Komatsu 930E-4 Manual

CEAM030002
Operation&Maintenance
Manual
930E -4
DUMP TRUCK
SERIAL NUMBERS 930E-4 A31879 – A31880
A31882 – A31883
A31892 – A31935
ENGINE 16V160
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2017 Komatsu
Printed in U.S.A
February 2017 Komatsu America Corp.

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INTRODUCTION
FOREWORD..................................................................................................................................1-2
ABOUTTHISMANUAL...................................................................................................................1-3
WARNINGS....................................................................................................................................1-4
CaliforniaProposition65Warnings.....................................................................................1-4
ALERTS.........................................................................................................................................1-5
TRUCKMODELILLUSTRATION.....................................................................................................1-6
NON-OEMPARTSINCRITICALSYSTEMS.....................................................................................1-7
STANDARDCHARTSANDTABLES
GENERALINFORMATION..............................................................................................................2-2
EffectOfSpecialLubricants...............................................................................................2-2
SuggestedSourcesForRustPreventiveGrease.................................................................2-2
STANDARDTIGHTENINGTORQUES.............................................................................................2-3
Class10.9CapscrewsAndClass10Nuts...........................................................................2-3
SAEGrade5AndGrade8Capscrews................................................................................2-4
SAEGrade9Capscrews...................................................................................................2-5
T-BoltClamps....................................................................................................................2-5
SplitFlangeClamps...........................................................................................................2-6
FlaredTubeAndHoseFittings...........................................................................................2-6
JIC37°SwivelNuts...........................................................................................................2-7
PipeThreadFittings...........................................................................................................2-8
O-RingBossFittings..........................................................................................................2-9
O-RingFaceSealFittings................................................................................................2-10
CONVERSIONMULTIPLIERS........................................................................................................2-11
MetricT oEnglish..............................................................................................................2-11
EnglishT oMetric.............................................................................................................2-12
TemperatureConversions................................................................................................2-13
GENERALSAFETY
GENERALSAFETY........................................................................................................................3-2
SafetyRules......................................................................................................................3-2
TruckSafetyFeatures........................................................................................................3-2
ClothingAndPersonalItems..............................................................................................3-2
UnauthorizedModication..................................................................................................3-2
LeavingTheOperator’sSeat..............................................................................................3-2
MountingAndDismounting................................................................................................3-2
FireExtinguishersAndFirstAidKits...................................................................................3-3
PrecautionsForHighT emperatureFluids............................................................................3-3
AsbestosDustHazardPrevention......................................................................................3-3
FirePrevention..................................................................................................................3-3
ROPSPrecautions.............................................................................................................3-3
PreventingInjuryFromWorkEquipment.............................................................................3-4
PrecautionsForOptionalAttachments................................................................................3-4
PrecautionsWhenStartingTheMachine.............................................................................3-4
PRECAUTIONSFORTRUCKOPERATION.....................................................................................3-5
SafetyIsThinkingAhead...................................................................................................3-5
SafetyAtTheWorksite......................................................................................................3-5
PreparingForOperation.....................................................................................................3-5
VentilationForEnclosedAreas...........................................................................................3-5
Mirrors,Windows,AndLights.............................................................................................3-5
BeforeStartingTheEngine................................................................................................3-5
SeatBeltsAndT ethers.......................................................................................................3-5
EmergencyEgressLadders...............................................................................................3-6
OPERATINGTHEMACHINE...........................................................................................................3-7
GeneralInformation...........................................................................................................3-7
930E-43
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StartingTheEngine...........................................................................................................3-7
TravelingInTheMachine...................................................................................................3-7
TravelingInReverse..........................................................................................................3-8
TravelingOnSlopes..........................................................................................................3-8
TravelingOnSnow............................................................................................................3-8
TravelingNearHighVoltageCables....................................................................................3-8
TravelingOnLooseGround...............................................................................................3-8
EnsuringGoodVisibility.....................................................................................................3-8
AvoidDamageT oTheDumpBody.....................................................................................3-8
SafeParkingOfTheMachine.............................................................................................3-9
LoadingTheMachine........................................................................................................3-9
DumpingTheMachine.......................................................................................................3-9
TowingTheMachine..........................................................................................................3-9
EXTERIORLIGHTING..................................................................................................................3-10
FogLights.......................................................................................................................3-10
Headlights.......................................................................................................................3-10
MirrorMountedBackupLights..........................................................................................3-10
DeckMountedFloodLightsandLadderLights..................................................................3-10
BrakeLights....................................................................................................................3-10
RetardLights....................................................................................................................3-11
Clearance/TurnSignalLights.............................................................................................3-11
BackupLights...................................................................................................................3-11
RetardLights....................................................................................................................3-11
BrakeLights.....................................................................................................................3-11
BackupAlarm..................................................................................................................3-12
BackupLamp..................................................................................................................3-12
PRECAUTIONSFORMAINTENANCE...........................................................................................3-13
BEFOREPERFORMINGMAINTENANCE...............................................................................3-13
SecuringTheDumpBody................................................................................................3-13
DURINGMAINTENANCE.......................................................................................................3-14
WarningT ag....................................................................................................................3-14
ProperT ools....................................................................................................................3-14
Attachments....................................................................................................................3-14
WorkingUnderTheMachine............................................................................................3-14
KeepingTheMachineClean............................................................................................3-14
AddingFuelOrOilToTheMachine..................................................................................3-14
RadiatorCoolantLevel.....................................................................................................3-15
UseOfLighting................................................................................................................3-15
HandlingHighPressureHoses.........................................................................................3-15
PrecautionsWithHighPressureOil..................................................................................3-15
MaintenanceNearHighT emperaturesAndHighPressures................................................3-15
RotatingFanAndBelts....................................................................................................3-15
WasteMaterials...............................................................................................................3-15
UseOfTie-OffAnchorDuringMaintenance.......................................................................3-16
HandlingTires.................................................................................................................3-16
TireMaintenance.............................................................................................................3-16
StoringTiresAfterRemoval..............................................................................................3-16
BatteryHazardPrevention...............................................................................................3-17
JumpStartingWithJumperCables...................................................................................3-17
JumpStartingWithReceptacles.......................................................................................3-18
WHENREPAIRSARENECESSARY.............................................................................................3-19
ObserveTheFollowingPrecautions..................................................................................3-19
SPECIALPRECAUTIONS.............................................................................................................3-20
PreliminaryProceduresBeforeWeldingOrPerformingMaintenance..................................3-20
4930E-4
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EngineShutdownProcedureBeforeWeldingorPerformingMaintenance...........................3-20
BeforeWeldingOnTheMachine,ObeyTheFollowingGuidelines:.....................................3-20
DischargingControlCabinetCapacitors............................................................................3-21
WARNINGANDCAUTIONS
GENERALINFORMATION..............................................................................................................4-2
PINPLATE.....................................................................................................................................4-2
GRADESPEEDCHART.................................................................................................................4-3
MACHINESAFETY.........................................................................................................................4-3
KEYSWITCH.................................................................................................................................4-5
OILFILLANDCHECK....................................................................................................................4-5
HIGHPRESSURES........................................................................................................................4-6
BATTERYANDISOLATIONBOX....................................................................................................4-9
HIGHVOLTAGE...........................................................................................................................4-12
WELDING....................................................................................................................................4-15
LIFTINGPOINTS..........................................................................................................................4-16
EMERGENCYDUMPING..............................................................................................................4-17
AUTOMATICLUBRICATIONFILL..................................................................................................4-18
ROPS/FOPS................................................................................................................................4-18
TOWING......................................................................................................................................4-18
LUBRICATIONCHART.................................................................................................................4-19
OPERATINGINSTRUCTIONS
PREPARINGFOROPERATION......................................................................................................5-2
SafetyIsThinkingAhead...................................................................................................5-2
WalkAroundInspection.....................................................................................................5-2
RETRACTABLELADDERSYSTEM(IfEquipped).............................................................................5-7
GeneralInformation...........................................................................................................5-7
LadderSystemDescription................................................................................................5-7
LadderSystemOperation...................................................................................................5-7
In-CabControlPanel.........................................................................................................5-8
GroundLevelControlBox................................................................................................5-10
EmergencyDownValve....................................................................................................5-11
PRE-SHIFTBRAKETEST.............................................................................................................5-12
Operation........................................................................................................................5-12
ServiceBrakeTest...........................................................................................................5-13
ParkingBrakeTest...........................................................................................................5-13
RetardSystemTest.........................................................................................................5-14
BrakeT estExitCriteria.....................................................................................................5-14
TRUCKOPERATION....................................................................................................................5-15
ENGINESTART-UPSAFETY.................................................................................................5-15
AfterEngineHasStarted..................................................................................................5-15
MACHINEOPERATIONSAFETYPRECAUTIONS...................................................................5-16
MachineOperationOnTheHaulRoad..............................................................................5-17
StartingOnAGradeWithALoadedTruck........................................................................5-17
RetardingOnAGrade.....................................................................................................5-17
Passing...........................................................................................................................5-18
Loading...........................................................................................................................5-18
OverloadSpeedLimitFunction.........................................................................................5-18
Dumping.........................................................................................................................5-19
LoweringTheDumpBody(WhenDumpingOnFlatGround)..............................................5-20
LoweringTheDumpBody(WhenDumpingOverABermOrIntoACrusher).......................5-20
SUDDENLOSSOFENGINEPOWERORLOSSOFDRIVESYSTEMFUNCTION...................5-21
EMERGENCYSTEERINGSYSTEM.......................................................................................5-21
Operation........................................................................................................................5-21
Pre-OperationT esting......................................................................................................5-21
930E-45
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AdditionalGuidelines.......................................................................................................5-22
KOMVISION(IfEquipped)......................................................................................................5-22
KomVisionSystemPrecautions........................................................................................5-22
ComponentLocations......................................................................................................5-23
MonitorPanel..................................................................................................................5-28
BrightnessSwitches........................................................................................................5-28
SystemPowerStatusIndicator.........................................................................................5-28
ForceDisplaySwitch.......................................................................................................5-28
CameraSwitches............................................................................................................5-28
MonitorDisplayModeSwitch............................................................................................5-29
ReferenceLineDisplaySwitch.........................................................................................5-29
LowerBodyDisplaySwitch..............................................................................................5-29
ObjectClearSwitch.........................................................................................................5-29
MonitorDisplay................................................................................................................5-29
CameraDisplayModes....................................................................................................5-31
Bird’sEyeViews..............................................................................................................5-32
ReferenceLines..............................................................................................................5-32
DumpBodyStatusDisplay...............................................................................................5-32
ErrorCodeDisplay..........................................................................................................5-33
InitialSettingScreen........................................................................................................5-34
RadarSystem.................................................................................................................5-34
ObjectDetectionRange...................................................................................................5-34
ObjectDetectionWarnings...............................................................................................5-35
ObjectClear....................................................................................................................5-38
START-UPINSPECTION.................................................................................................5-38
FUELDEPLETION.................................................................................................................5-39
SAFEPARKINGPROCEDURES............................................................................................5-39
NORMALENGINESHUTDOWNPROCEDURE......................................................................5-40
DISABLEDTRUCKCONNECTORS..............................................................................................5-41
GENERALINFORMATION.....................................................................................................5-41
HOISTSYSTEM....................................................................................................................5-41
Hookup...........................................................................................................................5-41
DumpingProcedure.........................................................................................................5-41
TOWING......................................................................................................................................5-43
SPECIALWIRINGHARNESS.................................................................................................5-43
TOWINGPROCEDURE.........................................................................................................5-43
PAYLOADMETERIVSYSTEM.....................................................................................................5-46
GENERALINFORMATION.....................................................................................................5-46
DataSummary................................................................................................................5-46
DataGathering................................................................................................................5-46
COMPONENTDESCRIPTION................................................................................................5-46
ElectronicDashDisplay...................................................................................................5-46
OperatorInputSwitches...................................................................................................5-46
BrakeLockSwitch...........................................................................................................5-47
PayloadMeterModule(PLM)...........................................................................................5-47
LoadLights.....................................................................................................................5-48
KeyswitchInput...............................................................................................................5-48
PayloadMeter(PLM)Power.............................................................................................5-49
SCOREBOARD.....................................................................................................................5-49
OPERATOR’SDISPLAYANDSWITCH...................................................................................5-49
SettingTheOperatorID...................................................................................................5-49
LoadAndTonCounter.....................................................................................................5-49
ViewingLiveSensorData................................................................................................5-50
PAYLOADOPERATION&CALCULATION..............................................................................5-50
6930E-4
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DescriptionofHaulCycleStates.......................................................................................5-50
HaulCycleDescription.....................................................................................................5-50
LoadCalculation..............................................................................................................5-51
CarryBack......................................................................................................................5-51
MeasurementAccuracy...................................................................................................5-51
SOURCESFORPAYLOADERROR........................................................................................5-51
PayloadError..................................................................................................................5-51
CriticalSuspensionFactors:.............................................................................................5-51
LoadingConditions..........................................................................................................5-52
PressureSensors............................................................................................................5-52
Swingloads.....................................................................................................................5-52
SpeedandDistance........................................................................................................5-52
HAULCYCLEWARNINGFLAGS...........................................................................................5-52
HaulCycleData..............................................................................................................5-52
HaulCycleWarningFlags................................................................................................5-55
AlarmRecords................................................................................................................5-56
FrameT orqueData..........................................................................................................5-58
SYSTEMCONFIGURATION...................................................................................................5-58
ConnectingT oThePayloadMeterIVWebServer..............................................................5-58
ConguringStaticIPAddress...........................................................................................5-58
RealTimeDataPage.......................................................................................................5-61
PayloadMeterIVSystemConguration............................................................................5-61
TruckModel....................................................................................................................5-63
PLMIVMountingOrientation(forOnboardInclinometers)..................................................5-63
GaugeDisplayUnits........................................................................................................5-64
PressureSensorUnits(forRTDwebpageonly)................................................................5-64
DateandTime.................................................................................................................5-64
PayloadGainFactor........................................................................................................5-64
PayloadLightTest...........................................................................................................5-64
TruckT areReset.............................................................................................................5-64
TruckDataConguration..................................................................................................5-65
InclinometerCalibration...................................................................................................5-65
OverloadThreshold.........................................................................................................5-66
CleanTruckT are.............................................................................................................5-67
TareReset......................................................................................................................5-69
CustomTruckConguration.............................................................................................5-69
FieldSoftwareUpdate......................................................................................................5-70
ViewingHaulCycleData..................................................................................................5-72
DownloadingHaulCycleData..........................................................................................5-73
ViewingAlarmData.........................................................................................................5-74
DownloadingAlarmData..................................................................................................5-75
UPLOADINGDATA..........................................................................................................5-77
CreatingaQuery.............................................................................................................5-78
DetailedMulti-PageReport..............................................................................................5-78
CreatingGraphs..............................................................................................................5-78
FieldSoftwareUpdateProcedure.....................................................................................5-78
AUTOMATICLUBRICATIONSYSTEM...........................................................................................5-87
GENERALINFORMATION.....................................................................................................5-87
COMPONENTDESCRIPTION................................................................................................5-87
Filter...............................................................................................................................5-88
HydraulicMotorandPump...............................................................................................5-88
GreaseReservoir............................................................................................................5-88
PressureReducingValve.................................................................................................5-88
FlowControlValve...........................................................................................................5-88
930E-47
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SolenoidValve.................................................................................................................5-89
VentValve.......................................................................................................................5-89
InterfaceModule..............................................................................................................5-89
Injectors..........................................................................................................................5-90
GreasePressureFailureSwitch.......................................................................................5-91
ReliefValve(unloadervalve)............................................................................................5-91
SYSTEMOPERATION...........................................................................................................5-91
FillingTheReservoir........................................................................................................5-91
PrimingTheAutomaticLubricationSystem........................................................................5-92
PREVENTIVEMAINTENANCEPROCEDURES......................................................................5-92
DailyLubricationSystemInspection..................................................................................5-92
250HourInspection.........................................................................................................5-93
1000HourInspection.......................................................................................................5-93
SYSTEMCHECKOUT............................................................................................................5-93
GeneralChecks...............................................................................................................5-93
LubricationCycleOperation.............................................................................................5-94
RESERVEENGINEOILSYSTEM(ifequipped)..............................................................................5-95
Operation........................................................................................................................5-95
LEDMonitorLight............................................................................................................5-96
ChangingOil...................................................................................................................5-96
OPERATORCABANDCONTROLS
CABINTERIOR..............................................................................................................................6-2
STEERINGWHEELANDCONTROLS.............................................................................................6-3
HornButton.......................................................................................................................6-3
Tilt/T elescopeLever.........................................................................................................6-3
Multi-FunctionTurnSignalSwitch.......................................................................................6-3
TurnSignalOperation........................................................................................................6-3
HighBeamHeadlightOperation.........................................................................................6-3
WindshieldWiperOperation...............................................................................................6-3
PEDALSANDRETARDERLEVER..................................................................................................6-5
DynamicRetarding............................................................................................................6-5
RetarderLever..................................................................................................................6-5
Brake/RetarderPedal........................................................................................................6-5
AcceleratorPedal..............................................................................................................6-5
OVERHEADPANELANDDISPLAYS...............................................................................................6-6
RadioSpeakers.................................................................................................................6-6
WarningAlarmBuzzer.......................................................................................................6-6
CabRadio.........................................................................................................................6-6
AirCleanerVacuumGauges..............................................................................................6-6
KomVision™Panel............................................................................................................6-6
CENTERCONSOLE.......................................................................................................................6-7
DirectionalControlLever....................................................................................................6-7
Override/FaultResetSwitch...............................................................................................6-7
EngineStopSwitch............................................................................................................6-7
WindowControlSwitches...................................................................................................6-8
HoistControlLever............................................................................................................6-8
RaisingTheDumpBody....................................................................................................6-8
LoweringTheDumpBody..................................................................................................6-8
RetardSpeedControl(RSC)AdjustDial.............................................................................6-8
RetardSpeedControl(RSC)Switch...................................................................................6-9
DataStoreButton..............................................................................................................6-9
12VAuxiliaryPowerOutlets...............................................................................................6-9
FireSuppressionControlOutlet..........................................................................................6-9
CommunicationRadioOutlet..............................................................................................6-9
8930E-4
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DIAGNOSTICPORTS...................................................................................................................6-10
KOMTRAXPlus..............................................................................................................6-10
InterfaceModule(IM).......................................................................................................6-10
PayloadMeter.................................................................................................................6-10
DriveSystemController(DSC).........................................................................................6-10
Engine(Cense)...............................................................................................................6-10
Engine(Quantum)...........................................................................................................6-10
OPERATORSEAT(Standard)........................................................................................................6-11
SeatBeltsAndT ethers......................................................................................................6-11
Adjustment.......................................................................................................................6-11
PASSENGERSEAT(Standard).....................................................................................................6-13
SeatBeltsAndT ethers.....................................................................................................6-13
Adjustment......................................................................................................................6-13
OPERATORSEAT(Optional)........................................................................................................6-14
SeatBeltsAndT ethers.....................................................................................................6-14
Adjustment......................................................................................................................6-14
PASSENGERSEAT(Optional)......................................................................................................6-16
SeatBeltsAndT ethers.....................................................................................................6-16
Adjustment......................................................................................................................6-16
HEATER/AIRCONDITIONERCONTROLS...................................................................................6-17
FanSpeedControlKnob..................................................................................................6-17
TemperatureControlKnob...............................................................................................6-17
AirFlowDirectionalKnob.................................................................................................6-17
Heater/AirConditionerVents............................................................................................6-17
INSTRUMENTPANEL..................................................................................................................6-18
ControlSymbols..............................................................................................................6-18
Heater/AirConditionerVents..........................................................................................6-19
StatusIndicatorLightPanel..............................................................................................6-19
HydraulicOilTemperatureGauge.....................................................................................6-19
CoolantT emperatureGauge............................................................................................6-19
Speedometer/DigitalDisplay............................................................................................6-19
FuelLevelGauge............................................................................................................6-19
DriveSystemTemperatureGauge....................................................................................6-20
HazardWarningLightSwitch............................................................................................6-20
Pre-ShiftBrakeTestSwitch..............................................................................................6-20
WheelBrakeLockControlSwitch.....................................................................................6-20
RestSwitch.....................................................................................................................6-20
EngineWarmUp.............................................................................................................6-21
HeatedMirrorSwitch(Optional)........................................................................................6-21
RotatingBeaconLightSwitch(Optional)...........................................................................6-21
KeySwitch......................................................................................................................6-21
WarningLight..................................................................................................................6-22
DigitalDisplayContrastButtons........................................................................................6-22
TurnSignalIndicators......................................................................................................6-22
PanelLightDimmer.........................................................................................................6-22
ModeSwitches................................................................................................................6-22
FogLightSwitch..............................................................................................................6-22
BackupLightSwitch........................................................................................................6-22
LadderLightSwitch.........................................................................................................6-22
Headlight/PanelIlluminationLightSwitch..........................................................................6-22
STATUSINDICATORLIGHTPANEL..............................................................................................6-23
STATUSINDICATORLIGHTSYMBOLS..................................................................................6-23
BodyUp..........................................................................................................................6-23
ParkingBrake..................................................................................................................6-23
930E-49
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PropelSystemNotReady................................................................................................6-23
NoPropel........................................................................................................................6-24
EngineWarmUp.............................................................................................................6-24
EngineShutdownDelay...................................................................................................6-24
RetardingGridDryer........................................................................................................6-24
WheelBrakeLock...........................................................................................................6-24
TractionControl...............................................................................................................6-24
RepairMonitor.................................................................................................................6-24
RetractableLadderDown.................................................................................................6-24
SnapshotInProgress......................................................................................................6-24
PantographEnergized.....................................................................................................6-24
PantographUp................................................................................................................6-25
ServiceBrake..................................................................................................................6-25
DynamicRetarding..........................................................................................................6-25
NoDCLinkVoltage.........................................................................................................6-25
DIGITALDISPLAYOPERATION....................................................................................................6-26
TogglingThroughMainLevelScreens...............................................................................6-26
TogglingThroughWarningScreens..................................................................................6-27
EnteringPayloadMeterData............................................................................................6-28
KOMTRAXPlus............................................................................................................................6-29
KOMTRAXPlusOPERATION.................................................................................................6-29
BasicPrecautions............................................................................................................6-29
InterfaceModule..............................................................................................................6-30
DOWNLOADINGKOMTRAXPlusDATA.................................................................................6-30
GeneralInformation.........................................................................................................6-30
KOMTRAXPlusDownloadingProcedure..........................................................................6-31
LocationOfDownloadedFiles..........................................................................................6-31
UPLOADINGKOMTRAXPlusDATA.......................................................................................6-32
ORBCOMM..................................................................................................................................6-34
KOMATSUWIRELESSBRIDGE(KWB).........................................................................................6-35
GeneralInformation.........................................................................................................6-35
VHMSDOWNLOADS.............................................................................................................6-35
GeneralInformation.........................................................................................................6-35
VHMSDownloadingProcedure........................................................................................6-36
ONBOARDCONTROLLERACCESS......................................................................................6-36
WirelessAccess..............................................................................................................6-36
WirelessAccessProcedure..............................................................................................6-36
WiredAccess..................................................................................................................6-37
WiredAccessProcedure..................................................................................................6-37
CHANGINGALAPTOP'SIPADDRESS..................................................................................6-37
CONNECTINGTOAWIRELESSNETWORK..........................................................................6-38
FUSESANDCIRCUITBREAKERS...............................................................................................6-40
VEHICLEELECTRICALCENTER89......................................................................................6-40
VEHICLEELECTRICALCENTER90......................................................................................6-42
VEHICLEELECTRICALCENTER91......................................................................................6-44
CIRCUITBREAKERS.............................................................................................................6-46
LUBRICATIONANDSERVICE
GENERALINFORMATION..............................................................................................................7-2
HYDRAULICSYSTEMSERVICE..............................................................................................7-2
HydraulicT ank...................................................................................................................7-2
HydraulicFilters.................................................................................................................7-3
HydraulicPumpDriveShaft................................................................................................7-3
WHEELMOTORSERVICE.......................................................................................................7-3
COOLANTLEVELSERVICE....................................................................................................7-3
10930E-4
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