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