Komatsu 930E-4 Operation & Maintenance Manual Download Page 17 | Manualshive

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INTRODUCTION

ALERTS

ALERTS

D.2-0000051268

The ALERT symbol is used with the following signal words:

• DANGER

• WARNING

• CAUTION

This symbol is used to alert the reader of hazards that can arise from improper operating and maintenance
practices.

•

DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if
proper precautions are not taken.

•

WARNING identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH
if proper precautions are not taken.

•

CAUTION is used for general reminders of proper safety practices OR to direct the reader’s attention
to avoid unsafe or improper practices which may result in damage to the machine.

930E-4

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Summary of Contents for 930E-4

Page 1: ...It is our policy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously Due to this continuous program of research and development revisions may be made to this publication It is recommended that customers contact their distributor fo...

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Page 3: ...ric 2 12 Temperature Conversions 2 13 GENERAL SAFETY GENERAL SAFETY 3 2 Safety Rules 3 2 Truck Safety Features 3 2 Clothing And Personal Items 3 2 Unauthorized Modification 3 2 Leaving The Operator s Seat 3 2 Mounting And Dismounting 3 2 Fire Extinguishers And First Aid Kits 3 3 Precautions For High Temperature Fluids 3 3 Asbestos Dust Hazard Prevention 3 3 Fire Prevention 3 3 ROPS Precautions 3 3...

Page 4: ...ERFORMING MAINTENANCE 3 13 Securing The Dump Body 3 13 DURING MAINTENANCE 3 14 Warning Tag 3 14 Proper Tools 3 14 Attachments 3 14 Working Under The Machine 3 14 Keeping The Machine Clean 3 14 Adding Fuel Or Oil To The Machine 3 14 Radiator Coolant Level 3 15 Use Of Lighting 3 15 Handling High Pressure Hoses 3 15 Precautions With High Pressure Oil 3 15 Maintenance Near High Temperatures And High P...

Page 5: ...adder System Description 5 7 Ladder System Operation 5 7 In Cab Control Panel 5 8 Ground Level Control Box 5 10 Emergency Down Valve 5 11 PRE SHIFT BRAKE TEST 5 12 Operation 5 12 Service Brake Test 5 13 Parking Brake Test 5 13 Retard System Test 5 14 Brake Test Exit Criteria 5 14 TRUCK OPERATION 5 15 ENGINE START UP SAFETY 5 15 After Engine Has Started 5 15 MACHINE OPERATION SAFETY PRECAUTIONS 5 1...

Page 6: ...bject Clear 5 38 START UP INSPECTION 5 38 FUEL DEPLETION 5 39 SAFE PARKING PROCEDURES 5 39 NORMAL ENGINE SHUTDOWN PROCEDURE 5 40 DISABLED TRUCK CONNECTORS 5 41 GENERAL INFORMATION 5 41 HOIST SYSTEM 5 41 Hookup 5 41 Dumping Procedure 5 41 TOWING 5 43 SPECIAL WIRING HARNESS 5 43 TOWING PROCEDURE 5 43 PAYLOAD METER IV SYSTEM 5 46 GENERAL INFORMATION 5 46 Data Summary 5 46 Data Gathering 5 46 COMPONEN...

Page 7: ...Inclinometers 5 63 Gauge Display Units 5 64 Pressure Sensor Units for RTD web page only 5 64 Date and Time 5 64 Payload Gain Factor 5 64 Payload Light Test 5 64 Truck Tare Reset 5 64 Truck Data Configuration 5 65 Inclinometer Calibration 5 65 Overload Threshold 5 66 Clean Truck Tare 5 67 Tare Reset 5 69 Custom Truck Configuration 5 69 Field Software Update 5 70 Viewing Haul Cycle Data 5 72 Downloa...

Page 8: ...ever 6 3 Multi Function Turn Signal Switch 6 3 Turn Signal Operation 6 3 High Beam Headlight Operation 6 3 Windshield Wiper Operation 6 3 PEDALS AND RETARDER LEVER 6 5 Dynamic Retarding 6 5 Retarder Lever 6 5 Brake Retarder Pedal 6 5 Accelerator Pedal 6 5 OVERHEAD PANEL AND DISPLAYS 6 6 Radio Speakers 6 6 Warning Alarm Buzzer 6 6 Cab Radio 6 6 Air Cleaner Vacuum Gauges 6 6 KomVision Panel 6 6 CENT...

Page 9: ...er Air Conditioner Vents 6 19 Status Indicator Light Panel 6 19 Hydraulic Oil Temperature Gauge 6 19 Coolant Temperature Gauge 6 19 Speedometer Digital Display 6 19 Fuel Level Gauge 6 19 Drive System Temperature Gauge 6 20 Hazard Warning Light Switch 6 20 Pre Shift Brake Test Switch 6 20 Wheel Brake Lock Control Switch 6 20 Rest Switch 6 20 Engine Warm Up 6 21 Heated Mirror Switch Optional 6 21 Ro...

Page 10: ...lus Downloading Procedure 6 31 Location Of Downloaded Files 6 31 UPLOADING KOMTRAX Plus DATA 6 32 ORBCOMM 6 34 KOMATSU WIRELESS BRIDGE KWB 6 35 General Information 6 35 VHMS DOWNLOADS 6 35 General Information 6 35 VHMS Downloading Procedure 6 36 ONBOARD CONTROLLER ACCESS 6 36 Wireless Access 6 36 Wireless Access Procedure 6 36 Wired Access 6 37 Wired Access Procedure 6 37 CHANGING A LAPTOP S IP AD...

Page 11: ...Y 1000 HOURS LUBRICATION AND MAINTENANCE 7 19 EVERY 4000 HOUR MAINTENANCE 7 20 EVERY 5000 HOUR MAINTENANCE 7 21 SPECIFICATIONS MAJOR COMPONENT DESCRIPTION 8 2 Truck and Engine 8 2 Traction Alternator 8 2 Main Control Cabinet 8 2 AC Induction Traction Motorized Wheels 8 2 Suspension 8 2 Operator s Cab 8 2 Power Steering 8 2 Dynamic Retarding Grid 8 2 Brake System 8 2 SPECIFICATIONS 8 3 Engine 8 3 A...

Page 12: ... 9 6 CD PLAYER 9 7 Playing A Compact Disc 9 7 Playing An MP3 DISC 9 7 CD Mode Displays 9 7 Button Functions 9 7 MP3 PLAYER 9 9 Playing MP3 Files 9 9 MP3 Mode Displays 9 9 Button Functions 9 9 iPod 9 11 Playing An iPod 9 11 iPod Mode Displays 9 11 Button Functions 9 11 WEATHERBAND USA Only 9 13 TROUBLESHOOTING 9 14 Tips About the Audio System 9 14 Understanding Radio Reception 9 14 Care Of The Comp...

Page 13: ...INTRODUCTION 930E 4 1 1 ...

Page 14: ...system The product identification number vehicle serial number contains information which will identify the original manufacturing bill of material for this unit This complete number will be necessary for proper ordering of many service parts and or warranty consideration The GVW is what determines the load on the drive train frame tires and other components The vehicle design and application guid...

Page 15: ...0 Komatsu Dr Cartersville GA 30121 United States of America Phone 678 721 3310 Email KACTECHPUBS KOMATSUNA COM If there is ever a question regarding the information in a particular section refer to the manual form number and use the address shown above to correspond The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the...

Page 16: ... operating or maintaining this machine This manual should be kept in or near the machine for reference and periodically reviewed by all personnel who will come into contact with it California Proposition 65 Warnings Diesel engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer birth defects or other reproduc...

Page 17: ...GER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken WARNING identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH if proper precautions are not taken CAUTION is used for general reminders of proper safety practices OR to direct the reader s attention to avoid unsafe or improper practices which may ...

Page 18: ...TRUCK MODEL ILLUSTRATION INTRODUCTION TRUCK MODEL ILLUSTRATION A 2 0000072148 1 6 930E 4 ...

Page 19: ...cations accordingly use of such parts may compromise the safe operation of Komatsu products and place the operator and others in danger should the part fail Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above Use of non OEM parts places f...

Page 20: ...NON OEM PARTS IN CRITICAL SYSTEMS INTRODUCTION 1 8 930E 4 ...

Page 21: ...STANDARD CHARTS AND TABLES 930E 4 2 1 ...

Page 22: ...ads of standard fasteners where standard torque values are applied The use of special friction reducing lubricants will significantly alter the clamping force being applied to fasteners during the tightening process If special friction reducing lubricants are used with the standard torque values listed in this chapter excessive stress and possible breakage of the fasteners may result Where the tor...

Page 23: ...se see list this page to achieve the same clamping forces provided below NOTE Torques are calculated to give a clamping force of approximately 75 of proof load The maximum torque tolerance shall be within 10 of the torque value shown In the following table under Capscrew Size the first number represents the shank diameter mm The second number represents thread pitch in millimeters Example M20 x 2 ...

Page 24: ... Grade 5 Torque Grade 8 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 1 4 28 10 8 8 1 11 14 9 11 1 52 5 16 18 20 3 15 2 07 28 21 2 90 5 16 24 22 16 2 21 30 22 3 04 3 8 16 34 25 3 46 47 35 4 84 3 8 24 41 30 4 15 54 40 5 5 7 16 14 54 40 5 5 79 58 8 0 7 16 20 61 45 6 2 84 62 8 57 1 2 13 88 65 9 122 90 12 4 1 2 20 95 70 9 7 129 95 13 1 9 16 12 122 90 12 4 169 125 17 3 Standard Tightenin...

Page 25: ...ightening Torque for SAE Hex Head and 12 Point Grade 9 Capscrews Capscrew Size 1 Torque N m Torque ft lb Torque kg m 0 250 20 16 12 1 7 0 312 18 33 24 3 3 0 375 16 57 42 5 8 0 438 14 95 70 9 7 0 500 13 142 105 14 5 0 562 12 203 150 20 7 0 625 11 278 205 28 3 0 750 10 488 360 49 7 0 875 9 780 575 79 4 1 000 8 1166 860 119 1 000 12 1240 915 126 1 125 7 1670 1230 170 Standard Tightening Torque for SA...

Page 26: ...0 Kilogram meters kg m 10 10 14 66 48 6 7 12 17 112 83 11 5 16 22 279 206 28 5 Flared Tube And Hose Fittings Table 2 6 Tightening Torque For Flared Tube And Hose Fittings Thread Diameter of Nut mm Width Across Flat mm Newton meters N m 10 Foot Pounds ft lb 10 Kilogram meters kg m 10 14 19 25 18 2 5 18 24 50 36 5 22 27 80 58 8 24 32 140 101 14 30 36 175 130 18 33 41 195 145 20 36 46 245 180 25 42 5...

Page 27: ... N m Foot Pounds ft lb 2 0 125 0 312 24 5 1 4 1 3 0 188 0 375 24 11 4 8 3 4 0 250 0 438 20 16 4 12 3 5 0 312 0 500 20 20 4 15 3 6 0 375 0 562 18 24 7 18 5 8 0 500 0 750 16 40 7 30 5 10 0 625 0 875 14 54 7 40 5 12 0 750 1 062 12 75 7 55 5 14 0 875 1 188 12 88 7 65 5 16 1 000 1 312 12 108 7 80 5 20 1 250 1 625 12 136 14 100 10 24 1 500 1 875 12 163 14 120 10 32 2 000 2 500 12 312 27 230 20 930E 4 2 ...

Page 28: ...Sealant ft lb Without Sealant N m Without Sealant ft lb 2 0 125 27 20 4 15 3 27 7 20 5 4 0 250 18 27 7 20 5 34 7 25 5 6 0 375 18 34 7 25 5 48 7 35 5 8 0 500 14 48 7 35 5 61 7 45 5 12 0 750 14 61 7 45 5 75 7 55 5 16 1 000 11 50 75 7 55 5 88 7 65 5 20 1 250 11 50 95 7 70 5 108 7 80 5 24 1 500 11 50 108 7 80 5 129 14 95 10 32 2 000 11 50 129 14 95 10 163 14 120 10 2 8 930E 4 ...

Page 29: ...ot Pounds ft lb 2 0 125 0 312 24 4 3 4 2 3 0 188 0 375 24 7 3 5 2 4 0 250 0 438 20 11 4 8 3 5 0 312 0 500 20 14 4 10 3 6 0 375 0 562 18 18 4 13 3 8 0 500 0 750 16 33 7 24 5 10 0 625 0 875 14 43 7 32 5 12 0 750 1 062 12 65 7 48 5 14 0 875 1 188 12 73 7 54 5 16 1 000 1 312 12 98 7 72 5 20 1 250 1 625 12 109 7 80 5 24 1 500 1 875 12 109 7 80 5 32 2 000 2 500 12 130 14 96 10 930E 4 2 9 ...

Page 30: ... Fittings Size Code Tube Size O D Threads UNF 2B Newton meters N m Foot Pounds ft lb 4 0 250 0 438 20 15 1 11 1 6 0 375 0 562 18 24 3 18 2 8 0 500 0 750 16 48 5 35 4 10 0 625 0 875 14 69 7 51 5 12 0 750 1 062 12 96 10 71 7 16 1 000 1 312 12 133 8 98 6 20 1 250 1 625 12 179 10 132 7 24 1 500 1 875 12 224 20 165 15 2 10 930E 4 ...

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