using site-
Voltages in excess of 1500 VDC may be present.
approved procedures. If so, proceed to Short
Any measurement and/or protective equipment
Isolated Capacitor Terminals on page 30-24.
used must be rated at 2000 VDC minimum.
Verify functionality of the measurement equip-
ment using site-approved procedures both
before and after performing control group mea-
surements.
Failure to observe these precautions may result
in death or serious personal injury.
FIGURE 20-10. APPLICATION OF GROUNDING STICKS TO
CAPACITOR TERMINALS
--- Page 8 ---
OM2217 5/11 Safety - Section 22
Page 22-7
INFORMATION DISPLAY HIGH VOLTAGE
This information decal is placed on the left door of the A high voltage danger decal is attached to the door of
control cabinet. the rear hatch cover. High voltage may be present!
Only authorized personnel should access this rear
housing.
These danger decals are mounted on all the AC drive
control housings and cabinets. High voltage may be
present! Only authorized personnel should access this
WIRELESS SIGNALS component.
Wireless signals from the truck’s KOMTRAX Plus
system can interfere with other wireless signals in the
area. This interference can cause a malfunction in a
blast zone resulting in an unintended detonation. Know
the locations of blast zones in the area and keep a safe
distance to avoid unintentional blasts. Operating
frequency of KOMTRAX Plus is 148 MHz to 150 MHz.
--- Page 9 ---
OM3062 8/11 Operating Instructions - Section 30
Page 30-7
OPERATION If the brake check light does not illuminate immedi-
ately after pressing the brake test switch, there is
The static brake test utilizes a momentary switch and
most likely a problem with the setup. Refer to the
a check light located in the overhead display panel.
setup conditions and take action to prepare the truck
for a brake test.
Brake Test Switch
The brake test switch is used to If there is a problem with the truck setup, the DID
initiate a brake test. Press on the panel will display the problem.
momentary switch to enter the For example if the engine is off:
brake test mode. If certain condi-
tions are met, the operator can ERROR Entering Brake Test
enter a brake test sequence. Engine not running
If the Truck is loaded:
ERROR Entering Brake Test
Truck is NOT Empty
Brake Check Light If all of the conditions are correct, except the brakes
The amber light is used to indi- are not set correctly, an error message will be dis-
cate when the truck is in the played. For example, if the service brake and parking
brake test mode. When illumi- brake are both applied together:
nated, a brake test is ready. ERROR Entering Brake Test
When flashing, the brake test is Set Brakes for Test
at the validation point, or the
retard system test is finished.
Brake Test Exit Criteria
Description Numerous conditions can occur which may interrupt
a brake test, including the following:
The operator can choose which brake test to per-
form, and will set the truck controls based on the set- • Any of the setup conditions becoming false
tings in Table 1. The drive system will detect the • Drive system fault which restricts the LINK or
position of the directional control lever, and will pre- Propel mode
pare for the appropriate test. The operator will then
• Truck Speed greater than 3.2 kph (2.0 mph)
press the brake test switch.
• Drive system at torque level for more than 30
If the brake check light is illuminated solid after seconds
pressing the brake test switch, the system is in brake
test mode and is ready for the chosen test to be initi- • Brake test requested, but not initiated by the
ated by the operator. After testing, the operator will operator within 60 seconds after pressing the
brake test switch
then determine if the truck passed the brake tests,
and if it is safe for operation.
Table 1: BRAKE TEST SETTINGS
Wheel Brake Service Brake Directional
Test Type Lock Pedal Control Lever
Service Brake OFF FULLY APPLIED NEUTRAL
Parking Brake OFF RELEASED PARK
Retard Test OFF RELEASED PARK
--- Page 10 ---
OM3062 8/11 Operating Instructions - Section 30
Page 30-17
8. The parking brakes must be released before 12. Minimize the tow angle at all times. Never
towing. To release the parking brake, follow the exceed 30 degrees. The towed truck must be
steps below to install a special wiring harness to steered in the direction of the tow bar.
release the parking brakes. 13. When the desired location has been reached,
a. Ensure switch (1) is in the OFF position. the operator in the towed vehicle is to apply the
service brakes, then turn switch (1) to the OFF
b. Connect one lead of the special wiring har-
position. This will apply the parking brakes.
ness to the 24VDC bus bar terminal on the
side wall in the auxiliary control cabinet for 14. Block the wheels to prevent roll-away.
the 24V supply. 15. Shut down the engine in the pulling vehicle.
c. Disconnect the truck wiring harness from Disconnect the hydraulic hoses.
parking brake solenoid (2, Figure 30-8). Con- 16. Disconnect special wiring harness (3) from the
nect special wiring harness (3, Figure 30-9) truck. Connect the truck wiring harness back to
to the parking brake solenoid. Attach short the parking brake solenoid.
lead (2) to ground.
17. Disconnect the tow bar.
d. WIth the window lowered, place the end of
the special wiring harness inside the cab so
the operator can control switch (1).
9. When ready to tow the disabled truck, remove
blocking from the wheels.
10. The operator in the disabled truck should now
move switch (1) to the ON position. This will
release the parking brakes.
11. Tow the disabled truck. Sudden movement may
cause tow bar failure. Smooth, gradual truck
movement is preferred. Do not tow the truck
any faster than 8 kph (5 mph).
FIGURE 30-2. BRAKE CABINET
1. Brake Manifold 2. Parking Brake Solenoid
FIGURE 30-1. PARKING BRAKE HARNESS
1. 24VDC Bus Bar 4. Connector
2. Switch (ON/OFF) 5. Ground Wire
3. Park Brake Solenoid
--- Page 12 ---
OM3233 8/11 Operator Cab And Controls - Section 32
Page 32-5
OVERHEAD PANEL AND DISPLAYS Status/Warning Indicator Light Panel
The components described below are located on the Status/ warning indicator panel (13) contains an array
overhead panel. Refer to Figure 32-1. of indicator lights to provide the operator with
important status messages concerning selected truck
Speakers functions. Refer to Instrument Panel and Indicator
Speakers (9, Figure 32-1) for the radio/CD player are Lights in this section for a detailed description of
located at the far left and right of the overhead panel. these indicators.
Warning Alarm Buzzer Air Cleaner Restriction Gauges
A warning alarm buzzer (10) will sound when Air cleaner restriction gauges
activated by any one of several truck functions. Refer (14) provide a continuous reading
to Instrument Panel and Indicator Lights in this of the maximum air cleaner
section for a detailed description of functions and restriction reached during
indicators that will activate this alarm. operation. The air cleaner(s)
should be serviced when the
Radio/CD Player gauge(s) shows the maximum recommended
restriction of 25 inches of H2O vacuum.
This panel will normally contain a radio/CD player
(11). Refer to Section 70 for a complete description of NOTE: After service, push the reset button on the
the radio/CD player and its functions. Individual face of the gauge to return the gauge to zero.
customers may use this area for other purposes,
such as a two-way communications radio.
Warning Indicator Light Dimmer Control
Dimmer control (12) below the radio/CD player
permits the operator to adjust the brightness of the
warning indicator lights.
--- Page 13 ---
OM3233 8/11 Operator Cab And Controls - Section 32
Page 32-15
Wheel Brake Lock Switch Engine Oil Pressure Gauge
Wheel brake lock switch (6, Figure Engine oil pressure gauge (9, Figure
32-7) should be used with engine 32-7) indicates pressure in the
running for dumping and loading engine lubrication system.
operations only. The brake lock
Normal operating pressure after
switch actuates the hydraulic brake
engine warm-up should be:
system which locks the rear wheel
service brakes only. When pulling Idle: 138 kPa (20 psi) minimum
into shovel or dump area, stop the Rated Speed: 310 - 483 kPa (45 - 70 psi)
truck using the foot-operated service
brake pedal. When truck is
completely stopped and in loading Right Turn Signal Indicator
position, apply the brake lock by pressing the top of
the rocker switch. To release the brake, press the Indicator (10, Figure 32-7) illuminates to indicate that
bottom of the rocker switch. the right turn signals are operating when the turn
signal lever on the steering column is moved upward.
NOTE: Use at the shovel and dump only to hold the Moving the lever to its center position will turn the
truck in position. indicator off.
Digital Tachometer
Digital tachometer (11, Figure 32-7) registers engine
Do not use the wheel brake lock switch to stop crankshaft speed in hundreds of revolutions per
the truck unless foot-operated treadle valve is minute (rpm).
inoperative. Use of this switch applies rear
service brakes at a reduced, unmodulated Governed Speed
pressure. Do not use brake lock for parking. With
engine stopped, hydraulic pressure will bleed Low Idle 750 rpm
down, allowing brakes to release. High Idle 1910 rpm
Full Load 1900 rpm
Hazard Warning Light Switch
Hazard warning light switch (7, Figure High Beam Indicator
32-7) flashes all the turn signal lights. When lit, high beam indicator (12, Figure 32-7)
Pressing the bottom of the rocker indicates that the headlights are on high beam. To
switch activates these lights. Pressing switch the headlights to high beam, push the turn
the top of the rocker switch turns indicator lever away from the steering wheel. For low
these lights off. beam, pull the lever toward the steering wheel.
Heater/Air Conditioner Vents Speedometer/Payload Meter Display
Heater/air conditioner vents (8, Figure 32-7) may be Speedometer/payload meter display (13, Figure 32-
directed by the operator to provide the most 7) indicates the truck speed in kilometers per hour
comfortable cabin air flow. (kph) or in miles per hour (mph). The display also
shows payload meter information. For more
information, see Section 60, Payload Meter III.
--- Page 14 ---
OM3233 8/11 Operator Cab And Controls - Section 32
Page 32-25
KOMTRAX PLUS
Operation
This system uses KOMTRAX Plus controller
(formerly known as VHMS) (6, Figure 32-11) to
The KOMTRAX Plus system uses wireless
gather data about the operation of the truck from
components that transmit via radio waves. It is
sensors and other controllers installed on the truck.
necessary to conform to local laws when using
The data stored in KOMTRAX Plus is collected by a
this system.
laptop personal computer (PC) or transmitted directly
by communications satellite (utilizing the ORBCOMM
Proper operation of the system is dependent on
controller). This data is then compiled at the Komatsu
good reception. Operating in tunnels, mountain
computer server. Based on this information, the
ranges and covered areas may prevent
servicing Komatsu distributor will suggest
communication of the system.
improvements and provide information aimed at