PDF Operation & Maintenance Manual Komatsu 930E-2 Dump Truck - 579 KB
The Komatsu 930E-2 is a powerhouse in the mining industry, known for its immense payload capacity and reliability.
This comprehensive Operation & Maintenance Manual is your essential guide to keeping this massive dump truck running at peak performance.
It provides detailed instructions for daily checks, routine servicing, and correct operating procedures to ensure safety and longevity.
Owning this manual helps prevent costly downtime and maximizes the productivity of your investment.
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--- Page 1 ---
CEAM012100
Operation & Maintenance
Manual
930E-2
DUMP TRUCK
SERIAL NUMBERS A30300 thru A30303
--- Page 3 ---
Introduction - Section 10 OM1037
Page 10-6
TABLE OF CONTENTS
SUBJECT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - SECTION / PAGE
Ash Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
L.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
R.H. Window Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
Engine Shutdown Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-7
Override/Fault Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
Retard Speed Control (RSC) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
Retard Speed Control (RSC) Adjust Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-8
PSC Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Engine Diagnostics Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
TCI Download Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Modular Mining System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
Payload Meter And Download Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-9
OPERATOR COMFORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-10
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS . . . . . . . . . . . . . . . . . . . . . 32-11
Heater/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Defroster Vent Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Fan Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
Heater/Air Conditioner Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-11
INSTRUMENT PANEL AND INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
CONTROL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-13
PANEL GAUGES, INDICATORS, AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Engine Shutdown Switch with 5 Minute Idle Timer Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-15
Fog Lights (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Ladder Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Manual Backup Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Panel Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Cab/Air Conditioner Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Rotating Beacon Light Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
Heated Mirror Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-16
--- Page 4 ---
Standard Charts and Tables - Section 12 OM1200
Page 12-4
TABLE VIII. TORQUE CONVERSIONS
Foot Pounds – ft. lbs. To Newton-meters (N.m)
FT.
LBS. 0 1 2 3 4 5 6 7 8 9
0 (N.m) 1.36 2.71 4.07 5.42 6.78 8.14 9.49 10.85 12.20
10 13.56 14.91 16.27 17.63 18.98 20.34 21.69 23.05 24.40 25.76
20 27.12 28.47 29.83 31.18 32.54 33.90 35.25 36.61 37.96 39.32
30 40.67 42.03 43.39 44.74 46.10 47.45 48.81 50.17 51.52 52.87
40 54.23 55.59 56.94 58.30 59.66 60.01 62.37 63.72 65.08 66.44
50 67.79 69.15 70.50 71.86 73.21 74.57 75.93 77.28 78.64 80.00
60 81.35 82.70 84.06 85.42 86.77 88.13 89.48 90.84 92.20 93.55
70 94.91 96.26 97.62 98.97 100.33 101.69 103.04 104.40 105.75 107.11
80 108.47 109.82 111.18 112.53 113.89 115.24 116.60 117.96 119.31 120.67
90 122.03 123.38 124.74 126.09 127.45 128.80 130.16 131.51 132.87 134.23
See NOTE on page 12-5 regarding table usage
TABLE IX. TORQUE CONVERSIONS
Foot Pounds – ft. lbs. To kilogram-meters (kg.m)
FT.
LBS. 0 1 2 3 4 5 6 7 8 9
0 (kg.m) 0.138 0.277 0.415 0.553 0.692 0.830 0.968 1.106 1.245
10 1.38 1.52 1.66 1.80 1.94 2.07 2.21 2.35 2.49 2.63
20 2.77 2.90 3.04 3.18 3.32 3.46 3.60 3.73 3.87 4.01
30 4.15 4.29 4.43 4.56 4.70 4.84 4.98 5.12 5.26 5.39
40 5.53 5.67 5.81 5.95 6.09 6.22 6.36 6.50 6.64 6.78
50 6.92 7.05 7.19 7.33 7.47 7.61 7.74 7.88 8.02 8.16
60 8.30 8.44 8.57 8.71 8.85 8.99 9.13 9.27 9.40 9.54
70 9.68 9.82 9.96 10.10 10.23 10.37 10.51 10.65 10.79 10.93
80 11.06 11.20 11.34 11.48 11.62 11.76 11.89 12.03 12.17 12.30
90 12.45 12.59 12.72 12.86 13.00 13.14 13.28 13.42 13.55 13.69
See NOTE on page 12-5 regarding table usage
TABLE X. PRESSURE CONVERSIONS
Pounds/square inch (psi) To Kilopascals (kPa)
Formula: psi x 6.895 = kPa
PSI 0 1 2 3 4 5 6 7 8 9
0 (kPa) 6.895 13.79 20.68 27.58 34.47 41.37 48.26 55.16 62.05
10 68.95 75.84 82.74 89.63 96.53 103.42 110.32 117.21 124.1 131.0
20 137.9 144.8 151.7 158.6 165.5 172.4 179.3 186.2 193.1 200.0
30 206.8 213.7 220.6 227.5 234.4 241.3 248.2 255.1 262.0 268.9
40 275.8 282.7 289.6 296.5 303.4 310.3 317.2 324.1 331.0 337.9
50 344.7 351.6 358.5 365.4 372.3 379.2 386.1 393.0 399.9 406.8
60 413.7 420.6 427.5 434.4 441.3 448.2 455.1 462.0 468.9 475.8
70 482.6 489.5 496.4 503.3 510.2 517.1 524.0 530.9 537.8 544.7
80 551.6 558.5 565.4 572.3 579.2 586.1 593.0 599.9 606.8 613.7
90 620.5 627.4 634.3 641.2 648.1 655.0 661.9 668.8 675.7 682.6
See NOTE on page 12-5 regarding table usage
--- Page 5 ---
Safety - Section 20 OM2030
Page 20-8
Traveling On Slopes
• Traveling on slopes could result in the machine tipping over or slipping.
• Do not change direction on slopes. To ensure safety, drive to level ground before turning.
• Do not travel up and down on grass, fallen leaves, or wet steel plates. These materials may make the machine
slip on even the slightest slope. Avoid traveling sideways, and always keep travel speed low.
• When traveling downhill, use the retarder to reduce speed. Do not turn the steering wheel suddenly. Do not use
the foot brake except in an emergency.
• If the engine should stop on a slope, apply the service brakes fully and stop the machine. Apply the parking
brake after the machine has stopped.
Ensure Good Visibility
• When working in dark places, install work lamps and head lamps. Set up extra lighting in the work area if
necessary.
• Discontinue operations if visibility is poor, such as in mist, snow, or rain. Wait for the weather to
improve to allow the operation to be performed safely.
Operate Carefully On Snow
• When working on snowy or icy roads, there is danger that the machine may slip to the side on even the
slightest slope. Always travel slowly and avoid sudden starting, turning, or stopping in these conditions.
• Be extremely careful when clearing snow. The road shoulder and other objects are buried in the snow and
cannot be seen. When traveling on snow-covered roads, always install tire chains.
Avoid Damage To Dump Body
• When working in tunnels, on bridges, under electric cables, or when entering a parking place or any other place
where there are height limits; always use extreme caution. The dump body must be completely lowered before
driving the machine.
Driving Near High Voltage Cables
• Driving near high-voltage cables can cause electric shock. Always maintain safe distances between the
machine and the electric cable as listed below.
Voltage Minimum Safety Distance
6.6 kV 3m 10 ft.
33.0 kV 4m 14 ft.
66.0 kV 5m 17 ft.
154.0 kV 8m 27 ft.
275.0 kV 10 m 33 ft.
The following actions are effective in preventing accidents while working near high voltages:
• Wear shoes with rubber or leather soles.
• Use a signalman to give warning if the machine approaches an electric cable.
• If the work equipment should touch an electric cable, the operator should not leave the cab.
• When performing operations near high voltage cables, do not allow anyone to approach the machine.
• Check with the electrical maintenance department about the voltage of the cables before starting operations.
--- Page 6 ---
Safety - Section 20 OM2030
Page 20-18
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK
Preliminary Procedures Before Welding or Performing Maintenance
Prior to welding and/or repairing a 930E dump truck, maintenance personnel should attempt to notify a Komatsu
service representative. Only qualified personnel, specifically trained for servicing the AC Drive System, should per-
form this service.
If it is necessary to perform welding or repair to the truck without the field engineer present, the following proce-
dures should be followed to ensure that the truck is safe for maintenance personnel to work on and to reduce the
chance for damage to equipment.
ANYTIME THE ENGINE IS RUNNING:
• Do not open any of the cabinet doors or remove any covers.
• Do not use any of the power cables for hand holds or foot steps.
• Do not touch the retarder grid elements.
Before opening any cabinets or touching a grid element or a power cable, the engine must be shutdown
and the red drive system warning lights must not be illuminated.
Normal Engine Shutdown Procedure
1. Stop the truck out of the way of other traffic on a level surface (dry, if possible) and free of overhead power
lines or other obstructions (in case dump body should need to be raised).
a. Reduce engine speed to idle. Allow the engine to cool gradually by running at low idle for approx. 5 min-
utes.
b. Place the directional selector switch in NEUTRAL.
c. Apply the parking brake switch. Be sure the “parking brake applied” indicator light in the overhead display
panel is illuminated.
2. Place rest switch in ON position to put AC drive system in “rest” mode of operation. Be sure the “rest” indicator
light in the overhead panel is illuminated.
3. With engine cooled down, turn keyswitch counterclockwise to OFF position for normal shutdown of engine.
If the engine does not shutdown with keyswitch, use engine shutdown switch on operator cab center console,
and hold this switch down until engine stops.
4. With keyswitch OFF, and engine stopped, wait at least 90 seconds. Insure the steering circuit is completely
bled down by turning the steering wheel back and forth several times. No front wheel movement will occur
when hydraulic pressure is relieved. If the vehicle continues to steer after shutdown, notify maintenance per-
sonnel.
5. Verify that all the link voltage lights are off (one on back wall of operator cab, and two on deck control cabi-
nets). Notify maintenance personnel if any light remains illuminated longer than five minutes after engine
shutdown.
6. Close and lock all windows, remove key from keyswitch, and lock the cab to prevent possible unauthorized
truck operation. Dismount the truck properly. Put wheel chocks in place.
--- Page 7 ---
Warnings And Cautions - Section 22 OM2200
Page 22-8 09/03
This decal is placed on the ground level engine shutdown switch which
is mounted on the right side of the front bumper structure. It specifies
that this switch is for emergency shutdown only.
This page illustrates a variety of decals which are mounted on deck mounted cabinets, housings, and structures
which must be lifted in a specific manner, and from specific points, in order to safely move or lift any of these struc-
tures.
If any of these decals are damaged or defaced, so that it is no longer legible, it should be replaced immediately.
Maintenance personnel must follow these lifting instructions.
--- Page 8 ---
Operating Instructions - Section 30 8/03 OM3038
Page 30-8
DUMPING
Raising The Dump Body
1. Pull into dump area with extreme caution. Make sure area is clear of persons and obstructions, including
overhead utility lines. Obey signals directed by the spotter, if present.
Avoid unstable areas. Stay a safe distance from edge of dump area.
Position the truck on a solid, level surface before dumping.
As the body raises, the truck center of gravity will move. Truck must be on
level surface to prevent tipping / rolling!
2. Carefully maneuver truck into dump position. When backing truck into dump position, use only the foot-oper-
ated brake pedal to stop and hold truck; Do not rely on wheel brake lock to stop truck; this control is not mod-
ulated and applies rear service brakes only.
3. When truck is stopped and in dump position, apply wheel brake lock and move the selector switch to the
NEUTRAL position.
The dumping of very large rocks (10% of payload, or greater) or sticky
material (loads that do not flow freely from the body) may allow the mate-
rial to move too fast and cause the body to move rapidly and suddenly.
This sudden movement may jolt the truck violently and cause possible
injury to the operator, and/or damage to the hoist cylinders, frame, and/or body hinge pins. If it is neces-
sary to dump this kind of material, refer to the WARNING in the following procedure:
4. Pull the lever to the rear to actuate hoist circuit. (Releasing the lever anywhere
during "hoist up" will hold the body at that position.)
5. Raise engine rpm to accelerate hoist speed. Refer to the CAUTION below.
If dumping very large rocks or sticky material as described in WARNING
above, slowly accelerate engine rpm to raise body. When the material
starts to move, release hoist lever to HOLD position. If material does not
continue moving and clear body, repeat this procedure until material has
cleared body.
6. Reduce engine rpm as last stage of hoist cylinder begins to extend and let engine go to low idle as last stage
reaches half-extension.
7. Release hoist lever as last stage of hoist cylinder reaches full extension.
8. After material being dumped clears body, lower body to frame.
Lowering The Dump Body
(When dumping on flat ground):
It is very likely when dumping on flat ground that the dumped material will build up enough to prevent the body from
lowering. In this case, the truck will have to be driven forward a short distance (just enough to clear the material)
before the body can be lowered.
1. Shift selector switch to FORWARD, release brake lock, depress override button and drive just far enough for-
ward for body to clear material. Stop, shift selector switch to NEUTRAL, and apply brake lock.
2. Move hoist lever forward to DOWN position and release. Releasing the lever places hoist control valve in the
FLOAT position allowing the body to return to frame.
--- Page 9 ---
Operator Cab And Controls - Section 32 OM3205
Page 32-4
GRADE/SPEED RETARD CHART The "short term" numbers listed on the chart indicate
the combination of speeds and grades which the
Grade/speed retard chart (8, Figure 32-1 & shown vehicle can safely negotiate for a short duration
below) provides the recommended MAXIMUM before system components reach the maximum
retarding limits at various truck speeds and grades allowable temperature during retarding. These
with a fully loaded truck. speeds are faster than the "continuous" values,
This decal in the truck may differ from the decal reflecting the thermal capacity of various system
below due to optional truck equipment such as: components. System components can accept heat-
wheel motor drive train ratios, retarder grids, tire ing at a higher-than-continuous rate for a short period
sizes, etc. Always refer to this decal in the opera- of time. Beyond this short duration of time, the sys-
tor's cab, and follow these recommendations for tem would become overheated.
truck operation. If the vehicle is operated at "short term" grade and
The operator should reference this chart before speed limits for a period of time exceeding thermal
descending any grade with a loaded truck. Proper capacity, the Propulsion System Controller (PSC)
use of dynamic retarding will maintain a safe speed. gradually reduces retarding effort from "short term" to
"continuous". The "retard @ continuous" indicator
light will illuminate alerting the operator of the retard-
ing reduction and the need for a reduction in speed.
The operator must use the service brakes to quickly
slow the truck to maximum "continuous" retarding
limits or less.
Do Not LIGHTLY apply the service brakes when
attempting to slow the truck on a downhill grade.
Overheating of the brakes will result. Fully apply
the brakes (within safe limits for road conditions)
in order to quickly slow the truck to maximum
"continuous" retarding limits or less.
NOTE: The "three minute" curve is a minimum and
the actual time limit could be greater. Ambient
temperature, barometric pressure and recent motor
power levels can affect this number.
The "short term" rating will successfully accommo-
date most downhill loaded hauls. It is necessary to
divide haul road grade segment length by allowable
speed to determine actual time on grade. If actual
time on the grade exceeds the allowable limits, the
grade will need to be negotiated at the "continuous"
speed.
Two speed lists are provided, one for continuous The "continuous" numbers on the chart indicate the
retarding, and the second, for short term (approx. 3- combination of speeds and grades which the vehicle
minute) retarding. Both lists are matched to the truck can safely negotiate for unlimited time or distance
at maximum Gross Vehicle Weight (GVW). The two during retarding.
ratings are guidelines for proper usage of the retard
function on downhill grades. DO NOT exceed these recommended MAXIMUM
speeds when descending grades with a loaded truck.
--- Page 11 ---
Operator Cab And Controls - Section 32 OM3205
Page 32-14
FIGURE 32-7. PANEL GAUGES, INDICATORS, AND CONTROLS
1. Keyswitch 15. Right Turn Signal Indicator Light
2. Engine Shutdown Switch with Timer Delay 16. High Beam Headlight Indicator Light
3. Backup Light Switch (N./O.) 17. Left Turn Signal Indicator Light
4. Ladder Light Switch (3 - Way) 18. Digital Speedometer
5. Fog Light Switch (N./O.) 19. Voltmeter Gauge
6. Panel Illumination Light(s) 20. Engine Oil Pressure Gauge
7. Vent(s) - Cab Air Conditioner/Heater 21. Engine Water Temperature Gauge
8. Not used on 930E 22. Fuel Gauge
9. Rotating Beacon Light Switch (N./O.) (Optional) 23. AC Drive System Temperature
10. Heated Mirror Switch (N./O.) (Optional) 24. Engine Hourmeter
11. Not used on 930E 25. Hydraulic/Brake Oil Temperature
12. Wheel Brake Lock Switch (N./O.) 26. AC Rest Switch
13. Parking Brake Switch (N./O.) 27. Headlights Switch (N./O.)
14. Digital Tachometer 28. Wiper / Washer Switch
29. Panel Illumination Lights Dimmer Rheostat
WIRE NUMBERS
1. 712/21PB/11S 11. 71/79M/SPR55/79H/72F/ 21. 712D/31TS/710/49
2. 11S/11TD/11R SPR54 22. 712D/38G/710/49
3. 712/47S/47L/710 12. 712BL/52B/39H/710/SPR59 23. 15V/72MT/49/710
4. 11L/48A/48B 13. 71/52C/21PB/21 24. 11L/36
5. 11L/48F 14. 41TS/74X/74Z/710 25. 15V/34BT/710/49
6. 49/710 15. 45R/710 26. 710/72RQ
7. N/A 16. 41H/710 27. 11D/41L/41TS
8. 712/28E 17. 45L/710 28. High 66S/Low 66L/710/66P
9. 11L/11RB 18. 41TS/77/77A/710 Park/712W / Washer 66
10. 712/69M/SPR56/SPR57/ 19. 712D/710/49 29. 49/41TS
SPR58 20. 712D/31PS/710/49
--- Page 12 ---
Operator Cab And Controls - Section 32 OM3205
Page 32-24
A3. Parking Brake
This amber parking brake indicator will illuminate when the parking brake is applied. Do not
attempt to drive truck with parking brake applied.
B3. Service Brake
This amber service brake indicator light will illuminate when the service brake pedal is applied
or when wheel brake lock or emergency brake is applied. Do not attempt to drive the truck
from stopped position with service brakes applied, except as noted in Section 30, Operating
Instructions - Starting On A Grade With A Loaded Truck.
C3. Body Up
This amber body up indicator, when illuminated, shows that the body is not completely down
on the frame. The truck should not be driven until body is down and the light is off.
D3. Dynamic Retarding
This amber dynamic retarding indicator light illuminates whenever the retarder pedal (or
retarder lever) is operated, RSC (Retarder Speed Control) is activated, or the automatic over-
speed retarding circuit is energized, indicating the dynamic retarding function of the truck is
operating.
E3. Stop Engine
This red engine monitor warning light will illuminate if a serious engine malfunction is detected
in the electronic engine control system.
• Electric propulsion to the wheelmotors will be discontinued.
• Dynamic retarding will still be available if needed to slow or stop the truck.
Stop the truck as quickly as possible in a safe area and apply
parking brake.
SHUT DOWN THE ENGINE IMMEDIATELY. Additional engine
damage is likely to occur if operation is continued.
Listed below are a few conditions that could cause the stop engine light to illuminate:
• Low Oil Pressure - red warning light will illuminate, but engine does not shutdown.
• Low Coolant Level - red warning light will illuminate, but engine does not shutdown.
• Low Coolant Pressure - red warning light will illuminate, but engine does not shutdown.
• High Coolant Temperature - red warning light will illuminate, but engine does not shutdown.
--- Page 13 ---
Lubrication & Service - Section 40 OM4036
Page 40-6
10 HOUR (DAILY) INSPECTION (Continued)
Truck Serial Number______________________ Site Unit Number_______________ Date_______________
Hourmeter_____________ Name of Service Technician___________________________________
TASK COMMENTS CHECKED INITIALS
13. FUEL FILTERS (Fuel Separators) - Drain water from
the bottom drain valve on each fuel separator.
14. AUTOMATIC LUBE SYSTEM -
• Check the grease reservoir; fill as required. Lube
Key “D”.
• When filling the reservoir, check the grease filter
indicator. Clean or replace the grease filter if the
indicator detects a problem.
• Inspect the system and check for proper
operation. Be certain the following important
areas are receiving adequate amounts of grease.
Lube Key “D”.
Steering Linkage
Final Drive Pivot Pin -
Rear Suspension Pin Joints - Upper & Lower
Body Hinge Pins -
Hoist Cylinders Pins - Upper & Lower
Anti-sway Bar - Both Ends
--- Page 14 ---
Automatic Lubrication System - Section 42 OM4200
Page 42-2
FIGURE 42-2. AUTO LUBE SYSTEM INSTALLATION
NOTE: The above illustration shows the standard location for the lube pump & reservoir (right platform). This
assembly may be located on left platform on some models.
1. L.H. Suspension, Top Bearing 13. R.H. Hoist Cylinder, Top Bearing
2. L.H. Suspension, Bottom Bearing 14. R.H. Hoist Cylinder, Bottom Bearing
3. L.H. Body Pivot Pin 15. R.H. Anti-Sway Bar Bearing
4. L.H. Hoist Cylinder, Top Bearing 16. Vent Hose
5. L.H. Hoist Cylinder, Bottom Bearing 17. Junction Box
6. L.H. Anti-Sway Bar Bearing 18. Pressure Switch, N.O., 2500 psi (17 237 kPa)
7. Rear Axle Pivot Pin 19. Grease Pump
8. Grease Supply From Pump 20. Vent Valve
9. Pressure Switch, N.O., 2000 psi (13 789 kPa) 21. Filter
10. R.H. Suspension, Top Bearing 22. Grease Supply to Injectors
11. R.H. Suspension, Bottom Bearing 23. Truck Frame
12. R.H. Body Pivot Pin 24. Injector
--- Page 15 ---
Automatic Lubrication System - Section 42 OM4200
Page 42-12
POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION
TROUBLE: Pressure Gauge Does Not Register Pressure
No system pressure to the pump motor. Check hydraulic hose from steering system.
No 24 VDC signal at pump solenoid. Determine problem in 24 VDC electric system.
Pressure reducing valve set too low. Refer to Pressure Control Valve Adjustment.
Relay (RB7K5) may be defective. Replace relay.
TROUBLE: Pump Pressure Builds Very Slowly Or Not At All
No signal at RB7K5 relay. Check Timer and CB7.
Pressure switch may be defective. Replace pressure switch.
Pressure reducing valve may be set too low. Refer to Pressure Control Valve Adjustment.
Grease viscosity may be too high for temperature Replace grease with a lower viscosity lubricant.
at which pump is operating.
Pump inlet check or outlet check may have foreign Remove, inspect and clean, if necessary.Inspect
matter trapped causing leakage. sealing surfaces between checks. Replace if rough
or pitted.
Lubricant supply line leaks or is broken. Repair lubricant supply line .
Insufficient hydraulic oil supply. Check oil pressure and flow to motor.
TROUBLE: Lube Cycle Timer Not Operating