ELTMAIN0087720 930E-4 Compressed PDF

Subject to 2020 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.
930E-4
Electric Drive Truck
Serial # A31729 and up
Lesson 2, Safety and
Pre-shift Inspections
Komatsu America Corp.
Cartersville Georgia USA
Copyright © 2020 All rights reserved.
Copyright © 2020 Technical Training ELTMAIN0087720E0BK2

930E-4 Pre Operation Inspection
2020 Terms of Use of Komatsu Training Materials
These training materials represent the confidential and proprietary information of

Komatsu America Corp. (Komatsu). These training materials have been issued to,
and may only be relied upon by, individuals authorized to participate in a Komatsu
sponsored training class and for use in the class. These training materials and their
contents may not be modified, copied, reproduced, published, uploaded, posted,
transmitted, distributed or otherwise used for any other purpose without prior written
authorization of a Komatsu officer. These training materials do not create,
supplement, amend or expand upon any warranties whatsoever concerning
Komatsu products. These training materials do not serve as a substitute for the
operation and maintenance manuals and technical supplements published by
Komatsu on the Komatsu products. These Terms of Use on the training materials
will be construed in accordance with and governed by the laws of the State of
Illinois, U.S.A. Any legal action filed by an individual or his employer or principal
against Komatsu arising out of related to these training materials will be filed
exclusively within a State or Federal court located in the County of Du Page or the
County of Cook, State of Illinois, U.S.A. In accepting these training materials and
participating in the Komatsu Sponsored training class, you and your employer or
principal consent and submit yourselves to the non-exclusive personal jurisdiction
and venue of these courts for such types of legal actions. 2020 © Komatsu America
Corp. All Rights Reserved.
Technical Training ELTMAIN0087720E0BK2

Slide 2
Objectives
By completing this course, you will:

● Know why we do a pre-shift
inspection
● Learn the steps to complete a

pre-shift inspection
● Identify safety problems
● Identify operator maintenance

points
● Identify problems, such as

cracks, missing bolts

Slide 3
KOMATSU Shop Manual
● Use CEBM028100 as supplied

with the new Equipment
● The Material in this course is to

be considered as a supplement
to the KOMATSU Shop Manual
● The Shop Manual contains

precise details of all topics
discussed in this training course
which should be considered as
your CORE reference document

Slide 4
General Information
● Protects you as well as your peers
● Identifies excessive wear, damage and

maintenance issues
● MSHA states that a pre-operation

inspection must be completed prior to
operating any machine.

Slide 5
General Information
Always adhere to Warning and Caution decals and labels.

Slide 6
Before inspection…
ALWAYS INSURE THAT

THE CAB IS UNOCCUPED
BEFORE PERFORMING A
PRE-SHIFT INSPECTION!!!

Slide 7
Inspection – Front End
Isolate machines in
accordance
with site procedures.
Slide 8
Inspect - Front of Truck
● Is truck secure?
● Appearance
● Handrails
● Ladder
● Steps
● Grill
● Radiator
● Headlights
● Battery Box
● Fluid Leaks
Slide 9
Fluid Check Points - Left Front of Truck
Auto Lube Tank
Front View

Slide 10
Inspection – Front
● Visually inspect all lights and safety equipment for damage.

● Look for damage to the front of machine, ladders, handholds etc.
● Look at radiator make sure there are no leaks or debris
● Look under the machine for any major leaks
● Empty dust pans or check ejectors on air cleaners

Slide 11
Inspect - Left Side of Truck

● Turbo Chargers
● Fan Drive Belt & Guard
● Loose Fittings
● Steps & Hand Holds
● Oily Rags & Trash
● Fluid Leaks
Engine Bay Light Switch

Slide 12
Air Intake Tubes
Exhaust Heat Blankets
Strut Mounting Bolts

Slide 13
Fluid Check Point - Left side of Engine
Engine Oil Dipstick
Note: Never add oil to the engine when a reserve oil system is being used.
Slide 14
Fluid Check Points-Underside of Engine, Fuel Filters
Fuel Filters
Tier 1 Filter Drains
Tier 2 Filter, no Drains

Slide 15
Inspect - Left Side Under Truck
Spindle and Steering

Horse Collar Steering Linkage Bolts
Arm Retaining Bolts

Slide 16
Inspect - Left Front Wheel and Tire (Front / Rear)
● Oil leaks
● Lug nuts none missing all tight
● Rim hardware
● Tires for bubbles and cuts

Slide 17
Strut
Strut
Mounting
Mounting Mounting
Bolts
Bolts Key

Slide 18
Inspect – Left Front Suspension
● Check Dirt ring

● Look at the inside side-wall of tires, for cuts and oil
Dirt Ring

Slide 19
Inspect - Left Mid Side
● Check Steering Accumulators,

Amplifier, Bleed Down Manifold and
hoses for leakage
● Check steering pivot points for signs

of excessive wear and adequate
grease
● Check condition of exhaust blanket

behind the Accumulators.
● Examine the flexible couplings

between air intake ductings

Slide 20
Breathers
Saddle Mounts
(BOTH SIDES)

Slide 21
Fluid Check Points - Left side of Truck
Secondary Hydraulic
Oil Fill Tube
Engine Off
Body DOWN
The Oil level must be
visible at the center of
the glass
Engine ON
Body DOWN
The Oil level must be
visible at the center of
the glass

Slide 22
Body Dump Cylinder

Frame Cracks
Nose Cone Bolts
Mounting
MountingBolts
Bolts&
Keepers
& Keepers

Slide 23
Inspect – Left Rear Tires and Wheels
● Lugs Loose or Missing

● Leakage
● Tires Cuts or Bubbles

Slide 24
Inspect - Rear of Machine

Before walking behind the truck, check
for any material that could FALL.
Body Up Limit
Switch
Bed Pins &

Keeper Bolts
Rear Struts
Rear Struts & & Dog Bone &
keeper bolts
keeper bolts Keeper Bolts
● Ensure that all grease points are getting grease

Slide 25
Inspect - Rear of Machine
● Rock ejectors
● Suspension height and leakage
● Lights
● Back-up Alarm
● Dump body hinge pins

● Anti Sway link condition
● Pins for grease
● Condition of hatch

Slide 26
Inspect - Right Side of Truck
● Inspection items, similar to the left side

● Rear duals - wheels, lugs, tires
● Hoist – cylinders leakage, pins and grease
● Fuel tank and mounts
● Right front wheel – oil leaks, steering & brakes
● Suspension “dirt ring” height and mountings
● Brake Accumulators
● Steering pins and bushes for wear and lubrication
● Engine air intake ducts and exhaust pipes

Slide 27
Inspect - Right Side of Truck
● Insure no damage or debris build up to retarder grids

● Hoist and steering filters – behind fuel tank

Slide 28
Fluid Check Points - Right side of Truck

Fill
Spout
Sight
Glasses
Wiggins
Quick-Fill Engine Oil
Reserve

Slide 29
Inspect - Right Mid Side
● Check Brake Accumulators
● Check mounting Structure
● Check the hoses
● Check condition of exhaust

blanket behind the Accumulators.
● Verify Emergency Braking backup.

Slide 30
Inspect - Right Side Engine Compartment Tier II Engines Only

● FUEL FILTERS – drain any water from the bottom
drain valve of each of the stage 1 fuel/ water
separators.
Note: refer to engine operation and maintenance

manual for fuel filter replacement instructions.

Slide 31
Inspect - Right Side Engine Compartment
● Check for any leaks, damage, fan belts, fan guard and
anything such as old rags that may have been left
Fan
Guard
Alt Belt
Gaurd

Slide 32
Inspect - RESERVE Engine Oil Management System

Engine oil is blended with fuel and burnt off, RESERVE oil is
added to sump which extends oil change intervals
LED Monitor
Light
Check Oil
Control Level
Unit
This system does not replace the need to check the engine oil dipstick!
Slide 33
The reserve oil tank for the engine is designed to add more oil capacity to the engine and to
make less frequent servicing of the engine oil. It has two sight glasses, the upper one
indicates a full tank, and the lower one indicates the level required to complete one
operational shift. The circulation of oil between the engine sump and reserve tank increases
the total volume of working oil. This dilutes the effects of contamination and loss of additives
and maintains the oil quality over longer periods. The control unit is used to refill oil reserve
tank. The RED knob is the POWER switch and the BLACK knob is the START switch. The
LED indicator on the left side of the control box tells us that the tank is full (Top Light), and
that the valve is open (Bottom Light).
LED Monitor Light
The pump unit is mounted on the side of the reserve tank, and is equipped with an LED
monitor light on one side.
• Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil
level.
• Regular Pulsing - Pump 2 is returning oil to the engine sump and raising the oil level.
• Irregular Pulsing - Oil is on the correct operating level.

Slide 34
Remote Fill Station Control
2 #2 - System Switch
#4 - “FULL” light 4
3 #3 - Start Switch
#5 - “VALVE OPEN” light 5

Slide 35

LED Monitor Light
The pump unit is mounted on the side of the reserve tank, and is equipped with an LED monitor light on one side.
• Steady - Pump 1 is withdrawing oil from the engine sump and bringing down the oil level.
• Regular Pulsing - Pump 2 is returning oil to the engine sump and raising the oil level.
• Irregular Pulsing - Oil is on the correct operating level.
Reserve Oil Tank Filling Procedure (Remote fill)

1. Connect the pressure supply hose from the new oil supply to the quick coupler on the truck. Open valve on supply hose
to apply pressure.
2. Pull out on switch (2) to turn the system on.
3. Push start switch (3). The VALVE OPEN light (5) should illuminate and the filling process will begin.
4. When tank is full, the VALVE OPEN light will turn off and FULL light (4) will illuminate.
5. Close the oil supply valve in the fill hose.
6. Press and hold start switch (3) for a couple of seconds.
7. Disconnect the new oil supply hose.
8. Push switch (2) to turn system power OFF.

Slide 36
Inspect – Maintenance connection ports
● Wiggins quick fill ports for:

 Hydraulic Oil
 Radiator Coolant
 Engine Oil
 Grease

Slide 37
Inspect - Front of Truck
● Check battery box

for damage.
● Check radiator for

damage and
coolant leaks
● Check headlights,
and fog lights
● Inspect Handrails
and Steps

Slide 38
Inspect - Lube Systems
● Automatic lubrication system
● Hydraulically operated
Manual activation

Slide 39
Before Climbing Ladder
● Make sure that both the battery disconnect switches

are in the “ON” position, that the Propel Lock-out is
turned clockwise, and the Emergency ground level
Shut down Button is “OUT” before ascending to the
cab.
Ground
Level
Shutdown
Propel Lock-out

Slide 40
Use Stairs and Handrails When Climbing Onto Truck
● Ensure ladders and hand

rails are in good shape and
clean of any foreign
materials, such as ice,
snow, oil or mud.
● Always use three points of
contact while mounting
ladder
● Check radiator level
sight glass while
ascending the ladder

Slide 41
Inspection - Deck
● Fire Suppression
● Hand rails, safety chains
● Mirrors clean
● Retarder grid covers and air inlet is free of debris
● All cabinets, good condition
● Do not open electrical cabinet doors, or grid covers when the
engine is running! Do not climb on or use power cables as hand holds.
Link On
light

Slide 42
Inspection - Deck Hydraulic Cabinet

● Check the hydraulic
cabinet behind the
operators cab for any signs
of oil leaks.
● Check for build up of mud
and spill rocks on deck and
under cabinet
● Check Windshield Washer
Reservoir
Inspect Fire Suppression Equipment

Slide 43

Slide 44

Slide 45
Pre-Start and Start Up Checks
 Ensure that Selector is in “Park”
 Sound horn once to alert area of your intentions
 Ensure all personnel are clear
 Rest switch set to on (System AT Rest)
 Verify that Emergency Stop is at RUN (Down)
 Key switch on, allow the central warning system to do a self test; all
monitor warning lights, gauges and alarm should sound for
approximately 3 seconds.

Slide 46
Start Up
 Turn the key switch to the start position hold until the engine starts.
NOTE: Truck is equipped with an engine pre-lube system. A noticeable
time delay will occur before engine actually cranks.
 Do not crank engine for more than 30 seconds, allow starter to cool for
two minutes between start attempts ( the monitoring system will force a
120 second wait and will limit the duration of failed starts to 30 seconds )
 Allow engine and hydraulics to warm before operating
 After engine has started move rest switch to the off position ( this will
energize the Drive System )
 If monitor panel / triangle warning lights come on – follow instructions in

text display shut down truck if necessary and notify maintenance.

Slide 47
Lawful Safe Operation
● Mine Safety Law states all operators must be task trained on

new or modified equipment (this includes all level of Maintenance
crews)
● Operators and Passengers must use the seatbelt provided.

Passengers must be seated in the cab
● If leaving cab, always set selector to PARK

Slide 48
Maintenance
Safety Hazards
& Aspects

Slide 49
Battery & Master Disconnect Switches
 Always switch batteries

off prior to working on
truck components
 These switches can be

used for lock out.

Slide 50
Brake System -- General
 Front and rear brakes apply

automatically when hydraulic
system pressure drops below
11.3 Mpa (1650 psi); exercise
caution and bleed down brake
accumulators before
commencing repairs
 Frame mounted brake

accumulators will store enough
energy for at least five
applications of the service
brakes
Danger oil stored under

high pressure

Slide 51
Working on Brake System
 Place wheel chocks
 Always bleed down steering

accumulators first; confirm
with steering wheel
 Next bleed down both brake

accumulators (hand valve 2
and 4)
 Leave hand valves open until

work is complete

Slide 52
Parking Brake
 Spring-applied and hydraulically released
 Externally mounted to GEB16 motor shaft
 Will not apply if travel speed is 0.8 kph (0.5 mph) or higher

Slide 53
Steering System Repairs
 Always shut down engine; turn

off ignition and listen for bleed
down activity
 Always double check that oil

pressure is near zero by trying
to turn the steering wheel
 Always exhaust nitrogen gas

pressure before removing an
accumulator from the truck
Danger oil stored under high

pressure

Slide 54
Drive System Control Cabinet
Refer to P&SN AA10122C

for safety details
The engine must be shut down, and the system should always be verified at
rest before opening doors.
Slide 55
Working Under a Hoisted Body
 Always use the safety sling

when working below a
hoisted body
 Always remove hoist

cylinders with body down
 Always check body guides

and readjust when required
or when the dump body is
replaced
 Check condition and “foot

print” of body pads, shim
when required

Slide 56

Slide 57
930E-4
End of Lesson 2, Safety and
Pre-shift Inspections

930/980E-4 Inspection and Safety

Slide 59
Komatsu 930E-4
General Electric Drive
Rear Dump Truck
Lesson 2.1
Filter Eliminator System
Operation and Maintenance

930E-4 Filter Eliminator System Operation and Maintenance

and may only be relied upon by, individuals authorized to participate in a Komatsu-
transmitted, distributed or otherwise used for any other purpose without the prior
written authorization of a Komatsu officer. These training materials do not create,
Komatsu for Komatsu products. These Terms of Use will be construed in
accordance with and governed by the laws of the State of Illinois, U.S.A. Any legal
action filed by an individual or his employer or principal against Komatsu arising out
of related to these training materials will be filed exclusively within a State or
Federal court located in the County of Du Page or the County of Cook, State of
Illinois, U.S.A. In accepting these training materials and participating in the
Komatsu-sponsored training class, you and your employer or principal consent and
submit yourselves to the non-exclusive personal jurisdiction and venue of these
courts for such types of legal actions. © 2020 Komatsu America Corp. All Rights
Reserved.

Slide 2
KOMATSU Shop Manual
● Use the correct manual as

supplied with the new Equipment

be considered as a supplement to
the KOMATSU Shop Manual


Slide 3
Course Objectives
After successful completion of this lesson, the student will…..

● Understand operation and components of the Komatsu 930E-4 Rear
Dump Truck, Engine Oil Filter Eliminator System.
● Learn about operational aspects
● Learn how to make use of the maintenance procedures in the Shop
Manual
● Identify the following items and components ;
Eliminator TM Full Flow Filter

Eliminator TM Back flush Flow Centrifuge
Maintenance items

Slide 4
Cummins ELIMINATOR Oil Filter TM
Protect your engine, increase machine productivity, increase profits. . .

Slide 5
Designed Objectives and Benefits
● Eliminate disposable filter costs

● Eliminate labor connected with disposable filters
 Disassembly
 Lube oil top off and reassembly
 Filter disposal
 Increase “Up-Time”
● Minimize progressive engine damage that may result
from lube system contaminants entering the engine
when removing spin-on filters
● Eliminate concern about inferior, after market spin-on
filters being installed on your engine

Slide 6
Designed Objectives and Benefits

Disposable filter costs.
The Eliminator filter not only eliminates the direct costs of the purchasing and disposing of disposable filters, it eliminates
the time, space, man power and logistics associated with ordering, stocking and keeping the field supplied with enough
filters.
This can be particularly costly when operating at remote sites around the world.
Increase equipment availability

Is particularly effective when used in conjunction with Centinnal (Field experience regarding increase in availability??).
Filter effectiveness:
The Eliminator filter has proven to provide a higher level of oil cleanliness than the standard, full flow w/bypass flow filter
system.
Eliminate possibility of dirt ingress, as occurs when changing disposable filters in the field. Full flow oil system remains
sealed, only the backflush flow to the centrifuge gets opened, this oil always must pass through the filter before going back
to the engine.

Slide 7
Simplistic System
● Bolts directly to engine

 Uses existing disposable filter head attachment points
● No external power requirements
 Uses engine oil pressure and flow for active items

Slide 8
Cross Section
Continuous and efficient back flushing

● Total filter surface cleaned every 90 seconds
● Solids won’t stick to filter mesh

Slide 9
Filter Design - Reliable Protection
● Full flow protection of the engine

● Robust, triple layer stainless steel mesh filter elements
 Fine filter mesh sandwiched between high strength support mesh
● Rated for 2068 kPa (300 psi) burst pressure
● Constant and low oil pressure drop across filter elements

Slide 10
Service and Maintenance
● Full flow filter service only at Engine overhaul

● Bypass flow centrifuge service ranges from 1000-2000
hour intervals
● Service interval dependent on:
 load factor
 machine application
 oil quality

Slide 11
Service and Maintenance
● Full flow filter assembly at Engine overhaul

 Clean and inspect hydraulic motor
 Clean and inspect filter discs
 Replace seals and “o” rings
● Back flush Flow Centrifuge

 1000 - 2000 hours
• Service frequency is dependent on machine load factor and oil quality
● Remove bowl liner with sludge

 Visually inspect bowl and spindle
 Reinstall bowl liner
 <30 minutes of labor required

Slide 12
Service and Maintenance – Centrifuge Design
● Pre-Cleaned oil drives centrifuge

 removes particles down to and below 2 μ, resulting in cleaner oil,
longer oil life, longer engine life
● Sludge collects on liner lining the centrifuge bowl wall

Slide 13

Slide 14
Komatsu 930E-4
Rear Dump Truck
Mechanical Systems
End of Lesson 2.1

Filter Eliminator System
Operation and Maintenance

Komatsu 930E-4
Rear Dump Truck
Mechanical Systems
Lesson 2.2
RESERVETM System
Operation and Maintenance Komatsu America Corp.

930E-4 Engine Oil Reserve System

Reserved.

Slide 2
KOMATSU Shop Manual




Slide 3
Course Objectives
After successful completion of this lesson, the student will…..

● Understand operation and components of the Komatsu 930E-4
Rear Dump Truck, Engine Oil RESERVE TM System
● Learn about operational aspects
● Learn how to make use of the maintenance procedures in the Shop
Manual
● Identify the following items and components ;
RESERVETM Reservoir and Pump assembly

RESERVETM Control and Fill Center

Slide 4
Reserve Engine Oil System
NEW R2000DF

Slide 5
Reserve Engine Oil System -- Features

● Increases the total oil volume by 30 or 60 gallon, extends
oil change intervals according to additional volume of oil
in RESERVE
● Makes up Cummins calibrated oil burn amounts
● Heated oil lines for reliable Artic Operation
● New Pump routine maintains a constant sump level, thus
prevents under\over fill situations
 Note: Oil top-up should be added to Reserve Tank and not the
Engine, adding oil to engine can lead to constant over-full condition

Slide 6
Reserve Engine Oil System -- Components

Slide 7
The Reserve system components are a 30 gallon reservoir (1),

Item (2). a dual pump station.
Item (3) A solenoid operated fill valve to facilitate reservoir filling and prevent over fills.
Item (4) is an in_line filter mesh for fill oil.
Item (5) is a spring loaded check valve/breather valve to allow expansion gasses to be diverted to
engine sump.
Item (6) is the fill solenoid is controlled by a “full level” float switch.
There are two sight glasses items (7), the upper glass is obviously “full”, the lower glass indicates
that the Reservoir has sufficient oil for at least one operating shift.
Item (8) is a manual Fill Cap which is provided with a level dipstick.
Item (9) is the Reservoir drain.
Item (10) is a suction strainer which threads into port (11).
Port (12) receives Sump oil from Pump #1
Port (13) holds the optional thermostatic switch that used by the heated Hose option for Artic
operation.
In addition to the Reservoir and pump station the Reserve system requires a special Cummins
manufactured sump adaptor to connect the suction and supply lines from the Reserve to the Engine,
note the formed suction pipe which is designed to pull air when the oil level drops below the run
mark.

Slide 8
Reserve Engine Oil System – R2000DF Pump Assembly
● Upper Pump (1) draws Oil

● Lower Pump (2) returns Oil
● Both Pumps stroke on a “flip
flop” routine
GREEN LED
RED LED
● Green LED indicates operational State

● Red LED indicates that a return cycle
malfunction is active.
 Frozen Lines
 Reservoir level is LOW
 Pump Defect

Slide 9

Slide 10
Reserve Engine Oil System -- Pumping Cycle

● Green alternating between solid “on” and “flashing” ; Pumps 1&2 are
controlling oil level correctly.
● Green LED solid “on”; Pump #1 drawing oil from Sump.
● Green LED “flashing”; Pump #1 is drawing Air.
● Red LED flashing; Pump #2 circuit has a
“return” oil malfunction;
 Reservoir EMPTY
 Return Line BLOCKED (frozen)
 Pump #2 DEFECTIVE

Slide 11
Reserve Engine Oil System -- Fill Station
● Connect oil supply line

● Start system (red)
● Push fill button (black)
● Auto shut-off
● Close oil supply
● Vent pressure (black)

Slide 12
Reserve System -- Maintenance
● Check Oil level Daily

 Oil burn rate +/- ½ liter/hour**
● Clean fill Oil Strainer (1) when required

● Clean (2 & 4) Suction strainer & Tank
Drain
 At every engine oil drain
 After any major failure
● Flush at Engine Rebuild

● Take note that “T” fitting #3 contains a
check valve ball to allow the tank to
breath into engine Sump
** Depends on size of engine and duty cycle

Slide 13

Slide 14
Komatsu 930E-4
Rear Dump Truck
Mechanical Systems
End of Lesson 2.2

RESERVETM System
Operation and Maintenance Komatsu America Corp.

930E-4
Lesson 2.3
Mechanical
Lubrication and Maintenance Komatsu America Corp.

930E-4 Mechanical Lubrication and Maintenance

and may only be relied upon by, individuals authorized to participate in a Komatsu
transmitted, distributed or otherwise used for any other purpose without prior written
authorization of a Komatsu officer. These training materials do not create,
Komatsu on the Komatsu products. These Terms of Use on the training materials
will be construed in accordance with and governed by the laws of the State of
Illinois, U.S.A. Any legal action filed by an individual or his employer or principal
against Komatsu arising out of related to these training materials will be filed
exclusively within a State or Federal court located in the County of Du Page or the
County of Cook, State of Illinois, U.S.A. In accepting these training materials and
participating in the Komatsu Sponsored training class, you and your employer or
principal consent and submit yourselves to the non-exclusive personal jurisdiction
and venue of these courts for such types of legal actions. 2020 © Komatsu America
Corp. All Rights Reserved.

Slide 2
KOMATSU Shop Manual
● Use CEBM028100 as supplied

with the new Equipment

be considered as a supplement
to the KOMATSU Shop Manual


Slide 3
Objectives
By completing this lesson you will...

● Understand the importance associated with lubrication
and maintenance of the Komatsu 930E-4 Dump Truck

Slide 4
Lubrication Chart

Slide 5
+ Level at 6 o’clock
115 lts (30 US gal)

or
230 lts (60 US gal) Hyd. Oil Level Running
Engine Oil level Coolant Level

Dipstick

Slide 6
10 Hour Inspection/Service
Exhaust piping
● Inspect the engine inlet air piping
 From the air cleaner to the engine
● Inspect the engine exhaust system
 From the Turbo charger the end of
the exhaust
Inlet piping
Exhaust piping

Slide 7
10 Hour Inspection/Service (cont.)
● Inspect the cooling air ductwork

 Inlet at the top of control cabinet to
the blower
 Blower to the rear axle ducting
SUPPORT BAND

Slide 8
Initial 50, 100, 250 Hour Service
● Replace both hoist/brake cooling

filters (1)
● Replace the steering/brake filter (2)
2
1
Hydraulic filters located

behind fuel tank
Replace O-ring and backup ring
Note: It is not necessary to draw a vacuum on the hydraulic system to replace filters.
Slide 9
Initial 50 & 250 Hour Service
Engine cooling fan drive

● Check the torque on the cooling fan
mounting cap screws (1)
tighten to 175 lbs. Ft. (237 nm)
Fan Mounting Bolts

Slide 10
Initial 50 Hour, and routine 250 hour Service, Tier I Engines
● FUEL FILTERS – replace all

three fuel filters / water
separators after the initial 50
hours of operation.
● Refer to engine operation
and maintenance manual for
routine 250 hour fuel filter
replacement instructions.

Slide 11
Initial 50 hour, and routine 250 Hour Service, Tier II Engines
● FUEL FILTERS – drain any water from the bottom

drain valve of each of the stage 1 fuel/ water
separators and replace all stage 1 & 2 fuel filter
elements after the initial 50 hours of operation.
Note: refer to engine operation and maintenance

manual for routine 250 hour fuel filter replacement STAGE 2
instructions.
STAGE 1

Slide 12
250 Hour Service

Engine Oil Sample Port
● The 930-4 engine is equipped with the
Centinal™oil system and Eliminator™
filter system. Always sample engine oil
at 250 hours intervals.
● Refer to Cummins bulletin AEB 48.04 in
the next slide for maintenance and oil
drain intervals, Lube key “A”.
● The CentinalTM system is a duty-cycle Strainer
dependent lubrication management
system whereby oil is blended with the
fuel and burned. This is standard
equipment on the 930E-4.
● Reserve oil tank fill up strainer
protection.
Filter
NOTE: There are no Full Flow engine oil filters to replace with the Eliminator System.
Slide 13
AEB 48.04 Bulletin
Oil sample point

Slide 14
Centrifuge Maintenance

Slide 15
250 Hour Service (cont.)

● Cooling system
 Check for proper coolant mixture, add coolant as required
 Change coolant filters
 Check cooling system hoses for damage and signs of deterioration
● Verify the Air Intake restriction gauges are operating in the green range.
Note: refer to engine operation & maintenance manual for coolant filter replacement
instructions and proper coolant mixture instructions.
Shutoff Valve
Coolant Filters

Slide 16

● FUEL TANK - drain water and sediment from the fuel tank. Refer to
section B, fuel tank – cleaning, in the shop manual.
● STEERING LINKAGE – check the torque on pin retaining bolt (1) on the
steering linkage. Tighten to 525 lbs. Ft. (712 nm) check the torque on tie
rod retaining nuts (2). Tighten to 310 lbs. Ft. (420 nm).
(2) 310 lbs. ft. (420 Nm)
Drain located on the bottom

of the fuel tank
(1) 525 lbs. ft. (712 Nm)

Slide 17
● Check the belt tension and condition of each accessory belt. Refer to
the engine operation & maintenance manual for specific adjustment
instructions.
● Grease Engine front trunion bearing.
Front Engine Trunion grease point
Main Fan & Air Conditioner belts Charging Alternator belt

Slide 18
● AC DRIVE BELT – check the belt for wear or damage. Verify the belt
tension is correctly set. Ensure the pulleys are aligned with each other
within 3 mm.(0.13 in)
● AUTOMATIC LUBE SYSTEM – perform 250 hour checks as outlined in
the automatic lubrication system section.

Slide 19
250 Hour Service
. Check that the Rear wheel

mounting nuts and studs.
. Remove two Drive Axle
plugs and check for
Motorized Wheel and Rear
axle housing oil leaks.
Drain Plugs

Slide 20
250 Hour Service .

● WHEEL MOTOR OIL - Change new, or rebuilt wheel motor gear oil following
the initial 500 hours of operation, thereafter, gear oil should be serviced in
accordance with General Electric’s service & maintenance manual GEK
91739A - section 5.24 and 5.25 .
Notes:
1. With the use of Synthetic oil, replacement or filtration on a time based interval is
not specified or required for oils with less than 1 year service.
2. Oil should be filtered and or replaced based on the oil sample tests of viscosity,
element levels and particle count and size.
6 o’clock
Proper Level Location

Slide 21
● FRONT WHEEL HUBS – wear metal inspection

● BATTERIES – check the electrolyte level and
add water if necessary.
● Cab air filter – clean the filter element with mild
soap and water. Rinse completely and dry with
pressure air of 275 kPa (40 psi) maximum.
Reinstall the filter.
Remove thumb screws and

cover to access cab filter

Slide 22
● BODY-UP & HOIST LIMIT

SWITCHES – check the operation
of the switches. Clean the sensing
areas of any dirt accumulation and
inspect the wiring for any signs of
damage.
Note: Refer to shop manual for
Body up switch – located on the inside of the
setting procedure and dimensions. right frame rail, even with the body guide
Magnetic
Striker
Proximity
Switch

Slide 23
● Hydraulic pump driveshaft U-Joints receive one

or two applications of grease
Note: 1. Every 10 hour (Daily) inspection and maintenance check should

also be performed at this time.

Slide 24
500 Hour Service

● HYDRAULIC SYSTEM FILTERS – change.
● Hydraulic tank – replace the tank breathers and high pressure filter
elements. Check the oil level. Add oil as necessary. Lube key “B”.
Engine off and the body down, oil should

be visible in the center of top sight glass
Engine running, body down, oil should be

visible in the center of bottom sight glass

Slide 25
● Replace both hoist circuit and

brake cooling filters (1)
● Replace the steering and brake
filter (2) 2
1
Hydraulic filters located

behind fuel tank
Replace O-rings and backup rings
Note: It is not necessary to draw a vacuum on the hydraulic system to replace filters.
Slide 26
● PARKING BRAKE
 Refer to the shop manual for Parking Brake Maintenance
● SUSPENSIONS
 Check for proper piston extension and charge pressure, both front
and rear
Dirt Ring

Slide 27
● FRAME & AXLE BOX INSPECTION

 Wash the truck, clean all the Weld joints and visually inspect the
entire frame and axle box for cracking or damage.

Slide 28
● KOMTRAX PLUS DOWNLOAD

 Perform a data download from the KOMTRAX Plus (VHMS)
controller and upload data to WEBCARE.
● THROTTLE & BRAKE PEDALS
 Lubricate the treadle roller and hinge pins with lubrication oil.
● HOIST ACTUATOR LINKAGE
 Check operation. Clean, lubricate, and adjust, as necessary.

Slide 29
RESERVE ENGINE OIL SYSTEM

● Check electrical system
connections for tightness, corrosion
and physical damage Oil pressure switch location
● Check, oil pressure switch, junction
boxes, remote control fill box and
30 Gal oil tank
circuit fuses (2).
● Examine all electrical cables over
their entire length for damage. Remote fill control box
● Examine all hoses, including those

on the reserve tank.
● Check for leaks, cracks or other
damage. Check all fittings for
tightness, leakage or damage.
VEC Fuse Locations

Slide 30

● Bladder accumulators
 Check the pre-charge pressure of both the steering and brake
system accumulators
Note: Failure to maintain the correct charge pressure could result in bladder failure.

Slide 31
● Body guide clearance, no greater than 4.8 mm (0.19 in)

● Rear body pad have clearance of 1.9 mm (0.075 in)
Rear Body pad

Clearance 1.9 mm (0.075”)
Note: 1. Every 10 hour (Daily) inspection and 250 hour lubrication and
maintenance check should also be performed at this time.
Slide 32
1000 Hour Service

● OPERATOR’S SEAT
 Apply grease to the slide rails. Use Lube Key “D”.
● HYDRAULIC TANK
 Drain the hydraulic tank and clean the inlet strainers. Fill the tank with
approximately 901Lt (238 gal.) of oil. Use Lube key “B”.
(Note: this period may be extended based on frequent oil analysis.
● POWER LADDER GREASING – Raise cover to grease

Cylinder pivots and also Ladder pivot points.
Grease points
STRAINERS DIFFUSER

Slide 33
1000 Hour Service
● AUTOMATIC BRAKE APPLICATION – Verify that the Service Brakes

apply automatically when the brake system pressure decreases below
the specified limit (11.4 Mpa--1650 psi). Refer to the Brake Checkout
Procedure in the shop manual for complete instructions to conduct this
test which involves opening one of the drain valves on the Brake
Manifold.
Brake Manifold Drain Valves

Slide 34
● AUTO LUBE PUMP HOUSING OIL LEVEL

 Remove the oil level stick, ensure oil is at the correct level
 Refill with 10W-30 motor oil.
● Clean debris from Radiator cooling area with clean water.
Full Mark
Wash out
Note: 1. Every 10 hour (Daily) inspection, 250 hour and 500 hour
lubrication and maintenance check should also be performed at this time.
Slide 35
2500 Hour Service Note: Every 10 hour (Daily) inspection, 250, 500 & 1000 lubrication and hour
maintenance check should also be performed at this time.
FRONT WHEELS (updated )

● Drain and refill with oil. Refer to Section “G” in the shop manual for detailed
instructions on changing the oil. Lube Key “E” (SAE 50).
NOTE: Oil may need to be changed more frequently, depending on mine

conditions and the results of the oil sample tests.
Sight glass
OIL level
should be
visible
Drain @ 6
o’clock position

Slide 36

Slide 37

Slide 38

Slide 39

Slide 40
5000 Hour Service

● AIR CLEANERS – clean the donaclone™ tubes in the pre-cleaner
section of the air filter housing. Refer to the shop manual for the
procedure.
Note: Do not use a hot pressure washer or high pressure air to clean the
tubes. Hot water/high pressure causes the pre-cleaner tubes to distort.
DonacloneTM Tubes
Note: 1. Every 10 hour (Daily) inspection, 250, 500 and 1000 hour
lubrication and maintenance checks should also be performed at this time.
Slide 41
10,000 Hour Service

Radiator
● Clean the cooling system with a quality
cleaning compound.
● Inspect cooling tubes for signs of impact
or corrosive damage and signs of
leakage.
● Flush with clean water and refill the
system with anti-freeze and water
solution.
● Check the cooling system anti-freeze
recommendations chart in the O & M
Sliced open
manual for the correct mixture. corroded tubes
● Refer to the operation and maintenance
manual for the correct additive mixture.
Note: 1. Every 10 hour (Daily) inspection, 250, 500,1000 and 5000 hour lubrication
and maintenance checks should also be performed at this time.

Slide 42
15000 Hour Service
• ALTERNATOR
 Replace alternator bearing
(refer to alternator publication for process)

Slide 43

Slide 44
930E-4
End of Lesson 2.3

Mechanical
Lubrication and Maintenance Komatsu America Corp.

Lubrication and Service -- Daily, 250 & 500 hour

Slide 46
Lubrication and Service -- Sun Gear 5000 hour inspection

Slide 47
Lubrication and Service – Planetary Gear Bearings 5000 hour inspection

Slide 48
Lubrication and Service – Thrust Washer 5000 hour inspection

Routine O.B and I.B. Thrust Washer inspection and
End Float measurements survey every 5000 hours,
UNLESS Oil analysis shows an increase in wear
metals
Hub End Float = 24 to 29 thou

Slide 49
Out Board Thrust Washer -- 5000 hour inspection
1. Block Wheels before proceeding

( it may be necessary to release Park Brake due to binding)
2. Remove Sun Pinion and inspect Thrust

Washer and Gears.
3. Check Outboard Thrust washers

Slide 50
In board Thrust Washer -- inspection
Block Wheels before proceeding

( it may be necessary to release Park Brake due to binding)
Remove Sun Pinion and inspect I.B. thrust washer

using method, (Fig 3 or 4)
FIG. 3
FIG. 4

Slide 51
In board Thrust Washer -- inspection continued
TOOL

Slide 52
Thrust Washer -- inspection table
ITEM DESCRIPTION 930E-4 980E-4

GDY 106 GDY 108C
1 Out Board ( O.B.) Thrust 17.78 mm 18.97 mm
Washer minimum thickness; (0.700”) (0.747”)
2 In Board ( I.B.) Thrust Washer No Spec listed 11.17 mm

minimum thickness; (0.440”)
3 NEW I.B. Thrust Washer 17.45 – 17.91 mm 9.829 – 10.287 mm
“in-situ” measurement (0.687 – 0.705 inch) (0..387 – 0.405 inch)
4 I.B. Thrust Washer; Go/No-Go 19.05 mm 12.85 mm
Gauge critical dimension (0.750”) (0.506”)

Slide 53

Slide 54
Lubrication and Service -- 5000 hour
Dictates a review of 5000hr steps

Slide 55
5000 Hour Service
• Inboard Thrust Washer Retainer Removal Tool

• Available from Komatsu Chile Reman

Slide 56
Komatsu 930E-4
Rear Dump Truck
Electrical Systems
Lesson 2.4
Lubrication and Electrical Komatsu America Corp.
Maintenance Cartersville Georgia USA

930E-4 Electrical Preventive Maintenance

Reserved.

Slide 2
KOMATSU Shop Manual




Slide 3
Objectives
By completing this Chapter you will:

. Understand the importance associated with the Electrical and
Lubrication maintenance of the Komatsu 930E-4 Haul Truck.

Slide 4
OHV Ddrive System

GEK91739K PDF

Slide 5
General Information in GEK91739K

Slide 6
General Information
. 1.2. RELATED PUBLICATIONS

 The following list represents publications that are related to specific
drive systems or components within drive systems. Publications are
frequently updated with new or additional information, use the most
current released of each publication (the highest letter revision). For
information on the latest revision, log into geminingsolutions.com.
 Motorized Wheel Service Manual - GDY106 ….. GEK–91680

 Alternator Service Manual, GTA41 - .…………... GEK–91678
 Dynamic Retarding Assembly, 17EM136 ……… GEK–91717
 Control Group, 17KG535 320/360/400Ton …… GEK–91733

Slide 7

Slide 8
DAILY INSPECTION
. MOTORIZED WHEEL
 Check axle box for leakage
 Check for external oil/grease
leakage
 Check wet disk brakes for oil
Drain Plugs
leaks

Slide 9
DAILY INSPECTION :
• ALTERNATOR
 Inspect the condition of the brush access
covers and gaskets.
 Visually inspect for mud or debris buildup.
• RETARDER ASSEMBLY
 Visually inspect for mud or debris buildup.
ACCESS COVERS
ACCESS COVERS
RETARDER ASSEMBLY

Slide 10
500 Hour Service
. MOTORIZED WHEEL
 Check gear case oil level.
 Clean axle box.
 Visually inspect for Motor Terminals
6 o’clock
 Verify the absence of oil leaks.
Proper Level Location
Drain Plugs

Slide 11
. CONTROL GROUP
 Inspect cabinet covers for loose or
missing hardware
 Check filter panel resistors
capacitors and connections
 Check ground fault resistors and
connections

Slide 12
. CONTROL GROUP
 Inspect terminal board insulators and connections
 Check the power cable connections to the main rectifier panel or
rectifier modules.

Slide 13
. CONTROL GROUP
 Check for any signs of arc or flash
damage
 Inspect contactor arc chutes
 Inspect contactor tips RP CONTACTOR TIPS
ARC CHUTE
Contact
Maintenance
GF contactor tips

Slide 14
1000 Hour Service
. RETARDER ASSEMBLY
 Clean commutator teflon band
 Check commutator/exciting coil condition
 Profile grid blower commutator.
Profile Probe installed in brush holder
Field Coils
There are 111 commutator bars

Slide 15

. RETARDER ASSEMBLY
 Inspect grid box structure
 Check tightness of exposed bolts.
 Check ground brush.
Ground Brush minimum length 9.5mm (0.375 in)

Slide 16

Retarding Assembly, continued
Check Ground Brush length

and freedom of movement
every 1000 hours of
operation

Slide 17
Control Group Maintenance

. Perform Vehicle Operation Tests VOT (8.19)
 Ground fault detection circuitry
 Battery and charging voltage check
 Verify speedometer calibration
 Verify speed event calibrations
 Check engine high/low idle settings and no load speed
 Check Low Blower Pressure alarm (if equipped)
 Check Dynamic Retarding System
 Load box test GEK91739A
 Check operation of grid blower motor(s) Controls
Maintenance Link
Note: 1. Every 500 hour maintenance check should also be performed at this time.

Slide 18
5000 Hour Service
. 930E MOTORIZED WHEEL

 Remove air deflector ducts
 Check wheel speed sensor plugs
and Power cable connections
 Check hydraulic lines for leakage
SPEED
SENSOR
View after
Louver is
removed

Slide 19
5000 Hour Service Cont.:
CONTROL GROUP – Check the CPU battery voltage
17FB187 CPU Card
Back-Up for Clock only

Slide 20
Komatsu 930E-4
Rear Dump Truck
Electrical Systems
End of Lesson 2.4

Lubrication and Electrical Komatsu America Corp.
Maintenance Cartersville Georgia USA

GF Contactor Maintenance
Method 1 Method 2
Slide 22
Tip Break (air gap) Tip Contact Force

Slide 23
RP Contactor
Maintenance

Slide 24

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Subject to 2020 Terms of Use of Komatsu Training Materials. © Komatsu America Corp. All Rights Reserved.

Copyright © 2020 Technical Training ELTMAIN0087720E0BK2

2020 Terms of Use of Komatsu Training Materials

These training materials represent the confidential and proprietary information of

Technical Training ELTMAIN0087720E0BK2

By completing this course, you will:

● Learn the steps to complete a

● Identify safety problems

● Identify operator maintenance

● Identify problems, such as

Technical Training ELTMAIN0087720E0BK2

KOMATSU Shop Manual

● Use CEBM028100 as supplied

● The Material in this course is to

● The Shop Manual contains

Technical Training ELTMAIN0087720E0BK2

● Protects you as well as your peers

● Identifies excessive wear, damage and

● MSHA states that a pre-operation

Technical Training ELTMAIN0087720E0BK2

Always adhere to Warning and Caution decals and labels.

Technical Training ELTMAIN0087720E0BK2

ALWAYS INSURE THAT

Technical Training ELTMAIN0087720E0BK2

Inspection – Front End

Inspect - Front of Truck

Fluid Check Points - Left Front of Truck

Auto Lube Tank

Technical Training ELTMAIN0087720E0BK2

● Visually inspect all lights and safety equipment for damage.

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Side of Truck

Engine Bay Light Switch

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Side of Truck

Air Intake Tubes

Exhaust Heat Blankets

Strut Mounting Bolts

Technical Training ELTMAIN0087720E0BK2

Fluid Check Point - Left side of Engine

Engine Oil Dipstick

Fluid Check Points-Underside of Engine, Fuel Filters

Tier 1 Filter Drains

Tier 2 Filter, no Drains

Inspect - Left Side Under Truck

Spindle and Steering

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Front Wheel and Tire (Front / Rear)

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Side of Truck

Technical Training ELTMAIN0087720E0BK2

Inspect – Left Front Suspension

● Check Dirt ring

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Mid Side

● Check Steering Accumulators,

● Check steering pivot points for signs

● Check condition of exhaust blanket

● Examine the flexible couplings

Technical Training ELTMAIN0087720E0BK2

Inspect - Left Side of Truck

Technical Training ELTMAIN0087720E0BK2

Fluid Check Points - Left side of Truck