New930e-4se Ceam031503 930e4se Omm A31937 Up PDF

CEAM031503
Operation & Maintenance

Manual
930E-4SE
DUMP TRUCK
SERIAL NUMBERS 930E-4SE A31937 and up

ENGINE 18V170
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 2018 Komatsu

Printed in U.S.A
October 2018 Komatsu America Corp.
READ AND UNDERSTAND THE OPERATION
& MAINTENANCE MANUAL BEFORE OPERATING
THIS VEHICLE OR PERFORMING ANY
MAINTENANCE.
Unsafe use of this machine may cause serious injury or death.

Operators and maintenance personnel must read this manual, must
be trained and authorized by the employer, before operating or
maintaining this machine. This manual should be kept in or near the
machine for reference and periodically reviewed by all personnel
who come in contact with the machine.
WARNING: Breathing diesel engine exhaust exposes you to

chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
WARNING: This product can expose you to chemicals including

lead, which is known to the State of California to cause cancer and
birth defects or other reproductive harm.
For more information go to www.P65warnings.ca.gov
INTRODUCTION
FOREWORD .................................................................................................................................. 1-2
ABOUT THIS MANUAL ................................................................................................................... 1-3
WARNINGS.................................................................................................................................... 1-4
California Proposition 65 Warnings ..................................................................................... 1-4
ALERTS ......................................................................................................................................... 1-5
TRUCK MODEL ILLUSTRATION ..................................................................................................... 1-6
NON-OEM PARTS IN CRITICAL SYSTEMS..................................................................................... 1-7
SOFTWARE LICENSE INFORMATION ............................................................................................ 1-8
STANDARD CHARTS AND TABLES
GENERAL INFORMATION .............................................................................................................. 2-2
Effect Of Special Lubricants ............................................................................................... 2-2
Suggested Sources For Rust Preventive Grease ................................................................. 2-2
STANDARD TIGHTENING TORQUES ............................................................................................. 2-3
Class 10.9 Capscrews And Class 10 Nuts........................................................................... 2-3
SAE Grade 5 And Grade 8 Capscrews................................................................................ 2-4
SAE Grade 9 Capscrews ................................................................................................... 2-5
T-Bolt Clamps.................................................................................................................... 2-5
Split Flange Clamps........................................................................................................... 2-6
Flared Tube And Hose Fittings ........................................................................................... 2-6
JIC 37° Swivel Nuts ........................................................................................................... 2-7
Pipe Thread Fittings........................................................................................................... 2-8
O-Ring Boss Fittings .......................................................................................................... 2-9
O-Ring Face Seal Fittings ................................................................................................ 2-10
CONVERSION MULTIPLIERS ........................................................................................................2-11
Metric To English ..............................................................................................................2-11
English To Metric ............................................................................................................. 2-12
Temperature Conversions ................................................................................................ 2-13
GENERAL SAFETY
GENERAL SAFETY ........................................................................................................................ 3-2
Safety Rules...................................................................................................................... 3-2
Truck Safety Features........................................................................................................ 3-2
Clothing And Personal Items .............................................................................................. 3-2
Unauthorized Modification .................................................................................................. 3-2
Leaving The Operator’s Seat.............................................................................................. 3-2
Mounting And Dismounting ................................................................................................ 3-2
Fire Extinguishers And First Aid Kits ................................................................................... 3-3
Precautions For High Temperature Fluids............................................................................ 3-3
Asbestos Dust Hazard Prevention ...................................................................................... 3-3
Fire Prevention .................................................................................................................. 3-3
ROPS Precautions............................................................................................................. 3-3
Preventing Injury From Work Equipment ............................................................................. 3-4
Precautions For Optional Attachments ................................................................................ 3-4
Precautions When Starting The Machine............................................................................. 3-4
PRECAUTIONS FOR TRUCK OPERATION ..................................................................................... 3-5
Safety Is Thinking Ahead ................................................................................................... 3-5
Safety At The Worksite ...................................................................................................... 3-5
Preparing For Operation..................................................................................................... 3-5
Ventilation For Enclosed Areas ........................................................................................... 3-5
Mirrors, Windows, And Lights ............................................................................................. 3-5
Before Starting The Engine ................................................................................................ 3-5
Seat Belts And Tethers....................................................................................................... 3-5
Emergency Exit from Operator’s Cab .................................................................................. 3-6
Emergency Egress Ladders ............................................................................................... 3-6
930E-4SE 3
OPERATING THE MACHINE........................................................................................................... 3-7
General Information ........................................................................................................... 3-7
Starting The Engine ........................................................................................................... 3-7
Traveling In The Machine ................................................................................................... 3-7
Traveling In Reverse .......................................................................................................... 3-8
Traveling On Slopes .......................................................................................................... 3-8
Traveling On Snow ............................................................................................................ 3-8
Traveling Near High Voltage Cables.................................................................................... 3-8
Traveling On Loose Ground ............................................................................................... 3-8
Ensuring Good Visibility ..................................................................................................... 3-8
Avoid Damage To The Dump Body ..................................................................................... 3-8
Safe Parking Of The Machine............................................................................................. 3-9
Loading The Machine ........................................................................................................ 3-9
Dumping The Machine ....................................................................................................... 3-9
Towing The Machine .......................................................................................................... 3-9
EXTERIOR LIGHTING .................................................................................................................. 3-10
Fog Lights ....................................................................................................................... 3-10
Headlights....................................................................................................................... 3-10
Mirror Mounted Backup Lights .......................................................................................... 3-10
Deck Mounted Flood Lights and Ladder Lights .................................................................. 3-10
Brake Lights .....................................................................................................................3-11
Retard Lights....................................................................................................................3-11
Clearance/Turn Signal Lights.............................................................................................3-11
Backup Lights...................................................................................................................3-11
Retard Lights....................................................................................................................3-11
Brake Lights .................................................................................................................... 3-12
Backup Alarm.................................................................................................................. 3-12
Backup Lamp .................................................................................................................. 3-12
PRECAUTIONS FOR MAINTENANCE........................................................................................... 3-13
BEFORE PERFORMING MAINTENANCE............................................................................... 3-13
Electrical System Isolation................................................................................................ 3-13
Securing The Dump Body ................................................................................................ 3-14
Jack Point Locations ........................................................................................................ 3-15
DURING MAINTENANCE....................................................................................................... 3-16
Warning Tag .................................................................................................................... 3-16
Proper Tools.................................................................................................................... 3-16
Attachments .................................................................................................................... 3-16
Working Under The Machine ............................................................................................ 3-16
Keeping The Machine Clean ............................................................................................ 3-16
Adding Fuel Or Oil To The Machine .................................................................................. 3-16
Radiator Coolant Level..................................................................................................... 3-17
Use Of Lighting................................................................................................................ 3-17
Handling High Pressure Hoses ......................................................................................... 3-17
Precautions With High Pressure Oil .................................................................................. 3-17
Maintenance Near High Temperatures And High Pressures................................................ 3-17
Rotating Fan And Belts .................................................................................................... 3-17
Waste Materials............................................................................................................... 3-17
Use Of Tie-Off Anchor During Maintenance ....................................................................... 3-17
Handling Tires ................................................................................................................. 3-18
Tire Maintenance ............................................................................................................. 3-18
Storing Tires After Removal.............................................................................................. 3-18
Battery Hazard Prevention ............................................................................................... 3-19
Jump Starting With Jumper Cables ................................................................................... 3-19
Jump Starting With Receptacles ....................................................................................... 3-20
4 930E-4SE
WHEN REPAIRS ARE NECESSARY ............................................................................................. 3-21
Observe The Following Precautions.................................................................................. 3-21
SPECIAL PRECAUTIONS............................................................................................................. 3-22
Preliminary Procedures Before Welding Or Performing Maintenance .................................. 3-22
Engine Shutdown Procedure Before Welding Or Performing Maintenance........................... 3-22
Before Welding On The Machine, Obey The Following Guidelines: ..................................... 3-22
Discharging Control Cabinet Capacitors ............................................................................ 3-23
WARNING AND CAUTIONS
PIN PLATE ..................................................................................................................................... 4-2
GRADE SPEED CHART ................................................................................................................. 4-3
MACHINE SAFETY......................................................................................................................... 4-3
KEY SWITCH ................................................................................................................................. 4-5
OIL FILL AND CHECK .................................................................................................................... 4-5
HIGH PRESSURES ........................................................................................................................ 4-6
BATTERY AND ISOLATION BOX .................................................................................................... 4-9
HIGH VOLTAGE ........................................................................................................................... 4-12
WELDING .................................................................................................................................... 4-15
LIFTING POINTS.......................................................................................................................... 4-16
EMERGENCY DUMPING.............................................................................................................. 4-17
AUTOMATIC LUBRICATION FILL.................................................................................................. 4-18
ROPS/FOPS ................................................................................................................................ 4-18
TOWING ...................................................................................................................................... 4-18
LUBRICATION CHART ................................................................................................................. 4-19
OPERATING INSTRUCTIONS
PREPARING FOR OPERATION ...................................................................................................... 5-2
Safety Is Thinking Ahead ................................................................................................... 5-2
Walk Around Inspection ..................................................................................................... 5-2
RETRACTABLE LADDER SYSTEM (If Equipped)............................................................................. 5-7
General Information ........................................................................................................... 5-7
Ladder System Description ................................................................................................ 5-7
Ladder System Operation................................................................................................... 5-7
In-Cab Control Panel ......................................................................................................... 5-8
Ground Level Control Box ................................................................................................ 5-10
Emergency Down Valve ................................................................................................... 5-10
PRE-SHIFT BRAKE TEST..............................................................................................................5-11
Operation .........................................................................................................................5-11
Service Brake Test........................................................................................................... 5-12
Parking Brake Test........................................................................................................... 5-12
Retard System Test ......................................................................................................... 5-13
Brake Test Exit Criteria..................................................................................................... 5-13
TRUCK OPERATION .................................................................................................................... 5-14
ENGINE START-UP SAFETY ................................................................................................. 5-14
After Engine Has Started.................................................................................................. 5-14
MACHINE OPERATION SAFETY PRECAUTIONS................................................................... 5-15
Machine Operation On The Haul Road.............................................................................. 5-16
Starting On A Grade With A Loaded Truck ........................................................................ 5-16
Retarding On A Grade ..................................................................................................... 5-16
Passing........................................................................................................................... 5-17
Loading........................................................................................................................... 5-17
Overload Speed Limit Function......................................................................................... 5-17
Dumping ......................................................................................................................... 5-18
Lowering The Dump Body (When Dumping On Flat Ground) .............................................. 5-19
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)....................... 5-19
930E-4SE 5
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION ................... 5-20
EMERGENCY STEERING SYSTEM ....................................................................................... 5-20
Operation ........................................................................................................................ 5-20
Pre-Operation Testing ...................................................................................................... 5-20
Additional Guidelines ....................................................................................................... 5-21
KOMVISION (If Equipped) ...................................................................................................... 5-21
KomVision System Precautions ........................................................................................ 5-21
Component Locations ...................................................................................................... 5-22
Monitor Panel .................................................................................................................. 5-26
Brightness Switches ........................................................................................................ 5-26
System Power Status Indicator ......................................................................................... 5-26
Force Display Switch ....................................................................................................... 5-26
Camera Switches ............................................................................................................ 5-26
Monitor Display Mode Switch............................................................................................ 5-27
Reference Line Display Switch ......................................................................................... 5-27
Lower Body Display Switch .............................................................................................. 5-27
Object Clear Switch ......................................................................................................... 5-27
Monitor Display................................................................................................................ 5-27
Camera Display Modes .................................................................................................... 5-29
Bird’s Eye Views.............................................................................................................. 5-30
Reference Lines .............................................................................................................. 5-30
Dump Body Status Display ............................................................................................... 5-30
Error Code Display .......................................................................................................... 5-31
Initial Setting Screen ........................................................................................................ 5-32
Radar System ................................................................................................................. 5-32
Object Detection Range ................................................................................................... 5-32
Object Detection Warnings ............................................................................................... 5-33
Object Clear .................................................................................................................... 5-36
Start-Up Inspection .......................................................................................................... 5-36
FUEL DEPLETION................................................................................................................. 5-37
SAFE PARKING PROCEDURES ............................................................................................ 5-37
NORMAL ENGINE SHUTDOWN PROCEDURE ...................................................................... 5-38
DISABLED TRUCK CONNECTORS .............................................................................................. 5-39
GENERAL INFORMATION ..................................................................................................... 5-39
HOIST SYSTEM .................................................................................................................... 5-39
Hookup ........................................................................................................................... 5-39
Dumping Procedure ......................................................................................................... 5-39
TOWING ...................................................................................................................................... 5-41
SPECIAL WIRING HARNESS................................................................................................. 5-41
TOWING PROCEDURE ......................................................................................................... 5-41
PAYLOAD METER IV SYSTEM ..................................................................................................... 5-44
Data Summary ................................................................................................................ 5-44
Data Gathering ................................................................................................................ 5-44
COMPONENT DESCRIPTION................................................................................................ 5-44
Electronic Dash Display ................................................................................................... 5-44
Operator Input Switches................................................................................................... 5-44
Brake Lock Switch ........................................................................................................... 5-45
Payload Meter Module (PLM) ........................................................................................... 5-45
Load Lights ..................................................................................................................... 5-46
Keyswitch Input ............................................................................................................... 5-47
Payload Meter (PLM) Power............................................................................................. 5-47
SCOREBOARD ..................................................................................................................... 5-47
OPERATOR’S DISPLAY AND SWITCH ................................................................................... 5-47
6 930E-4SE
Setting The Operator ID ................................................................................................... 5-47
Load And Ton Counter ..................................................................................................... 5-47
Viewing Live Sensor Data ................................................................................................ 5-48
PAYLOAD OPERATION & CALCULATION .............................................................................. 5-48
Description of Haul Cycle States....................................................................................... 5-48
Haul Cycle Description..................................................................................................... 5-48
Load Calculation.............................................................................................................. 5-49
Carry Back ...................................................................................................................... 5-49
Measurement Accuracy ................................................................................................... 5-49
SOURCES FOR PAYLOAD ERROR........................................................................................ 5-49
Payload Error .................................................................................................................. 5-49
Critical Suspension Factors: ............................................................................................. 5-49
Loading Conditions .......................................................................................................... 5-50
Pressure Sensors ............................................................................................................ 5-50
Swingloads ..................................................................................................................... 5-50
HAUL CYCLE WARNING FLAGS ........................................................................................... 5-50
Haul Cycle Data .............................................................................................................. 5-50
Haul Cycle Warning Flags ................................................................................................ 5-53
Alarm Records ................................................................................................................ 5-54
Frame Torque Data.......................................................................................................... 5-56
SYSTEM CONFIGURATION................................................................................................... 5-56
Connecting To The Payload Meter IV Web Server.............................................................. 5-56
Configuring Static IP Address ........................................................................................... 5-56
Real Time Data Page....................................................................................................... 5-59
Payload Meter IV System Configuration ............................................................................ 5-59
Truck Model .................................................................................................................... 5-61
PLM IV Mounting Orientation (for Onboard Inclinometers) .................................................. 5-61
Gauge Display Units ........................................................................................................ 5-62
Pressure Sensor Units (for RTD web page only) ................................................................ 5-62
Date and Time................................................................................................................. 5-62
Payload Gain Factor ........................................................................................................ 5-62
Payload Light Test ........................................................................................................... 5-62
Truck Tare Reset ............................................................................................................. 5-62
Truck Data Configuration.................................................................................................. 5-63
Inclinometer Calibration ................................................................................................... 5-63
Overload Threshold ......................................................................................................... 5-64
Clean Truck Tare ............................................................................................................. 5-65
Tare Reset ...................................................................................................................... 5-67
Custom Truck Configuration ............................................................................................. 5-67
Field Software Update...................................................................................................... 5-68
Viewing Haul Cycle Data .................................................................................................. 5-70
DOWNLOADING HAUL CYCLE DATA.............................................................................. 5-71
VIEWING ALARM DATA .................................................................................................. 5-72
DOWNLOADING ALARM DATA ....................................................................................... 5-73
UPLOADING DATA.......................................................................................................... 5-75
Creating a Query ............................................................................................................. 5-76
Detailed Multi-Page Report .............................................................................................. 5-76
Creating Graphs .............................................................................................................. 5-76
Field Software Update Procedure ..................................................................................... 5-76
AUTOMATIC LUBRICATION SYSTEM........................................................................................... 5-85
COMPONENT DESCRIPTION................................................................................................ 5-85
Filter ............................................................................................................................... 5-86
Hydraulic Motor and Pump ............................................................................................... 5-86
930E-4SE 7
Grease Reservoir ............................................................................................................ 5-86
Pressure Reducing Valve ................................................................................................. 5-86
Flow Control Valve........................................................................................................... 5-87
Solenoid Valve................................................................................................................. 5-87
Vent Valve....................................................................................................................... 5-87
Interface Module.............................................................................................................. 5-87
Injectors .......................................................................................................................... 5-88
Grease Pressure Failure Switch ....................................................................................... 5-89
Relief Valve (Unloader Valve) ........................................................................................... 5-89
SYSTEM OPERATION ........................................................................................................... 5-89
Filling The Reservoir ........................................................................................................ 5-89
Priming The Automatic Lubrication System........................................................................ 5-90
PREVENTIVE MAINTENANCE PROCEDURES ...................................................................... 5-90
Daily Lubrication System Inspection.................................................................................. 5-90
250 Hour Inspection......................................................................................................... 5-91
1000 Hour Inspection....................................................................................................... 5-91
SYSTEM CHECKOUT............................................................................................................ 5-91
General Checks............................................................................................................... 5-91
Lubrication Cycle Operation ............................................................................................. 5-92
RESERVE ENGINE OIL SYSTEM (if equipped) .............................................................................. 5-93
Operation ........................................................................................................................ 5-93
LED Monitor Light............................................................................................................ 5-94
Changing Oil ................................................................................................................... 5-94
OPERATOR CAB AND CONTROLS
CAB INTERIOR .............................................................................................................................. 6-2
STEERING WHEEL AND CONTROLS............................................................................................. 6-3
Horn Button....................................................................................................................... 6-3
Tilt / Telescope Lever ......................................................................................................... 6-3
Multi-Function Turn Signal Switch ....................................................................................... 6-3
Turn Signal Operation ........................................................................................................ 6-3
Windshield Wiper Operation ............................................................................................... 6-3
High Beam Headlight Operation ......................................................................................... 6-4
PEDALS AND RETARDER LEVER .................................................................................................. 6-5
Dynamic Retarding ............................................................................................................ 6-5
Retarder Lever .................................................................................................................. 6-5
Brake/Retarder Pedal ........................................................................................................ 6-5
Accelerator Pedal .............................................................................................................. 6-5
OVERHEAD PANEL AND DISPLAYS............................................................................................... 6-6
Radio Speakers................................................................................................................. 6-6
Warning Alarm Buzzer ....................................................................................................... 6-6
Cab Radio......................................................................................................................... 6-6
Air Cleaner Vacuum Gauges .............................................................................................. 6-6
KomVision™ Panel ............................................................................................................ 6-6
CENTER CONSOLE ....................................................................................................................... 6-7
Directional Control Lever.................................................................................................... 6-7
Override/Fault Reset Switch ............................................................................................... 6-7
Engine Stop Switch............................................................................................................ 6-7
Window Control Switches................................................................................................... 6-8
Hoist Control Lever ............................................................................................................ 6-8
Raising The Dump Body .................................................................................................... 6-8
Lowering The Dump Body .................................................................................................. 6-8
Retard Speed Control (RSC) Adjust Dial ............................................................................. 6-8
Retard Speed Control (RSC) Switch ................................................................................... 6-9
Data Store Button .............................................................................................................. 6-9
8 930E-4SE
12v Auxiliary Power Outlets................................................................................................ 6-9
Fire Suppression Control Outlet.......................................................................................... 6-9
Communication Radio Outlet .............................................................................................. 6-9
DIAGNOSTIC PORTS................................................................................................................... 6-10
KOMTRAX Plus .............................................................................................................. 6-10
Interface Module (IM)....................................................................................................... 6-10
PC Local Area Network (PC LAN) .................................................................................... 6-10
Drive System Controller (DSC) ......................................................................................... 6-10
Engine (Cense) ............................................................................................................... 6-10
Engine (Quantum) ........................................................................................................... 6-10
OPERATOR SEAT (Standard) ........................................................................................................6-11
Seat Belts And Tethers......................................................................................................6-11
Adjustment.......................................................................................................................6-11
PASSENGER SEAT (Standard) ..................................................................................................... 6-13
Seat Belts And Tethers..................................................................................................... 6-13
Adjustment...................................................................................................................... 6-13
OPERATOR SEAT (Optional) ........................................................................................................ 6-14
Adjustment...................................................................................................................... 6-14
PASSENGER SEAT (Optional) ...................................................................................................... 6-16
Adjustment...................................................................................................................... 6-16
HEATER / AIR CONDITIONER CONTROLS................................................................................... 6-17
Fan Speed Control Knob.................................................................................................. 6-17
Temperature Control Knob ............................................................................................... 6-17
Air Flow Directional Knob ................................................................................................. 6-17
Heater/Air Conditioner Vents ............................................................................................ 6-17
INSTRUMENT PANEL .................................................................................................................. 6-18
Control Symbols .............................................................................................................. 6-18
Heater / Air Conditioner Vents .......................................................................................... 6-19
Status Indicator Light Panel.............................................................................................. 6-19
Hydraulic Oil Temperature Gauge ..................................................................................... 6-19
Coolant Temperature Gauge ............................................................................................ 6-19
Speedometer/Digital Display ............................................................................................ 6-19
Fuel Level Gauge ............................................................................................................ 6-19
Drive System Temperature Gauge .................................................................................... 6-20
Hazard Warning Light Switch............................................................................................ 6-20
Pre-Shift Brake Test Switch .............................................................................................. 6-20
Wheel Brake Lock Control Switch ..................................................................................... 6-20
Rest Switch ..................................................................................................................... 6-20
Engine Warm Up (Optional).............................................................................................. 6-21
Heated Mirror Switch (Optional)........................................................................................ 6-21
Rotating Beacon Light Switch (Optional) ........................................................................... 6-21
Key Switch ...................................................................................................................... 6-21
Warning Light .................................................................................................................. 6-22
Digital Display Contrast Buttons........................................................................................ 6-22
Turn Signal Indicators ...................................................................................................... 6-22
Panel Light Dimmer ......................................................................................................... 6-22
Mode Switches ................................................................................................................ 6-22
Fog Light Switch .............................................................................................................. 6-22
Backup Light Switch ........................................................................................................ 6-22
Ladder Light Switch ......................................................................................................... 6-22
Headlight/Panel Illumination Light Switch .......................................................................... 6-22
STATUS INDICATOR LIGHT PANEL .............................................................................................. 6-23
930E-4SE 9
STATUS INDICATOR LIGHT SYMBOLS.................................................................................. 6-23
Body Up.......................................................................................................................... 6-23
Parking Brake.................................................................................................................. 6-23
Propel System Not Ready ................................................................................................ 6-23
No Propel........................................................................................................................ 6-24
Engine Warm Up ............................................................................................................. 6-24
Engine Shutdown Delay ................................................................................................... 6-24
Retarding Grid Dryer........................................................................................................ 6-24
Wheel Brake Lock ........................................................................................................... 6-24
Traction Control OFF ....................................................................................................... 6-24
Repair Monitor................................................................................................................. 6-24
Retractable Ladder Down................................................................................................. 6-24
Snapshot In Progress ...................................................................................................... 6-24
Pantograph Energized ..................................................................................................... 6-25
Pantograph Up ................................................................................................................ 6-25
Service Brake.................................................................................................................. 6-25
Dynamic Retarding .......................................................................................................... 6-25
No DC Link Voltage ......................................................................................................... 6-25
DIGITAL DISPLAY OPERATION .................................................................................................... 6-26
Toggling Through Main Level Screens............................................................................... 6-26
Toggling Through Warning Screens .................................................................................. 6-27
Entering Payload Meter Data............................................................................................ 6-28
KOMTRAX Plus ............................................................................................................................ 6-29
KOMTRAX Plus OPERATION ................................................................................................. 6-29
Basic Precautions............................................................................................................ 6-29
Interface Module.............................................................................................................. 6-30
DOWNLOADING KOMTRAX Plus DATA ................................................................................. 6-30
General Information ......................................................................................................... 6-30
KOMTRAX Plus Downloading Procedure .......................................................................... 6-31
Location Of Downloaded Files .......................................................................................... 6-31
UPLOADING KOMTRAX Plus DATA ....................................................................................... 6-32
ORBCOMM .................................................................................................................................. 6-34
KOMATSU WIRELESS BRIDGE (KWB) ......................................................................................... 6-35
VHMS DOWNLOADS............................................................................................................. 6-35
VHMS Downloading Procedure ........................................................................................ 6-36
ONBOARD CONTROLLER ACCESS ...................................................................................... 6-36
Wireless Access .............................................................................................................. 6-36
CHANGING A LAPTOP'S IP ADDRESS .................................................................................. 6-36
CONNECTING TO A WIRELESS NETWORK .......................................................................... 6-37
FUSES AND CIRCUIT BREAKERS ............................................................................................... 6-39
VEHICLE ELECTRICAL CENTER 89 ...................................................................................... 6-39
CIRCUIT BREAKERS............................................................................................................. 6-45
LUBRICATION AND SERVICE
HYDRAULIC SYSTEM SERVICE.............................................................................................. 7-2
Hydraulic Tank................................................................................................................... 7-2
Hydraulic Filters................................................................................................................. 7-3
Hydraulic Pump Drive Shaft................................................................................................ 7-3
WHEEL MOTOR SERVICE....................................................................................................... 7-3
COOLANT LEVEL SERVICE .................................................................................................... 7-3
10 930E-4SE
Radiator Filling Procedure .................................................................................................. 7-4
Coolant Specifications........................................................................................................ 7-4
Unacceptable Practices ..................................................................................................... 7-4
RESERVE ENGINE OIL SERVICE............................................................................................ 7-4
LED Monitor Lights ............................................................................................................ 7-5
Sight Gauge ...................................................................................................................... 7-5
Reserve Oil Tank Filling Procedure (Remote Fill) ................................................................. 7-5
Inline Screen ..................................................................................................................... 7-6
CAB AIR FILTER SERVICE ...................................................................................................... 7-6
FUEL SYSTEM SERVICE......................................................................................................... 7-7
Fuel Tank Cleaning ............................................................................................................ 7-7
Fuel Filter Service.............................................................................................................. 7-7
INTAKE AIR CLEANER SERVICE............................................................................................. 7-7
QUICK FILL SERVICE CENTER ............................................................................................... 7-8
TIE ROD INSPECTION AND TORQUE PROCEDURE ............................................................... 7-9
LUBRICATION CHART ................................................................................................................. 7-10
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION.............................................7-11
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.......................................... 7-12
EVERY 250 HOUR LUBRICATION AND MAINTENANCE ............................................................... 7-13
EVERY 500 HOUR LUBRICATION AND MAINTENANCE ............................................................... 7-15
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE ........................................................... 7-18
EVERY 4000 HOUR MAINTENANCE ............................................................................................ 7-19
EVERY 5000 HOUR MAINTENANCE ............................................................................................ 7-20
EVERY 18000 HOUR MAINTENANCE .......................................................................................... 7-21
SPECIFICATIONS
MAJOR COMPONENT DESCRIPTION ............................................................................................ 8-2
Truck and Engine ..................................................................................................................... 8-2
Traction Alternator .................................................................................................................... 8-2
Main Control Cabinet ................................................................................................................ 8-2
AC Induction Traction Motorized Wheels.................................................................................... 8-2
Suspension.............................................................................................................................. 8-2
Operator's Cab......................................................................................................................... 8-2
Power Steering ........................................................................................................................ 8-2
Dynamic Retarding Grid............................................................................................................ 8-2
Brake System .......................................................................................................................... 8-2
SPECIFICATIONS .......................................................................................................................... 8-3
Engine..................................................................................................................................... 8-3
AC Electric Drive System .......................................................................................................... 8-3
Dynamic Retarding................................................................................................................... 8-3
Battery Electric System............................................................................................................. 8-3
Service Capacities.................................................................................................................... 8-3
Hydraulic Systems.................................................................................................................... 8-3
Service Brakes......................................................................................................................... 8-4
Steering................................................................................................................................... 8-4
Standard Dump Body Capacities and Dimensions ...................................................................... 8-4
Tires ........................................................................................................................................ 8-4
Weight Distribution ................................................................................................................... 8-4
Overall Truck Dimensions ......................................................................................................... 8-4
RADIO
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER ............................................................... 9-2
Phone/Bluetooth Button ............................................................................................................ 9-2
Digital Display .......................................................................................................................... 9-2
CD Slot.................................................................................................................................... 9-2
Volume Knob/OK Button ........................................................................................................... 9-2
930E-4SE 11
SRC/PWR (Source/Power) Button............................................................................................. 9-3
NEXT Button............................................................................................................................ 9-3
Eject Button ............................................................................................................................. 9-3
USB Connection Port ............................................................................................................... 9-3
Auxiliary Jack Port.................................................................................................................... 9-3
SCAN/ASCN (Scan/Autoscan) Button........................................................................................ 9-3
PREV (Previous) Button ........................................................................................................... 9-3
DISP (Display) Button............................................................................................................... 9-3
ESC (Escape) Button ............................................................................................................... 9-3
RDM (Random) Button ............................................................................................................. 9-3
RPT (Repeat) Button ................................................................................................................ 9-4
Clock/Alarm Button................................................................................................................... 9-4
Browse Button ......................................................................................................................... 9-4
Play/Pause Button.................................................................................................................... 9-4
Preset Buttons ......................................................................................................................... 9-4
GENERAL FEATURES ................................................................................................................... 9-5
Audio Sources ......................................................................................................................... 9-5
Bluetooth Pairing...................................................................................................................... 9-5
RADIO OPERATION ....................................................................................................................... 9-6
Tuning ..................................................................................................................................... 9-6
Scanning ................................................................................................................................. 9-6
Performing a Regular Scan ....................................................................................................... 9-6
Performing an Autoscan ........................................................................................................... 9-6
Station Presets......................................................................................................................... 9-6
Storing Radio Station Presets ................................................................................................... 9-7
Tuning Radio Station Presets .................................................................................................... 9-7
CD OPERATION............................................................................................................................. 9-8
Using the CD Player ................................................................................................................. 9-8
Playing a CD............................................................................................................................ 9-8
Ejecting a CD........................................................................................................................... 9-8
IPOD OPERATION ......................................................................................................................... 9-9
iPod Support ............................................................................................................................ 9-9
Connecting an iPod .................................................................................................................. 9-9
Accessing iPod Menus ............................................................................................................. 9-9
USB DEVICE OPERATION ........................................................................................................... 9-10
Supported USB Devices ......................................................................................................... 9-10
Supported File Types.............................................................................................................. 9-10
Connecting a USB Device....................................................................................................... 9-10
Accessing USB Folders .......................................................................................................... 9-10
Accessing USB Playlists ......................................................................................................... 9-10
Scanning a USB Device...........................................................................................................9-11
AUXILIARY DEVICE OPERATION................................................................................................. 9-12
BLUETOOTH OPERATION ........................................................................................................... 9-13
Bluetooth Menu...................................................................................................................... 9-13
Enabling/Disabling Bluetooth................................................................................................... 9-13
Pairing a Bluetooth Device ...................................................................................................... 9-13
Deleting Previously Paired Devices ......................................................................................... 9-13
Connecting a Device .............................................................................................................. 9-14
Disconnecting a Device .......................................................................................................... 9-14
RECEIVER SYSTEM SETTINGS................................................................................................... 9-15
AUDIO CONTROL MENU....................................................................................................... 9-15
Adjusting Audio Settings .................................................................................................. 9-15
Audio Adjustment Options ................................................................................................ 9-15
Adjusting the Clock .......................................................................................................... 9-16
12 930E-4SE
Setting an Alarm .............................................................................................................. 9-16
Canceling an Alarm ......................................................................................................... 9-17
Turning off or Snoozing an Activated Alarm ....................................................................... 9-17
USER MENU ......................................................................................................................... 9-17
Adjusting User Settings .................................................................................................... 9-17
User Adjustment Options ................................................................................................. 9-17
TROUBLESHOOTING .................................................................................................................. 9-19
Radio Troubleshooting............................................................................................................ 9-19
CD Player Troubleshooting ..................................................................................................... 9-19
iPod Troubleshooting.............................................................................................................. 9-20
USB Troubleshooting.............................................................................................................. 9-20
Bluetooth Troubleshooting ...................................................................................................... 9-21
930E-4SE 13
14 930E-4SE
INTRODUCTION
930E-4SE 1-1
FOREWORD INTRODUCTION
FOREWORD F.1-0000051238
This manual is written for use by the operator and/or the service technician and is designed to help these persons
become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
All operators and maintenance personnel must read and understand the materials in this manual before
operating the truck or performing maintenance and/or operational checks on the truck. All safety notices,
warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction
of what is found on the truck.
A product identification plate is located on the frame in front of the right side front wheel and designates the
truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle
Weight) rating.
The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
The letter “E”, when present, designates an Electrical wheel motor drive system.
The product identification number (vehicle serial number) contains information which will identify the original
manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many
service parts and/or warranty consideration.
The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design
and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle
Weight + the fuel & lubricants + the payload.
To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from
the GVW rating. The result is the allowable payload.
NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload.
To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as
often as practical.
Exceeding the allowable payload will reduce expected life of truck components.
• Unsafe use of this machine may cause serious injury or death. Operators and maintenance
personnel must read and understand this manual before operating or maintaining this machine.
• This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
1-2 930E-4SE
INTRODUCTION ABOUT THIS MANUAL
ABOUT THIS MANUAL F.2-0000051237
This manual is written for use by the operator and/or the service technician. It is designed to help these persons
learn how to operate the truck and its systems in order to keep it operating safely and efficiently. All operators
and maintenance personnel must read and understand the materials in this manual before operating the truck
or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions
should be understood and followed when operating or performing repairs on the truck.
The front cover of this manual includes a form number. This form number should be referenced when ordering
additional copies of this manual, or for any other correspondence regarding the coverage in this manual.
Direct all inquiries to:
Komatsu America Corp
Literature Services
100 Komatsu Dr.
Cartersville, GA 30121
United States of America
Phone: 678-721-3310
Email: KACTECHPUBS@KOMATSUNA.COM
If there is ever a question regarding the information in a particular section, refer to the manual form number, and
use the address shown above to correspond.
The illustrations used in this manual are typical of the component shown and may not be an exact reproduction
of what is found on the truck.
This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right”,
“left”, “front”, or “rear” are made with respect to the operator's normal seated position, unless specifically stated
otherwise.
When assembly instructions are provided without references to torque values, standard torque values should be
assumed. Standard torque requirements are shown in torque charts in the following section and in the General
Information section of the truck service manual. Individual torques when provided in the text are in bold face
type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
930E-4SE 1-3
WARNINGS INTRODUCTION
WARNINGS F.3-0000051687
This material is proprietary to Komatsu America

Corp (KAC), and is not to be reproduced, used,
or disclosed except in accordance with written
authorization from KAC.
It is the policy of the company to improve

products whenever it is possible and practical
to do so. The company reserves the right to
make changes or add improvements at any time
without incurring any obligation to install such
changes on products sold previously.
Because of continuous research and

development, periodic revisions may be made to
this publication. Customers should contact their
local Komatsu distributor for information on the
latest revision.
• Unsafe use of this machine may cause serious injury or death. Operators and maintenance
personnel must read and understand this manual before operating or maintaining this machine.
• This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
California Proposition 65 Warnings
• Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
• Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer, birth defects or other reproductive harm. Wash
hands after handling.
• Mercury and mercury compounds are known to the State of California to cause developmental
problems. This machine may be equipped with optional HID lamps which contain mercury. There
is no risk of exposure unless the lamps are broken. However, the lamps must be reused, recycled
or properly disposed of in accordance with Local, State and Federal Laws at the end of their useful
lives.
1-4 930E-4SE
INTRODUCTION ALERTS
ALERTS D.2-0000051268
The ALERT symbol is used with the following signal words:

• DANGER
• WARNING
• CAUTION
This symbol is used to alert the reader of hazards that can arise from improper operating and maintenance
practices.
• WARNING identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH
if proper precautions are not taken.
• CAUTION is used for general reminders of proper safety practices OR to direct the reader’s attention
to avoid unsafe or improper practices which may result in damage to the machine.
930E-4SE 1-5
TRUCK MODEL ILLUSTRATION INTRODUCTION
TRUCK MODEL
ILLUSTRATION A.1-0000072098
1-6 930E-4SE
INTRODUCTION NON-OEM PARTS IN CRITICAL SYSTEMS
NON-OEM PARTS IN CRITICAL SYSTEMS C.3-0000051235
For safety reasons, Komatsu America Corp. strongly recommends against the use of non-OEM replacement
parts in critical systems of all Komatsu equipment. Critical systems include but are not limited to steering, braking
and operator safety systems
Replacement parts manufactured and supplied by unauthorized sources may not be designed, manufactured
or assembled to Komatsu's design specifications; accordingly, use of such parts may compromise the safe
operation of Komatsu products and place the operator and others in danger should the part fail.
Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems.
Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
Use of non-OEM parts places full responsibility for the safe performance of the Komatsu product on the supplier
and user. Komatsu will not in any case accept responsibility for the failure or performance of non-OEM parts in
its products, including any damages or personal injury resulting from such use.
930E-4SE 1-7
SOFTWARE LICENSE INFORMATION INTRODUCTION
SOFTWARE LICENSE INFORMATION A.3-0000074884
Some of Komatsu’s products are using Open Source Software (OSS). The Product Information web site
provides the license information for the OSS used in these products. Please visit the following URL to access
the information:
https://home.komatsu/en/ProductInfo/opensoft/KDUC600/
1-8 930E-4SE
STANDARD CHARTS AND TABLES
930E-4SE 2-1
GENERAL INFORMATION STANDARD CHARTS AND TABLES
If special friction-reducing lubricants are used with
GENERAL INFORMATION E.2-0000051234 the standard torque values listed in this chapter,
excessive stress and possible breakage of the
This manual provides dual dimensioning for many fasteners may result.
specifications. Metric units are specified first, with
U.S. standard units in parentheses. When torque Where the torque tables specify “Lubricated Threads”
values are not specified in the assembly instructions for the standard torque values listed, these standard
contained in this manual, use the standard torque torque values are to be used with simple lithium
value for the hardware being used. Standard value base chassis grease (multi-purpose EP NLGI) or a
torque tables are contained in this chapter for metric rust-preventive grease (see below) on the threads
and SAE hardware. and seats unless specified otherwise.
This truck is assembled with both metric and SAE NOTE: Ensure the threads of fasteners and tapped
(U.S.) hardware. Reference the correct table when holes are free of burrs and other imperfections before
determining the proper torque value. assembling.
Suggested Sources For Rust Preventive

• References throughout the manual to Grease
standard torques or other standard values NOTE: This list represents the current engineering
will be to one of the following tables. Do not approved sources for use in Komatsu manufacture. It
use standard values to replace specific torque is not exclusive. Other products may meet the same
values in assembly instructions. specifications of this list.
• American Anti-Rust Grease #3-X from Standard Oil
For values not shown in any of the charts or tables,
Company (also American Oil Co.)
standard conversion factors for most commonly used
measurements are provided in the following tables. • Gulf NoRust #3 from Gulf Oil Company.
• Mobilarma 355, Product No. 66705 from Mobil Oil
Effect Of Special Lubricants Corporation.
The Komatsu engineering department does not • Rust Ban 326 from Humble Oil Company.
recommend the use of special friction-reducing
lubricants, such as Copper Coat, Never-Seez®, and • Rustolene B Grease from Sinclair Oil Co.
other similar products, on the threads of standard • Rust Preventive Grease - Code 312 from the
fasteners where standard torque values are applied. Southwest Grease and Oil Company.
The use of special friction-reducing lubricants will
significantly alter the clamping force being applied to
fasteners during the tightening process.
2-2 930E-4SE
STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES
STANDARD TIGHTENING Table 2-1

TORQUES F.8-0000051233 Standard Tightening Torque for Metric
Class 10.9 Capscrews And Class 10 Nuts Class 10.9 Capscrews & Class 10 Nuts
The following specifications apply to required
assembly torques for all metric class 10.9 finished
hexagon head capscrews and class 10 nuts.
DO NOT lubricate capscrew threads and seats during
assembly. These specifications are based on the
Capscrew Torque Torque Torque
following hardware: Size N·m ft·lb kg·m
M6 x1 12 9 1.22
• All capscrews
M8 x 1.25 30 22 3.06
• All nuts
M10 x 1.5 55 40 5.61
• All hardened washers being phosphate and oil
coated M12 x 1.75 95 70 9.69
NOTE: If zinc-plated hardware is used, each piece M14 x 2 155 114 15.81
must be lubricated with simple lithium base chassis M16 x 2 240 177 24.48
grease (multi-purpose EP NLGI) or a rust preventive
M20 x 2.25 465 343 47.43
grease (see list, this page) to achieve the same
clamping forces provided below. M24 x 3 800 590 81.6
NOTE: Torques are calculated to give a clamping M30 x 3.5 1600 1180 163.2
force of approximately 75% of proof load. The M36 x 4 2750 2028 280.5
maximum torque tolerance shall be within ±10% of
the torque value shown.
In the following table under “Capscrew Size”, the first
number represents the shank diameter (mm). The
second number represents thread pitch in millimeters.
Example: M20 x 2.25

M20 = shank diameter (20 mm)
2.25 = thread pitch in millimeters
930E-4SE 2-3
STANDARD TIGHTENING TORQUES STANDARD CHARTS AND TABLES
SAE Grade 5 And Grade 8 Capscrews

Standard Tightening Torque for SAE Hex
The following specifications apply to required Head Capscrew And Nut Assembly
assembly torques for all grade 5 and grade 8
capscrews.
NOTE: Capscrew threads and seats shall be
lubricated when assembled. Unless instructions
specifically recommend otherwise, these standard Cap-
torque values are to be used with simple lithium base Torque Torque
screw
chassis grease (multi-purpose EP NLGI) or a rust- Grade 5 Grade 8
Size
preventive grease (see list, previous page) on the
threads. N·m ft·lb kg·m N·m ft·lb kg·m
NOTE: Torques are calculated to give a clamping 9/16-18 129 95 13.1 183 135 18.7
force of approximately 75% of proof load. The 5/8-11 169 125 17.3 237 175 24.2
maximum torque tolerance shall be within ±10% of
the torque value shown. 5/8-18 183 135 18.7 258 190 26.2
In the following table under Capscrew Size, the first 3/4-10 298 220 30.4 420 310 42.8
number represents the shank diameter (in.). The 3/4-16 319 235 32.5 454 335 46.3
second number represents threads per inch.
7/8-9 475 350 48.4 678 500 69.2
Example: 7/16 - 20 7/8-14 508 375 51.9 719 530 73.3
7/16 = shank diameter (7/16 inch (0.438 inch)) 1.0-8 712 525 72.6 1017 750 103.7
20 = threads per inch
1.0-12 759 560 77.4 1071 790 109.3
Table 2-2
1.0-14 773 570 78.8 1085 800 110.6
Standard Tightening Torque for SAE Hex 1 1/8-7 881 650 89.9 1424 1050 145
Head Capscrew And Nut Assembly 1 1/8-12 949 700 96.8 1546 1140 158
1 1/4-7 1234 910 125.9 2007 1480 205
1 1/4-12 1322 975 134.8 2142 1580 219
1 3/8-6 1627 1200 166 2630 1940 268
Cap-
Torque Torque 1 3/8-12 1776 1310 181 2874 2120 293
screw
Grade 5 Grade 8 1 1/2-6 2142 1580 219 3471 2560 354
Size
N·m ft·lb kg·m N·m ft·lb kg·m 1 1/2-12 2305 1700 235 3756 2770 383
1/4-20 9.5 7 0.97 13.6 10 1.38

1/4-28 10.8 8 1.11 14.9 11 1.52
5/16-18 20.3 15 2.07 28 21 2.90
5/16-24 22 16 2.21 30 22 3.04
3/8-16 34 25 3.46 47 35 4.84
3/8-24 41 30 4.15 54 40 5.5
7/16-14 54 40 5.5 79 58 8.0
7/16-20 61 45 6.2 84 62 8.57
1/2-13 88 65 9 122 90 12.4
1/2-20 95 70 9.7 129 95 13.1
9/16-12 122 90 12.4 169 125 17.3
2-4 930E-4SE
SAE Grade 9 Capscrews Standard Tightening Torque for SAE Hex

The following specifications apply to required Head and 12-Point, Grade 9 Capscrews
assembly torques for SAE Hex Head and 12-point,
grade 9 (170,000 psi minimum tensile), capscrews.
NOTE: Capscrew threads and seats shall be
lubricated when assembled. Unless instructions
specifically recommend otherwise, these standard Capscrew Torque Torque Torque
torque values are to be used with simple lithium base Size 1 N·m ft·lb kg·m
chassis grease (multi-purpose EP NLGI) or a rust- 1.125 - 12 1800 1330 184
preventive grease (see list, this page) on the threads.
1.250 - 7 2325 1715 237
NOTE: Torques are calculated to give a clamping
1.250 - 12 2495 1840 254
force of approximately 75% of proof load. The
maximum torque tolerance shall be within ±10% of 1.375 - 6 3080 2270 313
the torque value shown. 1.375 - 12 3355 2475 342
Table 2-3 1.500 - 6 4040 2980 411
Standard Tightening Torque for SAE Hex 1.500 - 12 4375 3225 445
Head and 12-Point, Grade 9 Capscrews
T-Bolt Clamps
Table 2-4
Tightening Torque For T-Bolt Type Hose

Capscrew Torque Torque Torque
Clamp (SAE J1508 Type TB)
Size 1 N·m ft·lb kg·m
0.250 - 20 16 12 1.7
0.312 - 18 33 24 3.3
0.375 - 16 57 42 5.8
0.438 -14 95 70 9.7
Newton Inch
0.500 -13 142 105 14.5 Thread Band
meters Pounds
Size Width
0.562 - 12 203 150 20.7 (N·m) (in·lb)
0.625 - 11 278 205 28.3 0.25-28 19.05 mm
8.5 ± 0.6 75 ± 5
UNF (0.75 in.)
0.750 - 10 488 360 49.7
0.875 - 9 780 575 79.4
1.000 - 8 1166 860 119
1.000 - 12 1240 915 126
1.125 - 7 1670 1230 170
1. Shank Diameter (in) — Threads per inch
930E-4SE 2-5
Split Flange Clamps

Table 2-5
Tightening Torque For Split Flange Clamp Bolts
Capscrew
Width Newton Foot Kilogram
Thread
Across meters Pounds meters (kg·m)
Diameter
Flat (mm) (N·m) ± 10% (ft·lb) ± 10% ± 10%
(mm)
10 14 66 48 6.7
12 17 112 83 11.5
16 22 279 206 28.5
Flared Tube And Hose Fittings

Table 2-6
Tightening Torque For Flared Tube And Hose Fittings
Kilogram
Thread Width Newton Foot
meters
Diameter of Across meters Pounds
(kg·m) ±
Nut (mm) Flat (mm) (N·m) ± 10% (ft·lb) ± 10%
10%
14 19 25 18 2.5
18 24 50 36 5
22 27 80 58 8
24 32 140 101 14
30 36 175 130 18
33 41 195 145 20
36 46 245 180 25
42 55 295 215 30
2-6 930E-4SE
JIC 37° Swivel Nuts

Table 2-7
Torque Chart For JIC 37° Swivel Nuts With Or Without O-ring Seals
Newton
Size Tube Size Threads Foot Pounds
meters
Code (OD) UNF-2B (ft·lb)
(N·m)
– 2 0.125 0.312 – 24 5 ± 1 4 ± 1
– 3 0.188 0.375 – 24 11 ± 4 8 ± 3
– 4 0.250 0.438 – 20 16 ± 4 12 ± 3
– 5 0.312 0.500 – 20 20 ± 4 15 ± 3
– 6 0.375 0.562 – 18 24 ± 7 18 ± 5
– 8 0.500 0.750 – 16 40 ± 7 30 ± 5
– 10 0.625 0.875 – 14 54 ± 7 40 ± 5
– 12 0.750 1.062 – 12 75 ± 7 55 ± 5
– 14 0.875 1.188 – 12 88 ± 7 65 ± 5
– 16 1.000 1.312 – 12 108 ± 7 80 ± 5
– 20 1.250 1.625 – 12 136 ± 14 100 ± 10
– 24 1.500 1.875 – 12 163 ± 14 120 ± 10
– 32 2.000 2.500 – 12 312 ± 27 230 ± 20
930E-4SE 2-7
Pipe Thread Fittings

Table 2-8
Torque Chart For Pipe Thread Fittings
With With Without Without

Size Pipe Thread
Sealant Sealant Sealant Sealant
Code Size
N·m ft·lb N·m ft·lb
–2 0.125 – 27 20 ± 4 15 ±3 27 ± 7 20 ± 5
–4 0.250 – 18 27 ± 7 20 ±5 34 ± 7 25 ± 5
–6 0.375 – 18 34 ± 7 25 ±5 48 ± 7 35 ± 5
–8 0.500 – 14 48 ± 7 35 ±5 61 ± 7 45 ± 5
– 12 0.750 – 14 61 ± 7 45 ±5 75 ± 7 55 ± 5
– 16 1.000 – 11.50 75 ± 7 55 ±5 88 ± 7 65 ± 5
– 20 1.250 – 11.50 95 ± 7 70 ±5 108 ± 7 80 ± 5
– 24 1.500 – 11.50 108 ± 7 80 ±5 129 ± 14 95 ± 10
– 32 2.000 – 11.50 129 ± 14 95 ±10 163 ± 14 120 ± 10
2-8 930E-4SE
O-Ring Boss Fittings

Table 2-9
Torque Chart For O-ring Boss Fittings
Newton Foot
Tube Size Threads
Size Code meters Pounds
(OD) UNF-2B
(N·m) (ft·lb)
– 2 0.125 0.312 – 24 4 ± 3 4 ± 2
– 3 0.188 0.375 – 24 7 ± 3 5 ± 2
– 4 0.250 0.438 – 20 11 ± 4 8 ± 3
– 5 0.312 0.500 – 20 14 ± 4 10 ± 3
– 6 0.375 0.562 – 18 18 ± 4 13 ± 3
– 8 0.500 0.750 – 16 33 ± 7 24 ± 5
– 10 0.625 0.875 – 14 43 ± 7 32 ± 5
– 12 0.750 1.062 – 12 65 ± 7 48 ± 5
– 14 0.875 1.188 – 12 73 ± 7 54 ± 5
– 16 1.000 1.312 – 12 98 ± 7 72 ± 5
– 20 1.250 1.625 – 12 109 ± 7 80 ± 5
– 24 1.500 1.875 – 12 109 ± 7 80 ± 5
– 32 2.000 2.500 – 12 130 ± 14 96 ± 10
930E-4SE 2-9
O-Ring Face Seal Fittings

Table 2-10
Torque Chart For O-ring Face Seal Fittings
Foot
Size Tube Size Threads Newton
Pounds
Code (O.D.) UNF-2B meters (N·m)
(ft·lb)
– 4 0.250 0.438 – 20 15 ± 1 11 ± 1
– 6 0.375 0.562 – 18 24 ± 3 18 ± 2
– 8 0.500 0.750 – 16 48 ± 5 35 ± 4
– 10 0.625 0.875 – 14 69 ± 7 51 ± 5
– 12 0.750 1.062 – 12 96 ± 10 71 ± 7
– 16 1.000 1.312 – 12 133 ± 8 98 ± 6
– 20 1.250 1.625 – 12 179 ± 10 132 ± 7
– 24 1.500 1.875 – 12 224 ± 20 165 ± 15
2-10 930E-4SE
STANDARD CHARTS AND TABLES CONVERSION MULTIPLIERS
CONVERSION
MULTIPLIERS G.3-0000051232
Metric To English
Table 2-11
Common Conversion Multipliers Metric To English
To Convert From To Multiply By
millimeter (mm) inch (in.) 0.0394
centimeter (cm) inch (in.) 0.3937
meter (m) foot (ft) 3.2808
meter (m) yard (yd) 1.0936
kilometer (km) mile (mi) 0.6210
square centimeters (cm2) square inch (in.2) 0.1550
square centimeters (cm2) square feet (ft2) 0.001
cubic centimeters (cm3) cubic inch (in.3) 0.061
liters (L) cubic inch (in.3) 61.02
cubic meters (m3) cubic feet (ft3) 35.314
liters (L) cubic feet (ft3) 0.0353
grams (g) ounce (oz) 0.0353
milliliter (mL) fluid ounce (fl oz) 0.0338
kilogram (kg) pound (mass) 2.2046
Newton (N) pounds (lb) 0.2248
Newton meters (N·m) kilogram force meters (kgf·m) 0.102
Newton meters (N·m) foot pounds (ft lb) 0.7376
kilogram force meters (kgf·m) foot pounds (ft lb) 7.2329
kilogram force meters (kgf·m) Newton meters (N·m) 9.807
kilopascals (kPa) pounds/square inch (psi) 0.1450
megapascals (MPa) pounds/square inch (psi) 145.038
kilograms/cm2 (kg/cm2) pounds/square inch (psi) 14.2231
kilograms/cm2 (kg/cm2) kilopascals (kPa) 98.068
kilogram (kg) short ton (tn) 0.0011
metric ton short ton (tn) 1.1023
liters (L) quart (qt) 1.0567
liters (L) gallon (gal) 0.2642
Watts (W) horsepower (hp) 0.00134
kilowatts (kW) horsepower (hp) 1.3410
930E-4SE 2-11
CONVERSION MULTIPLIERS STANDARD CHARTS AND TABLES
English To Metric
Table 2-12
Common Conversion Multipliers English to Metric
To Convert From To Multiply By
inch (in.) millimeter (mm) 25.40
inch (in.) centimeter (cm) 2.54
foot (ft) meter (m) 0.3048
yard (yd) meter (m) 0.914
mile (mi) kilometer (km) 1.61
square inch (in.2) square centimeters (cm2) 6.45
square feet (ft2) square centimeters (cm2) 929
cubic inches (in.3) cubic centimeters (cm3) 16.39
cubic inches (in.3) liters (L) 0.016
cubic feet (ft3) cubic meters (m3) 0.028
cubic feet (ft.3) liters (L) 28.3
ounce (oz) kilogram (kg) 0.028
fluid ounce (fl oz) milliliter (ml) 29.573
pound (lb) kilogram (kg) 0.454
pound (lb) Newton (N) 4.448
inch pounds (in. lb) Newton meters (N·m) 0.113
foot pounds (ft lb) Newton meters (N·m) 1.356
foot pounds (ft lb) kilogram force meters (kgf·m) 0.138
kilogram meters (kgm) Newton meters (N·m) 9.807
pounds/square inch (psi) kilopascals (kPa) 6.895
pounds/square inch (psi) megapascals (MPa) 0.007
kilograms/square centimeter
pounds/square inch (psi) 0.0704
(kg/cm2)
short ton (tn) kilogram (kg) 907.2
short ton (tn) metric ton (t) 0.0907
quart (qt) liters (L) 0.946
gallon (gal) liters (L) 3.785
horsepower (hp) Watts (w) 745.7
horsepower (hp) kilowatts (kw) 0.745
2-12 930E-4SE
STANDARD CHARTS AND TABLES CONVERSION MULTIPLIERS
Temperature Conversions
Table 2-13
Temperature Conversions
Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F°
Fahrenheit Celsius Fahrenheit Celsius Fahrenheit

Celsius C°
F° C° F° C° F°
121 250 2 482 63 145 293 4 40 104

118 245 473 60 140 284 2 35 95
116 240 464 57 135 275 – 1 30 86
113 235 455 54 130 266 – 4 25 77
110 230 446 52 125 257 – 7 20 68
107 225 437 49 120 248 – 9 15 59
104 220 428 46 115 239 – 12 10 50
102 215 419 43 110 230 – 15 5 41
99 210 410 41 105 221 – 18 0 32
96 205 401 38 100 212 – 21 –5 23
93 200 392 35 95 293 – 23 – 10 14
91 195 383 32 90 194 – 26 – 15 5
88 190 374 29 85 185 – 29 – 20 – 4
85 185 365 27 80 176 – 32 – 25 – 13
82 180 356 24 75 167 – 34 – 30 – 22
79 175 347 21 70 158 – 37 – 35 – 31
77 170 338 18 65 149 – 40 – 40 – 40
74 165 329 15 60 140 – 43 – 45 – 49
71 160 320 13 55 131 – 46 – 50 – 58
68 155 311 10 50 122 – 48 – 55 – 67
66 150 302 7 45 113 – 51 – 60 – 76
2. The numbers in the unmarked columns refer to temperature in either degrees Celsius (C°) or Fahrenheit (F°). Select a
number in this unmarked column and read to the left to convert to degrees Celsius (C°) or read to the right to convert
to degrees Fahrenheit (F°). If starting with a known temperature (either C° or F°), find that temperature in the marked
column and read the converted temperature in the center, unmarked column.
930E-4SE 2-13
CONVERSION MULTIPLIERS STANDARD CHARTS AND TABLES
2-14 930E-4SE
GENERAL SAFETY
930E-4SE 3-1
GENERAL SAFETY GENERAL SAFETY
Unauthorized Modification
GENERAL SAFETY E.70-0000051262 Any modification made to this vehicle without
authorization from Komatsu America Corp can
Safety Rules
possibly create hazards.
Safety records of most organizations will show that
the greatest percentage of accidents are caused by Before making any modification, consult your
unsafe acts of persons. The remainder are caused by authorized regional Komatsu America Corp
unsafe mechanical or physical conditions. Report all distributor. Komatsu will not be responsible for
unsafe conditions to the proper authority. any injury or damage caused by any unauthorized
modification.
The following safety rules are provided as a guide
for the operator. However, local conditions and Leaving The Operator’s Seat
regulations may add many more to this list.
NOTE: DO NOT touch any controls while leaving the
operator’s seat.
• Read and follow all safety precautions. Failure To prevent accidental operations from occurring,
to do so may result in serious injury or death. always perform the following:
• DO NOT apply the wheel brake lock. Move the
• Only trained and authorized personnel can operate directional control lever to the PARK position (this
and maintain the machine. will apply the parking brake).
• Follow all safety rules, precautions and instructions • Turn the key switch to the OFF position and wait for
when operating or performing maintenance on the the engine to stop.
machine.
• After the engine has stopped, wait two minutes
• When working with another operator or a person before exiting the cab. DO NOT leave the cab if
on work site traffic duty, ensure all personnel any warning messages are displayed or warning
understand all hand signals that are to be used. horns are sounding. Notify maintenance personnel
immediately.
Truck Safety Features • When exiting the machine, always lock
Learn the proper use of safety features such as safety compartments, and take the keys with you to
locks, safety pins, and seat belts. Always use these prevent entry from unauthorized persons.
safety features properly.
Mounting And Dismounting
Never remove any safety features. Always keep
safety features in good operating condition. Improper When mounting and dismounting the machine obey
use of safety features may result in serious bodily the following guidelines:
injury or death. • Never jump on or off the machine. Never climb on
or off a machine while it is moving.
Clothing And Personal Items
Avoid wearing loose • When climbing on or off a machine, face the
clothing, jewelry, and machine and use the hand-hold and steps.
loose long hair. They can • Never hold any control levers when getting on or off
catch on controls or in a machine.
moving parts and cause
serious injury or death. • Always maintain three-point contact with the
Additionally, never wear hand-holds and steps to ensure that you support
oily clothes as they are yourself.
flammable. • When bringing tools up to the operating deck,
always pass them by hand or pull them up by rope.
Wear a hard hat, safety glasses, safety shoes, a mask
and gloves when operating or maintaining a machine. • If there is any oil, grease, or mud on the hand-holds
Always wear the proper safety equipment required for or steps, wipe them clean immediately. Always
the job. Also, ensure that the work area is clear of keep these components clean. Repair any damage
other personnel during hazardous jobs. and tighten any loose bolts.
3-2 930E-4SE
Fire Extinguishers And First Aid Kits • Use an approved respirator, when necessary.
Ensure fire extinguishers
are accessible and proper Fire Prevention
usage techniques are
known. Provide a first aid
kit at the storage point.
Know what to do in the event of a fire and keep phone

numbers of persons you must contact in case of an
emergency in the cab.
Precautions For High Temperature Fluids

Immediately after
machine operation,
engine coolant, engine NOTE: DO NOT operate the machine near open
oil, and hydraulic oil are flames. Always ensure a fire extinguisher is present
hot and pressurized. If and in proper working condition.
the cap is removed or the
system is opened in any Remove any debris from the engine compartment.
way, there is danger of Check and repair any fuel, lubrication, and hydraulic
serious burns. systems leaks. Clean any excess oil, fuel or other
flammable fluids, and dispose of properly.
Allow heat and pressure to dissipate before
performing such tasks and follow proper procedures Keep oil and fuel in a designated location and
as outlined in the service manual. accessible by authorized personnel only. Fuel, oil,
and antifreeze can be ignited by a flame. These fluids
To prevent hot coolant from spraying: are extremely flammable and hazardous.
1. Stop the engine, and wait for the coolant When handling fuel and oil obey the following
temperature to decrease. guidelines:
2. Depress the pressure relief button on the
• Keep flames away from flammable fluids.
radiator cap.
• Stop the engine while refueling.
3. Turn the radiator cap slowly to allow pressure
to dissipate. • Never smoke while refueling.
To prevent hot engine oil spray: • Tighten all fuel and oil tank caps securely.
1. Stop the engine. • Refuel and maintain oil in well ventilated areas.
2. Wait for the oil temperature to cool down. ROPS Precautions

3. Turn the cap slowly to allow pressure to NOTE: When modifying or repairing the ROPS,
dissipate. always consult your nearest Komatsu distributor.
Even with the ROPS installed, the operator must
Asbestos Dust Hazard Prevention always use the seat belt when operating the machine.
Asbestos dust is
hazardous to your The ROPS is intended to protect the operator if the
health when inhaled. If machine rolls over. It is designed not only to support
you handle materials the load of the machine, but also to absorb the
containing asbestos energy of the impact. ROPS structures installed on
fibers, follow the equipment manufactured and designed by Komatsu
guidelines below: fulfills all of the regulations and standards for all
countries. If the ROPS is modified or repaired without
• Never use compressed air for cleaning. authorization from Komatsu, or is damaged when the
machine rolls over, the strength of the structure will
• Use water for cleaning and to control dust.
not be able to fulfill its intended purpose. Optimum
• Operate the machine or perform tasks with the wind strength of the structure can only be achieved if it is
to your back, whenever possible. repaired or modified as specified by Komatsu.
930E-4SE 3-3
Preventing Injury From Work Equipment Any injuries, accidents, and product failures resulting
from the use of unauthorized attachments will not be
Never position any part of your body between movable
the responsibility of Komatsu America Corp., or the
parts such as the dump body, chassis or cylinders.
authorized regional Komatsu distributor.
If the work equipment is operated, clearances will
change and may cause serious bodily injury or death.
Precautions When Starting The Machine
Precautions For Optional Attachments Never attempt to start the
engine by shorting across
NOTE: DO NOT use attachments that are the starter terminals. This
not authorized by Komatsu, or the authorized may cause fire, or serious
regional Komatsu distributor. Use of unauthorized injury or death to anyone
attachments could create a safety problem and in the machine’s path.
adversely affect the proper operation and useful life Start the engine from the
of the machine. operator’s seat only.
When installing and using optional equipment, read
the instruction manual for the attachment and the
information related to attachments in this manual.
3-4 930E-4SE
GENERAL SAFETY PRECAUTIONS FOR TRUCK OPERATION
PRECAUTIONS FOR TRUCK Mirrors, Windows, And Lights

OPERATION G.3-0000051230 Remove any dirt from the surface of the windshield,
cab windows, mirrors and lights. Good visibility may
Safety Is Thinking Ahead
prevent an accident. Adjust the mirrors to a position
Prevention is the best safety program. Prevent a where the operator can see best from the operator's
potential accident by knowing the employer's safety seat. Ensure headlights, work lights and taillights are
requirements and all necessary job site regulations. in proper working order. Ensure that the machine
In addition, know the proper use and care of all is equipped with the proper work lamps needed for
the safety equipment on the truck. Only qualified the operating conditions. Always replace any broken
operators or technicians may attempt to operate or mirrors, windows or lights.
maintain a Komatsu machine.
Before Starting The Engine
Safety At The Worksite
NOTE: DO NOT leave tools or spare parts lying
When walking to and from a truck, maintain a safe around or allow trash to accumulate in the cab of the
distance from all machines even when the operator truck. Keep all unauthorized reading material out of
is visible. Before starting the engine, thoroughly the truck cab. Keep the cab floor, controls, steps, and
check the area for any unusual conditions that could handrails free of oil, grease, snow, and excess dirt.
be dangerous. Examine the road surface at the job
site and determine the best and safest method of Before starting the engine perform the following:
operation. Choose an area where the ground is as • Read and understand the contents of the Operation
horizontal and firm as possible before performing the & Maintenance manual. Read safety and operating
operation. If you need to operate on or near a public instructions with special attention. Become
road, protect pedestrians and cars by designating a thoroughly acquainted with all gauges, instruments
person for work site traffic duty or by installing fences and controls before attempting operation of the
around the work site. truck.
Before operating the machine, the operator must • Read and understand the WARNING and
check the work area for obstacles and road conditions. CAUTION decals in the operator’s cab.
Always determine the travel roads to be used at the
work site. Travel roads must be maintained in order • Ensure the steering wheel, horn, controls and
to ensure safe machine travel. If travel through wet pedals are free of any oil, grease, or mud.
areas is necessary, check the depth and flow of water • Check operation of the windshield wiper, condition
before crossing the shallow parts. of wiper blades, and check the washer fluid
reservoir level.
Preparing For Operation • Be familiar with all steering and brake system
Normally use handrails and the diagonal stairway controls, warning devices, road speeds and loading
when mounting or dismounting the truck. Become capabilities, before operating the truck.
familiar with the emergency egress paths and their
operation. Always face vertical ladders and use Seat Belts And Tethers
handrails. Check the deck areas for debris, loose
hardware, and tools. Check for people and objects On both driver and passenger seats, check the seat
that remain on or around the truck. belt and tether fabric, buckles, all belt retractors, and
hardware for damage or wear. Replace any worn or
Become familiar with and use all protective equipment damaged parts immediately.
devices on the truck and ensure that these items
(anti-skid material, grab bars, seat belts, etc.) are Even if there are no signs of damage, replace both
securely in place. driver and passenger seat belts five years after seat
belt manufacture, or every three years after start
of use, whichever comes first. The passenger seat
Ventilation For Enclosed Areas belt date of manufacture label is sewn into the seat
If it is necessary to start belt near the buckle. The driver seat belt date of
the engine in an enclosed manufacture label is sewn into the shoulder harness
area, provide adequate belt, near the retractor end.
ventilation. Exhaust
fumes from the engine
can be lethal.
930E-4SE 3-5
PRECAUTIONS FOR TRUCK OPERATION GENERAL SAFETY
Emergency Exit from Operator’s Cab

The cab on this machine has doors on the left and right
sides. If the primary door does not open, exit from the
door on the other side.
Emergency Egress Ladders
1. Emergency Egress Latch
Figure 3-1 EMERGENCY EGRESS GATE

Be familiar with the emergency egress locations
and their operations. At each emergency egress
location, there is a gate that allows access to the
ladder. Lift up on emergency egress latch (1, Figure
3-1 EMERGENCY EGRESS GATE, page 3-6) to gain
access to the emergency egress ladder.
3-6 930E-4SE
GENERAL SAFETY OPERATING THE MACHINE
OPERATING THE
MACHINE G.4-0000051287 • A tire and rim assembly may explode if
General Information subjected to excessive heat. Personnel must
move to a remote or protected location if there
While operating the truck obey the following is a fire near the tire and wheel area or if the
guidelines: smell of burning rubber or excessively hot
• Wear seat belts at all times. Only authorized brakes is evident.
persons are allowed to ride in the truck. • If the truck must be approached, such as to
fight a fire, those personnel must do so only
• Passengers must be in the cab and belted in the while facing the tread area of the tire (front or
passenger seat. back), unless protected by use of large heavy
• DO NOT allow anyone to ride on the decks or on equipment as a shield. Stay at least 15 m (50
the steps of the truck. ft) from the tread of the tire.
• In the event of fire in the tire and wheel area
• DO NOT allow anyone to get on or off the truck while (including brake fires), stay away from the
it is in motion. truck for at least 8 hours or until the tire and
• DO NOT move the truck in or out of a building wheel are cool.
without a signal person present.
• Check for flat tires periodically during a shift. If
• Keep serviceable fire fighting equipment on hand.
the truck has been operating on a “flat”, the truck
Report used extinguishers for replacement or
must not be parked indoors until the tire cools. DO
refilling.
NOT stand in front of the rim and locking ring when
• Always move the directional control lever to PARK inflating a tire mounted on the machine. Observers
(this will apply the parking brake) when the truck is must not be permitted in the area and must be kept
parked and unattended. DO NOT leave the truck away from the side of such tires.
unattended while the engine is running.
NOTE: DO NOT use wheel brake lock when parking
Starting The Engine
the truck. • DO NOT attempt to start the machine by shorting
across the starter terminals. This may cause fire,
• Park the truck a safe distance away from other
or serious injury or death to anyone in machine’s
vehicles as determined by the supervisor.
path.
• Stay alert at all times! In the event of an emergency,
• DO NOT start the engine if a warning tag has been
be prepared to react quickly and avoid accidents.
attached to the controls.
If an emergency arises, know where to get prompt
assistance. When starting the engine, sound the horn as an alert.
• Know and obey hand signal communications Start and operate the machine only while seated in
between the operator and spotter. Use a signal the operator’s seat. DO NOT allow any unauthorized
person when other machines and personnel are persons in the operator's compartment or any other
present, the operator must move in and out of place on the machine.
buildings, and traveling through traffic.
Traveling In The Machine
• Immediately report any adverse conditions on haul
road, pit or dump area that may cause an operating When traveling on rough ground, travel at low speeds.
hazard. When changing direction, avoid turning suddenly.
Lower the dump body before traveling. If the engine
stops when the machine is in motion, emergency
steering and secondary braking enable the truck to
be steered and stopped. A fixed amount of reserve
oil provides temporary steering and braking to briefly
allow the truck to travel to a safe area. Apply
the brakes immediately and stop the machine as
quickly and safely as possible (off of the haul road, if
possible). Apply the parking brake.
930E-4SE 3-7
OPERATING THE MACHINE GENERAL SAFETY
Traveling In Reverse Minimum Safe

Before operating the Voltage
Distance
machine or work
equipment, do as follows: 50 kV or Less 3.1 m (10 ft.)
50 kV to 200 kV 4.6 m (15 ft.)
200 kV to 350 kV 6.1m (20 ft.)
• Ensure the backup alarm works properly.
350 kV to 500 kV 7.7 m (25 ft.)
• Sound the horn to warn people in the area. 500 kV to 750 kV 10.7 m (35 ft.)
• Check for personnel near the machine. Do a 750 kV to 1000 kV 13.8 m (45 ft.)
thorough check behind the machine.
• When necessary, designate a person to watch The following actions are effective in preventing
the area for the truck operator. This is particularly accidents while working near high voltages:
necessary when traveling in reverse.
• Wear shoes with rubber or leather soles.
• When operating in hazardous areas and areas with
• Use a signalman to give warning if the machine
poor visibility, designate a person to direct work site
approaches an electric cable.
traffic.
• If the work equipment touches an electric cable, the
NOTE: DO NOT allow any one to enter the line operator must not leave the cab.
of travel of the machine. This rule must be strictly
obeyed even with machines equipped with a back-up • When performing operations near high voltage
alarm or rear view mirror. cables, DO NOT allow anyone to approach the
machine.
Traveling On Slopes • Check with the electrical maintenance department
Traveling on slopes could result in the machine tipping about the voltage of the cables before starting
over or slipping. The retarder must be used to reduce operations.
speed when traveling downhill. If the engine shuts
down on a slope, apply the service brakes to fully stop Traveling On Loose Ground
the machine. Park the machine.
Avoid operating the machine near cliffs, overhangs,
• DO NOT change direction on slopes. To ensure and deep ditches. If these areas collapse, the
safety, drive to level ground before turning. machine could fall or tip over and result in serious
injury or death. Remember that ground surfaces in
• DO NOT travel up and down on grass, fallen leaves, these areas may be weakened after heavy rain or
or wet steel plates. These materials may make the blasting. Freshly laid soil and the soil near ditches is
machine slip on even the slightest slope. Avoid loose. Avoid these areas whenever possible.
traveling sideways, and always keep travel speed
low.
Ensuring Good Visibility
• DO NOT turn the steering wheel suddenly.
When working in dark places, install work lamps and
• DO NOT use the foot brake except in an emergency. head lamps. Discontinue operations if visibility is poor,
such as in mist, snow, or rain. Wait for the weather to
Traveling On Snow improve to allow the operation to be performed safely.
When working on snowy or icy roads, there is danger
that the machine may slip to the side on even the Avoid Damage To The Dump Body
slightest slope. Always travel slowly and avoid sudden
starting, turning, or stopping in these conditions. Be
extremely careful when clearing snow. The road • Driving with a raised dump body or raising the
shoulder and other objects are buried in the snow and dump body in an enclosed area, may result
cannot be seen. in serious damage and bodily injury or death.
Always drive with the dump body resting on
Traveling Near High Voltage Cables the frame.
Driving near high-voltage cables can cause electric

shock. Always maintain the safe distances between
the machine and the electric cable as listed below.
3-8 930E-4SE
GENERAL SAFETY OPERATING THE MACHINE
When working in tunnels, on bridges, under electric slowly operate the dump body. If necessary, use
cables, or when entering an enclosed area where chocks for the wheels or position a flagman. When
there are height limits, always use extreme caution. dumping on slopes, machine stability is poor and
The dump body must be completely lowered before there is danger of tip over. Always perform such
driving. operations using extreme care. Never travel with the
dump body raised.
Safe Parking Of The Machine
Towing The Machine
The operator must continue to use safety precautions
when preparing for parking and stopping the engine. Improper towing methods may lead to serious
personal injury and/or damage.
NOTE: In the event that the machine is being
used in consecutive shifts, any questionable truck Please refer to the following towing methods:
performance the operator may have noticed must be
• Tow with a solid tow bar. DO NOT tow with a cable.
checked by maintenance personnel before the truck
is released to another operator. • Use a towing device with ample strength for the
weight of this machine.
Park the truck on level ground, if possible. If it is
necessary to park on a grade, the truck must be • Towing vehicle must have adequate pulling and
positioned at right angles to the grade. Turn the braking capacity to both move and stop the towed
wheels into a suitable bank, when possible. truck under all conditions, including towing on a
grade.
Haul roads are not safe parking areas. In an
emergency, pick the safest spot most visible to other • When connecting a machine to be towed, DO NOT
machines in the area. If the truck becomes disabled allow anyone to go between the tow machine and
where traffic is heavy, mark the truck with warning the disabled machine.
flags in daylight, or flares at night. • Set the coupling of the disabled machine in a
straight line with the towing portion of the tow
Loading The Machine machine, and secure it in position.
NOTE: DO NOT leave the operator's seat during the • DO NOT stand next to the towing device while the
loading operation. truck is moving.
Ensure the surrounding area is safe. If so, stop the Refer to Operating Instructions - TOWING, page 5-41
machine in the correct loading position and evenly for the towing procedure.
load the body.
Dumping The Machine

Before dumping, check that there is no person or
objects behind the machine. Stop the machine in the
desired location. Give the determined signal, then
930E-4SE 3-9
EXTERIOR LIGHTING GENERAL SAFETY
EXTERIOR LIGHTING D.89-0000054339
1. Fog Lights 5. Ladder Lights

2. Headlights 6. Brake Lights
3. Mirror Mounted Backup Lights 7. Retard Lights
4. Deck Mounted Flood Lights 8. Clearance/Turn Signal Lights
Figure 3-2 FRONT LIGHTS
Fog Lights Mirror Mounted Backup Lights

Fog lights (1, Figure 3-2 FRONT LIGHTS, page 3-10) Mirror mounted backup lights (3) illuminate when
illuminate when the operator actuates the fog light the operator moves the directional control lever to
switch located on the dash. The fog lights are low REVERSE. The lights can also be activated by using
beam, low level lights used to illuminate a foggy work the backup light switch in the cab. Using the switch
area. turns the lights on regardless of directional control
lever position.
Headlights
Deck Mounted Flood Lights and Ladder
Headlights (2) consist of high beam and low beam
headlights. Low beam headlights illuminate when Lights
the operator actuates the headlight switch. The Deck mounted flood lights (4) illuminate the walkway
multi-function lever must be in the low beam position of the deck and ladder lights (5) illuminate the diagonal
for the low beam headlights to work. High beam ladder steps when the operator actuates the light
headlights illuminate when the operator actuates switch at the base of the ladder. These lights can
the high beam function on the multi-function lever. also be activated by using the ladder light switch in
The headlight switch must be on for the high beam the cab.
headlights to work. These lights are functional
regardless of key switch position.
3-10 930E-4SE
GENERAL SAFETY EXTERIOR LIGHTING
Brake Lights Clearance/Turn Signal Lights

Brake lights (6) will illuminate when the operator Clearance/turn signal lights (8) are dual function
depresses the brake pedal. The red light signals to amber lights. When the headlights are on, a low beam
traffic that the truck is stopping. clearance light will illuminate. When the operator
signals a left turn using the multi-function lever, the
Retard Lights left light will flash. When the operator signals a right
turn using the multi-function lever, the right light will
Retard lights (7) will illuminate when the operator uses flash. These lights are functional regardless of key
the retard function to slow the truck. The amber light switch position.
signals to traffic that the truck is slowing.
1. Backup Lights 4. Backup Alarm

2. Retard Lights 5. Junction Box
3. Brake Lights 6. Backup Lamp
Figure 3-3 REAR AXLE LIGHT BAR

NOTE: The brake light is functional at all times can also be activated by using the backup light switch
regardless of key switch position. All other lights (and in the cab. Using the switch turns the lights on
the backup alarm) are only functional with the key regardless of directional control lever position.
switch in the RUN position.
Retard Lights
Backup Lights
Retard lights (2) will illuminate when the operator uses
Backup lights (1, Figure 3-3 REAR AXLE LIGHT the retard function to slow the truck. The amber light
BAR, page 3-11) illuminate when the operator moves signals to traffic that the truck is slowing.
the directional control lever to REVERSE. The lights
930E-4SE 3-11
EXTERIOR LIGHTING GENERAL SAFETY
Brake Lights Backup Lamp

Brake light (3) will illuminate when the operator Backup Lamp (6) illuminates when the operator
depresses the brake pedal. The red light signals to moves the directional control lever to REVERSE. The
traffic that the truck is slowing. lamp can also be activated by using the backup light
switch in the cab. Using the switch turns the lamp on
Backup Alarm regardless of directional control lever position.
Backup alarm (4) will sound when the operator moves
the directional control lever to REVERSE. The alarm
can also be turned on by using the backup light switch.
Using the switch turns the alarm on regardless of
directional control lever position.
3-12 930E-4SE
GENERAL SAFETY PRECAUTIONS FOR MAINTENANCE
PRECAUTIONS FOR disconnect switch (4) and propel lockout lever (5).
MAINTENANCE C.3-0000051285 The isolation box is located on top of the front bumper,
on the left hand side. To disable the 24VDC electrical
BEFORE PERFORMING system, move both disconnect switches and the
MAINTENANCE G.9-0000051284 propel lockout lever to the OFF position. When the
switches and propel lockout lever are in the OFF
Before performing maintenance on the machine, position, LED lights (8) will be illuminated. The
perform the following: battery disconnect switches and propel lockout lever
• Before performing inspections or maintenance, stop can be padlocked in the OFF position to prevent
the machine on firm, flat ground. Lower the dump unauthorized truck operation. When the switches and
body, place the directional control lever to the PARK the propel lockout lever are in the ON position, LED
position (this will apply the parking brake), and turn lights (7) will be illuminated. Refer to the following
the key switch to the OFF position and wait for the table to ensure the correct disconnect is used to
engine to stop. isolate a desired circuit or system.
• Wait two minutes after the engine has stopped, and NOTE: This is the recommended usage of the battery
if no warning message is displayed, then turn the disconnect and propel lockout switches. Local
battery disconnect switches to the OFF position. regulations may be different.
Verify that the disconnects are functioning.
• Place wheel chocks around the wheels to prevent Recommended
Action
the truck from rolling. Isolation
• If the engine must be operated during maintenance,
24V Electrical
always move the directional control lever to the Starter Lockout
Troubleshooting
PARK position (this will apply the parking brake).
Always perform this work with two people. One 24V Electrical
Master Lockout
person must be in the operator's seat to stop the Maintenance/Repair
engine if necessary. Never move any controls not High Voltage/Propulsion
related to the task at hand during these situations. None
Troubleshooting
Apply the propel lockout lever to prevent the truck
from moving if the engine must operate during High Voltage
Master Lockout
maintenance. When the propel lockout lever is in Maintenance/Repair
the OFF position and the LED light is illuminated, Hydraulic
the drive system is locked out and the truck will Propel Lockout
Troubleshooting
not propel. When the propel lockout lever is in the
ON position and LED light is illuminated, the drive Hydraulic
Starter Lockout
system is active and the truck can be driven. Maintenance/Repair
• When servicing the machine, use care not to touch Engine Troubleshooting Propel Lockout
any moving parts. Never wear loose clothing. Engine Repair Master Lockout
• When performing service with the dump body Mechanical Repair Starter Lockout
raised, always place the dump lever in the HOLD Master Lockout &
position, and apply the lock (if equipped). Install Weld Repair
Alternator Isolation
the body-up safety cable securely.
Fueling Starter Lockout
• Use caution in the work area and be aware of any
potential overhead debris or objects. Lube/General
Starter Lockout
Maintenance
Electrical System Isolation Shift Change Walk
Starter Lockout
Isolation box (6, Figure 3-4 ISOLATION BOX Around
ASSEMBLY (COVERS REMOVED), page 3-14) Oil Sample Collection Propel Lockout
contains master disconnect switch (3), starter
930E-4SE 3-13
PRECAUTIONS FOR MAINTENANCE GENERAL SAFETY
1. Engine Shutdown Switch 4. Starter Disconnect Switch 7. LED Lights (On)

2. Access Ladder Light Switch 5. Propel Lockout Lever 8. LED Lights (Off)
3. Master Disconnect Switch 6. Isolation Box
Figure 3-4 ISOLATION BOX ASSEMBLY (COVERS REMOVED)

Securing The Dump Body
• To avoid serious personal injury or death,

the body retention sling must be installed
whenever personnel are required to perform
maintenance on the truck while the dump
body is in the raised position.
• The Komatsu body-up safety sling can only be
used with a Komatsu body. Non-OEM body
may not accommodate the Komatsu body-up
safety sling. The end user must ensure that a
proper cable/sling is used.
3-14 930E-4SE
Proper jack point locations must be used. The jacks

at locations must be located on the frame rails.
If a tow bumper reinforcement group is installed, it is
acceptable to place jack stands under tow hooks at
locations (4). However, do not position jacks outside
of the tow hooks.
1. Rear Body Ear 3. Body Retention Sling

2. Shackle and Pin
Figure 3-5 BODY RETENTION SLING

INSTALLATION
To hold the dump body in the up position, perform the
following:
1. Raise the body to its maximum height.
2. Install two shackles (2, Figure 3-5 BODY
RETENTION SLING INSTALLATION, page
3-15) and body retention sling (3) between rear
body ear (1) and the axle housing.
3. Secure the shackle pins with cotter pins.
4. Move the hoist lever to the FLOAT position
to slowly lower the body until the cable is
supporting the full weight of the body. Then
move the hoist lever to the HOLD position.
5. After maintenance work is completed, return
1. Under Rear 3. Under Torque Tube
the sling to stored position.
Suspensions 4. Under Tow Hooks (if
2. Under Front equipped)
Jack Point Locations Suspensions
When a truck is being stored for any period of time
or being secured for maintenance work, portable jack Figure 3-6 JACKING LOCATIONS BOTTOM VIEW
stands or permanent jack stands may be used.
The jack stands must be adequately rated for the size
of the truck. Ensure that the jacks stands are on a
solid and level surface.
930E-4SE 3-15
DURING MAINTENANCE G.31-0000051281 Keeping The Machine Clean

Spilled oil, grease,
Warning Tag
scattered tools, etc. can
cause you to slip or
trip. Always keep your
machine clean.
If water gets into the electrical system, there is danger

that the machine may move unexpectedly and/or
damage to components may occur. DO NOT use
water or steam to clean any sensors, connectors, or
the inside of the operator’s compartment.
NOTE: DO NOT spray water into the retarding grids.
Excess water in the retarding grids can cause a
ground fault, which will prevent propulsion. Never
spray water into the rear wheel electric motor covers.
Damage to the wheel motor armatures may occur.
Use extreme care when washing the electrical control
cabinet. DO NOT allow water to enter the control
Always attach a warning tag to the control lever in the cabinet around the doors or vents. DO NOT allow
operator's cab to alert others that you are working on any water to enter the cooling air inlet duct above
the machine. Attach additional warning tags around the electrical control cabinet. If water enters the
the machine, if necessary. Never start the engine control cabinet (through any opening or crevice) major
or operate the controls while a person is performing damage to the electrical components may occur.
maintenance. Serious injury or death may result.
These tags are available from your Komatsu Adding Fuel Or Oil To The Machine
distributor, Part No. 09963-A1640.
Proper Tools
Use only tools suited to the task. Using damaged, low
quality, faulty, or makeshift tools can cause personal
injury. Extra precaution must be used when grinding,
welding, and using a sledge-hammer.
Attachments
Place attachments, that
have been removed from
the machine, in a safe
place and manner to When adding fuel or oil to the machine, obey the
prevent them from falling. following guidelines:
• Spilled fuel and oil may cause slipping. Always
Working Under The Machine clean up spills, immediately.
Always lower all movable • Always tighten the cap of the fuel and oil fillers
work equipment to securely.
the ground or to their
lowest position before • Never use fuel for washing any parts.
performing service • Always stop the engine before adding fuel or oil.
or repairs under the
machine. • Always add fuel and oil in a well-ventilated area.
Always chock the tires of the machine securely. Never

work under the machine if the machine is poorly
supported.
3-16 930E-4SE
Radiator Coolant Level Maintenance Near High Temperatures

If it is necessary to add And High Pressures
coolant to the radiator, Immediately after
stop the engine. Allow stopping the truck, the
the engine and radiator engine coolant and
to cool down before operating oils are at high
adding the coolant. Lift temperature and under
the pressure relief lever high pressure.
on the radiator cap and
slowly loosen the cap to In these conditions, opening the system or replacing
relieve pressure during filters may result in burns or other injury. Wait for the
removal. temperature to cool and pressure to subside before
performing the inspection and/or maintenance as
Use Of Lighting outlined in the service manual.
When checking
fuel, oil, coolant, or Rotating Fan And Belts
battery electrolyte, Keep a safe distance
always use lighting from rotating parts such
with anti-explosion as the radiator fan and
specifications. If lighting fan belts. Serious bodily
without this protection is injury may result from
used, there is a danger of direct or indirect contact
explosion. with rotating parts and
flying objects.
Handling High Pressure Hoses
DO NOT bend high-pressure hoses or hit them with Waste Materials
hard objects. DO NOT use any bent or cracked piping, Obey appropriate laws
tubes or hoses. They may burst during use. Always and regulations when
repair any loose or broken hoses. Fuel and/or oil leaks disposing of harmful
may result in a fire. objects such as oil, fuel,
coolant, solvent, filters,
Precautions With High Pressure Oil batteries, and others.
Always put fluids drained from your machine in

appropriate containers. Never drain fluids directly
onto the ground. Never dump oil or other harmful
fluids into a sewer system, rivers, etc.
The machine may be equipped with optional high
intensity discharge lamps which contain mercury.
When working with high pressure oil, obey the
These lamps must be reused, recycled or properly
following guidelines:
disposed of in accordance with applicable local, state
• Always remember that work equipment circuits are and federal laws.
always under pressure.
• DO NOT add oil, drain oil, or perform maintenance Use Of Tie-Off Anchor During
or inspections before completely releasing the Maintenance
internal pressure. While working at
heights during assembly,
• Small, high pressure pin-hole leaks are extremely maintenance or repair
dangerous. The jet stream of high-pressure oil of the haul truck,
can pierce the skin and eyes. Always wear safety workers should wear an
glasses and thick gloves. Use a piece of cardboard appropriate fall protection
or a sheet of wood to check for oil leakage. harness and attach it to
• If you are hit by a jet of high-pressure oil, consult a a tie-off anchor or tie-off
doctor immediately for medical attention. point.
930E-4SE 3-17
Komatsu anchor (58B-98-75190) is available for use The tire inflation pressure and permissible speeds,
with fall protection harnesses. Carefully read and given in this manual, are general values. The actual
understand the harness maker’s instructions before values may differ, depending on the type of tire and
using any fall protection harness. the specific operating conditions. For details, please
consult the tire manufacturer.
The load carrying capacity of anchor (58B-97–75190)
is 2 270 kg (5,000 lbs). NOTE: DO NOT weld near the rim or tire if the tire is
inflated.
NOTE: The anchor must not be used for lifting.
When the tires become overheated, a flammable
Handling Tires gas is produced inside the tire which can ignite.
It is particularly dangerous if the tires become
overheated while the tires are pressurized. If the
• DO NOT stand in front of a rim and locking ring gas generated inside the tire ignites, the internal
when inflating a tire mounted on the machine. pressure will suddenly rise, and the tire will explode,
Observers must not be permitted in the area. resulting in danger and/or death to personnel in the
• DO NOT weld or heat the rim assembly with area. Explosions differ from punctures or tire bursts
the tire mounted on the rim. Resulting gases because the destructive force of the explosion is
inside the tire may ignite, causing explosion extremely large.
of the tire and rim.
Tire Maintenance
Rim and tire maintenance can be hazardous unless If the proper procedure for performing maintenance or
the correct procedures are followed by trained replacement of the wheel or tire is not used, the wheel
personnel. or tire may burst, causing damage, serious injury, or
even death. When performing such maintenance,
Improperly maintained or inflated tires can overheat
consult your shop manual, your authorized regional
and burst due to excessive pressure. Improper
Komatsu distributor, or the tire manufacturer.
inflation can also result in cuts in the tire caused by
sharp stones. Both of these conditions can lead to
tire damage, serious personal injury, or even death.
Storing Tires After Removal
To safely maintain a tire, adhere to the following

conditions:
• Before a tire is removed from a vehicle for tire
repair, the valve core must be partially removed to
allow deflation, and then the tire/rim assembly can
be removed. During deflation, persons must stand
outside of the potential trajectory of the locking ring
of a multi-piece wheel rim. Store the tires in a warehouse in which unauthorized
persons cannot enter. If the tires are stored outside,
• After the tire/rim assembly is installed on the erect a fence around the tires with warning signs.
vehicle, inflate the tires to their specified pressure. Stand the tire on level ground, and chock it securely
Abnormal heat is generated, particularly when the so that it cannot roll or fall over. If the tire falls, flee
inflation pressure is too low. the area as quickly as possible. The tires for mining
• Use the specified tires. equipment are extremely heavy. DO NOT attempt to
hold a tire upright when the tire is falling. The weight
To prevent injury from the wheel rims during tire of these tires may lead to serious injury or death.
inflation, use one of the following:
Mounted tires stored as spares must be inflated to the
1. A wheel cage or other restraining device that minimum inflation pressure necessary to keep the tire
will constrain all wheel rim components during beads properly seated. Maximum inflation pressure
an explosive separation of a multi-piece wheel of the stored tire must, in no instance, exceed 15% of
rim, or during the sudden release of air. the tire’s cold inflation pressure.
2. A stand-off inflation device which permits
a person to stand outside of the potential
trajectory of the wheel components.
3-18 930E-4SE
Battery Hazard Prevention master disconnect switch to the OFF position.

Disconnect the positive (+) battery cables first, then
disconnect the negative (-) battery cables.
Before repairing the electrical system or when 1. Off 2. On

performing welding, turn the key switch to the OFF
position. Wait two minutes after the engine has Figure 3-7 MASTER DISCONNECT SWITCH
stopped, and if no warning message is displayed,
NOTE: If the Master Disconnect Switch is OFF, and
then turn the master disconnect switch and starter
a wrench on the negative (-) terminal touches the
disconnect switch to the OFF position.
battery box frame, a spark will occur if any electrical
Battery electrolyte contains sulfuric acid and can component on the truck was left in the ON position.
quickly burn the skin and eat holes in clothing. If
• When connecting battery cables, always move
electrolyte comes in contact with skin, immediately
the master disconnect switch to the OFF position.
flush the area with water.
Connect the negative (-) cables first, then the
Battery acid can cause blindness if splashed into the positive cables (+) last.
eyes. Always wear safety glasses or goggles when
• Tighten battery terminals securely. Loose terminals
working with batteries. If acid gets into the eyes, flush
can generate sparks and could lead to an explosion.
them immediately with large quantities of water and
see a doctor immediately. • Tighten battery caps securely.
If acid is accidentally ingested, drink a large quantity
Jump Starting With Jumper Cables
of water, milk, beaten eggs or vegetable oil. Call a
doctor or poison prevention center immediately.
When working with batteries, obey the following • Always wear safety glasses or goggles when
guidelines: starting the machine with jumper cables. DO
NOT allow the two machines to touch while
• Batteries generate hydrogen gas. Hydrogen gas jump starting with another machine.
is very explosive, and is easily ignited with a small
spark or flame.
• Before working with batteries, stop the engine
and turn the key switch to the OFF position. Wait • Always use caution when using tools near
two minutes after the engine has stopped. If no the batteries. If any tool touches between the
warning message is displayed, then turn the battery positive (+) terminal and the chassis, it will
disconnect switches to the OFF position. cause sparks.
• Avoid short-circuiting the battery terminals through

accidental contact with metallic objects, such as When jump starting the machine with jumper cables,
tools, across the terminals. obey the following guidelines:
• When removing or installing a battery, positively 1. Ensure the parking brake is applied on both
identify the positive (+) terminal and negative (-) machines. The engine on the good machine
terminal and use precautions not to short circuit must be operating.
between the terminals. 2. Ensure the size of the jumper cables and clips
• This truck is equipped with a master disconnect are suitable for the battery size. Inspect the
switch on the battery ground circuit. When cables and clips for any damage or corrosion.
disconnecting battery cables, always move the
930E-4SE 3-19
3. Ensure the key switch and the master battery

disconnect switch on the disabled machine are
in the OFF position. • Always use caution when using tools near
the batteries. If any tool touches between the
4. Connect the batteries in parallel: positive to positive (+) terminal and the chassis, it will
positive and negative to negative. cause sparks.
5. Connect the positive (24VDC +) cable from the
good machine to the (24VDC +) on the disabled When jump starting the machine with receptacles,
machine first. obey the following guidelines:
6. Then connect the ground cable from the 1. Ensure the parking brake is applied on both
negative (-) battery terminal on the good machines. The engine on the good machine
machine to the frame of the disabled machine, must be operating.
as far away as possible from the batteries.
This will prevent a spark from possibly starting 2. Inspect the cables and connectors for any
a battery fire. damage or corrosion.
7. Move the master battery disconnect switch to 3. Ensure the key switch and master battery
the ON position. Allow time for the batteries to disconnect switch on the disabled machine are
charge. in the OFF position.
8. If starting with a jumper cable, perform the 4. Connect the jumper cable to the receptacle
operation with two people. One person must on the good machine to the receptacle on the
be in the cab of the disabled machine, the disabled machine.
other person must be working with the jumper 5. Allow time for the batteries to charge.
cables.
NOTE: The batteries will charge even with the master
9. If the batteries are low, DO NOT attempt to battery disconnect switch in the OFF position.
start the machine with only one set of jumper
cables installed. Install the second set of 6. If starting with a jumper cable, perform the
jumper cables in the same way as already operation with two people. One person must
described. be in the cab of the disabled machine, the
other person must be working with the jumper
10. Attempt to start the disabled machine. cables.
11. For jumper cable removal, disconnect the 7. If the batteries are low, DO NOT attempt to
ground or negative (-) cable first, then the start the machine with only one set of jumper
(24VDC +) cable last. cables installed. Install the second set of
NOTE: If any tool touches between the positive (+) jumper cables in the same way as already
terminal and the chassis, it will cause sparks. Always described.
use caution when using tools near the batteries. 8. Turn the master battery disconnect switch
to the ON position and attempt to start the
Jump Starting With Receptacles disabled machine.
9. For jumper cable removal, disconnect the
cables from each machine.
• Always wear safety glasses or goggles when
starting the machine with jumper cables. DO NOTE: If any tool touches between the positive (+)
NOT allow the two machines to touch while terminal and the chassis, it will cause sparks. Always
jump starting with another machine. use caution when using tools near the batteries.
3-20 930E-4SE
GENERAL SAFETY WHEN REPAIRS ARE NECESSARY
WHEN REPAIRS ARE all current regulations for handling and recycling
NECESSARY E.8-0000051280 refrigerants are followed.
• Follow package directions carefully when using
Observe The Following Precautions
cleaning solvents.
• If an auxiliary battery assist is needed, refer to Jump
• Any operating fluid, such as hydraulic oil Starting with Jumper Cables or Jump Starting with
or brake fluid escaping under pressure, can Receptacles earlier in this section.
have sufficient force to enter a person's body
• Before performing any welding on the truck, always
by penetrating the skin. Serious injury and
turn the battery disconnect switches to the OFF
possibly death may result if proper medical
position and disconnect the alternator positive
treatment by a physician familiar with this
cable. Failure to do so may seriously damage the
injury is not received immediately.
battery and electrical equipment. It is not necessary
to disconnect or remove any control circuit cards
on electric drive dump trucks.
• DO NOT stand in front of a rim and locking ring Always fasten the welding machine ground (-) lead
when inflating a tire mounted on the machine. to the piece being welded; the grounding clamp
Observers must not be permitted in the area. must be attached as near as possible to the weld
• DO NOT weld or heat the rim assembly with area. Never allow welding current to pass through
the tire mounted on the rim. Resulting gases ball bearings, roller bearings, suspensions, or
inside the tire may ignite, causing explosion hydraulic cylinders. Always avoid laying welding
of the tire and rim. cables over or near the vehicle electrical harnesses.
Welding voltage could be induced into the electrical
harness and cause damage to components.
• Only qualified maintenance personnel who
understand the systems being repaired must • If a truck is to be towed for any reason, use a rigid
attempt repairs. tow bar. Check the truck cab for decals for special
towing precautions. (Refer to TOWING, page 5-41.)
• Many components on the Komatsu truck are large
and heavy. Ensure that lifting equipment - hoists, • Drain, clean and ventilate fuel tanks and/or
slings, chains, lifting eyes - are of adequate capacity hydraulic tanks before making any welding repairs.
to handle the lift.
• Relieve pressure in lines or hoses before making
• DO NOT stand under a suspended load. DO NOT any disconnects.
work under raised body unless body safety cables,
• After adjustments or repairs, replace all shields,
props, or pins are in place to hold the body in up
screens and clamps.
position.
• Working near tires can be dangerous. Use extreme
• DO NOT repair or service the truck while the engine
caution when working around tires.
is running, except when adjustments can only be
made under such conditions. Keep a safe distance • Only a qualified operator or experienced
from moving parts. maintenance personnel who are also qualified in
operation can move the truck under its own power
• When servicing any air conditioning system with
in the repair facility or during road testing after
refrigerant, wear a face shield and cold resistant
repairs are complete.
gloves for protection against freezing. Ensure
930E-4SE 3-21
SPECIAL PRECAUTIONS GENERAL SAFETY
SPECIAL PRECAUTIONS F.25-0000051279 NOTE: If the red lights on the exterior of the control
cabinet and/or the back wall of the center console
Preliminary Procedures Before Welding continue to be illuminated after the above procedure,
Or Performing Maintenance a fault has occurred. Leave all cabinet doors in place;
DO NOT touch the retard grid elements; DO NOT
disconnect any power cables, or use them as hand
• Before opening any cabinets or touching a or foot holds.
grid element or a power cable, the engine
must be shutdown and the red drive system
warning lights must not be illuminated. • Notify your Komatsu service representative,
immediately. Only qualified personnel,
Prior to welding and/or repairing, maintenance specifically trained for servicing the A-C drive
personnel must attempt to notify a Komatsu service system, must perform this service.
representative. Only qualified personnel, specifically
trained for servicing the AC drive system, must 7. Replace all covers and doors and place the
perform this service. GF cutout switch and battery disconnect
switches in their original positions. Reconnect
Engine Shutdown Procedure Before all harnesses prior to starting the truck.
Welding Or Performing Maintenance
Normal operation of the drive system at shutdown will Before Welding On The Machine, Obey
leave the system safe to maintain. However, in the The Following Guidelines:
event of a system failure, performing the following • Before doing any welding on the truck, always
procedure prior to any maintenance activities will disconnect the battery charging alternator lead
ensure that no hazardous voltages are present in the wire.
AC drive system.
• DO NOT weld on retarding grid or control cabinet.
1. Before shutting down the engine, verify there Consult GE for repair guideline.
are no warning messages being displayed on
the instrument panel. • Power cables must be cleated in wood or other
non-ferrous materials. DO NOT repair cable cleats
2. If any drive system warnings are illuminated by encircling the power cables with metal clamps or
on the status indicator light panel, DO NOT hardware. Always inspect power cable insulation
attempt to open any cabinets, disconnect any prior to servicing the cables and prior to returning
cables, or reach inside the retarder grid cabinet the truck to service. Discard cables with broken
without a trained drive system technician insulation.
present - even if engine is off.
• Power cables and wiring harnesses must be
3. If there are no drive system warning messages, protected from weld spatter and heat.
refer to Safe Parking Of The Machine, page 3-9
for parking instructions. • Always fasten the welding machine ground (-) lead
to the piece being welded; the grounding clamp
4. After the engine has been off for at least five must be attached as near as possible to the weld
minutes, inspect the link voltage lights on area.
the exterior of the main control cabinet. If all
lights are off, the retard grids, wheel motors, • Always avoid laying welding cables over or near the
alternator, and related power cables are safe vehicle electrical harnesses. Welding voltage could
to work on. be induced into the electrical harness and cause
damage to components.
5. Locate the GF cut-out switch in the front
access panel on the left side of the main control • Never allow welding current to pass through ball
cabinet. Place the switch in the CUTOUT bearings, roller bearings, suspensions, or hydraulic
position. This will prevent the alternator from cylinders.
re-energizing and creating system voltage until
the switch is returned to the previous position.
6. Ensure both battery disconnect switches are
in the OFF position. Verify that the battery
disconnects are functioning.
3-22 930E-4SE
GENERAL SAFETY SPECIAL PRECAUTIONS
Discharging Control Cabinet Capacitors Because a danger can still exist with the capacitor
charge lights OFF, refer to the shop manual “Manual
Complete all of these steps before accessing any High
Discharge of Capacitors” before servicing the drive
Voltage area:
system. Adhere to the proper procedures for disabling
The control cabinet is equipped with two capacitor the drive system. Only authorized service personnel
charge lights, one on the exterior of the cabinet and are allowed to service the drive system.
one in the interior. The capacitor charge lights, when
OFF, indicate to service personnel that the drive
system is safe to work on. Certain drive system
failures, however, can result in a condition where one
or more capacitors can remain in a charged state
even though the capacitor charge lights are OFF.
930E-4SE 3-23
SPECIAL PRECAUTIONS GENERAL SAFETY
3-24 930E-4SE
WARNING AND CAUTIONS
930E-4SE 4-1
GENERAL INFORMATION WARNING AND CAUTIONS
because of customer options, individual trucks may
GENERAL INFORMATION C.3-0000051318 have plates and decals that are different from those
shown here.
The following pages give an explanation of the
warning, caution, and service instruction plates and The plates and decals must be kept clean and legible.
decals attached to the truck. The plates and decals If any decal or plate becomes illegible or damaged, it
listed here are typical of this Komatsu model, but must be replaced with a new one.
PIN PLATE A.4-0000073410
A product identification plate is located on the frame

in front of the right side front wheel and shows the
truck model number, maximum GVW and Product
Identification Number (PIN).
NOTE: This product identification plate may vary
depending on engine options.
The PIN consists of 19 total characters. The first and
last characters are tamper preventative symbols (*).
The remaining 17 alpha/numeric characters are used
to identify 5 characteristics of the machine. The 5
characteristics are detailed below.
WMC - Character positions 1, 2 and 3 identify the
Worldwide Manufacturer Code (WMC). The WMC
designates the manufacturer of the product. Komatsu
brand products are identified with the letters KMT.
MDS - Character positions 4, 5, 6, 7 and 8 identify the
Machine Descriptor Section (MDS). The MDS code
identifies general information regarding machine
specifications. The MDS is a code for the machine
type and model.
CL - Character position 9 identifies the Check Letter
(CL). The CL is used to verify the accuracy of the
individual PIN.
YDC - Character position 10 identifies the year
designation code which refers to the year the machine
was completed
PC - Character position 11 identifies the plant code
which defines the location of manufacture.
SN - Character positions 12, 13, 14, 15, 16, and 17
identify the Serial Number (SN). The SN is a unique
sequential number.
4-2 930E-4SE
WARNING AND CAUTIONS GRADE SPEED CHART
GRADE SPEED CHART A.2-0000061051
A grade/speed retard chart is located on the left

front post of the operator's cab and provides the
recommended maximum speeds to be used when
descending various grades with a loaded truck.
Always refer to the decal in operator's cab. This
decal may change with optional truck equipment such
as wheel motor drive train ratios, retarder grids, tire
sizes, etc.
MACHINE SAFETY D.16-0000051326
Warning plates are mounted on the frame in front of,

and to the rear, of both front tires. All personnel are
warned that the clearances change when the truck is
steered and could cause serious injury.
930E-4SE 4-3
MACHINE SAFETY WARNING AND CAUTIONS
Warning plates are attached to both the hydraulic tank

and fuel tank to alert technicians not to work on the
truck with the body in the raised position unless the
body-up retention device (cable/sling) is in position.
A caution decal is also attached to the door of the rear

hatch cover to alert personnel that hot exhaust air is
present and may cause injury.
This caution decal is also placed around the retarding
grid cabinet.
This information decal is placed on the outside of the

door panel on the control cabinet wall that faces the
right side of the operator cab.
This decal is located by the emergency ladder on both

sides of the truck.
4-4 930E-4SE
WARNING AND CAUTIONS KEY SWITCH
This decal is located in the cab on the overhead dash

panel. Wireless signals from the truck’s KOMTRAX
Plus system can interfere with other wireless signals
in the area. This interference can cause a malfunction
in a blast zone resulting in an unintended detonation.
Know the locations of blast zones in the area and
keep a safe distance to avoid unintentional blasts.
Operating frequency of KOMTRAX Plus is 148 MHz
to 150 MHz.
KEY SWITCH E.2-0000051325
A warning decal is located below the key switch, to the

right of the steering column on the instrument panel.
The warning stresses the importance of reading the
operator's manual before operation.
OIL FILL AND CHECK C.3-0000051324
A plate on the side of the hydraulic tank furnishes

instructions for filling the hydraulic tank.
Keep the system open to the atmosphere only as
long as absolutely necessary to lessen the chances
of system contamination. Service the tank with clean
Type C-4 hydraulic oil. All oil being put into the
hydraulic tank must be filtered using filters rated at
three microns.
930E-4SE 4-5
HIGH PRESSURES WARNING AND CAUTIONS
A caution decal is attached below the hydraulic tank

oil level sight gauge. Check level with body down,
engine stopped, and key switch OFF. Add oil per filling
instructions, if oil level is below top of sight glass.
A wheel motor oil level decal is attached to the gear

cover on both electric wheel motors. This decal
stresses the fact that the truck must be on a level
surface and parked for 20 minutes prior to checking
the oil level. This is necessary in order to get an
accurate reading.
HIGH PRESSURES F.43-0000051323
A warning plate is mounted on top of the radiator

surge tank cover near the radiator cap. The engine
cooling system is pressurized. Always turn the key
switch OFF and allow the engine to cool before
removing the radiator cap. Unless the pressure
is first released, removing the radiator cap after the
engine has been operating for a time will result in the
hot coolant being expelled from the radiator. Serious
scalding and burning may result.
These danger plates are mounted on the outside of

each frame rail by the steering accumulators and
the brake accumulators. These danger plates alert
technicians to read the warning labels attached to the
side of each of the accumulators (see below) prior to
releasing internal nitrogen pressure or disconnecting
any hydraulic lines or hardware. There are similar
decals mounted on top of each of the accumulators
(both steering and brake) with the same danger
message.
4-6 930E-4SE
WARNING AND CAUTIONS HIGH PRESSURES
Warning decals are applied to the inside of the

brake system cabinet behind the operator cab.
These decals remind servicing technicians to close
the accumulator drain valves after they have been
opened to bleed brake pressure. It further warns not
to over-tighten the drain valves to prevent damage to
the valve seat(s).
This warning plate is located on the inside and outside

of the brake system cabinet doors. This warning plate
alerts the technician to stop the engine, turn the key
switch OFF, and open the drain valves on all three
accumulators to bleed the hydraulic system pressure
before disconnecting a brake line.
This danger plate is attached to all four suspensions.

The plate contains instructions for releasing internal
pressure before disconnecting any hardware. Serious
injury can occur if these directions are not followed.
930E-4SE 4-7
HIGH PRESSURES WARNING AND CAUTIONS
• Any operating fluid, such as hydraulic oil

or brake fluid escaping under pressure, can
have sufficient force to enter a person's body
by penetrating the skin. Serious injury and
possibly death may result if proper medical
treatment by a physician familiar with this
injury is not received immediately.
A warning plate is attached to the hydraulic tank to

inform technicians that high pressure hydraulic oil
is present during operation. When it is necessary
to open the hydraulic system, ensure the engine
is stopped and key switch is OFF to bleed down
hydraulic pressure. There is always a chance of
residual pressure being present. Open fittings slowly
to allow all pressure to bleed off before removing any
connections.
This warning decal is located below the battery

disconnect switches and on the front of the battery
box to warn personnel not to disconnect the batteries
during the first 90 seconds after turning the key switch
off.
Turn the key switch to the OFF position and wait for
the engine to stop. After the engine has stopped, wait
two minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the OFF
position.
The first 90 seconds after the key switch is turned
off is the bleeddown process. Turning the battery
disconnect switches off within 90 seconds could
interrupt the bleeddown process and leave stored
energy in the accumulator. Wait two minutes
after the engine has stopped, then observe for
bleeddown malfunction warning message on the
instrument panel. If warning is being displayed,
notify maintenance immediately. Turning the battery
disconnect switches to the OFF position sooner than
two minutes could mask a problem that was detected
during the bleeddown process.
This decal is placed on both front wheel hubs to warn

about hot oil inside the wheel hubs. Remove the oil
level plug carefully to avoid injury.
4-8 930E-4SE
WARNING AND CAUTIONS BATTERY AND ISOLATION BOX
BATTERY AND ISOLATION

BOX D.43-0000051322
This plate is placed on isolation box cover and the
battery box cover to indicate that the battery system
(24VDC) is a negative (-) ground system.
This decal is located on the battery box cover.

It details the correct procedure for disconnecting
the battery cables from the batteries. Before
disconnecting the battery cables, turn the key switch
to the OFF position and wait for the engine to stop.
After the engine has stopped, wait two minutes, and
if no warning message is displayed, then turn the
battery disconnect switches to the OFF position.
This decal is placed on the cover for the ground

level engine shutdown switch to indicate where
the emergency shutdown control is located. The
shutdown switch is mounted above the isolation box.
This decal is located below the engine shutdown

switch. It is used for emergency shutdown only. Push
the button in to stop the engine.
930E-4SE 4-9
BATTERY AND ISOLATION BOX WARNING AND CAUTIONS
This decal is located on the isolation box. The

isolation box contains the disconnect switches that
can be used to isolate the cranking motor, battery
and propulsion system circuits.
These plates are located above the battery disconnect

switches on the isolation box to indicate the OFF and
ON positions of the switches.
The master switch will disconnect the batteries from
the entire electrical system.
The cranking motor switch will disconnect the power
supply to the two cranking motors. This will prevent
the truck from starting, but will allow for diagnostic
testing of the electrical system if the master switch is
still ON.
Stop the engine and turn the key switch to the OFF
position. After the engine has stopped, wait two
minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the
OFF position. After the key switch is turned OFF,
the interface module remains on, monitoring the
park brake function and the accumulator bleeddown
function. If a failure in either system is detected, an
alarm will sound to notify the operator of a failure in
that system. If the battery disconnect switches are
turned OFF without waiting two minutes, a potential
failure could be masked. Always use the battery
disconnect switches before:
• Storing the machine for more than one month
• Replacing electrical system components
• Performing welding maintenance
• Handling batteries, or starting with jumper cables
• Replacing fuses or fusible links
4-10 930E-4SE
WARNING AND CAUTIONS BATTERY AND ISOLATION BOX
This plate is located above the propel lockout lever on

the isolation box to indicate the OFF and ON positions
of the lever. When this lever is placed in the OFF
position, the truck’s AC electric drive system is locked
out and the truck will not propel. When the lever is
placed in the ON position, the truck’s AC electric drive
system will function and the truck can be driven.
This decal is located above the ladder light switch box

mounted at the base of the diagonal ladder. Rotate
the switch up or down to turn the ladder and deck
lights on or off.
930E-4SE 4-11
HIGH VOLTAGE WARNING AND CAUTIONS
• Sulfuric acid is corrosive and toxic. Use

proper safety gear, goggles, rubber gloves
and rubber apron when handling and
servicing batteries. Get proper medical help
immediately, if required
Attached to the exterior of both battery compartments

is a danger plate. This plate stresses the need
to keep from making any sparks near the battery.
When another battery or 24VDC power source is
used for auxiliary power, all switches must be OFF
prior to making any connections. When connecting
auxiliary power cables, positively maintain correct
polarity. Connect the positive (+) posts together and
then connect the negative (-) lead of the auxiliary
power cable to a good frame ground. DO NOT
connect to the negative posts of the truck battery
or a ground near the battery box. This hookup
completes the circuit but minimizes danger of sparks
near the batteries.
HIGH VOLTAGE E.33-0000051321
A high voltage danger plate is attached to the door of

the rear hatch cover. High voltage may be present!
Only authorized personnel can access this rear
housing.
4-12 930E-4SE
WARNING AND CAUTIONS HIGH VOLTAGE
These warning plates are mounted on all of the AC

drive control housings and cabinets.
High voltage may be present, with or without, the
engine running.
Only authorized personnel can access these
cabinets.
930E-4SE 4-13
HIGH VOLTAGE WARNING AND CAUTIONS
This decal is placed near two different indicator lights:

• On the front of the control box which is mounted on
the right side of the main control cabinet.
• On the outside of the left control cabinet wall that
faces the right side of the operator cab.
NOTE: When any of these indicator lights are on,
high voltage is present throughout the propulsion and
retarding system. Extreme care must be exercised!
This caution decal is placed on the back of the control

cabinet to alert service technicians that this area
contains capacitors and must not be disturbed in any
manner.
4-14 930E-4SE
WARNING AND CAUTIONS WELDING
WELDING E.6-0000051320
This caution decal is on the front of the battery box

to alert servicing technicians that before doing any
welding on the truck, always disconnect the battery
charging alternator lead wire before making any
welding repairs.
Turn the key switch to the OFF position and wait for
the engine to stop. After the engine has stopped, wait
two minutes, and if no warning message is displayed,
then turn the battery disconnect switches to the
OFF position. Then disconnect the battery charging
alternator lead wire.
NOTE: Always fasten the welding machine ground (-)

lead to the piece being welded; grounding clamp must
be attached as near as possible to the weld area.
Never allow welding current to pass through ball

bearings, roller bearings, suspensions, or hydraulic
cylinders. Always avoid laying welding cables over
or near the vehicle electrical harnesses. Welding
voltage could be induced into the electrical harness
and possibly cause damage to components.
930E-4SE 4-15
LIFTING POINTS WARNING AND CAUTIONS
LIFTING POINTS E.39-0000051319
This page illustrates a variety of decals which are

mounted on deck mounted cabinets, housings, and
structures which must be lifted in a specific manner,
and from specific points, in order to safely move or lift
any of these structures.
If any of these decals are damaged or defaced, so that
it is no longer legible, it must be replaced immediately.
NOTE: Maintenance personnel must follow these
lifting instructions.
4-16 930E-4SE
WARNING AND CAUTIONS EMERGENCY DUMPING
EMERGENCY DUMPING E.2-0000051378
A decal plate located on the frame near the left hoist

cylinder provides the operator or technician with the
hook-up procedure for dumping a loaded, disabled
truck. The use of a functional truck for hydraulic power
is required.
Refer to the shop manual for additional instructions for
using this procedure.
930E-4SE 4-17
AUTOMATIC LUBRICATION FILL WARNING AND CAUTIONS
AUTOMATIC LUBRICATION
FILL D.3-0000051377
This decal is located on the automatic lubrication
reservoir informing the technician that the cover
must never be removed for filling purposes as there
is potential for dirt or debris entering the system.
Always fill the grease reservoir through the coupling
provided where the grease passes through a filter
before entering the reservoir.
ROPS/FOPS D.2-0000051375
A plate attached to the right rear corner of the cab

states the Rollover Protective Structure (ROPS) and
Falling Object Protective Structure (FOPS) meet
various SAE performance requirements.
NOTE: DO NOT make modifications to this structure,
or attempt to repair damage without written approval
from Komatsu. Unauthorized repairs will void
certification. DO NOT drill, cut, or weld on the
ROPS/FOPS structure.
TOWING E.20-0000051374
A decal plate is located on the frame near the

hydraulic tank. It provides the operator or technician
with the hydraulic hook-up procedure before towing a
disabled truck, by using a functional truck for hydraulic
power. Refer to the TOWING PROCEDURE, page
5-41 in this manual for additional instructions on
towing.
A decal plate is located near the tow bumper.

It provides the operator or technician with the
instructions for towing an empty truck. Refer to the
TOWING PROCEDURE, page 5-41 in this manual
for additional instructions on towing.
4-18 930E-4SE
WARNING AND CAUTIONS LUBRICATION CHART
LUBRICATION CHART A.2-0000075967
The lubrication chart is mounted on the right hand

side of the radiator grille structure. Refer to the lube
chart in the lubrication and service section later in this
manual for more complete lubrication instructions.
930E-4SE 4-19
LUBRICATION CHART WARNING AND CAUTIONS
4-20 930E-4SE
OPERATING INSTRUCTIONS
930E-4SE 5-1
PREPARING FOR OPERATION OPERATING INSTRUCTIONS
Walk Around Inspection
PREPARING FOR At the beginning of each shift, a careful walk around
OPERATION A.4-0000076167 inspection of the truck must be performed before the
operator attempts engine start-up. A walk around
The safest trucks are those which have been properly inspection is a systematic ground level inspection of
prepared for operation. At the beginning of each shift, the truck and its components to ensure that the truck
a careful check of the truck must be made by the is safe to operate before entering the operator's cab.
operator before starting the engine.
Start at the left front corner of the truck (Figure 5-1
Safety Is Thinking Ahead WALK AROUND INSPECTION, page 5-3), and move
in a counter-clockwise direction. Move front-to-rear,
Prevention is the best safety program. Prevent a across the rear, and continuing forward up the
potential accident by knowing the employer's safety opposite side of the truck to the original starting point.
requirements, all necessary job site regulations, as
well as use and care of the safety equipment on the If these steps are performed in sequence, and are
truck. Only qualified operators or technicians can repeated from the same point and in the same
operate or maintain a Komatsu truck. direction before every shift, many potential problems
may be avoided, or scheduled for maintenance.
Safe practices start before the operator gets to the Unscheduled downtime and loss of production can
equipment! be reduced as a result.
• Wear the proper clothing. Loose fitting clothing, Local work practices may prevent an operator from
unbuttoned sleeves and jackets, jewelry, etc., can performing all tasks suggested here. To the extent
catch on a protrusion and cause a potential hazard. permitted, the operator must follow this or a similar
• Always use the personal safety equipment provided routine.
for the operator such as hard hats, safety shoes,
safety glasses or goggles. There are some
conditions when protective hearing devices must • High voltage may be present on this truck!
also be worn for operator safety. DO NOT open any electrical cabinet doors on
the truck while the engine is operating! Never
• When walking to and from the truck, maintain a safe
climb on any power cables or use power
distance from all machines, even if the operator is
cables for handholds or footholds!
visible.
5-2 930E-4SE
OPERATING INSTRUCTIONS PREPARING FOR OPERATION
1. Operator Cab 10. Brake Accumulators 19. Rear Suspension

2. Auto Lubrication 11. Hoist Filters 20. Rear Axle Hatch
3. Radiator 12. Steering Filter 21. AC Electric Motor
4. Reserve Oil System 13. Fuel Tank 22. Hydraulic Tank
5. Engine 14. Hoist Cylinder 23. Steering Pump
6. Engine Mounted Fuel Filters 15. Rear Axle Housing 24. Hoist Pump
7. Stage 1 Tier 2/4 Fuel Filters, If 16. Wet Disc Brake 25. Steering Accumulators
Applicable 17. Wheel Motor Transmission 26. Alternator
8. Suspension 18. Rear Tires
9. Wet Disc Brake
Figure 5-1 WALK AROUND INSPECTION

1. As you complete the walk around inspection damage. Also visually check for wires cuts,
look for any leaks, worn parts, and
930E-4SE 5-3
short-circuits, or loose terminals. Contact 10. Move behind the front wheel and ensure the
maintenance to repair any issues found. steering cylinder is properly greased and that
the mounting hardware is tight. Ensure all
2. Start at left front of the truck. While performing
suspension attaching hardware is secure and
the walk around inspection, visually inspect
inspect the mounting key area for evidence of
all lights and safety equipment for external
wear. Check that the suspension rod extension
damage from rocks or misuse. Ensure lenses
is correct, and that there are no leaks. Ensure
are clean and unbroken. Make sure that the
the suspension protective boot is in good
battery box covers are in place and secure.
condition. Inspect the hub and brakes for any
3. Inspect auto lube system. Check all grease unusual conditions. Check the entire area for
hoses for signs of damage and inspect each leaks.
lubrication point for a bead of lubricant around
11. Check for damaged or missing latches on
the seal as you walk around the truck. Report
traction alternator inspection covers. Check for
to maintenance if any hoses need to be
any cracks or damage to the traction alternator
replaced (follow autolube checkout procedure
blower.
in the Shop Manual if a hose needs to be
replaced) or if a lubrication point is dry (trouble 12. Inspect the sight glass on hydraulic tank. With
shoot and repair). Refer to AUTOMATIC the engine stopped and the body down, the
LUBRICATION SYSTEM, page 5-85, for hydraulic oil level must be visible in the center
specific details concerning the auto lube of the upper sight glass.
system.
13. If equipped, verify all hydraulic tank shut off
4. Visually check the intake air cleaner Vacuator® valves are locked in their fully open positions.
valve for any damage. If damage is found
14. Move around the hydraulic tank and in front of
contact maintenance. Maintenance should
the rear dual tires. Inspect hoist cylinder for
refer to INTAKE AIR CLEANER SERVICE,
any damage and leaks. Inspect both upper
page 7-7.
and lower hoist cylinder pins for integrity and
5. Move in front of the left front tire. Inspect the for proper greasing.
hub and brake assemblies for leaks and any
15. Look under the lower edge of the chassis to
abnormal conditions.
ensure the flexible duct that carries the air from
6. Visually inspect AC and fan belt for obvious the blower to the final drive housing is in good
signs of wear. Check the security and condition condition with no holes or breakage. Also,
of the AC and fan guards. Check for engine look up at the main hydraulic pumps to see
leaks and abnormal noises and vibration. that there is no leakage or any other unusual
Inspect air intake tubes, turbos, and exhaust condition with the pumps or the pump drive
tube for leaks and integrity. Visually check for shafts.
any loose hardware.
16. Move around the left side dual tires. Use mirror,
7. Check that all suspension attaching hardware if needed, to visually look between the dual
is secure and inspect the mounting key area for tires to ensure that all wheel nuts/studs are
evidence of wear. Check that the suspension in place. Inspect the wheel for any oil that
rod extension is correct, and that there are would indicate brake leakage or wheel motor
no leaks. Ensure the suspension protective leakage. Contact maintenance to tighten wheel
boot is in good condition. Inspect the hub and nuts/studs or repair any other issues found.
brakes for any unusual conditions. Check the
17. Check the dual tires for cuts, damage or
entire area for leaks.
bubbles. Check for evidence of incorrect tire
8. Inspect the anchor end of the steering cylinder inflation. If the truck has been operating on a
for proper greasing and all parts are secure. flat tire, the tire must be cool before moving
the truck inside a building. Check for any rocks
9. Move outside of the front wheel. Ensure that
that might be lodged between the dual tires.
all of the mounting nuts/studs are in place and
tight. Check the tires for cuts, damage, or 18. Inspect the left rear suspension for damage
bubbles. Check for evidence of incorrect tire and for correct rod extension. Check for leaks.
inflation. Visually inspect for damaged, loose, Ensure that the covers over the chrome piston
or missing wheel mounting nuts and studs. rod are in good condition. Inspect for proper
greasing.
5-4 930E-4SE
OPERATING INSTRUCTIONS PREPARING FOR OPERATION
19. Open the rear hatch cover. Inspect for leaks 29. Visually check the intake air cleaner Vacuator®
around wheel motor mounting to rear housing, valve for any damage. If damage is found
and also brake hoses and fittings. Close and contact maintenance. Maintenance should
latch hatch. refer to INTAKE AIR CLEANER SERVICE,
page 7-7.
20. While standing in front of the rear hatch, look
up to see that rear lights are in good condition, 30. While in front of the radiator, inspect for any
along with the back-up horns. Look up at the debris in the radiator and remove. Check for
anti-sway bar to see that it is getting proper any coolant leaks. Inspect headlights and fog
greasing. Also look at both body hinge pins lights.
for greasing and any abnormal condition.
31. Before climbing the ladder to first level, ensure
Check the hoist limit switch and clear any
that the ground level engine shutdown switch
mud/debris. Check integrity and condition of
is ON. If equipped, inspect the fire control
the body-up limit switch. Remove any mud/dirt
actuator. Ensure that the safety pin and the
accumulation from the switch.
plastic tie that prevents accidental actuation
21. Perform the same inspection on the right rear are in place and in good condition. Ensure that
suspension as done on the left. the battery disconnect switches are activated.
Ensure the isolation and lockout switches are
22. Move in behind the right dual tires. Check the
on (closed).
dual tires for cuts, damage or bubbles. Check
for evidence of incorrect tire inflation. If the 32. Always use handrails and the ladder when
truck has been operating on a flat tire, the tire mounting or dismounting the truck. Clean the
must be cool before moving the truck inside a ladder and steps and hand rails of any foreign
building. Check for any rocks that might be material, such as ice, snow, oil or mud.
lodged between the dual tires.
33. Use the stairs and handrails while climbing
23. Ensure that all wheel nuts/studs are in place from the first level to the cab deck.
and tight. Inspect the wheel for any oil that
34. If equipped with a retractable ladder system:
would indicate brake leakage or wheel motor
leakage. Contact maintenance to tighten wheel a. Visually inspect the ladder for mechanical
nuts/studs or repair any other issues found. damage. If movement is impaired in any
way, the assembly must be repaired.
24. Move in front of the right dual tires and inspect
hoist cylinder in the same manner as the left b. Visually inspect for cleanliness. Ensure the
side. ladder is dry and free from grease and oil.
25. Move around the fuel tank. Inspect the c. Ensure correct oil level is maintained in the
mounting hardware for the fuel tank at the reservoir.
upper saddles and at the lower back side of
d. Raise and lower the ladder. Check
the tank. Check the hoist filters for leaks.
for loose parts or any adverse noise
26. Move in behind the front of the right front conditions.
wheel, check the hub and brakes for leaks
e. Ensure the movement alarm and both UP
and any unusual condition. Inspect the
and DOWN LEDs operate correctly.
steering cylinder for secureness and for proper
greasing. Inspect the engine compartment for f. Check for any change in equipment
any leaks and unusual conditions. Inspect the appearance, especially that which will
fan guard and belts. Check for any rags or affect ladder system stability.
debris behind the radiator.
27. With the engine stopped, check the engine oil
level. To obtain an accurate measurement, • If the engine has been running, allow the
remove the dipstick and wipe it off. Then coolant to cool before removing the fill cap
reinsert the dipstick and remove it again to or draining the radiator. Serious burns may
check the oil level. Use the service light if result if skin comes in contact with hot
necessary. coolant.
28. If the truck is equipped with an engine oil

35. Use the coolant level sight gauge to check the
reserve tank, check that the oil level is visible
coolant level in the radiator. If it is necessary
in the upper sight glass.
930E-4SE 5-5
to remove the radiator cap, ensure that the 40. Stow personal gear in the cab in a manner that
engine is off, then relieve the coolant pressure does not interfere with truck operation. Dirt
by slowly removing the radiator cap. or trash buildup, specifically in the operator's
cab, must be cleaned. DO NOT carry tools or
36. Inspect the covers over the retarding grids and
supplies in the cab of the truck or on the decks.
ensure they are secure. Inspect the main air
inlet to ensure it is clear. Ensure all cabinet 41. Adjust the seat and the steering wheel for use.
door latches are secure.
42. Read and understand the description of all
37. Move to the back of the cab. Open the doors operator controls. Become familiar with
to the brake cabinet and inspect for leaks. all control locations and functions before
operating the truck.
38. Inspect the air inlet of the alternator to ensure
that the grill is properly positioned. Dispose of 43. If equipped, raise the retractable ladder using
debris around the inlet. Inspect the canopy for the in cab control panel.
holes or punctures that may allow debris to fall
44. See PRE-SHIFT BRAKE TEST, page 5-11 to
into this area and repair if necessary.
perform the pre-shift brake test.
39. Clean the cab windows and mirrors. Clean out
the cab floor as necessary. Ensure steering
wheel, controls and pedals are free of any oil,
grease or mud.
5-6 930E-4SE
OPERATING INSTRUCTIONS RETRACTABLE LADDER SYSTEM (If Equipped)
RETRACTABLE LADDER SYSTEM 9. Check to ensure no personnel are on or in the

(If Equipped) E.28-0000051316 immediate vicinity of the ladder while it is in
motion.
General Information
10. The ladder must be kept clean and free of
moisture, grease and oil.
11. When in the truck’s cab, always use the in-cab
control panel to raise the ladder.
12. Report defects to maintenance personnel
immediately.
Ladder System Description

The RLS is an electro-hydraulic ladder powered by the
truck’s 24VDC electrical system. The RLS provides a
safe means to mount and dismount the truck under
normal and emergency conditions. The RLS consists
of two main control components, the in-cab control
panel and the power pack that operates the ladder.
• The in-cab control panel is a microprocessor
that controls, monitors, stores and reports ladder
system operational data.
• The electro-hydraulic power pack is in a ground
level stainless steel cabinet. It houses the main
control hydraulics and electrical components that
lower and raise the ladder.
The RLS also contains wiring harnesses, hydraulic
hoses and an emergency down valve.
Figure 5-2 RETRACTABLE LADDER SYSTEM
The following safety procedures, at a minimum, must Ladder System Operation
be followed to ensure safe operation and use of the During normal operation, a person can lower or raise
Retractable Ladder System (RLS). the RLS by using the following components:
1. DO NOT run or jump on the ladder. • In-cab control panel
2. DO NOT overload the ladder. Use the ladder • Emergency down valve
one person at a time.
NOTE: The master disconnect switch located in the
3. Hold onto the handrail when using the ladder. isolation box and the isolation switch in the power pack
4. Face the ladder when ascending or must both be in the ON position for the RLS to operate.
descending. As an added safety measure, the RLS uses a parking
5. DO NOT attempt to ride on the ladder while it brake interlock that requires the parking brake to be
is being raised or lowered or while the truck is set before the ladder can be operated under normal
in motion. conditions. The RLS will automatically raise the ladder
if the operator moves the directional control lever out
6. Visually check the ladder before use to ensure of PARK and fails to press the [UP] button on the
the unit has not been damaged. in-cab control panel before attempting to drive the
7. Ensure the ladder is in the fully down position truck.
before boarding.
8. Keep hands and fingers away from pinch points
while the ladder is in motion.
930E-4SE 5-7
RETRACTABLE LADDER SYSTEM (If Equipped) OPERATING INSTRUCTIONS
In-Cab Control Panel If the IN CAB LOCKOUT message is displayed on

the control panel screen, then the RLS can only be
operated from the ground level control box mounted
• When in the operator’s cab, always use the next to the battery isolation box. All other control panel
[UP] button on the control panel to raise functionality is still available including fault indication
the ladder instead of moving the directional and audible alarms.
control lever out of PARK. The automatic
Digital Display Screen
operation of the ladder when the parking
brake is released is an emergency feature In-cab control panel display screen (1, Figure 5-3
only. DO NOT move the directional control IN-CAB CONTROL PANEL, page 5-8) provides the
lever out of PARK to raise the ladder as part user with system status, error/fault messages, and
of normal operation. a visual indicator of the ladder’s position (lowered,
raised, and in motion).
Command Buttons
[LEFT] button (2) is for scrolling left when entering a
password.
[RIGHT] button (3) is for scrolling right when entering
a password.
[ENTER] button (4) is a multi-function button used
for ladder system alarm acknowledgement and menu
access when in Display Mode. This button is also
used to confirm or accept changes shown on the
display screen. Press this button to confirm or accept
changes listed on the display screen.
[EXIT] button (7) is a multi-function button used for
1. Display Screen 6. 15–Pin Harness Plug ladder system alarm acknowledgement and menu
2. [LEFT] Button 7. [EXIT] Button access when in Display Mode. This button is also
3. [RIGHT] Button 8. [DOWN] Button used to exit from the menu screens. Press this button
4. [ENTER] Button 9. [UP] Button to exit from menu screens.
5. USB Port [DOWN] button (8) is a dual function control that is
used to lower the ladder during normal operation and
Figure 5-3 IN-CAB CONTROL PANEL
scroll through the menu displays. Pressing this button
The in-cab control panel is located on the left side of and holding it briefly will cause the ladder to lower.
the dash and contains a microprocessor that controls, Pressing and releasing this button one time will scroll
displays, monitors, stores, and reports ladder system down one line of menu display, and holding it will result
operational data. The in-cab control panel provides in continuous menu scrolling.
real time position of the ladder to the operator.
[UP] button (9) is a dual function control that is used
The in-cab control panel features a digital display to raise the ladder during normal operation and scroll
screen, command buttons ([UP], [DOWN], [ENTER], through the menu displays. Pressing this button
[EXIT], [LEFT], [RIGHT]) for operating the ladder and and holding it briefly will cause the ladder to raise.
navigating through the various menu display screens, Pressing and releasing this button one time will scroll
a USB key port and RS 232 port for downloading up one line of menu display, and holding it will result
ladder system operational data to a laptop computer in continuous menu scrolling.
for troubleshooting. Refer to Figure 5-3 IN-CAB
CONTROL PANEL, page 5-8.
While the ladder is in motion, the direction (up or
down) can be changed by pressing the opposite
direction ([UP] or [DOWN]) button on the control
panel.
5-8 930E-4SE
OPERATING INSTRUCTIONS RETRACTABLE LADDER SYSTEM (If Equipped)
Raising the Ladder The RLS uses a limit switch to monitor ladder travel
to the UP position. If the ladder fails to strike the limit
The ladder will typically be in the lowered position on a switch or the limit switch fails to close, a fault alarm
stationary truck. The in-cab control panel will indicate will activate after a short delay and the in-cab control
that the access is DOWN, as shown here: panel will display this message, as shown here:
To raise the ladder, press and hold (temporarily) NOTE: The fault alarm must be acknowledged by
the [UP] button located on the in-cab control panel. pressing the [EXIT] or [ENTER] buttons on the control
The illustrated ladder on the screen will animate and panel. Once the alarm has been acknowledged,
begin to rise to the UP position and the UP arrow (on the fault message will be replaced by a FAULT IN
the control panel button) will flash. When the ladder SYSTEM message. A defective limit switch will
is completely raised, the [UP] button will remain prevent normal RLS operation and must be corrected
illuminated continuously. immediately.
When the ladder has reached its raised travel position Lowering the Ladder
and strikes the limit switch, the control panel will
indicate that the access is UP, as shown here: NOTE: The directional control lever must be in PARK
before the ladder can be lowered.
To lower the ladder, press and hold (temporarily) the
[DOWN] button located on the in-cab control panel.
The illustrated ladder on the screen will animate and
begin to lower to the DOWN position and the [DOWN]
button will flash.
When the ladder has reached its lowered travel
position, the control panel will indicate that the access
is DOWN, as shown here:
The RLS power pack will continue to operate for

three more seconds to charge hydraulic accumulator.
During this time, the UP arrow will continue to flash
until the cycle is complete.
When the ladder is completely lowered, the [DOWN]

button will remain illuminated continuously.
930E-4SE 5-9
RETRACTABLE LADDER SYSTEM (If Equipped) OPERATING INSTRUCTIONS
Ground Level Control Box Emergency Down Valve

Ground level control box (1, Figure GROUND LEVEL
CONTROL BOX) is located next to the battery
isolation box and contains toggle switch (2) that
lowers and raises the ladder.
NOTE: The parking brake must be applied before the
ladder can be lowered. If toggle switch (2) is held
in either position for more than ten seconds, a fault
will be activated and will need to be acknowledged by
pressing either the [EXIT] or [ENTER] buttons located
on the in-cab control panel.
Raising the Ladder
To raise the ladder, push toggle switch (2) to the
LADDER UP position and release. Ladder operation
via this switch is the same as using the in-cab control
panel. Any ladder movement will be shown on the
in-cab control panel.
Lowering the Ladder
To lower the ladder, push toggle switch (2) to the
LADDER DOWN position and release. Ladder
operation via this switch is the same as using the
in-cab control panel. Any ladder movement will be
shown on the in-cab control panel.
1. Emergency Down Valve

2. Grille
Figure 5-4 EMERGENCY DOWN VALVE

In an emergency, the RLS ladder can be lowered
by using the emergency down valve (1, Figure 5-4
EMERGENCY DOWN VALVE, page 5-10) mounted
on the frame above the left hand side headlight
assembly. The emergency down valve relieves ladder
system hydraulic pressure and allows the ladder to
smoothly lower to the ground.
To lower the ladder, rotate the handle on the
emergency down valve clockwise. The ladder will
lower smoothly until it reaches the ground.
To reset the ladder, rotate the handle
counterclockwise to its original position and, with
power restored to the power pack, press the [UP]
button to raise the ladder.
NOTE: The handle on the emergency down valve
must be in the original position before re-activating the
ladder.
5-10 930E-4SE
OPERATING INSTRUCTIONS PRE-SHIFT BRAKE TEST
PRE-SHIFT BRAKE TEST B.13-0000051681 drive system will detect the position of the directional
control lever, and will prepare for the appropriate test.
NOTE: Komatsu recommends that operators perform The operator will then press the brake test switch.
static brake tests to verify that the braking systems
are adequate at the beginning of each shift before If the brake check light is illuminated solid after
operating the truck. pressing the brake test switch, the system is in brake
test mode and is ready for the chosen test to be
The static brake test allows the operator to check initiated by the operator. After testing, the operator
the service brake, parking brake and the dynamic will then determine if the truck passed the brake tests,
retarder. The purpose of these tests is to verify the and if it is safe for operation.
functionality of the service brake, parking brake and
retarder systems at the time they are tested. If the brake check light does not illuminate
immediately after pressing the brake test switch, there
After performing each test, it is the operator’s is most likely a problem with the setup. Refer to the
responsibility to determine if the truck passed each setup conditions and take action to prepare the truck
test and if the truck is safe for operation. for a brake test.
The order of performing the brake tests, (service If there is a problem with the truck setup, the DID panel
brake, parking brake or retard system) does not will display the problem.
matter. Each brake test is a separate test, where one
brake system or all three can be tested at any time. For example if the engine is off:
If an operator has questions during brake testing, refer • ERROR: Entering Brake Test, Engine Not Running
to the drive system Diagnostic Information Display
If the Truck is loaded:
(DID) panel, located on the back wall of the cab for
guidance. • ERROR Entering Brake Test, Truck is Not Empty
If all of the conditions are correct, except the brakes
• If the truck fails any brake test, notify are not set correctly, an error message will be
maintenance personnel immediately. Do not displayed. For example, if the service brake and
resume operation unless the truck passes all parking brake are both applied together:
brake tests. • ERROR Entering Brake Test, Set Brakes for Test
Table 5-1 BRAKE TEST SETTINGS

Operation Wheel Service Directional
The static brake test Test
Brake Brake Control
utilizes a momentary Type
switch and a check light Lock Pedal Lever
located on the dash Service Fully
Off Neutral
panel. Brake Applied
Parking
Off Released Park
Brake
The brake test switch is used to initiate a brake test.
Press on the momentary switch to enter the brake test Retard
Off Released Park
mode. If certain conditions are met, the operator can Test
enter a brake test sequence.
NOTE: The drive system will not enter any brake test
The amber light in the top of the switch is used to if the truck is loaded.
indicate when the truck is in brake test mode, and is
referred to as the brake check light. When illuminated, Before performing any brake test, the following
a brake test is ready. When flashing, the brake test conditions must be met:
is at the validation point, or the retard system test is
• Dump body is empty.
finished.
• Truck located outside on a flat area, where truck
The operator can choose which brake test to perform, movement is allowed.
and will set the truck controls based on the settings in
Table 5-1 BRAKE TEST SETTINGS, page 5-11. The
930E-4SE 5-11
PRE-SHIFT BRAKE TEST OPERATING INSTRUCTIONS
“Service Brake Test ACTIVE, Check Truck

Movement when Light Flashes”
• Ensure the area around the truck is free of
personnel and objects. Some truck movement NOTE: The drive system can only detect if the service
could occur during brake testing. brakes are applied. It can not detect the percentage
• The drive system is unable to determine if the of application. It is up to the operator to press hard
truck is on a hill or in a parking ditch. Testing enough on the service brake pedal to achieve a full
during these conditions will affect test results. brake application.
6. Once torque has reached the limit for the
Before performing any brake test, the truck must be in service brake test, the brake check light will
the following state: begin to flash. This is the indication for the
operator to make a determination as to the
• Engine at (low idle) status of the service brake system.
• Drive system ready (Ready Mode)
• If the truck did not move, the service brake
• Dump body down system passed the test.
• No drive system warning messages displayed • If the truck moved during the test, the service
brake system failed the test.
• Can not be in LIMP mode.
7. Release the accelerator pedal and the torque
• Zero ground speed
will be reduced, the test will stop and the brake
check light will turn off.
Service Brake Test
8. Place the directional control lever in the PARK
position. Release the service brake pedal.
• If the truck fails any brake test, notify 9. If the truck failed the service brake test, notify
maintenance personnel immediately. Do not maintenance personnel immediately.
resume operation unless the truck passes all
brake tests. NOTE: If the operator partially or fully releases
the accelerator pedal during the test, torque will
be reduced and the brake check light will go back
To perform the service brake test, obey the following
on solid when torque falls below the test set point.
guidelines:
The operator can re-apply the accelerator pedal to
1. Firmly depress the service brake pedal. increase torque and the brake check light will again
flash when the torque is at the test limit.
2. Place the directional control lever in the
NEUTRAL position. Ensure the wheel brake If the test exits abnormally, or if the operator simply
lock switch is OFF. does not press the accelerator pedal far enough to
achieve the torque level for the service brake test, the
3. Press the brake test switch and wait for the
DID panel will display:
brake check light to be on solid.
“Brake Test ERROR, Test did NOT complete”
4. Fully depress the service brake pedal. Ensure
full brake application is reached. Failure to Parking Brake Test
reach full brake application will affect the
service brake test results.
The DID panel will display: • If the truck fails any brake test, notify
maintenance personnel immediately. Do not
“Service Brake Test READY, Press Accel Pedal resume operation unless the truck passes all
to Start” brake tests.
5. With the service brake pedal still fully applied,
fully depress the accelerator pedal. The drive To perform the parking brake test, obey the following
system controller will enter propel mode and guidelines:
generate torque up to the service brake limit.
Maintain full service brake pressure during the 1. Place the directional control lever in the PARK
test. position.
The DID panel will display: 2. Press the brake test switch and wait for the
5-12 930E-4SE
OPERATING INSTRUCTIONS PRE-SHIFT BRAKE TEST
The DID panel will display: 3. Fully depress the retard pedal. The drive
system controller will ramp up the engine
“Parking Brake or Retard Test READY, Press
speed, close RP1, close RP2, close RP3
Accelerator or Retard Pedal to Start”
(if present), turn on the choppers, and test
3. Fully depress the accelerator pedal. The drive the retarding system. The system will verify
system controller will enter propel mode and current flow through each grid leg and the grid
generate torque up to the park brake limit. blower motor.
The DID panel will display: 4. The DID panel will display the current status of
the test.
“Park Brake Test ACTIVE, Check Truck
Movement when Light Flashes” “Retard System Test ACTIVE, RP1, RP2,
RP3, CHOP” (Elements are added as the test
4. Once the torque has reached the limit for the
progresses.)
parking brake test, the brake check light will
begin to flash. This is the indication for the Upon successful completion of the test, the
operator to make a determination as to the light will flash for 10 seconds indicating a
status of the parking brake system. successful test. The DID panel will display:
• If the truck did not move, the park brake “Retard System Test PASSED”
system passed the test. “Retard System Test FAILED or Incomplete”
• If the truck moved during the test, the
NOTE: If the brake check light never flashes, but turns
park brake test has failed. Release the
off, the test has failed.
accelerator pedal. If the truck starts to roll,
apply the service brakes to hold the truck 5. When the operator releases the retard pedal,
stationary. Notify maintenance personnel the test will stop and the brake check light will
immediately. turn off.
5. When the operator releases the accelerator 6. If the retard system failed the test, notify
pedal, torque will be reduced. The test will maintenance personnel immediately. Do not
stop and the brake check light will turn off. resume operation unless the truck passes all
brake tests.
Retard System Test
Brake Test Exit Criteria
Conditions which may interrupt a brake test, including
• If the truck fails any brake test, notify
the following:
maintenance personnel immediately. Do not
resume operation unless the truck passes all • Any of the setup conditions becoming false
brake tests.
• Drive system fault which restricts the LINK or Propel
mode
To perform the retard system test, obey the following
guidelines: • Truck Speed greater than 3.2 kph (2.0 mph)
• Drive system at torque level for more than 30
1. Place the directional control lever in the PARK
seconds
position.
• Brake test requested, but not initiated by the
2. Press the brake test switch and wait for the
operator within 60 seconds after pressing the brake
test switch
The DID panel will display:
“Parking Brake or Retard Test READY, Press
Accel or Retard Pedal to Start”
930E-4SE 5-13
TRUCK OPERATION OPERATING INSTRUCTIONS
TRUCK OPERATION D.1-0000051314 NOTE: This truck is equipped with an engine prelube
system. With this feature, a noticeable time delay
ENGINE START-UP SAFETY C.91-0000051311 may occur (while the engine lube oil passages are
being filled and pressurized) before engine cranking
will begin.
• Never attempt to start the engine by shorting
across the cranking motor terminals. This 8. After the engine has started, place the rest
may cause a fire, or serious injury or death to switch in the OFF position to enable the drive
anyone in the machine’s path. system.
NOTE: The electric cranking motors have a 30
NOTE: Start the engine from the operator’s seat only. second time limit. If the 30 second limit is reached,
cranking will be prohibited for two minutes. After two
Always obey the following guidelines when starting the minutes, cranking will be allowed. If the 30 second
engine: limit is reached seven consecutive times, the key
1. Ensure all personnel are clear of the truck switch must be turned to the OFF position. This will
before starting the engine. Always sound allow the interface module to power down and reset,
the horn as a warning before actuating any which requires seven minutes to complete. A warning
operational controls. If the truck is in an will appear in the digital display if the 30 second time
enclosure, ensure there is adequate ventilation limit or seven attempts reached.
before start-up. Exhaust fumes are dangerous! NOTE: In cold ambient conditions and when the
2. The directional control lever must be in the engine is cold, the engine rpm will not increase above
PARK position before starting. low idle speed until the engine controller determines
it is safe to do so. This time delay will vary from 30
NOTE: The park brake will always be applied seconds to 11 minutes which allows the coolant and
whenever the directional control lever is in the park engine oil to warm up.
position.
After Engine Has Started
3. The retractable ladder, if equipped, must be in
the UP position before starting. 1. Become thoroughly familiar with steering and
emergency controls. After the engine has
4. Move the rest switch to the ON position to put been started, DO NOT accelerate engine
the drive system in rest mode of operation. speed or drive truck until low pressure and
Refer to the INSTRUMENT PANEL, page 6-18 warning systems are normal, and the coolant
section for information about the rest switch. temperature is at least 71° C (160° F).
5. If the truck is equipped with auxiliary cold 2. With the service brakes applied, move the
weather heater system(s), DO NOT attempt directional control to the NEUTRAL position,
to start the engine while the heaters are in then apply the wheel brake lock. Release
operation. Damage to coolant heaters will the service brakes. Test the truck steering in
result! extreme right and left directions. If the steering
6. The key switch is a four position (ACC, OFF, system is not operating properly, shut the
RUN, START) switch. The ACC position is not engine off immediately. Determine the steering
currently used. When the switch is rotated one system problem and have it repaired before
position clockwise, it is in the RUN position resuming operation.
and all electrical circuits (except START) are 3. Operate each of the truck's brake circuits
activated. Turn key switch to the RUN (not at least twice prior to operating and moving
START) position. Verify that all indicator lights the truck. These circuits include individual
and gauges are functioning. activation from the operator's cab of the service
7. With the directional control lever in PARK, brake, parking brake, and wheel brake lock.
and after the message “System Initializing” With the engine running and with the hydraulic
is displayed on the dash, rotate the key circuit fully charged, activate each circuit
switch fully clockwise to the START position, individually.
and hold this position until the engine starts To operate each brake circuit, perform the
(see NOTE below). The START position is following:
spring-loaded and will return to RUN when the
key is released. a. Park the truck on level ground.
5-14 930E-4SE
OPERATING INSTRUCTIONS TRUCK OPERATION
b. To operate the park brake, place the

directional control lever in the PARK
position. • The truck is equipped with traction control
(often referred to as "slip/slide" control). If
c. To operate the wheel brake lock, apply this function becomes inoperative, operating
the service brake and move directional the truck with stalled or free spinning wheel
control lever to neutral. Release service motors may cause serious damage to wheel
brakes, and apply wheel brake lock. Turn motors! If the truck does not begin to move
the wheel brake lock OFF, then back ON within ten seconds after depressing the
again. throttle pedal (directional control lever in
d. Release wheel brake lock and apply a drive position), release the throttle pedal
service brakes several times. and allow wheels to regain traction before
accelerating again.
e. With service brakes applied, move
directional control lever to PARK.
• Always look to the rear before reversing the truck.
4. If any application or release of any brake circuit Watch for and obey the ground spotter's hand
appears sluggish or improper, or if warning signals before traveling in reverse. Sound the horn
alarms are activated on application or release, (three blasts). The spotter will have a clear view of
shut the engine off and notify maintenance the total area at the rear of the truck.
personnel. DO NOT operate the truck until the
brake circuit in question is fully operational. • Operate the truck only while properly seated with
seat belt fastened. Keep hands and feet inside the
5. Check the gauges, check for warning cab compartment while the truck is in operation.
messages and instruments before moving
the truck to ensure proper system operation • Check gauges and instruments frequently during
and proper instrument functioning. Pay operation for proper readings.
special attention to braking and steering circuit • Observe all regulations pertaining to the job site's
hydraulic warning messages. If any warning traffic patterns. Be alert to any unusual traffic
messages are displayed, shut off the engine patterns. Obey the spotter's signals.
immediately and determine the cause.
• Match the truck speed to haul road conditions and
6. Ensure the headlights, work lights and tail lights slow the truck in congested areas. Keep a firm grip
are in proper working order. Good visibility may on the steering wheel at all times.
prevent an accident. Check operation of the
windshield wipers. • DO NOT allow the engine to run at idle for extended
periods of time.
7. After engine startup, allow the reserve engine
oil pumping unit to run for 5 minutes before • Check the brake lock performance periodically to
operating the truck. Check the operation of the ensure safe loading and dumping.
pumping unit. Refer to LED Monitor Light, page
5-94 in Reserve Engine Oil System.
• DO NOT use the brake lock for parking.
MACHINE OPERATION SAFETY When the engine is turned off, hydraulic
pressure will bleed down, allowing the brakes
PRECAUTIONS H.27-0000051309
to release!
After the truck engine is started and all systems are
functioning properly, the operator must follow all local • Proceed slowly on rough terrain to avoid deep ruts
safety rules to ensure safe machine operation. or large obstacles. Avoid traveling close to soft
edges and near the edges of a fill area.
• If the red warning light is illuminated and • Truck operation requires a concentrated effort by
any warning messages are displayed, or if the driver. Avoid distractions of any kind while
any gauge reads in the red area during truck operating the truck.
operation, a malfunction is indicated. Stop the
truck as soon as safety permits, and stop the
engine. Have the problem corrected before
resuming truck operation.
930E-4SE 5-15
Machine Operation On The Haul Road • When operating the truck in darkness, or when
visibility is poor, DO NOT move the truck unless
While traveling on the haul road, obey the following
all headlights, clearance lights, and tail lights are
guidelines:
on. DO NOT back the truck if the back-up alarm or
• Always stay alert. If unfamiliar with the haul road, lights are inoperative. Always dim the headlights
drive with extreme caution. Cab doors must remain when approaching oncoming vehicles.
closed at all times if the truck is in motion or • Check the tires for proper inflation during each
unattended. shift. If the truck has been operating on a flat or
• Obey all road signs. Keep the truck under control under-inflated tire, the truck must remain outside of
at all times. Govern truck speed by the road any buildings until the tire cools.
conditions, weather and visibility. Report poor
haul road conditions immediately. Muddy or icy Starting On A Grade With A Loaded Truck
roads, pot holes or other obstructions can present Initial propulsion with a loaded truck should begin from
hazards. a level surface whenever possible. If the truck must be
• Initial propulsion with a loaded truck must begin started on a hill or grade, use the following procedure:
from a level surface whenever possible. At times,
1. Apply the wheel brake lock.
starting on a hill or grade cannot be avoided. Refer
to Starting On A Grade With A Loaded Truck, page 2. Release the service brake pedal. Do not use
5-16 later in this chapter. the retarder to hold the truck on the grade.
• Before traveling in reverse, give a back-up signal of 3. With the brake lock applied, move the
three blasts with the horn and wait until the area is directional control lever to a drive position
clear. Before starting forward, signal with two blasts (FORWARD or REVERSE) and increase the
with the horn and wait until the area is clear. These engine RPM with the throttle pedal.
signals must be given each time the truck is moved
4. As the engine RPM approaches maximum
forward or backward.
RPM, and the operator senses the propulsion
• Use extreme caution when approaching a haul effort working against the wheel brake lock,
road intersection. Maintain a safe distance from release the brake lock and let truck movement
oncoming vehicles. start. As the truck speed increases above
5-8 kph (3-5 mph), the drive system controller
• Maintain a safe distance when following another
(DSC) will drop the propulsion if the retarder is
vehicle. Never approach another vehicle from the
applied.
rear, in the same lane, closer than 15 m (50 ft).
When driving on a down grade, this distance must NOTE: Releasing and reapplying dynamic retarding
not be less than 30 m (100 ft). during a hill start will result in loss of propulsion.
• If the warning light on the dash panel illuminates and
Retarding On A Grade
a warning message is displayed on the dash panel
during operation, steer the truck immediately to a The grade/speed retard chart provides the
safe area away from other traffic, if possible, and recommended maximum retarding limits for
stop the truck. descending grades with a fully loaded truck.
• DO NOT stop or park on a haul road unless The decal in the truck may differ from the decal shown
unavoidable. If the truck must be stopped on a haul here due to optional truck equipment such as wheel
road, park in a safe place, move the directional motor drive train ratios, retarder grids, tire sizes, etc.
control lever to PARK, and shut the engine off Always refer to the decal in the operator's cab and
before leaving the cab. Block the wheels securely follow the recommendations for truck operation.
and notify maintenance personnel for assistance.
The operator must reference this chart before
• While driving on a slope, maintain a speed that will descending any grade with a loaded truck. Proper
ensure safe driving and provide effective retarding use of dynamic retarding will maintain a safe speed.
under all conditions. Refer to Dynamic Retarding,
page 6-5. Refer to the grade/speed retard chart in Two speed lists are provided, one for continuous
the operator's cab to determine maximum safe truck retarding, and the second for short term retarding.
speeds for descending various grades with a loaded Both lists are matched to the truck at maximum Gross
truck. Vehicle Weight (GVW). The two ratings are guidelines
for proper usage of the retard function on downhill
grades.
5-16 930E-4SE
The “continuous” numbers on the chart indicate the

combination of speeds and grades which the vehicle
can safely negotiate for unlimited time or distance
during retarding.
DO NOT exceed these recommended maximum
speeds when descending grades with a loaded truck.
Passing
• DO NOT pass another truck on a hill or on a blind
curve.
• Before passing, ensure the road ahead is clear. If a
disabled truck is blocking your lane, slow down and
pass with extreme caution.
• Use only the areas designated for passing.
1. Grade Speed Chart Loading

Figure 5-5 GRADE SPEED CHART LOCATION To load the truck, perform the following:
The “short term” numbers listed on the chart indicate 1. Approach the loading area with caution.
the combination of speeds and grades which the Remain at a safe distance while the truck
vehicle can safely negotiate for a short duration ahead is being loaded.
before system components reach the maximum 2. DO NOT drive over unprotected power cables.
allowable temperature during retarding. These
speeds are faster than the “continuous” values, 3. When approaching or leaving a loading area,
reflecting the thermal capacity of various system watch for other vehicles and for personnel
components. System components can accept heating working in the area.
at a higher-than-continuous rate for a short period of 4. When pulling in under a loader or shovel, follow
time. Beyond this short duration of time, the system the spotter’s or the shovel operator’s signals.
would become overheated. The truck operator may speed up loading by
If the vehicle is operated at “short term” grade and observing the location and loading cycle of the
speed limits for a period of time, it is possible to truck being loaded ahead, and then following a
exceed the thermal capacity of the drive system similar pattern.
components. The drive system controller will then 5. During loading, the operator must stay in the
gradually reduce the retarding effort from “short term” truck cab with the engine running. Place the
to “continuous”. A warning buzzer will sound alerting directional control lever in NEUTRAL and apply
the operator 15 seconds before the reduction in the brake lock.
retarding performance will take place and the need
for a reduction in speed. A warning message will 6. When loaded, pull away from the shovel as
also be displayed on the instrument panel to reduce quickly as possible with extreme caution.
truck speed. The operator must use the retard speed
control (RSC) or retard lever to quickly slow the truck
Overload Speed Limit Function
to the maximum retarding limits (or less) based on NOTE: The setting for payload trigger and speed limits
the grade the truck is currently traveling. If additional are adjustable by local site preference.
braking effort is required to slow the truck down to (or
below) recommended speeds, use the brake pedal The overload speed limit function limits the speed of
as necessary. the truck if a payload limit setting has been exceeded.
The overload signal becomes true (24 volts) when the
The “short term” rating will successfully accommodate PLM early estimate of payload exceeds the preset
most downhill loaded hauls. If actual time on the grade payload ton threshold.
exceeds the allowable limits, the grade will need to be
negotiated at the “continuous” speed. The PLM early estimate of payload calculation occurs
at 12 seconds of travelling 160 M (525 ft) above 5
kph (3 mph) after being loaded. Once the overload
signal becomes true, it stays true until the payload is
dumped.
930E-4SE 5-17
By default, the overload speed limit is disabled (option 2. Avoid unstable areas. Keep a safe distance
0 in the General Electric configuration file). The from the edge of the dump area. Position the
configuration file can be set to: truck on a solid, level surface before dumping.
Option 1 - Overload speed limit is imposed. 3. Carefully maneuver the truck into the dump
or position. When backing the truck into the dump
Option 2 - No propel restriction is imposed and logged. position, use only the brake pedal to stop and
The truck cannot move under its own power when the hold the truck. DO NOT rely on the brake lock
overload signal becomes true. to stop the truck. This control is not modulated
and applies the rear service brakes only.
The overload speed limit can be adjusted by modifying
the configuration file. Use the Payload Service 4. When the truck is stopped and in dump
Software Lite Version (available for download at position, apply the brake lock and move the
www.KomatsuAmerica.net) to set the overload directional control lever to the NEUTRAL
threshold. position.
When option 1 is selected, and the overload signal 5. Pull the hoist lever to the rear (to RAISE
is true, tractive effort is reduced to attempt to respect position) to actuate the hoist circuit. (Releasing
the speed limit setting. The retard effort will not be the lever anywhere during the raise cycle will
engaged to lower the speed of the truck. Once the hold the body at that position.)
truck speed matches that of the overload speed limit
setting, limited propel efforts and retarding efforts will
be used as necessary. This feature maintains the • As the body raises, the truck center of gravity
truck speed at the maximum of the overload speed will move. The truck must be on level surface
limit setting. to prevent tipping/rolling!
Dumping
• DO NOT move the truck with the dump body

raised except for emergency purposes only.
Failure to lower the body before moving
the truck may cause damage to the hoist
cylinders, frame and/or body hinge pins.
• Dumping very large rocks (10% of payload

or greater) or sticky material (loads that do
not flow freely from the body) may allow
the material to move too fast and cause the
body to move rapidly and suddenly. This
sudden movement may jolt the truck violently,
possibly causing injury to the operator and/or
damage to the hoist cylinders, frame, and/or
body hinge pins.
1. Raise 3. Float
Perform the following 2. Hold 4. Lower
when raising the dump Figure 5-6 HOIST CONTROL
body:
6. Raise the engine rpm to accelerate the hoist
1. Approach the dump area with extreme caution. speed.
Ensure the area is clear of persons and 7. Reduce the engine rpm as the last stage of
obstructions, including overhead utility lines. the hoist cylinder begins to extend. Keep the
Obey signals as directed by the spotter, if engine speed at low idle as the last stage
present. reaches half-extension.
5-18 930E-4SE
8. Release the hoist lever as the last stage of the c. Stop, move the directional control lever to
hoist cylinder reaches full extension. NEUTRAL, apply the brake lock, and lower
the body.
NOTE: If the directional control lever is in REVERSE
when the dump body is raised, reverse propel is NOTE: When an attempt to lower the body is
inhibited. To deactivate, lower the dump body and unsuccessful because of material obstruction, raise
move the directional control lever out of REVERSE. the body back up. This will help to prevent the body
from suddenly dropping when pulling away from the
Lowering The Dump Body (When obstruction.
Dumping On Flat Ground)
3. With the body returned to the frame, move the
directional control lever to FORWARD, release
• DO NOT move the truck with the dump body the brake lock, and carefully leave the dump
raised except for emergency purposes only. area.
the truck may cause damage to the hoist Lowering The Dump Body (When
cylinders, frame and/or body hinge pins. Dumping Over A Berm Or Into A Crusher)
Perform the following

• DO NOT move the truck with the dump body
when lowering the dump
raised except for emergency purposes only.
body:
the truck may cause damage to the hoist
It is very likely when cylinders, frame and/or body hinge pins.
dumping on flat ground
that the dumped material
will build up enough to Perform the following
prevent the body from when lowering the dump
lowering. body:
In this case, the truck will have to be driven forward 1. Move the hoist lever to the LOWER position
a short distance (just enough to clear the material) and release. Releasing the lever places the
before the body can be lowered. hoist control valve in the FLOAT position,
allowing the body to return to the frame.
1. Shift the directional control lever to FORWARD,
release the brake lock, depress the override NOTE: If dumped material builds up at the rear of the
button and drive just far enough forward for body and the body cannot be lowered, perform Steps
the body to clear the material. Stop, shift the a and b below:
directional control lever to NEUTRAL, and a. Move the hoist lever back to the RAISE
apply the brake lock. position to fully raise the dump body.
2. Move the hoist lever forward to the LOWER Release the hoist lever to return it to the
position and release. Releasing the lever HOLD position.
places the hoist control valve in the FLOAT
NOTE: DO NOT drive forward if the tail of the body will
position, allowing the body to return to the
not clear the crusher wall in the fully raised position.
frame.
b. Move the directional control lever to
If dumped material builds up at the rear of the
FORWARD, release the brake lock.
body and the body cannot be lowered, then
Depress the override button and drive
perform the following steps:
forward to clear the material. Stop, shift
a. Move the hoist lever back to the RAISE the directional control lever to NEUTRAL,
position to fully raise the dump body. Then apply the brake lock and lower the body
release the lever so it returns to the HOLD again.
position.
NOTE: When an attempt to lower the body is
b. Move the directional control lever to unsuccessful because of material obstruction, raise
FORWARD, release the brake lock, the body back up. This will help to prevent the body
depress the override button, and drive from suddenly dropping when pulling away from the
forward to clear the material. obstruction.
930E-4SE 5-19
2. With the body returned to the frame, move the 6. If safe to do so, have maintenance personnel
directional control lever to FORWARD, release place wheel chocks or other mechanisms in
the brake lock, and carefully leave the dump front or behind the wheels, depending on the
area. slope, to reduce the risk of the truck rolling.
7. If traffic is heavy near the disabled machine,
SUDDEN LOSS OF ENGINE POWER mark the truck with warning flags during
OR LOSS OF DRIVE SYSTEM daylight hours or use flares at night. Adhere to
FUNCTION F.13-0000051428 local regulations.
The loss of engine power and/or drive system will
result in loss of retard/propel functions on the truck. EMERGENCY STEERING
Under loss of retard/propel conditions, the truck SYSTEM F.7-0000051427
should be immediately stopped using the service
Operation
brakes. In all cases, the service brakes should be
utilized to stop the truck. This truck is equipped with an emergency steering
system. This system is a backup in the event of
loss of oil supply to the main steering system. The
• Dynamic retarding will not be available. DO emergency steering system was designed to meet or
NOT use the service brakes for continuous exceed SAE J1511 and ISO 5010 standards.
retarding purposes.
If the red warning light and alarm are activated, a
failure in the hydraulic oil supply to the steering and
If the engine and/or drive system functionality is lost, brake system exists. When the alarm is activated,
there is enough hydraulic pressure stored in the brake typically there is enough hydraulic pressure stored
and steering accumulators to allow the operation of in the brake and steering accumulators to allow
the steering and brake functions. However, this oil brief operation of the steering and brake functions.
supply is limited so it is important to stop the truck as However, this oil supply is limited. Therefore, it is
quickly and safely as possible. important to stop the truck as quickly and safely as
possible after the alarm is first activated.
If the brake supply pressure drops to a pre-determined
level, the red warning light will illuminate and a If the oil pressure continues to decrease, the brake
buzzer will sound. If the brake pressure continues auto-apply feature will activate the service brakes to
to decrease, the auto-apply feature will activate and stop the truck.
the service brakes will apply automatically to stop the
truck. Pre-Operation Testing
When loss of engine power or drive system function NOTE: Komatsu recommends that operators perform
occurs, perform the following: this test to verify that the steering accumulator
precharge pressure is adequate at the beginning of
1. Bring the truck to a safe stop as quickly as each shift before operating the truck.
possible by using the foot pedal to apply the
service brakes. If possible, safely steer the
truck to the side of the road while braking. • Ensure no one is near the front tires during
2. As soon as the truck has stopped moving, park this test. All personnel are warned that
the truck. clearances change when the steering wheel
is turned and this could cause serious injury.
3. Slowly release the service brakes to check the
capacity of the parking brake. If the parking
brake can not hold the truck stationary, apply This test can only be performed with an empty truck.
the service brakes and hold them ON. DO NOT 1. Park the empty truck on flat, level ground.
turn the key switch OFF, and DO NOT release Lower the dump body onto the frame and stop
the service brakes. the engine. Ensure the Key Switch is in the
4. Notify maintenance personnel immediately. OFF position.
5. If the truck is on level ground, or if the parking 2. Wait at least 90 seconds to verify that all
brake can hold the truck stationary and the hydraulic pressure has been relieved from
truck is in a stable condition, it is then OK to the steering accumulators. Turn the steering
turn the key switch OFF. wheel from stop to stop. If the front wheels do
not move, there is no hydraulic pressure.
5-20 930E-4SE
3. Check the hydraulic tank oil level. The oil level illuminate and the warning buzzer will sound.
must be visible in the center of the upper sight This is normal.
glass and must not cover the entire upper sight
9. If the front wheels cannot be turned fully to
glass. Add oil if necessary. DO NOT overfill.
the left and right, or if the red warning light
4. Turn the Key Switch to the ON position, but DO and buzzer do not activate, immediately notify
NOT start the engine. maintenance personnel. DO NOT operate the
truck until the problem is corrected.
• If any warning messages are displayed
immediately notify maintenance personnel. If the truck passes this test, the emergency steering
DO NOT operate the truck until the problem system is functioning properly.
is corrected.
Additional Guidelines
5. Start the engine and allow the steering
accumulators to fully charge. Turn the steering • When the truck body is raised, DO NOT allow
wheel so that the front wheels are straight. anyone below it unless the body-up retaining cable
is in place.
6. Check the hydraulic tank oil level while the
engine is on. • DO NOT use the fire extinguisher for any purpose
other than putting out a fire! If an extinguisher is
• If the oil level is visible in center of the lower discharged, report the occurrence so the used unit
sight glass and does not cover the entire can be refilled or replaced.
lower sight glass, the steering accumulators
are adequately charged. Proceed to Step 7. • DO NOT allow unauthorized personnel to ride in the
truck. DO NOT allow anyone to ride on the ladder
• If the oil level is below the lower sight or outside of the truck cab. Passengers must be
glass, the steering accumulators are not belted into the passenger seat during travel.
adequately charged. Stop the engine and
turn the Key Switch to the OFF position. • DO NOT leave the truck unattended while the
Immediately notify maintenance personnel. engine is running. Move the directional control
DO NOT operate the truck until the problem lever to PARK, then shut the engine off before
is corrected. getting out of the cab.
KOMVISION (If Equipped) A.3-0000071817

• Engine should be allowed to run at low speed
KomVision System Precautions
to allow time to gradually cool down before
using the emergency engine stop switch to • Clean and inspect all KomVision components at
shut engine OFF. Failure to do so could result truck startup. Repair or replace any damaged
in reduced service life for various engine components as soon as possible.
parts.
• The KomVision system requires approximately 30
seconds to be operational after the keyswitch is
7. Shut the engine off by using the emergency moved to the ON position. If the system does not
engine stop button located on the center become fully operational after 30 seconds, consider
console. Leave the Key Switch in the ON this a system fault and contact maintenance
position. This allows the steering accumulators personnel immediately.
to retain their hydraulic charge.
• Do not use the KomVision system if any component
• If the red warning light and buzzer do is not functioning properly. The entire system must
activate, turn the Key Switch OFF and notify be in good working order to be a reliable warning
maintenance personnel. DO NOT operate system.
the truck until the problem is corrected.
• Do not place any loose items near the controller at
• If the steering accumulators are adequately the rear of the operator cab. Loose items may slide
charged, the red warning light and buzzer will into and damage the controller.
not activate. Continue to the next step.
• Do not disassemble any KomVision system
8. Turn the steering wheel from stop to stop. The component. Electrical failures, electrical shock or
front wheels must turn fully to the left and to a fire may occur.
the right. Eventually, the red warning light will
• The KomVision system is only to be used as an
additional warning system. The operator must
930E-4SE 5-21
remain alert and use the cab windows to stay aware destination before it is shipped. Operating the
of the truck’s surroundings while driving. truck with a damaged or unapproved short range
radar may be a violation of the law. Removing,
• The KomVision system does not operate when the
replacing or adjusting the KomVision system or
truck speed is more than 15 kph (9 mph).
any components must be done by an authorized
• To ensure reliable system operation, remove any service technician.
mud and dirt that builds up around the camera
• When the KomVision system is shipped with the
mounts and radar mounts during truck operation.
truck, only the rules and standards of the original
• Adequate light and clear ambient conditions are country of destination are considered. Therefore, if
necessary for reliable use of the camera system. a truck that is equipped with the KomVision system
Using the KomVision system at night, or in dark, is received by a country other than the original
foggy, rainy, snowy or extremely dusty conditions is country of destination, the rules and standards of
not recommended due to limited visibility. that country may not apply.
• The view from the cameras is limited due to their
positioning. Be aware of obstacles that may be
above the view of the cameras. • This truck is equipped with KomVision
360 degree camera system that improves
• The camera image that is shown on the monitor operator visibility. However, this system does
display may differ from the actual visibility due to not ensure safe operation, and operators
the image conversion process that is performed by should always follow the Operation and
the KomVision system. Maintenance Manual instructions for proper
• The reference lines that are provided on the monitor safety procedures in operation of the truck.
display are only estimated distances based on Komatsu does not assume responsibility for
operating straight ahead on flat ground. Factors accidents or damages which may occur when
such as sloping or uneven ground, steering angle, relying on this system.
as well as the dump body load and type of tires that
are installed, must be considered when judging
distances.
Component Locations
The KomVision system is a 360 degree camera/radar
• The radar system is used to detect large objects
system that is intended to provide additional protection
such as utility vehicles. Smaller objects, such as
against truck accidents and possible property
a person, may not be detected by the radar system.
damage. The warnings that the system provides will
• If the truck dimensions are changed, the KomVision alert the operator to the presence of nearby obstacles
system must be adjusted to accommodate the so the operator can stop, slow down or steer the truck
changes. away from a potential hazard.
• The short range radar used in the KomVision
system must be approved by the country of
5-22 930E-4SE
Cameras And Radars
1. RH Front Camera 5. Radar 1

2. LH Front Camera 6. Radar 8
3. LH Rear Camera 7. Radar 7
4. Radar 2
Figure 5-7 FRONT AND LEFT
930E-4SE 5-23
1. Rear Camera 3. Radar 6

2. Radar 5
Figure 5-8 REAR
5-24 930E-4SE
Monitor Panel And Controller
1. Monitor Panel 2. Controller
Figure 5-9 MONITOR PANEL AND CONTROLLER
930E-4SE 5-25
Monitor Panel
1. Monitor Display 6. Monitor Display Mode Switch

2. Brightness Switches 7. Reference Line Display Switch
3. System Power Status Indicator 8. Lower Body Display Switch
4. Force Display Switch 9. Object Clear Switch
5. Camera Switches
Figure 5-10 MONITOR PANEL
System OFF — Green

Brightness Switches
light is off.
Pressing this switch
makes the monitor
display lighter.
Force Display Switch
Pressing this switch Pressing this switch
makes the monitor disables the non-display
display darker. mode of the monitor
display when the truck
The level of brightness that is selected at the time of is traveling at 15 kph (9
system shutdown will remain the same at the time of mph).
the next system startup. The operator should adjust
the level of brightness as needed at the beginning of Camera Switches
operation. Pressing any of these
switches will change
System Power Status Indicator the camera view on the
monitor display to the
System ON — Green light is on. selected camera.
System warming up — Green light is blinking.
5-26 930E-4SE
If there are any errors, pressing the UP arrow will scroll Lower Body Display Switch
the error display upward. When the monitor display
is in the dual display
If there are any errors, pressing the DOWN arrow will
mode, pressing this
scroll the error display downward.
switch will turn the lower
body display on the left
Monitor Display Mode Switch side on or off.
If force display switch (4)
is off, pressing this switch
Object Clear Switch
allows the operator to
Pressing this switch will
toggle the monitor display
clear an object detection
from dual display mode
warning. If there are
to single display mode
multiple objects detected,
to non-display mode and
the object with the highest
back to dual display
priority alarm will be
mode.
cleared first.
If force display switch (4) is on, pressing this switch
Holding this switch for three seconds will deactivate
allows the operator to toggle the monitor display
the object alarm for 30 seconds. The indicator shown
between dual display mode and single display mode.
on the switch will also appear on the monitor display.
Holding this switch and object clear switch (9) at the
Holding this switch and monitor display mode switch
same time for at least three seconds will activate the
(6) at the same time for at least three seconds will
radar startup inspection mode.
activate the radar startup inspection mode.
Reference Line Display Switch
Monitor Display
Pressing this switch will
turn the reference lines After the keyswitch is moved to the ON position, the
shown on the monitor KomVision logo will be shown on the monitor display
display on or off. for 30 seconds while the system starts up. Then,
normal camera images will be shown.
930E-4SE 5-27
1. Camera Display 7. Bird’s Eye Camera Indicator

2. Reference Lines 8. System Error Indicator
3. Radar Startup Inspection Mode Indicator 9. Camera Error Indicator
4. Fault Indicator 10. Input/Output Error Indicator
5. Read Manual Indicator 11. Communication Error Indicator
6. Radar System On/Off Indicator 12. Radar Error Indicator
Figure 5-11 MONITOR DISPLAY — SINGLE DISPLAY MODE
5-28 930E-4SE
1. Camera Display 8. System Error Indicator

2. Reference Lines 9. Camera Error Indicator
3. Radar Startup Inspection Mode Indicator 10. Input/Output Error Indicator
4. Fault Indicator 11. Communication Error Indicator
5. Read Manual Indicator 12. Radar Error Indicator
6. Radar System On/Off Indicator 13. Bird’s Eye View Display
7. Bird’s Eye Camera Indicator
Figure 5-12 MONITOR DISPLAY — DUAL DISPLAY MODE
Camera Display Modes • the direction control lever is moved to the NEUTRAL
position or the PARK position.
The single display mode will be shown on the monitor
display when: • the display mode switch is used to select the dual
display mode.
• the direction control lever is moved to the
REVERSE position. The non-display mode (single display mode with a
blank camera view) will be shown on the monitor
• the display mode switch is used to select the single
when:
display mode.
• the direction control lever is moved to the
The dual display mode will be shown on the monitor
FORWARD position, the force display switch is off,
display when:
and the truck speed is more than 15 kph (9 mph).
• the direction control lever is moved to the • the display mode switch is used to select the
FORWARD position and the truck speed is less non-display mode.
than 15 kph (9 mph).
930E-4SE 5-29
If the camera that is selected for viewing is broken or Dump Body Status Display
disconnected, the camera display with be solid blue.
In the dual display mode, the truck image in the bird’s
eye view on the left side of the monitor display is also
Bird’s Eye Views an indicator of the dump body status.
In the dual display mode, the left side of the
monitor display shows a bird’s eye view graphical
representation of the truck.
• When the direction control lever is moved to the
NEUTRAL position, the PARK position, or the truck
speed is less than 15 kph (9 mph), the bird’s eye
view display will show an oval shaped projection
image.
• When the truck speed is more than 15 kph (9 mph)
and the force display switch is on, the bird’s eye
view display will show a flat surface projection
image.
• When the truck speed is more than 15 kph (9 mph)
and the force display switch is off, the monitor
display will change to the non-display mode.
1. Dump Body 2. Dump Body
Bird’s eye camera indicator (7, Figure 5-11 MONITOR Empty/Lowered Loaded/Lowered
DISPLAY — SINGLE DISPLAY MODE, page 5-28)
will show which camera view is currently selected for
the monitor display. The outer frame of the indicator
will flash during normal operation. If the outer frame of
the indicator does not flash during normal operation,
restart the system.
Reference Lines
Reference lines (2), which appear on both the camera
display and bird’s eye view, use different colors to
indicate the following distances from the truck:
• 0 m (0 ft) — White
• 0 m (0 ft) to 3 m (10 ft) — Red
• 3 m (10 ft) to 5 m (16 ft) — Yellow
• 5 m (16 ft) to 7 m (23 ft) — Green 1. Dump Body 2. Dump Body
Empty/Raised Loaded/Raised
5-30 930E-4SE
Error Code Display

Error codes will be displayed in the lower left part of
the monitor display. If there are many error codes, use
the UP arrow and DOWN arrow on the monitor panel
to scroll through the list of error codes.
1. Error Code Display
Figure 5-13 ERROR CODE DISPLAY
930E-4SE 5-31
Initial Setting Screen

If the initial setting screen is shown on the monitor
display, the KomVision system’s initial settings must
be input before it can be operated. Contact your
Komatsu representative for service.
Figure 5-14 INITIAL SETTING SCREEN

Radar System The active range of object detection around the truck
is 7.6 m (25 ft) to the front and rear, and 3.6 m (12
Object Detection Range ft) to both sides. The radar system is used to detect
The radar system is activated only when the truck is large objects such as utility vehicles. Smaller objects,
stopped or the truck speed is less than 15 kph (9 mph). such as a person, may not be detected by the radar
system.
5-32 930E-4SE
Figure 5-15 RADAR SYSTEM OBJECT

DETECTION RANGE
Object Detection Warnings
1. Camera View 2. Object Indicator
Figure 5-16 MONITOR DISPLAY — SINGLE DISPLAY MODE
930E-4SE 5-33
1. Blinking Red Box 2. Object Marker
Figure 5-17 MONITOR DISPLAY — DUAL DISPLAY MODE

In the single display mode, the radar system warns the The color of the object marker changes according to
operator that an object is within range by: its proximity to the truck.
• placing a blinking red box on the appropriate section • 0 m (0 ft) to 3 m (10 ft) — Red
of the small bird’s eye view indicator, and
• 3 m (10 ft) to 5 m (16 ft) — Yellow
• placing a colored marker on the object in the monitor
• 5 m (16 ft) or more — Green
display.
An audible alarm will also sound when an object is
In the dual display mode, the radar system warns the
detected. There are three different alarm levels that
operator that an object is within range by:
will sound depending on the location of the object and
• placing a blinking red box on the appropriate section the speed and gear selection of the truck.
of the bird’s eye view on the left side of the monitor
• High — three 70 ms bursts repeated every 250 ms
display,
• Mid — three 70 ms bursts repeated every 750 ms
• placing a colored marker on the object in the bird’s
eye view on the left side of the monitor display, and • Low — three 70 ms bursts repeated every 1250 ms
• changing the camera view on the right side of the If two or more objects are detected at the same time,
monitor display to the appropriate area. the alarm will be activated for the object with the
highest priority.
The radar system tracks the movement of an object by
updating the location of the object marker every 500 Table 5-2 Object Detection Alarm Priorities, page 5-35
ms. The current location and previous two locations shows, from left to right, the priorities of the automatic
will be shown on the monitor display. camera view changes and their audible alarms.
5-34 930E-4SE
Table 5-2 Object Detection Alarm Priorities

Gear Truck Camera Area/Alarm Level
Speed
FORWARD less than Front/High RH LH RH LH Rear/Mid
15 kph (9 Front/High Front/High Rear/Mid Rear/Mid
mph)
NEUTRAL 0 kph (0 Front/Mid Rear/Mid RH LH RH LH
mph) Front/Low Front/Low Rear/Low Rear/Low
PARK 0 kph (0 Front/Off Rear/Off RH LH RH LH
or mph) Front/Off Front/Off Rear/Off Rear/Off
Wheel
Brake ON
REVERSE less than Rear/High RH LH RH LH Front/Mid
15 kph (9 Rear/High Rear/High Front/Mid Front/Mid
mph)
Depending on the truck travel status, the KomVision NOTE: If the single display mode has been manually
system will alert the operator to the presence of an selected while the truck is in NEUTRAL, PARK or
object in several ways. Refer to Table 5-3 Object FORWARD, the monitor display will automatically
Detection Warning Configurations, page 5-35. change to dual display mode if an object is detected.
Table 5-3 Object Detection Warning Configurations

Truck Travel Display Auto Camera Audible Alarm Display Object Marker
Status Mode View Change Emphasis
NEUTRAL Dual display ON ON Bird’s eye view & ON
Small bird’s eye
indicator
PARK or Wheel Dual display ON OFF Bird’s eye view & ON
Brake ON Small bird’s eye
indicator
FORWARD Dual display OFF ON Bird’s eye view & ON
less than 15 kph Small bird’s eye
(9 mph) indicator
FORWARD Dual display OFF OFF OFF OFF
more than 15
kph (9 mph)
Force display
switch ON
FORWARD Non-display OFF OFF OFF OFF
more than 15
kph (9 mph)
Force display
switch OFF
REVERSE Single OFF ON Small bird’s eye ON
less than 15 kph display indicator
(9 mph)
REVERSE Single OFF OFF OFF OFF
more than 15 display
kph (9 mph)
930E-4SE 5-35
Object Clear 2. Use a soft cloth (damp or dry) to clean the radar
sensors. The front of the radar sensors must
If the object moves out of the radar’s detectable range,
remain free of water and mud buildup.
the alarm will automatically turn off.
3. Holding the monitor
To clear an alarm while
the object is still within the display mode switch
detectable range, press and the object clear
the object clear switch switch at the same
on the monitor panel to time for at least three
clear the warning. If seconds to activate
there are multiple objects the radar startup
detected, the object with inspection mode.
the highest priority alarm
• The radar alarm will begin to sound.
will be cleared first.
• The radar startup inspection mode indicator
Holding this switch for three seconds will deactivate will begin to flash yellow.
the object alarm for 30 seconds. The indicator shown
on the switch will also appear on the monitor display. • The detection areas corresponding to the
eight radars will appear solid yellow on the
Start-Up Inspection monitor display.
Camera Inspections
1. Check each camera and camera mount for
damage or deformities. Carefully clear any
mud or dirt buildup around the cameras.
2. Use a soft cloth (damp or dry) to clean the
camera lens. Check for cracks and scratches.
3. Activate the KomVision system. Use the
camera view switches to check that all of
the camera views are shown on the monitor
display.
4. If any of the camera views is distorted or
unclear, clean the camera lens one more time.
If there is no improvement, repair or replace
the camera.
5. If any of the camera views is solid blue, that
camera is broken. Replace the camera.
Radar Inspections
NOTE: If possible, perform the radar inspections in a
large, wide-open area with no obstacles.
Figure 5-18 RADAR DETECTION AREAS
1. Check each radar and radar mount for damage
or deformities. Carefully clear any mud or dirt 4. While holding a corner reflector facing toward
buildup around the radars. the truck, walk around the truck two times at a
distance of 2 m (6.5 ft).
5-36 930E-4SE
Camera Cleaning
Using canned air, a soft brush or a damp cloth clean
the exterior of the camera. For greasy buildups, use
warm soapy water and dry off the housing with a
micro-fiber cloth.
• If using a pressure washer, water pressure

must not exceed 9.8 MPa (1420 psi).
FUEL DEPLETION D.3-0000051426
• Operating the truck to fuel depletion forces

Figure 5-19 RADAR REFLECTOR the injector train into a no-follow condition.
5. After completing step 4, check the monitor No fuel flow between the plungers may cause
display. The radar system is operating properly damage to the injectors and the overhead due
if: to adhesive wear, resulting in costly repairs
and unnecessary downtime.
• The radar alarm is no longer sounding.
• The radar startup inspection mode indicator
will flash green.
• Allowing the Komatsu truck to operate
• All of the detection areas corresponding to until fuel depletion can lead to unsafe
the eight radars are no longer solid yellow on operating conditions possibly resulting in an
the monitor display. uncontrollable vehicle and/or personal injury.
6. If any of the detection areas on the monitor
display are still solid yellow, clean the DO NOT allow the fuel tank to become empty. The
corresponding radar sensor again and repeat high pressure injection (HPI) fuel system uses fuel
the startup inspection. If the problem remains, to adjust fuel delivery timing. Metered fuel is also
replace the radar sensor. used to lubricate the injector plunger and barrel. The
maximum demand for metered fuel is required during
The radar startup inspection mode indicator will
high speed / low load conditions.
disappear once the direction control lever is
moved out of PARK.
SAFE PARKING
7. If you must drive the truck after the startup PROCEDURES F.6-0000051425
inspection has failed, turn off the engine, then
start the truck again in order to deactivate the Ensure the truck body is empty. Completely lower the
radar startup inspection mode. Remember that dump body. If the machine must be parked on a slope,
the radar system is not functioning properly. follow local regulations to secure the truck to prevent
Drive carefully. the machine from moving.
Refer to the following procedure to park the machine:
Monitor Panel And Controller Cleaning
1. Move the directional control lever to PARK (this
Use a soft cloth (damp or dry) to clean the monitor will apply the parking brake). DO NOT apply
panel and display. If there is a lot of dirt buildup, use the wheel brake lock.
a small amount of neutral detergent. Do not use paint
thinner or isopropyl alcohol. 2. Turn the key switch to the OFF position and
wait for the engine to stop. This could take
Use a soft cloth (damp or dry) to clean the outside up to three minutes for a hot engine to cool
of the controller. Excessive dust buildup may cause down. After the engine has stopped, wait two
electrical failures. minutes before exiting the cab. If any warning
messages are displayed, or the warning buzzer
is sounding, DO NOT leave the cab. Notify
maintenance personnel immediately.
930E-4SE 5-37
3. When exiting the machine, always lock The engine may continue to run for up to
compartments, and take the keys with you to three minutes after the Key Switch is turned
prevent entry from unauthorized persons. OFF, if the parking brake has been set. The
engine may stop before three minutes has
4. Place wheel chocks around the wheels to
elapsed if the engine coolant is not too hot,
prevent the truck from rolling.
and the engine speed and fuel delivery have
NOTE: If the engine is running, and the truck is been low for a period of time before the Key
stationary and no brakes are applied, the red warning Switch was placed in the OFF position. The
light will illuminate and fault code will appear in the engine shutdown delay indicator light will be
digital display. The operator must apply one of the illuminated during the shutdown sequence.
following braking systems: the service brakes, the
NOTE: When the key switch is turned OFF, the
wheel brake lock or the parking brake to prevent truck
parking brake will automatically be set, even if it was
roll away and to clear the warning/fault code.
not set already by the operator. The wheel brake lock
will be disabled, even if it was set by the operator.
NORMAL ENGINE SHUTDOWN
PROCEDURE G.12-0000051424 4. With the Key Switch OFF and engine stopped,
wait at least two minutes. If any warning
1. Park on a level surface, free of overhead power messages are displayed, notify maintenance
lines or other objects that could prevent raising personnel immediately.
the dump body. Reduce engine speed to idle
and place the directional control lever in PARK. 5. Ensure the steering circuit is completely bled
This will apply the parking brake. DO NOT down by turning the steering wheel back
apply the wheel brake lock. and forth several times. No front wheel
movement will occur when hydraulic pressure
Ensure the parking brake indicator light is is relieved. If the front tires continue to steer
illuminated. after the engine is stopped, notify maintenance
NOTE: If the truck starts to roll, apply the personnel.
service brakes and notify maintenance personnel 6. Verify both link voltage lights on the electrical
immediately. cabinet are off. Notify maintenance personnel
2. Place the rest switch in the ON position to put if the lights remain illuminated longer than five
the AC drive system in rest mode. Ensure the minutes after the engine has been stopped.
no propel indicator light is illuminated. 7. If equipped, lower the retractable ladder.
3. Turn the Key Switch counterclockwise to the 8. Close and lock all windows. Remove the
OFF position to stop the engine. key from the Key Switch and lock the cab to
NOTE: There is also an emergency engine stop prevent possible unauthorized truck operation.
switch located at ground level at the right or left front Properly dismount the truck. Put wheel chocks
corner of the truck. When this switch is activated, the in place.
engine will stop immediately, with no cooling off time. NOTE: If the engine must be shut down immediately,
stop the truck, shift the directional control lever to
PARK, turn the key switch OFF, then pull up on the
• Engine should be allowed to run at low speed emergency engine stop switch located in the operator
to allow time to gradually cool down before cab center console. Push the switch back down to
using the emergency engine stop switch to enable engine operation.
shut engine OFF. Failure to do so could result
in reduced service life for various engine
parts.
5-38 930E-4SE
OPERATING INSTRUCTIONS DISABLED TRUCK CONNECTORS
DISABLED TRUCK Figure 5-20 HOIST CONNECTIONS, page 5-39

CONNECTORS D.1-0000051229 shows a typical hookup from an operational truck. The
disabled truck may be another of the same model, or
GENERAL INFORMATION C.1-0000051423 a different Komatsu electric drive truck model.
Refer to the Shop Manual for repair and The hoist circuit relief valves are adjusted to 18 616
troubleshooting procedures for the hoist system kPa (2,700 psi).
components and steering system components. Refer
to the Shop Manual for repair and troubleshooting Hookup
procedures for the hydraulic brake system
components. Ensure there is an adequate, clear area to dump the
loaded truck. When the operational truck is in position,
HOIST SYSTEM D.5-0000051421
stop the engine and wait two minutes to allow the
hydraulic system to bleed down. Ensure hydraulic
Sometimes it is necessary to dump a load from the pressure has bled off before connecting hoses.
body of a truck when the hoist system is inoperable.
To use this feature, two hoses (supply and return) Obey the following guidelines when hooking up the
must be connected to a hydraulic source (such as an disabled truck to the operational truck.
operational truck or an auxiliary power unit). 1. With the operational truck parked as close
as possible to the disabled truck, attach a
hose from power up quick disconnect (1) of
the operational truck to power down quick
disconnect (2) of the disabled truck. (Hose
must be rated to withstand 18 616 kPa (2,700
psi) or greater pressure.
NOTE: The power down circuit will use a smaller
diameter hose (tube) than the power up circuit.
2. Connect another hose from power down quick
disconnect (2) of the operational truck to power
up quick disconnect (1) of the disabled truck.
NOTE: If both trucks are the same model, the hoses
will be installed at the quick disconnects but will be
crossed when connected.
Dumping Procedure
To raise the body, perform the following:
1. On the disabled truck, move the hoist control to
1. Power Up Quick Disconnect power up and then release it to place the hoist
2. Power Down Quick Disconnect pilot valve in the HOLD position (leave in this
3. Over Center Valve position during entire procedure).
Figure 5-20 HOIST CONNECTIONS 2. Start the engine on the good truck, place the
hoist control in the power down position and
NOTE: The matching quick disconnect coupling for
increase engine rpm to high idle to dump the
items (1 & 2) is PB4684.
disabled truck. If the body of the disabled truck
Quick disconnect fittings (1) and (2, Figure 5-20 fails to raise, increase the operational truck’s
HOIST CONNECTIONS, page 5-39) are provided on power down relief pressure as follows:
the over center valve to allow operation of the hoist
a. Stop the engine and wait two minutes to
circuit for temporary truck operation if the hoist pump,
allow the hydraulic system pressure to
hoist valve or other hoist system component is not
bleed down.
operational. This will allow maintenance personnel to
raise the truck body to dump the load before moving
the disabled truck.
930E-4SE 5-39
DISABLED TRUCK CONNECTORS OPERATING INSTRUCTIONS
b. Remove the cap from the hoist pilot 2. After body is lowered, stop the engine and wait
valve relief valve located in the hydraulics two minutes to allow the hydraulic system to
components cabinet behind the cab. While bleed down. Then disconnect the hoses.
counting the number of turns, slowly screw
3. Reduce power down relief valve pressure
the relief valve adjustment screw clockwise
to normal on the good truck by turning the
until it bottoms.
adjustment counterclockwise the same number
To lower the body, perform the following: of turns as required in step 2b of the body
dumping procedure.
1. Place the hoist control of the good truck
in FLOAT to lower the body. If necessary, 4. Check power down relief pressure using
momentarily place the hoist control in POWER instructions in the shop manual.
UP until the body is able to descend in FLOAT. 5. Check hydraulic tank oil level.
Do not accelerate the engine.
5-40 930E-4SE
OPERATING INSTRUCTIONS TOWING
TOWING F.6-0000051288 • Switch (2) must be connected to the other end of the
harness so the operator can use the switch while
seated in the cab.
• Before towing a truck, many factors must be • The harness must be fitted with connector (4) to
carefully considered. Serious personal injury allow it to be plugged into parking brake solenoid
and/or significant property damage may result (3) inside the brake cabinet. Ground wire (5) leading
if important safety practices, procedures and from this connector must be long enough to connect
preparation for moving heavy equipment are to a ground block using the second ring terminal.
not observed.
Connector (4) consists of:
A disabled machine may be towed after the following • one housing (PB8538)
precautions have been taken.
• two sockets (08191-05430)
• DO NOT exceed 8 kph (5 mph) while towing.
• one wedge (PB8540)
• DO NOT tow with a cable. Use a solid tow bar. Use
a towing device with ample strength for the weight
of this truck.
• Towing vehicle must have adequate pulling and
braking capacity to both move and stop the towed
truck under all conditions, including towing on a
grade.
• Inspect towing components, such as tow bars and
couplings, for any signs of damage. Never use
damaged or worn components to tow a disabled
vehicle.
• Keep a safe distance from the trucks and towing
apparatus while towing a vehicle.
• When connecting a truck that is to be towed, do not
allow anyone to go between the tow vehicle and the
disabled vehicle.
• Set the coupling of the truck being towed in a
straight line with the towing portion of the tow truck
and secure it in position.
• An operator must remain in the cab of the towed 1. 24VDC Bus Bar 4. Connector
vehicle at all times during the towing procedure. Terminal 5. Ground Wire
2. Switch (ON/OFF)
SPECIAL WIRING HARNESS E.4-0000051420
3. Park Brake Solenoid
Before towing, a special wiring harness must be made Figure 5-21 PARKING BRAKE HARNESS
in order to release the parking brake. The harness CONNECTION DIAGRAM
will require approximately 9 meters (30 ft) of #14 wire, TOWING PROCEDURE C.59-0000060791
one ON/OFF switch (capable of carrying 2 amps of
current) and two ring terminals. 1. Turn off the engine.
Refer to Figure 5-21 PARKING BRAKE HARNESS 2. Block the wheels on the disabled truck to
CONNECTION DIAGRAM, page 5-41 for a diagram prevent movement while preparing the truck
of the special wiring harness circuit. for towing and while attaching the tow bar.
• Using a ring terminal, one end of the harness 3. Towing vehicle must have adequate pulling
must connect to 24VDC Bus Bar Terminal (1) in and braking capacity to both move and stop
the auxiliary control cabinet to supply 24V to the the towed truck under all conditions, including
parking brake solenoid. towing on a grade.
4. Ensure that the tow bar has adequate strength
(approximately 1.5 times the empty vehicle
930E-4SE 5-41
TOWING OPERATING INSTRUCTIONS
weight of truck being towed). Install tow bar NOTE: If truck is being towed using a tow truck (front
between the two vehicles. wheels off ground), it is not necessary for operator to
remain in truck during transport. With the ON/OFF
5. If necessary, install quick disconnect fittings to
switch in the ON position the park brake is released,
the bleeddown manifold to allow the hydraulic
the retractable ladder will automatically raise. From
system to be operational. Install hydraulic
ground have another person push ground level ladder
connections for steering/braking between the
override button, located on front bumper, to lower
tow vehicle and the disabled vehicle. An
retractable ladder. After operator has reached ground
auxiliary power unit can also be used.
level pull emergency stop button to raise retractable
6. After the hydraulic connections are made, ladder.
check the disabled vehicle braking and steering
11. Tow the disabled truck. Sudden movement
systems for normal operation. Install 24 100
may cause tow bar failure. Smooth, gradual
kPa (3,500 psi) pressure gauges on both the
truck movement is preferred. Do not exceed 8
BF test port and the BR test port on the brake
kph (5 mph) while towing.
manifold in the brake cabinet. Ensure proper
pressure is displayed on the gauge when NOTE: Minimize the tow angle at all times. Never
depressing the brake pedal. exceed 30 degrees. The towed truck must be steered
in the direction of the tow bar.
7. If the truck is loaded, dump the entire load.
Never pull or tow a loaded truck. Refer to 12. When the desired location has been reached,
Dumping Procedure, page 5-39. the operator in the towed vehicle must apply
the service brakes, then move the switch to
8. The parking brakes must be released before
the OFF position. This will apply the parking
towing. To release the parking brakes, use
brakes.
the following steps to install the special wiring
harness. 13. Block the wheels on the towing vehicle and on
the disabled truck to prevent roll-away.
a. Ensure that the ON/OFF switch is in the
OFF position (as shown in diagram). 14. Turn off the engine in the towing vehicle.
b. Connect one lead of the special wiring 15. If installed, disconnect the hydraulic hoses at
harness to a 24VDC terminal on bus bar the quick disconnect fittings on the bleeddown
(1, Figure 5-22 AUXILIARY CONTROL manifold.
CABINET, page 5-42) on the right side wall
16. Disconnect the special wiring harness from the
of the auxiliary control cabinet for the 24V
truck. Connect the truck wiring harness to the
supply power.
parking brake solenoid.
c. Disconnect the truck wiring harness from
17. Disconnect the tow bar.
parking brake solenoid (2, Figure 5–23
BRAKE CABINET, page 5-43). Connect
the special wiring harness to the parking
brake solenoid. Connect the ground wire
from the connector to a ground block in the
right side of the brake cabinet.
d. Lower the window and place the switch
end of the special wiring harness inside the
cab so the operator can control the parking
brake with the ON/OFF switch.
9. When ready to tow the disabled truck, remove
the blocking from the wheels.
10. The operator in the disabled truck should now
move the ON/OFF switch to the ON position. 1. 24VDC Bus Bar
This will release the parking brakes.
Figure 5-22 AUXILIARY CONTROL CABINET
5-42 930E-4SE
OPERATING INSTRUCTIONS TOWING
Image Tag Expected within Figure Tag
Figure 5–23 BRAKE CABINET

1. Brake Manifold
2. Parking Brake Solenoid
930E-4SE 5-43
PAYLOAD METER IV SYSTEM OPERATING INSTRUCTIONS
PAYLOAD METER IV messages. The bottom display includes units.

SYSTEM A.2-0000071708 Payload can be displayed in short tons, long tons or
metric tons.
GENERAL INFORMATION B.10-0000071844
Payload Meter IV (PLM IV) measures, displays

and records the weight of material being carried by
an off-highway truck. The pressure data from the
suspensions is combined with incline, speed and
other inputs to calculate the weight of the payload
carried in the truck body. The payload weight is
displayed to the operator through the digital display on
the dashboard as the shovel operator loads the truck
body, and through the Red/Amber/Green payload
lights or optional “Scoreboard” monitor mounted to
the side of the truck.
Data Summary
The payload meter creates and stores more than
10,000 haul cycles in memory. Each haul cycle is
recorded with information described in data structure
Figure 5-24 TRUCK ELECTRONIC DISPLAY UNIT
Table . Oldest data records will be overwritten as the
internal memory is filled. Operator Input Switches
The operator Input
Data Gathering Switches allow the
NOTE: Precise calibrations and configurations are toggling through warning
important to ensure accurate payload calculations. screens and various truck
information.
The PLM IV uses an Internet browser interface
instead of a stand-alone software program. For
users with previous PLM III experience, there is no
additional software required to download and view
payload meter data and fault information.
For PLM IV, they are used to:
The user can directly log into the payload meter by
• Enter the operator ID number (0000–9999)
entering the PLM IV controller’s assigned IP address
into the address bar of a standard web browser such • View and Clear the total loads and payload counter
as Internet Explorer® or Google Chrome®. Refer for a shift period
to the Komatsu truck Shop Manual for SYSTEM
• View live readings from the inclinometer and
CONFIGURATION, page 5-56 for instructions on
pressure sensors
configuring PLM IV.
The operator switches are
COMPONENT DESCRIPTION A.17-0000071858
1. SELECT – The left showing an UP and DOWN
Electronic Dash Display arrow. This is used to step through the various
screens or displays as described in the manual.
The Electronic Dash Display is used to display
payload information. See DIGITAL DISPLAY 2. OK – The right switch showing an “OK.” This
OPERATION, page 6-26. is used to select an option for the displayed
screen.
The Payload Meter (PLM) uses the lower display for
payload information in conjunction with the operator For troubleshooting, the inputs from the switches to
switches to navigate to different modes and enter the PLM are normally open circuit and the switch
information, as well as to display of various status makes momentary contact.
5-44 930E-4SE
OPERATING INSTRUCTIONS PAYLOAD METER IV SYSTEM
Brake Lock Switch • Two USB 2.0 Type - A Connectors (3) for USB drive
connection.
The brake lock is used to lock the rear brakes on the
truck. Locking the rear brakes is necessary for the •
accurate calculation of swingloads during the loading
process. Without the brake lock applied, the PLM
will not calculate swingloads. PLM will assume that
the truck was loaded using a continuous load and
the system will flag the haul cycles record. All other
functions will be normal regardless of brake lock
usage.
NOTE: It is very important for user to use Brake
Lock for accurate payload state detection. The drive
selector switch should be in NEUTRAL during loading,
and the PARK BRAKE should not be engaged.
Payload Meter Module (PLM)

The PLM IV controller (1, Figure 5-25 PLM IV
LOCATION, page 5-45) is contained in a black
housing mounted on the PLM IV communication
module (2). The two devices are located in the
auxiliary control cabinet.
NOTE: Opening the payload meter housing will result
in voiding the warranty.
1. 10/100 Mbps Ethernet RJ45 Connector

2. LEDs
3. USB 2.0 Type-A Connectors
Figure 5-26 PLM IV COMMUNICATION MODULE

The PLM IV provides two USB ports for Real Time
data collection and Field Software reprogramming. At
any point of time only one USB port shall be active.
The USB drive does not add memory storage capacity
to the PLM IV and cannot be used to download
payload data from the device.
The USB 2.0 connectors allow flash drives to become
accessible to the PLM.
1. PLM IV Controller
The PLM IV uses the USB ports for the following two
2. PLM IV Communication Module functions:
Figure 5-25 PLM IV LOCATION 1. Upon USB drive (1, Figure 5-27 USB DRIVE
The connections to the truck wiring are made on COMMUNICATIONS, page 5-46) insertion, the
one end of the PLM IV while the other end provides system will begin recording real time data at 50
connection points for diagnostics and technical samples per second to the drive. A new file will
service. be created for every new haul cycle, and will
be named according to the corresponding haul
• One 10/100Mbps Ethernet RJ45 Connector (1, cycle number.
Figure 5-26 PLM IV COMMUNICATION MODULE,
page 5-45) for direct connection to a network or 2. USB drives that store PLM software updates
computer. can be used in conjunction with the web server
to upload new system software to PLM IV.
930E-4SE 5-45
Load Lights
PLM IV uses load lights (1, Figure 5-28 LOAD LIGHTS
AND SCOREBOARD, page 5-46 or an optional
score board to indicate to the shovel operator the
approximate weight of the material in the truck.
The score board reads the current weight in tons.
The load lights progressively indicate to the shovel
operator the approximate weight of the material in the
truck.
The load lights are illuminated only when the brake
1. USB Drive lock is applied.
Figure 5-27 USB DRIVE COMMUNICATIONS

Follow the Field Software Update procedure for field
software reprogramming instructions.
To collect real time data:
1. Turn OFF the truck Key Switch for two minutes
(or until all the LEDs on the communication
board turn OFF).
2. Insert a 2 or 4GB USB drive (formatted with
Windows FAT 32 default) into either USB port.
3. Turn ON the Key Switch and operate the truck 1. Load Lights
normally. 2. PLM Scoreboard (Optional)
4. Turn OFF the Key Switch and wait for two
Figure 5-28 LOAD LIGHTS AND SCOREBOARD
minutes or all LEDs on the communication
board turn OFF before removing the USB A flashing green light indicates the next swingload will
drive. make the measured load greater than 50% of rated
load. A solid green light indicates that the current load
The PLM IV provides five visual LED indicators to is greater than 50% of rated capacity.
monitor system status:
A flashing amber light indicates the next swingload will
• The USB1 and USB2 indicators are active when make the measured load greater than 90% of rated
the drive is providing power. The lights are inactive load. A solid amber light indicates that the current load
for overcurrent or initialization errors, and can be is greater than 90% of rated capacity.
cleared by a system reset.
A flashing red light indicates the next swingload will
• The LINK indicator is for Ethernet connectivity, and make the measured load greater than 105% of rated
blinks during intersystem communication. load. A solid red light indicates that the current load is
• The PULSE indicator is toggled ON/OFF every greater than 105% of rated capacity.
second to indicate the system is working. As long
The optimal loading target is a solid green and amber
as it is blinking the system is running.
lights with a flashing red light. This indicates that the
• The HAUL indicator is reserved for future use. load is between 90% and 105% of rated load for the
Ignore status of this indicator. truck and the next swingload will load the truck over
105%.
NOTE: While collecting log file data by USB or field
software update, always remember to take the USB
drive out of the payload meter after completion of the
task. USB drive should not be left in its communication
slot permanently. Real time data is written at 50
samples per second and could fill USB drive. Once
the USB drive is full, Payload meter stops writing
data.
5-46 930E-4SE
Keyswitch Input
The PLM monitors the status of the keyswitch.
Turning the keyswitch ON alerts the PLM IV to
power on. When the keyswitch is turned OFF, the
payload meter will begin the process of powering
off. The payload meter does not receive its electrical
power from the keyswitch circuit. The PLM will
remain ON for several seconds after the keyswitch is
removed. When the keyswitch power is removed, the
payload meter performs a series of internal memory
operations before turning itself off. To allow these
operations to complete, the keyswitch should be
turned OFF for at least 30 seconds before turning the
keyswitch back ON, or wait until all the LEDs on PLM
IV Communication Board turns OFF.
1. Processor LED
Payload Meter (PLM) Power 2. Data Receive LED
The PLM receives its power from the battery circuit Figure 5-29 SCOREBOARD
on the truck. Removing battery power from the PLM OPERATOR’S DISPLAY AND
before removing keyswitch and waiting 15 seconds
may result in lost haul cycle data or data file corruption.
SWITCH A.3-0000073399
The PLM turns itself off approximately 30 seconds Setting The Operator ID
after the keyswitch power is removed.
The current operator ID number is recorded with each
NOTE: It is very important to use the keyswitch to haul cycle. The number can be between 0 and 9999.
shutdown the payload meter before removing battery
power. Failure to do so may result in data corruption. Press OK to enter the Payload Data sub-menu.
Press the Up and Down Arrows navigate to Driver
ID display. Once in the Driver ID display, pressing
SCOREBOARD A.4-0000073983
the Up and Down Arrows will scroll through the
The PLM scoreboard is a sturdy three digit LED alphanumeric characters as well as Delete and Apply.
electronic display. The scoreboard displays swingload When the desired character is found press OK to
estimation and early estimation payload values. select that character. The displayed ID number cursor
It receives data packets from the PLM device in will automatically go to the next character position.
real-time. During normal operation the scoreboard Repeat for the next characters. After the ID has been
will display data from the latest valid packet for up to changed navigate to the Apply (looks like a right
10 seconds. If a valid data packet is not received for arrow) icon and press OK. If at any time you want to
more than 10 seconds, the scoreboard will turn off delete a character in the ID navigate to the Delete
all display segments. The scoreboard will continue (looks like a trash can) icon and press OK to delete
normal operation as soon as a valid packet is received the current character.
from PLM.
If no buttons are pressed for 30 seconds, the display
The Processor LED (1, Figure 5-29 SCOREBOARD, will return to Warning List Display, the number being
page 5-47) blinks when power is applied and the entered will be lost and the operator ID returns to the
processor is running. It blinks approximately once previous number.
per second under normal conditions. Fast blinking
indicates data reception. The Data Receive LED (2) Load And Ton Counter
blinks every time data is received.
PLM IV allows the truck operator to monitor and track
the total tons hauled and the number of haul cycles
during the shift. This display can be cleared at the
beginning of each shift to allow the operator to record
how many loads and tons have been hauled during
the shift.
930E-4SE 5-47
To get to the “Load and Ton Counter” display use "States" or stages of a typical haul cycle
the Left Arrow of the operator switches to scroll to
1. Tare Zone
the Payload Data” main level screen. Press OK to
enter the Payload Data sub-menu. Press the Up and 2. Empty
Down Arrows to navigate to the Load Counter/Total
3. Loading
Ton Counter display.
4. Maneuvering
Clearing the total ton counter or total load counter
clears both records. To clear the total ton and total 5. Final Zone
load counter, perform the following:
6. Hauling
1. Using the operator switches, scroll through the 7. Dumping
displays until the “Payload Data” screen.
8. After Dump
2. Once in the “Payload Data” screen, scroll until
you reach the “Load and Ton Counter” screen.
Haul Cycle Description
Viewing Live Sensor Data A new haul cycle is started after the load has been
dumped from the previous cycle. The PLM will stay
There are two ways to view Live Sensor Data. in the After Dump state for up to 11 seconds, or until
• Using the PLM IV web server, navigate to the Real the truck reaches 8 km/h (5 mph), to confirm that the
Time Data Page. This will be covered later in the load has actually been dumped. If the current payload
document. is less than 20% of rated load, the PLM will switch
to the Tare Zone and begin calculating a new empty
• Using the Electronic Dash. tare. If, after dumping, the payload has not dropped
The display can be used to quickly show the current below 20% of rated load the meter will either return to
readings from the four suspension pressure sensors the Maneuvering or Hauling states. In this case, the
and the inclinometer. This can be used during False_Body_Up flag will be recorded in the haul cycle
regularly scheduled service periods to check the record.
state of the suspensions. These displays are live and While in the Tare Zone state, and moving faster than
will update as the values change. The live displays 5 km/h (3 mph), the PLM calculates the empty sprung
cannot be cleared and the OK position of the operator weight of the truck. This tare value will be subtracted
switch will have no effect. from the loaded sprung weight to calculate the final
All four of the suspension pressure sensors and the payload. The PLM will switch from the Tare Zone
inclinometer angle are shown on one display. To get to the Loading state if swingloads are detected. By
to the live sensor display use the Left Arrow of the raising the dump body while in the Empty or Tare Zone
operator switches to scroll to the “PAYLOAD DATA” states, the PLM can be manually switched back to the
main level screen. Press OK to enter the Payload Tare Zone to calculate a new tare.
Data sub-menu. Press the Up and Down Arrows to From the Empty state, the PLM will switch to the
navigate to the live sensor display. Loading state through one of two means. If the
The inclinometer displays whole degrees of positive brake lock is applied, the PLM will be analyzing the
incline is truck nose up (symbol + followed by degrees) suspension pressures to detect a swingload. If a
or negative incline is truck nose down (symbol – swingload is detected, the meter will switch to the
followed by angle). Loading state. The minimum size for swingload
detection is 10% of rated load. Swingload detection
PAYLOAD OPERATION & usually takes 4- 6 seconds.
CALCULATION A.2-0000073480 The second method to switch from Empty state to
Loading state is through continuous loading. This can
Description of Haul Cycle States happen if the brake lock is not used during loading.
The typical haul cycle can be broken down into eight If the load increases above 50% of rated load for 10
distinct stages or states. Each state requires the seconds without the brake lock applied, the meter will
Payload Meter (PLM) to make different calculations switch to loading and record the continuous_loading
and store different data. flag in the haul cycle.
5-48 930E-4SE
The PLM switches from Loading to Maneuvering as memory as the final load. The final load is determined
soon as the truck begins moving. The maneuvering by a series of calculations made while the truck is
zone is 160 m and is designed to allow the operator to traveling to the dump site.
reposition the truck under the shovel. More payload
can be added anytime within the maneuvering zone. Carry Back
Once the truck travels 160 m (0.1 miles) the PLM
switches to the Final Zone and begins calculating Carry back is calculated as the difference between the
payload. If the body is raised while the PLM is in the new truck tare and the clean truck tare. The clean
Maneuvering state, the NO FINAL LOAD flag will be truck tare is calculated using the PLM web server.
recorded in the haul cycle record, no payload will be When the suspensions are serviced or changes are
calculated, and the meter will switch to the Dumping made that may affect the sprung weight of the truck, a
state. new clean truck tare should be calculated.
While in the Final Zone moving faster than 5 km/h (3 Measurement Accuracy
mph), the PLM calculates the loaded sprung weight
of the truck. The same advanced algorithm is used to Payload measurements are typically repeatable within
calculate the empty and loaded sprung weights. The 1%. Accuracy for a particular scale test depends
PLM will switch from the Final Zone to the Dumping on specific combinations of pressure sensors and
state if the body up signal is received. If the truck payload meters as well as the specifics of each scale
has moved for less than 1 minute in the Final Zone, test. Comparisons from different scale tests are often
the PLM will calculate the final payload using an made without considering the differences introduced
averaging technique which may be less accurate. If by the specific installation and operation of the scales
this happens, the average_load flag will be recorded for each test. In addition, each pressure sensor and
in the haul cycle. PLM introduces it’s own nonlinearity. Each truck
becomes an individual combination of sensors and
The PLM switches to the Dumping state when the PLM. Errors from these sources can introduce up to a
dump body rises. The PLM will switch from Dumping ±7% bias in the PLM calculations for a specific scale
to After Dump when the dump body comes back down. test, for an individual truck.
From the after_dump, the PLM will switch to one of
three states: Because the PLM calculates a new empty tare for
each payload, a detailed scale test must weigh the
1. If the average payload is greater than 20% trucks empty and loaded for each haul cycle. Using a
of rated load and no final payload has simple average of two or three empty truck weights as
been calculated, the PLM will return to the an empty tare for the entire scale test will introduce
Maneuvering state. After the truck travels significant errors when comparing scale weights to
160 m (0.1 mile) the meter will switch to PLM IV weights.
the Final Zone and attempt to calculate the
payload again. The False_Body_Up flag will SOURCES FOR PAYLOAD
be recorded in the haul cycle record. ERROR A.4-0000073398
2. If the average payload is greater than 20% Payload Error
of rated load and the final payload has been
calculated, the PLM will switch back to the The number one source of errors in payload
Hauling state. The False_Body_Up flag will be calculation is improperly serviced suspensions.
recorded in the haul cycle record. The Payload Meter (PLM) calculates payload by
measuring differences in the sprung weight of the
3. If the average payload is less than 20% of rated truck when it is empty and when it is loaded. The
load, the PLM will switch to the Tare Zone and sprung weight is the weight of the truck supported by
begin to calculate a new empty tare. the suspensions. The only method for determining
sprung weight is by measuring the pressure of the
Load Calculation nitrogen gas in the suspensions. If the suspensions
The final load calculation is different from the last are not properly maintained, the PLM cannot
swingload calculation. The accuracy of the swingload determine an accurate value for payload. The two
calculation depends on loading conditions and critical factors are proper oil height and proper
the position of the truck during Loading. The last nitrogen charge.
swingload calculation is not the value recorded in
Critical Suspension Factors:
• Proper oil height.
930E-4SE 5-49
• Proper charge with nitrogen to the correct Pressure Sensors

suspension extension. See service manual for
Small variations in sensors can also contribute to
correct extension.
payload calculation errors. Every pressure sensor
If the suspensions are overcharged, the PLM will is slightly different. The accuracy differences of
not be able to determine the empty sprung weight of individual sensors along the range from 0 to 4000
the truck. The suspension cylinder must be able to psi can add or subtract from payload measurements.
travel up and down as the truck drives empty. The This is also true of the sensor input circuitry within
pressure in an overcharged suspension can push individual payload meters. These differences can
the suspension rod to full extension. In this case, stack up 7% in extreme cases. These errors will be
the pressure inside the cylinder does not accurately consistent and repeatable for specific combinations
represent the force necessary to support that portion of payload meters and sensors on a particular truck.
of the truck.
Swingloads
If the suspensions are undercharged, the PLM will
not be able to determine the loaded sprung weight Swingload calculations can be affected by conditions
of the truck. The suspension cylinder must be able at the loading site. Parking the truck against the berm
to travel up and down as the truck drives loaded. or large debris can cause the PLM to inaccurately
If the pressure in an undercharged suspension calculate individual swingloads. While the PLM
cannot support the load, the suspension will collapse system uses an advanced calculation algorithm to
and make metal-to-metal contact. In this case, the determine swingloads, loading site conditions can
pressure inside the cylinder does not accurately affect the accuracy. It's critical the Brake Lock is used
represent the force necessary to support that portion without the Park Brake.
of the truck.
NOTE: The Payload Meter will not calculate
Low oil height can also introduce errors by not swingloads unless the Brake Lock, without the Park
correctly supporting a loaded truck. This is why the Brake, is used during the loading process.
correct oil height and nitrogen charge are the most
critical factors in the measurement of payload. If the HAUL CYCLE WARNING
suspensions are not properly maintained, accurate FLAGS A.9-0000073397
payload measurement is not possible. In addition,
suspension maintenance is very important to the life Haul Cycle Data
of the truck. All data is calculated and stored in metric units within
the payload meter. The data can be downloaded
Loading Conditions directly into the .CSV file format. Units for displaying
Brake Lock engagement without using the Park Brake haul cycle data and for downloading haul cycle data
is critical during the loading process. file should be configured in the System Configuration
web page. Whether the user has configured Metric,
NOTE: Only by engaging the Brake Lock with the Short or Long tons, the data on both the real time
truck in Neutral, No Park Brake, will the Payload Meter data page and the view haul cycle data page will be
properly calculate swingloads. converted to the selected unit. The haul cycle file
download will be in the selected unit.
In addition, this condition reduces stress on the
suspensions, drive system, brakes, and frame. Refer to Table 5-4 HAUL CYCLE DATA, page 5-51 for
A large number of "Continuous Loading" flags in details on each column of the haul cycle record.
payload data can be an indication of poor loading site
practices. Addressing these "Continuous Loading" NOTE: Pressure Sensor selection is only for Real
flags will create an opportunity for site improvement Time data display.
leading to better production.
The final load is calculated as the truck travels away
from the shovel. Variations in road conditions and
slope are compensated for in the complex calculations
performed by the PLM.
5-50 930E-4SE
Figure 5-30 PLM IV CONFIGURATION
The units noted in table below are the actual units are referenced in seconds since the haul cycle start
stored in the data file. The value for the haul cycle time. The following information is recorded for each
start time is the number of seconds since January 1, haul cycle.
1970 to start of the haul cycle. All other event times
Table 5-4 HAUL CYCLE DATA

Data Unit Remark
Haul Cycle Record
Number Haul cycle number since the start of the file
Number
Up to 22 characters can be stored in this field to identify the truck.
Truck # alpha-numeric
Typically this field will be just the truck number
930E-4SE 5-51
Data Unit Remark

Haul Cycle Start Date of haul cycle start, haul cycle starts when the meter transitions
MM/DD/YYYY
Date from Dumping to Empty state after the previous haul cycle
Haul Cycle Start Time of haul cycle start, haul cycle starts when the meter transitions
HH:MM:SS
Time from Dumping to Empty state after the previous haul cycle
Payload tons Net calculated payload of the haul cycle
Number of Swing
number The number of swing loads detected by the payload meter
loads
This is a 4 digit number that can be entered by the operator at the
Operator ID number
start of the shift
Each letter represents a particular warning message about the haul
Status Flags alpha
cycle
Carry Back tons The difference between the latest empty tare and the clean truck tare
Total Cycle Time HH:MM:SS Time from the start to the end of the haul cycle
Empty Run Time HH:MM:SS Time in the Tare Zone and Empty states with the truck moving
Empty Stop Time HH:MM:SS Time in the Tare Zone and Empty states with the truck stopped
Loading Time HH:MM:SS Time in the Loading state
Time in the Maneuvering, Final Zone and loaded states with the truck
Loaded Run Time HH:MM:SS
moving
Time in the Maneuvering, Final Zone and loaded states with the truck
Loaded Stop Time HH:MM:SS
stopped
Dumping Time HH:MM:SS Time in the Dumping state
Actual start time when the meter transitions from empty to Loading
Loading Start Time HH:MM:SS
state
Loading Dump Actual start time when the meter switches from loaded to Dumping
HH:MM:SS
Time state
Loaded Haul
m Distance traveled while loaded
Distance
Empty Haul
m Distance traveled while empty
Distance
Loaded Max Speed km/h Maximum speed recorded while the truck is loaded
Loaded Max Speed
HH:MM:SS Time stamp when the max speed occurred
Time
Empty Max Speed km/h Maximum speed recorded while the truck is empty
Empty Max Speed
HH:MM:SS Time stamp when the max speed occurred
Time
Peak Positive Positive frame torque is measured as the frame twists in the clockwise
ton-meter
Frame Torque direction as viewed from the operator's seat
Peak Positive
HH:MM:SS Time stamp when the positive peak torque occurred
Frame Torque Time
Peak Negative Negative frame torque is measured as the frame twists in the
ton-meter
Frame Torque counter-clockwise direction as viewed from the operator's seat
Peak Negative
HH:MM:SS Time stamp when the negative peak torque occurred
Frame Torque Time
5-52 930E-4SE
Data Unit Remark

Peak Sprung Load tons Peak dynamic load calculation
Peak Sprung Load
HH:MM:SS Time stamp when the peak instantaneous load calculation occurred
Time
Front-Left
t-km/h Tire ton-km/h for haul cycle
Tire-Ton-km/h
Front-Right
Tire-Ton-km/h
Average Rear
Tire-Tonkm/h
Micro Fail Torque No unit Micro Fail from Rainflow torque Counting
Micro Fail Sprung
No unit Micro Fail from Rainflow Sprung Weight Counting
Weight
Maneuvering Torque average collected during Maneuvering while driving at greater
ton-meter
Torque than 3 mph
Torque average collected during Final Zone while driving at greater
Final Zone Torque ton-meter
than 3 mph
The empty (tare) sprung weight calculated while the truck was driving
Tare Sprung Weight tons
empty
Payload Estimate
tons The payload value of the last swingload calculated at the loading site
@ Shovel
Quick Payload The payload estimate calculated as the truck is driving away from
tons
Estimate the loading site
Gross Payload tons The payload estimate of the full load (Net Payload + Carry Back)
Unique Serial # number Haul cycle number since the first haul cycle
Fuel Consumption Liters/Gallons Fuel consumed for complete haul cycle
These values are internal calculations used in the continued
Reserved 2-10 number
development of the PLM IV system and should be ignored
Haul Cycle Warning Flags may be a problem with the wiring or the brake lock
was not used. The payload meter will not measure
The payload meter expects haul cycles to progress in
swingloads unless the brake lock is used during the
a particular way. When something unexpected takes
loading process.
place, the system records a warning flag.
Loading to Dumping Transition (B)
Several events within the haul cycle can cause a
This message indicates the payload meter senses
warning flag to be generated. Each one indicates an
a body up input during the loading process.
unusual occurrence during the haul cycle. They do
This message is usually accompanied by a
not necessarily indicate a problem with the payload
“No_Final_Load (C)” flag.
meter or payload calculation.
No Final Load (C)
Continuous Loading (A)
This message indicates the payload meter is unable to
This message indicates the truck is loaded over 50%
determine the final payload in the truck. Typically, this
full without the payload meter sensing swingloads.
means that the payload meter switched from a loaded
This indicates that a continuous loading operation
state to the dumping state before the load could be
was used to load the truck. It may also indicate
accurately measured.
that the payload meter did not receive the brake
lock input while the truck was being loaded. There
930E-4SE 5-53
Maneuvering to Dumping Transition (D) the payload meter was shut down. This can happen
This message indicates the payload meter senses a when the main battery disconnect is used to shut the
body-up input during the maneuvering or repositioning truck down instead of the key switch. A haul cycle with
process indicating that the operator has dumped the this warning flag should not be considered accurate.
load. It may also be generated if the body-up signal Haul cycles with this warning are displayed in red on
is not properly reaching the payload meter and the the Payload Summary window and are not included in
weight in the truck falls dramatically while the truck is the summary statistics for reports on display.
maneuvering or repositioning.
Haul Cycle Too Long (M)
Average Load or Tare Used (E) This message indicates that the haul cycle took longer
This message indicates that the recorded payload than 18.2 hours to complete. The times stored for
may not be as accurate as a typical final load particular events may not be accurate. This does not
calculation. Typically, this is recorded when loading affect the payload calculation.
begins before an accurate tare is calculated or the
Sensor Input Error (N)
load is dumped before the load can be accurately
This message indicates an alarm was set for one of
measured.
the critical sensor inputs during the haul cycle. Critical
Final Zone to Dumping Transition (F) sensors are the four pressure sensors, the speed
This message indicates the payload meter senses sensors, and the inclinometer. Any flat suspension
a body-up while it is calculating the final payload or machine speed alarms will set this flag as well.
indicating that the operator has dumped the load. Without these inputs, the payload meter cannot
It may also be generated if the body-up signal is calculate payload. A haul cycle with this warning flag
not properly reaching the payload meter and the should not be considered accurate.
weight in the truck falls dramatically while the truck is
False Swingload (O)
calculating the final payload.
This message indicates the payload meter detected
False Body Up (H) a swingload, but less than 20% load was measured
This message indicates that the body was raised on the truck after it had driven 160 meters from
during the haul cycle without the load being dumped. the loading site. When this condition occurred, the
The body-up signal indicated that the truck was payload meter considered the swingload to be “false”
dumping, but the weight of the truck did not fall below and returned to the “tare zone” state. All distance and
20% of the rated load. speed statistical calculations that occurred during the
“false swingload” are recorded as part of the empty
Body Up Signal Failed (I) statistics.
This message indicates that the load was dumped
without a body-up signal being received by the
payload meter. The weight of the truck fell below
Alarm Records
20%, but the payload meter did not receive a body-up The payload meter stores alarm records to give
signal from the sensor. service personnel a working history of the system.
All codes are viewed by downloading alarm data
New Tare Not Calculated (K)
files from PLM IV or directly logging onto PLM IV
This message indicates the payload meter was not
web server. Refer to DOWNLOADING ALARM
able to accurately calculate a new empty sprung
DATA, page 5-73 Download Alarm Data procedure
weight for the truck to use as the tare value for the
for more information. Active alarms could be viewed
haul cycle. The tare value from the last haul cycle
by logging onto PLM IV web server. Each code has
was used to calculate payload.
a specific cause and should lead to an investigation
Incomplete Haul Cycle (L) for correction. Some failures can be overcome by
This message indicates the payload meter did not payload meter, such as Haul Cycle Too Long or False
have proper data to start the haul cycle after powering Body Up. However, failures with the suspension or
up. When the PLM IV powers off, it records the data inclinometer sensors cannot be overcome. Haul cycle
from the haul cycle in progress into memory. This flag data will indicate an alarm condition was present
indicates that this data was not recorded the last time during the cycle.
5-54 930E-4SE
Table 5-5 PAYLOAD METER ALARMS

Fault Code Name Description
Left front sensor
1 malfunction - Input current > 22 ma
signal high
Left front sensor
2 malfunction - Input current < 2 ma
signal low
Right front
sensor
3 Input current > 22 ma
malfunction -
signal high
Right front
sensor
4 Input current < 2 ma
malfunction -
signal low
Left rear sensor
5 malfunction - Input current > 22 ma
signal high
Left rear sensor
6 malfunction - Input current < 2 ma
signal low
Right rear
sensor
7 Input current > 22 ma
malfunction -
signal high
Right rear
sensor
8 Input current < 2 ma
malfunction -
signal low
Inclinometer
Duty cycle upper limit 95% (incorrect mounting or malfunction
9 malfunction -
inclinometer device)
signal high
Inclinometer
Duty cycle lower limit 57% (incorrect mounting or malfunction
10 malfunction -
inclinometer device)
signal low
Speed input
11 Failed to receive the speed signal from drive system.
failure
Body-up input Payload meter detects dumping activity without receiving a body
13
failure up signal
Checksum
14
failed
Memory write Indicates possible memory problem at power up. Cycle power and
16
failure recheck.
Memory read Indicates possible memory problem at power up. Cycle power and
17
failure recheck.
Rear right Rear right suspension locked in as flat. 5 bad suspension haul
18
suspension flat cycles in a row.
930E-4SE 5-55
Fault Code Name Description

Rear left Rear left suspension locked in as flat. 5 bad suspension haul cycles
19
suspension flat in a row.
20 Time change PLM IV time has been changed by more than 10 minutes.
User selected to reset the tare value. Payload for corresponding
21 Tare value reset
haul cycle will be not be accurate.
Excessive
22 Carryback is excessive and requires clean tare calibration.
carryback
User switch fault Select switch ON for more than 2 minutes, may indicate short to
26
- SELECT ground.
User switch fault
27 Set switch ON for more than 2 minutes, may indicate short to ground.
- SET
Frame Torque Data Configuring Static IP Address

Payload meter records the maximum peak positive The service computer must have an IP address
and negative frame torque values as part of a haul in the same network as the payload meter for
cycle record. The frame torque is a measure of the communication to occur. A static IP address must be
twisting action along the centerline of the truck. set on the service computer if:
Positive frame torque is measured when the 1. The service computer is directly connected to
suspension forces on the front of the truck act to the RJ45 port on the payload meter;
twist the frame in the clockwise direction as viewed
or
from the operators seat. Negative frame torque is
measured when the forces from the suspension act 2. The service computer and payload meter are
in the opposite direction. connected to the same Ethernet switch and
there is no device on the switch acting as a
For example, if the left front and right rear pressure DHCP server.
raises as the right front and left rear pressure drops,
the truck frame experience twisting motion along the To configure static IP Address for laptop connection
longitudinal centerline. In this case, the payload meter follow the steps listed below.
will record a positive frame torque.
1. Right click on a Wired Connection icon in the
bottom right corner.
SYSTEM CONFIGURATION A.3-0000073396
2. Click on “Open Network and Sharing Center.”
Connecting To The Payload Meter IV Web
Server 3. On the Network and Sharing Center window,
click on “Change adapter setting” on the left
The PLM IV webserver allows users to configure the hand bar.
payload meter system, view real time data, update
the payload meter software, and download haul cycle 4. Right click on the computer's Wired Connection
and alarm record data. PLM IV can be connected Device.
to a service computer via Cat5e cable connection 5. Click on "Properties.
from the RJ45 Ethernet Port on the payload meter
communication board or it can be connected to a 6. Click on "Internet Protocol Version 4
wireless radio on the truck if wireless connection is (TCP/IPv4) to highlight the option.
desired. 7. Click on "Properties."
Once connected, use a web browser like Internet 8. Select "Use the following IP address:."
Explorer® or Google Chrome™ to access the web
server. 9. Fill in the following IP Settings:
NOTE: The service computer static IP address must

be configured within the same network range as the
payload meter.
5-56 930E-4SE
a. Set the service computer’s IP address b. Subnet mask to 255.255.255.0

within the same IP address range of
10. Click "OK."
PLM IV. For example if PLM IV has an
assigned IP address of 192.168.3.128, 11. Click "OK."
set the IP address of service computer
NOTE: To return the service computer’s network card
192.168.3.XXX ( here XXX is any number
to normal operation, follow steps 1 through 7, but in
between 1 and 254, but not 128, because
step 8 select “Obtain an IP address automatically.”
128 is already assigned to PLM IV in this
example.)
930E-4SE 5-57
Figure 5-31 STATIC IP ADDRESS CONFIGURATION
Once the PC’s IP Address is set: • At the login page, enter Username “plm” and
Password “pass”
• Open Internet Explorer on PC
• Click “Connect”
• Enter the IP Address of PLM IV on a particular truck
(or Default Static IP Address)
5-58 930E-4SE
Real Time Data Page

The Real Time Data (RTD) page is mainly for
observing the data and time, suspension pressure
values, truck speed, haul cycle status, digital outputs
and other vital information. The page is refreshed
itself every 1 second. With every refresh this page
indicates normal operation of PLM IV. The suspension
pressures are inputs from each four pressure sensors.
Incline-angle is read from the on-board inclinometers.
The suspension pressures are inputs from each of
the four pressure sensors.
Incline-angle is read from the on-board Inclinometers.
Connecting to PLM IV may take several seconds
depending on the speed of local Ethernet activity. NOTE: The units are displayed here not on the
Allow at least 30 seconds for PLM IV box to boot after electronic digital display on the truck.
turning truck Key Switch ON. If the connection fails to
open, verify the CAT5e cable is good. On the service Each digital output lists the present condition “ON” or
laptop go to ‘Network and Sharing’ settings, choose “OFF” and diagnostic status of “NORMAL”, “OPEN” or
“Change Adapter Settings” option, by right clicking “SHORT”. Typical condition is NORMAL. If there is no
choose “Disable” and then “Enable” on “Local Area lamp connected, or there is a broken wire, then the
Connection Network” icon. status will be OPEN. If there is electrical short circuit,
the output will be disabled until the system restart and
If the connection problem persists then reboot the status will be displayed as “SHORT”.
PLM IV by turning truck Key Switch OFF and Turning
ON after all LED on Communication board turned off. Status Flags are “Haul Cycle Warning Flags,” indicate
situations that the payload meter defines as abnormal
All payload meter configurations are set from the to a standard haul cycle process.
web server. After log-in credentials are entered, the
PLM IV homepage looks like Figure 5-32 PLM IV Clean Tare Status will display the status “CLEAN
HOMEPAGE, page 5-59 below. TARE COMPLETE” normally as-well-as the final
Clean Tare value, unless the user is performing a new
clean tare. The operation typically takes 15 minutes.
During this operation the Clean Tare Status shows
“Clean Tare in Progress…”
Figure 5-33 REAL TIME DATA

Payload Meter IV System Configuration
The configuration page has option to permanently
save several truck specific settings. There is no need
Figure 5-32 PLM IV HOMEPAGE to reboot the payload meter after updating any of
these configurations.
930E-4SE 5-59
NOTE: Some of the configuration parameters

require a password to change. The password for all
parameters except the Payload Gain is “Kac2300”.
This is case sensitive. The password for the payload
gain, which is a critical setting, is not included in this
document.
Figure 5-34 PAYLOAD METER IV CONFIGURATIONS
There are ten configuration parameters on this page. • Pressure Sensor Units (for RTD web page only)
Below is a description of each.
• Date and Time
• Truck Model
• Payload Gain Factor
• PLM IV Mounting Orientation
• Payload Light Test
• Gauge Display Units
• Truck Tare Reset
5-60 930E-4SE
• Drive System type

• Truck Tire Monitor (Michelin Truck Tire Monitoring
System)
Truck Model
There are many different truck models available for
selection. The correct truck model must be selected
for the payload meter to accurately estimate payloads.
Figure 5-35 TRUCK MODEL SELECTION

PLM IV Mounting Orientation (for
Onboard Inclinometers)
It is important to configure the payload meter
according to its mounted position in the auxiliary
control cabinet. Refer to Figure 5-36 PAYLOAD
METER MOUNTING ORIENTATION, page 5-62 for
configuring the positions inside the auxiliary control
cabinet. Match the wall that the payload meter is
mounted on, to the number of the wall in the image.
930E-4SE 5-61
• Position (1) Right Tire • Position (3) Truck Forward

• Position (2) Truck Rear • Position (4) Left Tire
Figure 5-36 PAYLOAD METER MOUNTING ORIENTATION

Gauge Display Units and keep the system powered on to recharge the clock
power supply. Format for Date and Time: MM/DD/YY
These units can be displayed in Metric, Short or Long
HH:MM:SS
Tons.
• When viewing in either Short or Long Tons, the Payload Gain Factor
speed and distance are displayed in miles.
• When viewing in Metric Tons, the speed and
• DO NOT modify unless required.
distance are displayed in kilometers.
Pressure Sensor Units (for RTD web Default payload gain factor is 100, but the user has
page only) the option to adjust this value between 90 to 110.
It is advised NOT to change the default payload
When viewing the Pressure Sensor Units on the Real gain value, as this change will affect all payload
Time Data (RTD) web page, the units can be displayed calculations.
in either Kg/cm2 or PSI. When recording the RTD to a
USB memory flash drive, the Pressure Sensor Units Payload Light Test
are always recorded in Kg/cm2.
This allows the user to test the Green, Amber, and
Date and Time Red lights in a case where a new harness cable
is made or the lights are replaced. Checking the
The current payload meter time is shown on the Real check-box corresponding to the light and clicking the
Time Data Page, page 5-59. It is important to set TestPayloadLights button will cause that light to turn
correct date and time information, see Payload Meter on. The light will remain on for five minutes, before
IV System Configuration, page 5-59 for settings. Each returning to original state. More than one light may
time the truck is powered ON, PLM IV receives a be turned on at a time.
date & time message from KOMTRAX Plus. If the
truck does not have a KOMTRAX Plus it retains the Truck Tare Reset
user saved date and time values. The payload meter
will hold a date and time for approximately 30 days
without power if the battery is charged fully. If the • DO NOT modify unless required.
date and time is lost, reset the current information,
5-62 930E-4SE
This option allows user to reset the Truck Tare to its warranty claims. The Komatsu distributor number
default. DO NOT use this function unless the payload goes in this field. This field holds 20 alphanumeric
meter state machine is locked up or has calculated characters.
an unusually low tare value. Check the system for a
Komatsu assigns a number to each customer. The
SENSOR LOW PRESSURE alarm.
KMS Customer field can hold the name of the mine
or operation where the truck is in service. This
Truck Data Configuration number is used for warranty claims. This Komatsu
This page allows the user to configure Haul Cycle customer number goes in this field. This field holds
Data headers, Real Time Data and Alarm Data for 20 alphanumeric characters.
data download files. These fields include the truck
OS (Operating System) Version Number and PLM IV
frame serial number, customer unit number, distributor
Software Version Number are automatically updated
information, and customer information.
after a software update. The user has to visit this page
to verify the software version number.
If the user fails to enter the Frame Serial Number,
Customer Unit number and distributor number, the
default “Unknown” will be saved. The user is required
to save these fields only once. In the case of field
software updates the previously saved data will be
retained.
NOTE: A password is required to make changes to
these parameters. “Kac2300”
Inclinometer Calibration
The inclinometer calibration procedure is designed to
compensate for variations in the mounting position of
the inclinometer. The inclinometer input is critical to
the payload calculation.
To calibrate the inclinometer use the instructions
below or those provided on the Payload Meter IV
Configurations screen.
1. This procedure should be performed
on relatively flat ground like that of the
maintenance area. Make sure that the
Figure 5-37 TRUCK DATA INFORMATION SCREEN
suspensions are properly serviced.
The frame serial number is found on the plate
2. With the truck stopped and the parking brake
mounted to the truck frame located on the lower right
engaged, turn the steering wheel quickly left
rail facing the right front tire. It is important to enter
and right to loosen the suspensions. Press
the correct frame serial number as this is one of the
the “START Sample 1” button to take the first
key fields used in off-truck databases.
inclinometer sample.
The customer unit, or truck number, is the specific
3. Turn the truck around and park in the exact
truck number assigned to each piece of equipment
same spot as before, but facing the other
for quick identification at the mine site. This number,
direction.
or name, can be entered in the Customer Unit
Number field. It is important to enter the unique 4. With the truck stopped and the parking brake
truck number as this is one of the key fields used in engaged, turn the steering wheel quickly left
off-truck databases. This field holds 20 alphanumeric and right to loosen the suspensions. Press the
characters. “START Sample 2” button to take the second
inclinometer sample.
Komatsu assigns a number to each distributor. The
KMS Distributor is the name of the distributor that 5. Press the “CalibrateInclinometer” button for the
helped install the system. This number is used for payload meter to average the two samples and
determine the mounting offset value.
930E-4SE 5-63
Figure 5-38 PAYLOAD METER IV CONFIGURATION

Overload Threshold
This option can be adjusted to set the load carrying
capacity at which truck speed becomes limited. The
speed limitation will help prevent frame or suspension
damage in the event of an overload. By default this
value is 110% of the rated load capacity.
5-64 930E-4SE
Figure 5-39 OVERLOAD THRESHOLD VALUE

Clean Truck Tare The Clean Truck Tare should only be initiated if the
payload meter is in the TARE_ZONE or EMPTY
The payload meter uses the clean truck tare value
states. If you attempt to initiate a Clean Truck Tare
to calculate the carryback load of each haul cycle.
while the truck is loaded, the Clean Truck Tare
The carryback value in the haul cycle record is the
calculations will not start. It will show “ Truck should
calculated empty truck tare minus the clean truck tare.
be in Empty or Tare Zone state.”
This procedure should be performed after service
NOTE: The truck must be driven continuously for
to the suspensions or when significant changes are
11 minutes at a minimum speed of 5 Km/hr (3.1
made to the sprung weight of the truck. Before
mph). The payload meter does not calibrate while the
performing this procedure, it is critical that the truck
machine is stopped.
is cleaned, the suspensions are filled to the proper oil
height and charged to the proper nitrogen pressure. NOTE: Drive on actual haul roads during the
calibration process; otherwise, inaccurate payload
Once the clean tare is started, the payload meter will
readings may result.
begin to calculate the clean empty sprung weight of
the truck. This calculation continues while the truck NOTE: DO NOT use the wheel brake lock during
drives to the next loading site. Once the procedure calibration. Inaccurate payload readings may result.
is started, the status of the process progress can be
monitored in Real Time Data page. The truck does
not need to be moving to start this procedure.
930E-4SE 5-65
Once the calibration is complete, confirm that the may record a very low empty sprung weight value. In
payload meter states “CLEAN TARE COMPLETE” on this case, after the body is installed, the payload meter
the Real Time Data display page. Verify the displayed may mistakenly conclude that the weight of the body
value is in the expected range for the truck type. alone constitutes a load, and refuse to return the truck
Once complete, the payload meter is ready to begin to the empty (TARE_ZONE) condition. In unusual
loading. conditions such as this, the Clean Truck Tare option
will allow the user to override the measured empty
Remember, this operation should only be performed in sprung weight value with a default value and force the
special circumstances. For instance, if the truck was truck back to the empty (TARE_ZONE) condition.
driven without the body installed, the payload meter
Figure 5-40 CLEAN TRUCK TARE CONFIGURATION
5-66 930E-4SE
Tare Reset conditions such as this, the Clean Truck Tare option
will allow the user to override the measured empty
Resets the vehicle tare weight to the default value
sprung weight value with a default value and force
(around 40% of rated payload).
the truck back to the empty (Tare Zone) condition.
This operation should only be performed in special
circumstances. For instance, if the truck was driven Custom Truck Configuration
without the body installed, the payload meter may
Visit the Custom Truck Configuration web page to
record a very low empty sprung weight value. In this
configure certain custom dump truck bodies.
case, after the body is installed, the payload meter
may mistakenly conclude that the weight of the body NOTE: If custom load light thresholds have been
alone constitutes a load, and refuse to return the configured, the load light percentages must be
truck to the empty (Tare Zone) condition. In unusual re-saved to use the updated unsprung weight.
Figure 5-41 CUSTOM TRUCK CONFIGURATION SCREEN

First, select the correct truck model so the payload
meter can accurately estimate payloads.
930E-4SE 5-67
Figure 5-42 SELECTING TRUCK MODEL

Next, the Custom Truck Configuration Page allows the number is always follows 58B06026xx. Here xx is
user to set the load threshold percentages for the load sub version number. For example the latest software
lights. file is 58B0602604.S19). The file to be downloaded
is the same as the part number. This disk is then
The default is Green (50%), Amber (90%), and Red inserted into either of the USB ports on the payload
(105%). meter communication board. Once the user enters
the Admin Password from Figure 5-43 START FLASH
Field Software Update PROGRAM SCREEN, page 5-69, the new software
PLM IV has the capability to update its software in image can be uploaded to the payload meter.
the field. The user can obtain the latest released NOTE: It is advised not to update the software unless
version of software from the Komatsu ExtraNet, then there is a fix or enhancement that is related to the
unzip and copy the file to a FAT32 formatted USB specific truck which the payload meter is installed.
memory drive, preferably 2 GB. It is important to
only have one file on the USB drive. The software
5-68 930E-4SE
Figure 5-43 START FLASH PROGRAM SCREEN

The software update process is initialized by pressing This entire process will take between 20 and 25
“Program Now” on Figure 5-44 SOFTWARE FIELD minutes. At the end of the install, the payload meter
UPDATE STATUS SCREEN, page 5-70. will restart causing the web server to disconnect.
NOTE: Follow the instructions on the web page. Login to the payload meter web server again and
Failure to follow the instructions could result in Figure 5-37 TRUCK DATA INFORMATION SCREEN,
unusable PLM IV hardware. page 5-63 to verify that the software version number
has successfully updated.
930E-4SE 5-69
Figure 5-44 SOFTWARE FIELD UPDATE STATUS SCREEN

NOTE: It is important that the payload meter Does Not Viewing Haul Cycle Data
lose power during this process. Power loss before the
PLM IV records several parameters important
install is complete can cause corruption of the payload
to analyzing each haul cycle. This data can be
meter application.
downloaded or viewed from the web server. For quick
NOTE: In case of failure to field software update, viewing, this page displays 25 haul cycles at a time.
please contact Komatsu Support Team for help.
A haul cycle number can be entered in the field at the
top of the page, and when the “Next” button is pressed
the records starting with that number will be displayed.
5-70 930E-4SE
Figure 5-45 HAUL CYCLE DATA SCREEN

DOWNLOADING HAUL CYCLE DATA The PLM will store up to nine files with up to 2048
haul cycles in each file. Each file will have a separate
To download the haul cycle record of Payload Meter
download link under “Download Haul Cycle Data,” with
(PLM), press the link underneath “Download Haul
the most recent file on the bottom of the list. Once full
Cycle Data.” This will start the download of payload
it will delete the oldest file.
data in CSV format to the user’s service computer.
This file can be opened in Microsoft Excel® for NOTE: User must save downloaded Alarm file with
viewing or analysis. unique name on service PC.
930E-4SE 5-71
Figure 5-46 HAUL CYCLE DATA DOWNLOAD

VIEWING ALARM DATA An alarm number can be entered in the field at the top
of the page, and when the “GoNext” button is pressed
PLM IV tracks several parts of the PLM system for
the records starting with that number will be displayed.
abnormalities in operation. These abnormalities
create alarms that can be downloaded or viewed from
the web server. For quick viewing, this page displays
25 alarms at a time.
5-72 930E-4SE
Figure 5-47 ALARM RECORDS SCREEN

DOWNLOADING ALARM DATA the most recent file on the bottom of the list. The
maximum number of Alarm Records at any point of
To download the alarm history of payload meter, press
time is 3648. At that point the oldest files will be
the link underneath “Download Alarm Data.” This
deleted to save new files.
will start the download of the alarm history in CSV
format to the user’s service computer. This file can be NOTE: User must save downloaded Alarm file with
opened in Microsoft Excel® for viewing or analysis. unique name on service PC.
The PLM will store up to two files with up to 1824
alarms in each file. The two files will have a separate
download link under “Download Alarm Data,” with
930E-4SE 5-73
Figure 5-48 ALARM DATA DOWNLOAD
5-74 930E-4SE
UPLOADING DATA
Figure 5-49 UPLOADING HAUL CYCLE AND ALARM DATA
The Payload Meter (PLM) application uses data that the left side of the screen, and enter the specific
has been uploaded and stored on the server. The information about the location, distributor, and
reports generated by the application are in PDF customer.
(Adobe) format. CSV files are also available for
2. Click the “Browse” button to locate the file
special analysis. The upload feature allows you to
desired for uploading. Multiple files can be
send the PLM data stored on your computer to the
submitted at once by clicking a new “Browse”
server.
button for each file.
To access the PLM application, perform the following:
NOTE: An uploaded file can either contain data for a
1. Open the internet browser and go to group of trucks or an individual truck. The uploaded
https://www.mykomatsu.com. User id and file can also contain previously uploaded data with
password is required. If you need access, recent data. The application will automatically sort the
either contact your administrator or click machines.
“Register Now”. 3. When all the files have been selected, click the
2. Once logged in, there will be “Go To” links for “Upload” button. The time it takes to complete
the applications that you have access to. Click the upload will depend on the number and size
“Go to PLM” to access the PLM application. of the file(s) submitted.
NOTE: If no link exists, send an email to: 4. Once the uploading is finished, click “Process
servicesystems@komatsuna.com. Include your the file(s)”.
company and contact information. 5. When the files are finished processing, a
To upload PLM information to the server, perform the report will be generated that will display graphs
following: corresponding to what months were included
within the PLM data for each truck.
1. Once logged in and at the “Payload
Management” screen, click “Data Upload”, on
930E-4SE 5-75
NOTE: If you receive a “Mismatch” error, it means Detailed Multi-Page Report

that a specific truck was not registered on the
The detail report starts with the summary report and
system beforehand. Please send an email to
follows with pages of data for each haul cycle. The
servicesystems@komatsuna.com to register the
report shows date, time, payload, cycle times, cycle
machine. Be sure to include the truck serial number
distances, speeds and the number of swing loads.
and ownership information.
The detailed report contains the information listed
Payload data can be uploaded to
below:
“www.MyKomatsu.com” where a payload
management report can be generated to analyze • Customer Information
payload data. The data analysis tools allow the user
• Machine Information
to monitor the performance of the payload systems
across the fleet. Analysis begins when the "View • Reporting Period
Payload Data" button is pressed. This starts an "all
• Load Distribution
trucks, all dates, all times" query of the database and
displays the results in the Payload Summary Form. • Alarms
The user can change the query by changing the dates, • Critical Warning Flags
times, or trucks to include in the query for display.
• Non-Critical Warning Flags
NOTE: Data can be uploaded in any units, Metric • Productivity
tons, Short tons, or Long tons. The database always
maintains a common unit of Metric tons. User has • Swingload Occurrence
option to generate the detailed report in Metric tons • Haul Distance
or Short tons.
• Weekly Activity
NOTE: It is recommended that data be uploaded in
only one unit of measure, either metric (long ton) or • Daily Activity
English (short ton). When data is uploaded in multiple • Speed and Tire
units some resolution may be lost due to rounding.
• Weight and Torque
Creating a Query NOTE: Some haul cycles may contain the Sensor
The program defaults to show all trucks, all types, all Input warning flag. This warning indicates that one
dates and all times for the initial query. The display of the four pressure sensors or the inclinometer was
can be narrowed by selecting which trucks or types to not functioning properly during the haul cycle. Haul
view and for what dates and times. It is important to cycles with this warning are displayed in red on the
carefully select the query data and press the “Query Payload Summary window and are not included in the
Database & Display” button before printing a report. summary statistics for reports or display.
Choosing one particular truck number will limit the
Creating Graphs
data in the displays, summaries and reports to the one
selected truck. To create reports for truck number 374, The PLM data could be downloaded directly in .CSV
select 374 from the pull-down menu and hit the “Query format and user could generate graphs that quickly
Database and Display” button. summarize payload data. These graphs can be
customized by choosing required date range.
The truck type is the size of the truck from the family of
Komatsu trucks. This allows the user to quickly view User could use Microsoft Internet Explorer® or Google
results from different types of trucks on the property. Chrome® or any other browsers to connect to PLM
For example, a separate report can be generated for device and no PC Software required for downloading
830E and 930E trucks. The default query starts in PLM data.
1995 and runs through the current date on the PC. To
narrow the range to a specific date, change the “From” Field Software Update Procedure
and “To” dates.
The user shall follow the instructions listed below
The time range sorts the times of the day for valid carefully for successful software reprogramming. This
dates. Changing the time range to 6:00AM to 6:00PM process is required to perform only when there is a
will limit the payloads displayed to the loads that new software release available in Komatsu Extranet
occurred between those times for each day of the or there is published Parts & Service News (PSN)
date range. Times are entered in 24:00 format. with new features or field change requests.
5-76 930E-4SE
From PLM IV home page, select Field Software

Update link to reprogram payload meter firmware.
Figure 5-50 FIELD SOFTWARE UPDATE
NOTE: The process might take up to 25 minutes. NOTE: The firmware file name will be the software
part number. For example 58B0602604.S19 is the
NOTE: Do not power down or disconnect the USB latest version of the software available in Extranet
memory disk during the software process. where 04 is sub version number.
NOTE: Doing so may result in permanent damage to NOTE: Do not modify the file name or edit the file
PLM IV. contents.
1. Download the latest version of the payload 3. Format a 2GB USB memory disk and copy the
meter firmware from the Komatsu Extranet, 58B06026XX.S19 file on to it.
completely new suite of SW needed, see the
Extranet, web address is as follows: NOTE: A memory disk larger than 2GB takes more
time to mount & unmount
https://www.komatsuamerica.net/northamerica/
4. Keep only one copy of the files on the USB
komtraxvhmsplm/vhmsplm/usefulinformation/ memory disk.
komtraxplusplmsoftware/ 5. Insert the USB disk into one of the USB slots
2. Unzip the 58B060260xx.zip file. on Payload Meter Communication Board.
930E-4SE 5-77
6. Turn the Keyswitch ON. 8. The next screen is initiate the software update.
7. Login to PLM IV web server and click on
StartProgram button by navigating onto Field
Software Update screen.
Figure 5-51 PROGRAM NOW
If the USB disk is mounted successfully, then the next

screen will be displayed “software re-programming
initialization is in progress.”
Figure 5-52 INITIALIZATION
If the USB is not mounted or file is not detected

or corrupted then “USB Error” messages will be
displayed.
5-78 930E-4SE
Figure 5-53 ERROR/FILE CORRUPTION

If the software previously installed successfully, and latest software version, then reboot the PLM IV. Turn
the system does not detect the USB disk then the OFF Key Switch, wait until all of the LED’s on the
message “Verify the software version number” will Communication Board turn OFF, then turn Key Switch
be displayed. If user chooses to update the very ON.
Figure 5-54 VERIFY THE SOFTWARE VERSION

If user has to repeat the above step, reboot PLM initializing the software re-programming as described
IV, with correct firmware version until the message in 5-52 INITIALIZATION, page 5-78, the next screen
as in 5-52 INITIALIZATION, page 5-78 Software will displayed as in 5-55 USB MEMORY DISK
re-program initialization appears. After successfully VERIFICATION, page 5-80.
930E-4SE 5-79
Figure 5-55 USB MEMORY DISK VERIFICATION

Successful completion of the memory disk verification
the complete file checksum verification will be
initialized. As shown in the 5-56 COMPLETE FILE
CHECKSUM VERIFICATION (7 MINUTES), page
5-80.
Figure 5-56 COMPLETE FILE CHECKSUM VERIFICATION (7 MINUTES)

The file checksum process might take up to 7 minutes.
The message with appropriate decrementing time is
displayed.
5-80 930E-4SE
After successfully completing the file checksum

the payload meter flash memory will be erased to
reprogram new firmware.
Figure 5-59 ERASE MEMORY PROGRESS
Memory erasing could take 2 to 3 minutes to complete. Appropriate error messages will be displayed in
Reprogramming progress status messages will be case of erase failure. User has to contact Komatsu
displayed after successfully erasing the flash memory. Customer Support Team with error details.
Figure 5-60 APPLICATION REPROGRAMMING INITIALIZATION
930E-4SE 5-81
Application reprogramming could take around 8

minutes to complete, the progress messages will be
displayed starting with 5%, 15%, 25% etc.
Figure 5-61 APPLICATION REPROGRAMMING PROGRESS 5%
5-82 930E-4SE
Within a few seconds of the program successfully NOTE: After a successful software update, if the PLM
reaching 100%, the PLM IV will automatically reboot. IV does not reboot immediately, the user must wait
Click Reboot PLM IV if the payload meter does until the PLM IV reboots, or turn the keyswitch OFF
not reboot automatically within 10 seconds. It is until all the LEDs on the PLM IV Communication Board
recommended to remove the USB memory disk turns OFF before turning the keyswitch ON.
when 100% complete message is displayed. When
the PLM IV reboots the web page will ask user to
reconnect.
Figure 5-64 APPLICATION REPROGRAMMING SUCCESSFUL

Finally, the user must login and verify the software
version number by navigating to Truck Configuration
web page.
930E-4SE 5-83
Figure 5-65 VERIFY THE SOFTWARE VERSION NUMBER
5-84 930E-4SE
OPERATING INSTRUCTIONS AUTOMATIC LUBRICATION SYSTEM
AUTOMATIC LUBRICATION COMPONENT DESCRIPTION E.11-0000051467

SYSTEM C.3-0000051429
GENERAL INFORMATION E.29-0000051468
The automatic lubrication system is a pressurized

lubricant delivery system which delivers a controlled
amount of lubricant to designated lube points. The
system is controlled by logic in the Interface Module
which signals a solenoid valve to operate a hydraulic
motor powered grease pump. Hydraulic oil for pump
operation is supplied by the truck steering circuit.
A 24VDC solenoid mounted on the manifold turns the
pump on and off. The pump is driven by the rotary
motion of the hydraulic motor, which is then converted
to reciprocating motion through an eccentric crank
mechanism. The pump is a positive displacement,
double-acting type as grease output occurs on both
the up and the down stroke.
1. Hose From Filter 8. Pipe Plug

2. Filter 9. Dipstick
3. Hydraulic Motor and 10. Flow Control Valve
Pump Assembly 11. Not Used in This
4. Pressure Reducing Application
Valve 12. Grease Reservoir
5. Solenoid Valve 13. Vent Hose
6. Override Switch
7. Vent Valve
Figure 5-66 PUMP & RESERVOIR COMPONENTS
930E-4SE 5-85
AUTOMATIC LUBRICATION SYSTEM OPERATING INSTRUCTIONS
assembly is mounted on the grease reservoir and

filters the grease prior to refilling the reservoir. Bypass
• Over-pressurizing the system, modifying indicator (1) alerts service personnel when the filter
parts, using incompatible chemicals and requires replacement.
fluids, or using worn or damaged parts may
result in equipment damage and/or serious Hydraulic Motor and Pump
personal injury.
• This equipment generates very high grease Rotary hydraulic motor and pump is a fully
pressure. Extreme caution must be used hydraulically operated grease pump. An integrated
when operating this equipment. Pressurized pump control manifold is incorporated with the motor
fluid leaking from loose or ruptured to control input flow and pressure.
components can result in fluid being injected
The pump housing must be filled to the proper level
into the skin and body causing serious
with SAE 10W-30 motor oil. Use dipstick (9, Figure
injury and possibly the need for amputation.
5-66 PUMP & RESERVOIR COMPONENTS, page
Adequate protection is recommended to
5-85) to check the oil level at 1,000 hour intervals. If
prevent splashing of material onto skin or
necessary, add oil to the correct level that is marked
into the eyes.
on the dipstick.
• If any fluid appears to penetrate the skin, get
emergency medical care immediately! Do not
treat as a simple cut. Tell attending physician
exactly what fluid was injected. • Hydraulic oil supply inlet pressure must not
exceed 24 132 kPa (3,500 psi). Exceeding the
rated pressure may result in damage to the
Filter system components and personal injury.
High pressure hydraulic fluid from the truck steering

system is reduced by the pressure reducing valve
located on the manifold on top of the pump motor. This
pressure can be read if pipe plug (8) is removed, and
a gauge is installed on the manifold.
Grease Reservoir
• Hydraulic oil supply inlet pressure must not

exceed 24 132 kPa (3,500 psi). Exceeding the
rated pressure may result in damage to the
system components and personal injury.
Reservoir (12) has an approximate capacity of 41

kg (90 lbs) of grease. When the grease supply is
replenished by filling the system at the service center,
the grease is passed through the filter to remove
contaminants before it flows into the reservoir.
Pressure Reducing Valve

1. Bypass Indicator 6. Spring Pressure reducing valve (4), located on the manifold,
2. Housing 7. Bowl reduces the hydraulic supply pressure (from the truck
3. O-Ring 8. O-Ring steering circuit) to a suitable operating pressure for the
4. Backup Ring 9. Plug hydraulic motor used to drive the lubricant pump.
5. Filter Element
NOTE: The pressure reducing valve has been
Figure 5-67 FILTER ASSEMBLY factory adjusted and the setting should not be
Filter element (5, Figure 5-67 FILTER ASSEMBLY, disturbed unless grease output pressure is outside
page 5-86) must be replaced if bypass indicator the recommendations.
(1) shows excessive element restriction. The filter
5-86 930E-4SE
A pressure gauge can be installed where pipe plug (8) Vent Valve
is located. The pressure gauge will indicate hydraulic
With vent valve (7) closed, the pump continues to
oil pressure to the inlet of the hydraulic motor. Normal
operate until maximum grease pressure is achieved.
pressure is 2 413 - 2 586 kPa (350–375 psi).
As this occurs, the vent valve opens and allows the
grease pressure to drop to zero, so the injectors can
Flow Control Valve recharge for their next output cycle.
Flow control valve (10), mounted on the manifold,
controls the amount of oil flow to the hydraulic motor. Interface Module
NOTE: The flow control valve has been factory The interface module provides a 24VDC
adjusted and the setting should not be disturbed. timed-interval signal to energize the solenoid valve,
providing oil flow to operate the grease pump motor.
Solenoid Valve This interface module is mounted in the auxiliary
control cabinet.
Solenoid valve (5), when energized, allows oil to flow
to the hydraulic motor.
930E-4SE 5-87
1. LH Suspension, Bottom Bearing 9. RH Suspension, Bottom Bearing 17. Pipe Plug (Oil Level)
2. LH Hoist Cylinder, Top Bearing 10. RH Hoist Cylinder, Top Bearing 18. Not Used In This Application
3. LH Hoist Cylinder, Bottom 11. RH Hoist Cylinder, Bottom 19. Grease Pump
Bearing Bearing 20. Vent Valve
4. LH Anti-Sway Bar Bearing 12. Rear Axle Pivot Pin 21. Filter
5. LH Suspension, Top Bearing 13. RH Anti-Sway Bar Bearing 22. Grease Supply To Injectors
6. LH Body Pivot Pin 14. RH Suspension, Top Bearing 23. Injectors
7. RH Body Pivot Pin 15. Grease Reservoir 24. Pressure Switch, N.O., 13 790
8. Grease Supply From Pump 16. Vent Hose kPa (2,000 psi)
Figure 5-68 LUBRICATION INJECTORS

Injectors
Each injector delivers a controlled amount of
pressurized lubricant to a designated lube point.
Refer to Figure 5-68 LUBRICATION INJECTORS,
page 5-88.
5-88 930E-4SE
Grease Pressure Failure Switch NOTE: The system will remain at rest until the next
lubrication cycle turns on and initiates a new grease
Pressure switch (24) is a normally open switch set
cycle. During the normal lubrication cycle, if grease
at 13 790 kPa (2,000 psi). If the appropriate grease
pressure fails to reach 13 790 kPa (2,000 psi) at the
pressure is not achieved during the normal pump
pressure switch located on the rear axle housing,
cycle, the warning system will be activated. The
a repair indicator light will illuminate on the monitor
repair indicator light will illuminate on the monitor
display panel. In addition, fault A190 “Auto Lube
dash panel and a message will be displayed on the
Fault” will be shown in the repair fault menu.
digital display notifying the operator a problem exists
in the lube system.
Filling The Reservoir
Relief Valve (Unloader Valve)
There is a relief valve that protects the pump from high
pressures. The relief valve is set at 27 580 kPa (4,000
psi).
SYSTEM OPERATION A.19-0000053765
During truck operation, the lubrication cycle logic (in

the interface module) will energize the system at a
preset time interval. The interface module provides
a path to ground to energize the pump solenoid valve
allowing hydraulic oil provided by the steering pump
circuit to flow to the pump motor and initiate a pumping
cycle.
The hydraulic oil from the steering circuit is directed 1. Automatic Lubrication Fill Connector
through the pressure reducing valve and the flow Figure 5-69 SERVICE CENTER
control valve before entering the motor. Pump
pressure can be read on optional pressure gauge The grease reservoir has an approximate capacity of
mounted on the manifold. With oil flowing into 41 kg (90 lb) of grease. When the grease supply is
the hydraulic motor, the grease pump will operate, replenished by filling the system at the service center,
pumping grease from the reservoir to the injectors, the grease is passed through the filter to remove
through a check valve, and to the vent valve. During contaminants before it flows into the reservoir.
this period, the injectors will meter the appropriate To fill the automatic lubrication system reservoir,
amount of grease to each lubrication point. perform the following:
NOTE: Each lube injector services only one grease 1. Connect an external grease supply to
point. In case of pump malfunction, each injector is automatic lubrication fill connector (1, Figure
equipped with a covered grease fitting to allow the use 5-69 SERVICE CENTER, page 5-89) of the
of external lubricating equipment. service center.
When grease pressure reaches the setting of pressure 2. Remove the vent hose from the reservoir.
switch, the switch contacts will close and energize
the relay. Energizing this relay removes power from 3. Pump grease into the reservoir, from the
the hydraulic motor/pump solenoid and the pump service center, until grease is seen through the
will stop. The relay will remain energized until the vent hose port. Once grease is present, stop
interface module completes its 120 second ON cycle. filling.
After the pump solenoid valve is de-energized, 4. Disconnect external grease supply from the
hydraulic pressure in the manifold drops and the vent service center and reconnect the vent hose to
valve will open releasing grease pressure in the lines the reservoir.
to the injector banks. When this occurs, the injectors
are then able to recharge for the next lubrication
cycle.
930E-4SE 5-89
Lubricant Required For Automatic Lubrication 2. Remove injector manifold plug (5, Figure
System 5-71 INJECTOR MANIFOLD, page 5-90) from
injector manifold. Always start with the injector
Grease requirements will depend on ambient
manifold closest to the pump. The last grease
temperatures encountered during truck operation:
line to be purged should be the main grease
• Above 32°C (90°F) - Use NLGI No. 2 multipurpose line to the rear axle (longest grease line).
grease (MPG). 3. Disconnect main supply line (2, Figure 5-70
• -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 AUTO LUBE MAIN SUPPLY LINE, page 5-90)
multipurpose grease (MPG). from vent valve (1). Connect an external
grease supply to main supply line (2).
• Below -32°C (-25°F) - Refer to local supplier for
extreme cold weather lubricant requirements. 4. Pump grease in main supply line (2) until
grease appears at the injector manifold plug.
Priming The Automatic Lubrication 5. Re-install the injector manifold plug. Repeat for
System remaining injector groups.
The system must be full of grease and free of air After all main supply lines are purged of air, the injector
pockets to function properly. After maintenance, if circuits must now be primed.
primary or secondary lubrication lines were replaced,
it will be necessary to prime the system to eject all To prime the secondary supply lines, perform the
entrapped air. following:
1. If necessary, disconnect an injector grease
line from the component that particular injector
supplies grease to.
2. Remove injector grease zerk cap (4, Figure
5-71 INJECTOR MANIFOLD, page 5-90)
from each injector and connect an external
grease supply to injector grease zerk (2) on
the injector.
3. Pump grease into the injector until grease
appears at the far end of the individual grease
line or the joint being greased.
1. Vent Valve 2. Main Supply Line
4. Reconnect injector grease line to the
component, remove the external grease
Figure 5-70 AUTO LUBE MAIN SUPPLY LINE supply, and reinstall injector grease zerk cap.
5. Repeat steps 1 through 4 until all secondary
supply lines have been primed.
6. After all grease lines are primed, use the
override switch to cycle the automatic
lubrication pump a few times to lube the
components.
PREVENTIVE MAINTENANCE
PROCEDURES E.6-0000051465
Use the following maintenance procedures to ensure
1. Injector Indicator 4. Injector Grease Zerk proper system operation.
2. Injector Grease Zerk Cap
3. Injector Cover 5. Injector Manifold Plug Daily Lubrication System Inspection
1. Check the grease reservoir level after each
Figure 5-71 INJECTOR MANIFOLD shift of operation. Grease usage should be
To prime the main supply lines, perform the following: consistent from day-to-day operations. Lack of
lubricant usage would indicate an inoperative
1. Fill lube reservoir with lubricant, if necessary.
5-90 930E-4SE
system. Excessive usage would indicate a a. Remove all injector cover caps to allow
broken supply line. visual inspection of the injector cycle
indicator pins during system operation.
2. Check filter bypass indicator when filling
reservoir. Replace element if bypassing. b. Start truck engine.
3. Check all grease hoses from the injectors to the c. Actuate lube system override switch. The
lubrication points. hydraulic motor and grease pump should
operate.
a. Repair or replace all damaged feed line
hoses. d. With the grease under pressure, check
each injector assembly. The cycle indicator
b. Ensure that all air is purged and all new pin should be retracted inside the injector
feed line hoses are filled with grease before body.
returning the truck to service.
e. When the system is at 16 203 - 17 237 kPa
4. Inspect the key lubrication points for a bead (2,350 - 2,500 psi), the pump should shut
of lubricant around seal. If a lubrication point off and the pressure in the system should
appears dry, troubleshoot and repair problem. drop to zero, venting back to the grease
reservoir.
250 Hour Inspection
f. After the system has vented, check the
1. Check all grease hoses from the injectors to the injector indicator pins. All of the pins should
lubrication points. be visible. Replace or repair any defective
a. Repair or replace all worn or broken hoses. injectors.
b. Ensure that all air is purged and all new g. Install all injector cover caps.
feed line hoses are filled with grease before h. Initiate one or more lubrication cycles to
returning the truck to service. check the system operation.
2. Check all grease supply line hoses from the NOTE: Turning the key switch to the ON position will
pump to the injectors. not initiate a lube cycle. To initiate a lube cycle while
a. Repair or replace all worn / broken supply the truck is stationary, select manual lube using the
lines. dash display panel, or use the switch on the lubrication
pump. The system should build 13 790 kPa (2,000
b. Ensure that all air is purged and all new psi) at the rear axle during normal pump cycle.
supply line hoses are filled with grease
before returning the truck to service. i. If the system is working properly, the
machine is ready for operation.
3. Check the grease reservoir level.
j. If the system is malfunctioning,
a. Fill the reservoir if the grease level is low. immediately report problem to
Check the filter bypass indicator when maintenance personnel.
filling the reservoir. Replace the element if
bypassing. 1000 Hour Inspection
b. Check the reservoir for contaminants. 1. Using the dipstick, check the pump housing
Clean the reservoir, if required. oil level. If necessary, refill with SAE 10W-30
c. Ensure that all filler plugs, covers and motor oil.
breather vents on the reservoir are intact
and free of contaminants. SYSTEM CHECKOUT C.9-0000051738
4. Inspect all bearing points for a bead of lubricant General Checks

around the bearing seal. To check system operation, proceed as follows:
It is good practice to manually lube each
1. Remove the dust covers from the injectors.
bearing point at the grease fitting provided on
each Injector. This will indicate if there are 2. Start the engine.
any frozen or plugged bearings, and it will help
3. Actuate the manual override on the solenoid
flush the bearings of contaminants.
valve at the pump assembly and observe pin
5. System Checkout movement at each injector.
930E-4SE 5-91
4. Check for pump, hose or injector damage or

leakage with the system under pressure.
5. After checking system, stop the engine.
Observing normal precautions regarding high
voltage present in the propulsion system before
attempting to repair lube system.
6. Re-install the injector dust covers.
Lubrication Cycle Operation

The time between lube events is determined by the
setting selected in the dash panel. Refer to Figure
5-72 LUBRICATION MENU, page 5-92 for lubrication
menu screens. With the key switch ON, scroll through
the display menu screens and select either 8, 15, 24 or
30 minutes between lube cycles. The default setting
is 15 minutes.
NOTE: To activate access to the lube interval screen
the Operator ID must be changed to 5625. After
making a change the ID should be reset to any value
other than 5625. Refer to Toggling Through Main
Level Screens, page 6-26 for menu screens to follow
when changing the Operator ID.
NOTE: Turning the key switch to the ON position
will not initiate a lube cycle. To initiate a lube cycle
while the truck is stationary, select manual lube using
the dash display panel, or use the switch on the
lubrication pump. The truck must be moving before
the lube system will initiate lube cycles based on the
time interval selected.
Figure 5-72 LUBRICATION MENU
5-92 930E-4SE
OPERATING INSTRUCTIONS RESERVE ENGINE OIL SYSTEM (if equipped)
RESERVE ENGINE OIL SYSTEM (if Operation

equipped) A.18-0000071908
The reserve engine oil system works by constantly
circulating the engine oil between the engine oil pan
and a supplementary external reserve tank while
maintaining the appropriate running oil level. The
intent is that a larger volume of engine oil slows the
oil deterioration, allowing longer periods between oil
changes.
The normal reserve system capacity of oil carried
in the tank can be one half or nearly the same
(depending on tank size) volume inside the engine.
In the process of continuous adjustment of the engine
oil level, there is a constant circulation of oil between
the engine and the reserve tank. The volume of
oil in the tank becomes part of the working oil for
the engine. Oil change intervals may usually be
extended in proportion to the increased working oil
volume. Extension beyond a proportional increase
is often possible, but should be undertaken only
as determined by oil sampling and analysis. Local
conditions such as engine application, climate, and
fuel quality should be taken into consideration before
determining permissible oil life.
A heated suction line is installed between the reserve
oil pump and engine oil pan which allows the pump
to function down to minimum ambient temperature
of -30C (-22F). Engine oil becomes more viscous
in lower temperatures, causing the pumps to work
harder and wear more quickly. Heating the oil
keeps the oil less viscous, thus maintaining the
corresponding flow rate at the inlet of the reserve
pump.
An optional heated return line is available which 1. Reserve Tank 8. Fill Cap
extends the minimum ambient temperature to -40C 2. Sight Gauge 9. Oil Level Switch
(-40F). 3. Thermostat Switch 10. Air Relief Valve
4. Suction Line from 11. Return Line to Engine
Engine Oil Pan Oil Pan
5. Pumping Unit 12. Fill Valve
6. Remote Fill Line 13. Oil Strainer Screen
7. Inline Screen
Figure 5-73 RESERVE TANK COMPONENTS

Engine oil is circulated between the engine sump
and the reserve tank by two electrically driven pumps
within a single pumping unit (5, Figure 5-73 RESERVE
TANK COMPONENTS, page 5-93). The pumping
unit, which is mounted on the side of the reserve tank,
is equipped with two LED monitor lights: red on one
side, green on the other side.
930E-4SE 5-93
RESERVE ENGINE OIL SYSTEM (if equipped) OPERATING INSTRUCTIONS
Pump 1 and Pump 2 are interlocked. Once the engine Table 5-6 PUMP AND LED ACTION CHART
is started, the pumps run continuously. This action
Description Green LED Red LED
returns oil from the reserve tank and raises the engine
oil level until air is no longer drawn by Pump 1. A Flashing Flashing
The oil level is continuously adjusted at the control B Solid Flashing
point by alternating between the withdrawal and return C Flashing Off
of oil in the engine oil pan. Pump 1 draws oil from the
engine oil pan at a preset control point determined by Flashing/Solid
the height of the suction tube. Pump 2 returns oil back D Off
to the engine oil pan. Oil above this point is withdrawn (Mixed
and transferred to the reserve tank. This lowers the Flashing)
level in the engine oil pan until air is drawn.
LED Monitor Light

The following light indications should be used to
understand pump operation.
After engine startup, allow the pumping unit to run for
5 minutes before operating the truck. The green LED,
see Figure 5-74 PUMPING UNIT, page 5-94, will
alternate between flashing and solid (mixed flashing)
and red LED (4) should be off. This verifies that
the system is working properly, pumps 1 and 2 are
synchronized and pumping oil, and the engine oil
level is correct.
1. Pump 1 3. Green LED
Use Table 5-6 PUMP AND LED ACTION CHART, 2. Pump 2 4. Red LED
page 5-94 below to help identify the various LED
status indicators. Figure 5-74 PUMPING UNIT
A. If both LED lights are flashing the unit is operating Changing Oil
with no oil pumping through pumps 1 or 2. Obey the following guidelines when changing the oil.
B. If the green LED light is solid and the red LED 1. Drain both the engine sump and the reserve
is flashing the unit is running oil through only pump tank. Refill both the engine and reserve tank
1. Pump 1 is withdrawing oil from the engine oil pan with new oil to proper levels.
and the reserve tank is low on oil. This is an unlikely
scenarios, but it is possible for short periods of time. 2. Change engine and reserve tank filters as
If pump 1 is pumping oil from the engine, the tank required.
probably has not run dry. 3. Check that the oil strainer screen is not clogged
C. If the green LED is flashing and the red LED is off, or damage.
the pump is receiving air from the engine oil pan (the 4. Start the engine and check for proper
oil level is below the withdrawal point of the pickup operation.
tube). This is normal for short periods of time, but
if this persists for too long, it is advised to check the NOTE: DO NOT use the oil in the reserve tank to fill
pumping unit and tank oil level. Normally, the reserve the engine sump. Both must be at proper level before
oil pump should return oil back to the engine oil pan, starting the engine.
continuously adjusting the oil level until air is no longer 5. The engine oil level must be checked with the
drawn by the reserve oil pump. engine dipstick at every shift change. If the oil
D. If the green LED is in a mixed flashing cycle level in the engine is incorrect, check for proper
(Flashing/Solid) and the red LED is Off the unit is operation of the reserve engine oil system.
running oil through pumps 1 and 2 simultaneously. 6. The oil level in the reserve tank must also be
This indicates that pump 1 is alternately pumping oil checked at every shift change. Use dipstick
and air. This only happens when the engine oil level on fill cap (8) to check oil level. If necessary,
is correct and indicates that the complete system is add oil to the reserve tank by using the quick
operating correctly.
5-94 930E-4SE
OPERATING INSTRUCTIONS RESERVE ENGINE OIL SYSTEM (if equipped)
fill system utilizing tank fill valve (12). For filling Oil must always be visible in lower sight gauge
instructions, refer to Lubrication and Service- (2).
RESERVE ENGINE OIL SERVICE, page 7-4
in this manual.
930E-4SE 5-95
RESERVE ENGINE OIL SYSTEM (if equipped) OPERATING INSTRUCTIONS
5-96 930E-4SE
OPERATOR CAB AND CONTROLS
930E-4SE 6-1
CAB INTERIOR OPERATOR CAB AND CONTROLS
CAB INTERIOR A.36-0000070600
1. Steering Wheel 7. Instrument Panel 12. AM/FM Radio / CD Player

2. Retard Pedal 8. Grade/Speed Retard Chart 13. KomVision Monitor
3. Throttle/Accelerator Pedal 9. Radio Speakers 14. Heater/Air Conditioner Vents
4. Retarder Lever 10. Warning Alarm Buzzer 15. Air Cleaner Vacuum Gauges
5. Heater/Air Conditioner Controls 11. Windshield Wipers 16. Cup Holder
6. Recirculation Filter
Figure 6-1 CAB INTERIOR - OPERATOR VIEW
6-2 930E-4SE
OPERATOR CAB AND CONTROLS STEERING WHEEL AND CONTROLS
STEERING WHEEL AND Multi-Function Turn Signal Switch

CONTROLS E.31-0000051460
Steering wheel (1, Figure 6-2 STEERING WHEEL &
CONTROLS, page 6-3) can be telescoped "in" and
"out" and the tilt angle can be adjusted to provide
a comfortable steering wheel position for most
operators.
Multi-function turn signal switch (4) is used to activate

the turn signal lights, the windshield wipers, and to
select either high or low beam headlights.
Turn Signal Operation

Move the lever upward to
signal a right turn. Move
the lever downward to
signal a left turn. An
indicator in the top, center
of the instrument panel
will illuminate to indicate
turn direction selected.
Refer to Instrument Panel
and Indicator Lights in
1. Steering Wheel 4. Multi-Function Turn this section.
2. Horn Button Signal Switch
3. Tilt/Telescope Lever 5. Retarder Lever NOTE: If the truck is not equipped with a
self-canceling turn signal, the turn signal will
Figure 6-2 STEERING WHEEL & CONTROLS not automatically cancel after the turn has been
completed.
Horn Button
The horn is actuated by pushing the horn button (2) Windshield Wiper Operation
in the center of the steering wheel. Ensure that the
horn operates before moving the truck. Observe all For windshield wiper operations refer to Table 6-1
local safety rules regarding the use of the horn as a WINDSHIELD WIPER OPERATION, page 6-3
warning signal device before starting the engine and
Table 6-1 WINDSHIELD WIPER OPERATION
moving the vehicle.
Windshield Wipers OFF
Tilt / Telescope Lever Intermittent - Long Delay
The steering column can be telescoped or the wheel Intermittent - Medium Delay
tilted with lever (3).
Intermittent - Short Delay
Adjust the tilt of the steering wheel by pulling the lever
toward the steering wheel and moving the wheel to the Low Speed
desired angle. Releasing the lever will lock the wheel High Speed
in the desired location.
Depressing the button at the end of
Adjust the telescope function by pushing the lever the lever will activate the windshield
forward to unlock. After positioning as desired, washer.
release the lever to the lock position.
NOTE: The windshield wipers will not come on
automatically when activating the washer. This must
be done manually.
930E-4SE 6-3
STEERING WHEEL AND CONTROLS OPERATOR CAB AND CONTROLS
High Beam Headlight Operation Moving the switch back to the original position will
Pulling the lever inward return the headlights to low beam.
(toward the rear of
the cab) changes the
headlights to high beam.
When the high beams
are selected, the indicator
in the top center of the
instrument panel will
illuminate.
6-4 930E-4SE
OPERATOR CAB AND CONTROLS PEDALS AND RETARDER LEVER
PEDALS AND RETARDER NOTE: The retarder lever must be rotated back to the
LEVER B.58-0000060899 OFF position before the truck will resume the propel
mode of operation.
Dynamic Retarding
The lever and foot-operated retarder/service brake
Dynamic retarding is a braking torque (not a brake) pedal can be used simultaneously or independently.
produced through electrical generation by the The Drive System Controller (DSC) will determine
wheelmotors when the truck motion (momentum) is which device is requesting the most retarding effort
the propelling force. and apply that amount.
For normal truck operation, dynamic retarding must be
used to slow and control truck speed. Brake/Retarder Pedal
Brake/retarder pedal (2, Figure 6-1 CAB INTERIOR
Dynamic retarding is available in
- OPERATOR VIEW, page 6-2) is a single,
FORWARD/REVERSE at all truck speeds above 0
foot-operated pedal that controls both retarding and
kph/mph; however, as the truck speed slows below 5
service brake functions. The first portion of pedal
kph (3 mph), the available retarding force may not be
travel commands retarding effort through a rotary
effective. Use the service brakes to bring the truck
potentiometer. The second portion of pedal travel
to a complete stop.
modulates service brake pressure directly through a
Dynamic retarding will not hold a stationary truck on hydraulic valve. Thus, the operator must first apply,
an incline. Use the parking brake or wheel brake lock and maintain, full dynamic retarding in order to apply
for this purpose. the service brakes. Releasing the pedal returns brake
and retarder to the OFF position.
Dynamic retarding is available in NEUTRAL only when
truck speed is above 5 kph (3 mph). When the pedal is partially depressed, the dynamic
retarding is actuated. As the pedal is further
When dynamic retarding is in operation, engine rpm depressed, to where dynamic retarding is fully
will automatically go to an advance retard speed applied; the service brakes (while maintaining
setting. This rpm will vary depending on temperature full retarding) are actuated through a hydraulic
of several electrical system components. valve which modulates pressure to the service
Dynamic retarding will be applied automatically if the brakes. Completely depressing the pedal causes full
speed of the truck obtains the maximum speed setting application of both dynamic retarding and the service
programmed in the control system software. brakes. Indicator light (15, Figure 6-12 STATUS
INDICATOR LIGHTS, page 6-23) will illuminate, and
When dynamic retarding is activated, an indicator light an increase in pedal resistance will be felt when the
will illuminate. The grade/speed retard chart must service brakes are applied.
always be used to determine safe downhill speeds.
Refer to the grade speed chart in the cab. For normal truck operation, dynamic retarding (lever
or foot-operated pedal) should be used to slow and
Retarder Lever control the speed of the truck.
Retarder lever (5, Figure 6-2 STEERING WHEEL & Service brakes should be applied only when dynamic
CONTROLS, page 6-3) mounted on the right side retarding requires additional braking force to slow the
of the steering column can be used to modulate truck speed quickly or when bringing the truck to a
retarding effort. The lever will command the full range complete stop.
of retarding and will remain at a fixed position when
released. Accelerator Pedal
• When the lever is rotated to full “up” Accelerator pedal (3) is a foot-operated pedal which
(counterclockwise) position, it is in the OFF/no allows the operator to control engine rpm depending
retard position. An adjustable detent holds the on pedal depression.
lever in the OFF position. Refer to the shop manual It is used by the operator to request torque from the
for adjustment procedures. motors when in forward or reverse. In this mode, the
• When the lever is rotated to full “down” (clockwise) propulsion system controller commands the correct
position, it is in the full ON/retard position. engine speed for the power required. In NEUTRAL,
this pedal controls engine speed directly.
• For long downhill hauls, the lever may be positioned
to provide desired retarding effort, and it will remain
where it is positioned.
930E-4SE 6-5
OVERHEAD PANEL AND DISPLAYS OPERATOR CAB AND CONTROLS
OVERHEAD PANEL AND Air Cleaner Vacuum Gauges

DISPLAYS D.15-0000054540 Air cleaner vacuum gauges provide a continuous
The items listed below are located on the overhead reading of the maximum air cleaner restriction
panel. Refer to Figure 6-1 CAB INTERIOR - reached during operation. The air cleaner(s) must
OPERATOR VIEW, page 6-2 for the location of be serviced when the gauge(s) shows the maximum
each item. A brief description of each component is recommended restriction of 635 mm (25 in.) of H2O
documented below. vacuum.
NOTE: After service, push the reset button on face of
Radio Speakers gauge to allow the gauge to return to zero.
Radio speakers for the AM/FM Radio / CD Player are
located at the far left and right of the overhead panel. KomVision™ Panel
The KomVision system is a 360 degree camera/radar
Warning Alarm Buzzer system. The KomVision monitor displays warnings
Warning alarm buzzer will sound when activated that will alert the operator to the presence of nearby
by any one of several truck functions. Refer to obstacles so the operator can stop, slow down or
INSTRUMENT PANEL, page 6-18 in this section for steer the truck away from a potential hazard. The
a detailed description of functions and indicators that KomVision system does not operate when the truck
will activate this alarm. speed is more than 15 kph (9 mph).
Cab Radio
This panel will normally contain AM/FM Radio/CD
Player. Refer to the Radio chapter for a more
complete description of the radio and its functions.
Individual customers may use this area for other
purposes, such as a two-way communications radio.
6-6 930E-4SE
OPERATOR CAB AND CONTROLS CENTER CONSOLE
CENTER CONSOLE D.96-0000051505 PARK, or damage may occur to the park brake. When
the key switch is ON, and the control lever is in PARK,
the parking brake indicator light will be illuminated.
NOTE: The directional control lever must be in PARK
to start the engine. DO NOT move the directional
control lever to the PARK position at the shovel or
dump.
Select FORWARD drive by moving the control lever to
the F position.
Select REVERSE drive by moving the control lever
to the R position. DO NOT allow the control lever
to travel too far and go into the PARK position when
REVERSE is desired.
NOTE: The truck must be completely stopped before
the control lever is moved to a drive position or into
PARK. A drive system fault will be recorded if the
control lever is placed into the PARK position while
the truck is still moving.
Override/Fault Reset Switch

Override/fault
reset switch (3) is
1. Center Console 8. Retarder Speed spring-loaded to the OFF
2. Directional Control Control Dial position. When pushed
Lever 9. Retarder Speed in and held, this switch
3. Override/Fault Reset Control Switch may be used for several
Switch 10. Data Store Button functions.
4. Engine Stop Switch 11. 12V Auxiliary Power 1. This switch permits the operator to override
5. LH Window Control Outlets the body-up limit switch and move the truck
Switch 12. Fire Suppression forward when the directional control lever is in
6. RH Window Control Control Outlet FORWARD, the dump body is raised, and the
Switch 13. Communication brakes are released.
7. Hoist Control Lever Radio Outlet
Use of the override switch for this purpose is
Figure 6-3 CENTER CONSOLE intended for emergency situations only!
Directional Control Lever 2. The push button deactivates the retard pedal
Directional control lever (2, Figure 6-3 CENTER function when truck speed is below 5 kph (3
CONSOLE, page 6-7) is mounted on a console to the mph).
right of the operator's seat. It is a four position lever 3. The override switch is also used to reset an
that controls the park, reverse, neutral, and forward electric system fault when the truck is stopped.
motion of the truck. Before moving the directional
control lever, apply the service brakes to completely Engine Stop Switch
stop the truck. Depress the button on the side to Engine stop switch (4) is
release the detent lock, then move the control lever to used to stop the engine.
the desired position. When the control lever is in the Pull the switch up to
center N position, it is in NEUTRAL. When the control stop the engine. Push
lever is in the P position, it is in PARK, and the parking the switch back down to
brake will be applied. The parking brake is spring enable engine operation.
applied and hydraulically released. It is designed
to hold the truck stationary when the engine is off Use this switch to stop the engine if the key switch fails
and the key switch is turned OFF. The truck must be to operate, or to stop the engine without turning off the
completely stopped before moving the control lever to 24 VDC electrical circuits.
930E-4SE 6-7
CENTER CONSOLE OPERATOR CAB AND CONTROLS
A ground level engine stop switch is also located at 4. Release hoist control lever as the last stage
the right or left front corner of the truck, depending on reaches full extension.
ladder access.
5. After material being dumped clears the body,
lower the body to frame.
Window Control Switches
Refer to Dumping, page 5-18 for more
The window control switch (5, 6) controls the operation complete details concerning this control.
of the window. The switch is spring-loaded to the OFF
position. Lowering The Dump Body
• Pushing the front of the switch raises the cab Move hoist control lever forward to DOWN position
window. and release. Releasing the lever places hoist control
• Pushing the rear of the switch lowers the window. valve in the FLOAT position allowing the body to return
to frame.
Hoist Control Lever
Retard Speed Control (RSC) Adjust Dial
Hoist control lever (7) is a four position hand-operated
Retard speed control (RSC) adjust dial (8, Figure 6-3
lever located between the operator seat and the
CENTER CONSOLE, page 6-7) allows the operator
center console (see Figure 6-4 HOIST CONTROL,
to vary the downhill truck speed that the retard speed
page 6-8).
control system will maintain when descending a
grade. This function can be overridden by either the
accelerator or retard pedal.
The retard speed setting will be displayed to the
operator on the digital display in the instrument panel.
When the dial is rotated
counterclockwise toward
this symbol, the truck will
descend a grade at lower
speeds.
When the dial is rotated

clockwise toward this
symbol, the truck speed
will increase.
Always refer to the Grade/Speed Chart in the

1. Raise 3. Float operator's cab and follow the recommendations
2. Hold 4. Lower for truck operation. DO NOT exceed these
recommended MAXIMUM speeds when descending
Figure 6-4 HOIST CONTROL
grades with a loaded truck.
Raising The Dump Body Throttle pedal position will override RSC setting.
1. Pull the hoist control lever to the rear to actuate If operator depresses throttle pedal to increase
hoist circuit. (Releasing the lever anywhere truck speed, dynamic retarding will not come on
during “hoist up” will place the body in HOLD unless truck over speed setting is reached or the
at that position.) brake/retarder pedal (or retarder lever) is used. When
throttle pedal is released and RSC switch is on,
2. Raise engine rpm to increase hoist speed.
dynamic retarding will come on at, or above, the
3. Reduce engine rpm as the last stage of the RSC dialed speed and will adjust truck speed to, and
hoist cylinders begin to extend and then let the maintain, the dialed speed. The dialed speed will
engine go to low idle as the last stage reaches be displayed on the digital display in the instrument
half-extension. panel.
6-8 930E-4SE
OPERATOR CAB AND CONTROLS CENTER CONSOLE
To adjust RSC control, pull switch (9) ON and start Retard Speed Control (RSC) Switch
with dial (8) rotated toward fastest speed while driving Retard speed control
truck at desired maximum speed. Relax throttle pedal (RSC) switch (9) turns the
to let truck coast and turn RSC adjusting dial slowly system on and off. Push
counterclockwise until dynamic retarding is activated. the knob in for OFF and
Dynamic retarding will now be activated automatically pull the knob out to turn
anytime the “set” speed is reached, the RSC switch is the system ON.
on, and throttle pedal is released.
Data Store Button
With RSC switch on and dial adjusted, the system
will function as follows: As truck speed increases to Data store button (10) is for use by qualified
the “set” speed and throttle pedal released, dynamic maintenance personnel to record in memory a
retarding will apply. As truck speed tries to increase, snapshot of the AC drive system.
the amount of retarding effort will automatically adjust
to keep the selected speed. When truck speed 12v Auxiliary Power Outlets
decreases, the retarding effort is reduced to maintain Outlets (11) can be used to provide 12VDC power for
the selected speed. If truck speed continues to tools and accessories.
decrease to approximately 5 kph (3 mph) below “set”
speed, dynamic retarding will turn off automatically. Fire Suppression Control Outlet
If truck speed must be reduced further, the operator Outlet (12) can be used to provide power for an
can turn the adjust dial to a new setting or depress optional fire suppression control system with the key
the brake/retarder pedal (or use the retarder lever). switch ON.
If the operator depresses the brake/retarder pedal or
uses the retarder lever and the retard effort called
Communication Radio Outlet
for is greater than that from the automatic system, Outlet (13) can be used to provide power for an
the brake/retarder pedal or retarder lever will override optional 2-way communication radio with the key
RSC. switch ON.
930E-4SE 6-9
DIAGNOSTIC PORTS OPERATOR CAB AND CONTROLS
DIAGNOSTIC PORTS B.2-0000071907 Interface Module (IM)

Interface module (IM) diagnostic port (2) is used
to connect the interface module to a computer for
installing software.
PC Local Area Network (PC LAN)

PC LAN diagnostic port (3) is used to download data
from the payload meter and GE systems. Refer to
PAYLOAD METER IV SYSTEM, page 5-44 for a more
complete description of the payload meter and its
functions.
Drive System Controller (DSC)

Drive system controller (DSC) diagnostic port (4) is
1. KOMTRAX Plus 4. Drive System used to access diagnostic information for the Drive
Diagnostic Port Controller Port System Controller (DSC) .
2. Interface Module 5. Engine Diagnostic
Diagnostic Port Port (CENSE) Engine (Cense)
3. PC Local Area 6. Engine Diagnostic Engine diagnostic port (CENSE) (5) is a three pin
Network (PC LAN) Port (QUANTUM) connector used to access diagnostic information for
Port the engine monitoring system.
Figure 6-5 DIAGNOSTIC PORTS
Engine (Quantum)
The diagnostic ports shown in Figure 6-5
DIAGNOSTIC PORTS, page 6-10 are located on the Engine diagnostic port (QUANTUM) (6) is a nine pin
back wall of the cab next to the D.I.D. Panel. connector used to access diagnostic information for
the engine control system.
KOMTRAX Plus
KOMTRAX Plus diagnostic port (1) is used to
download truck operation data from the KOMTRAX
Plus controller.
6-10 930E-4SE
OPERATOR CAB AND CONTROLS OPERATOR SEAT (Standard)
OPERATOR SEAT use, whichever comes first. The passenger seat

(Standard) G.5-0000051504 belt date of manufacture label is sewn into the seat
belt near the buckle. The driver seat belt date of
manufacture label is sewn into the shoulder harness
belt, near the retractor end.
• Check the condition of the tethers at the same time
the seat belts are checked. Look for worn, frayed
or torn material and check all hardware, as well.
Replace worn or damaged parts immediately.
Adjustment
The following adjustments must be made while sitting
in the seat. Refer to Figure 6-6 OPERATOR SEAT
CONTROLS, page 6-11.
• Headrest - Move headrest (1) up or down to the
desired position. It can also be tilted forward by
pulling on the top of the headrest. There are four
positions. Pulling the headrest completely forward
will release the ratchet mechanism and return the
headrest to the furthest back position.
• Seat Height - Push and hold seat height switch (2)
to adjust the height of the seat. Release the switch
when the desired height is reached. Optimum
ride height is obtained when the suspension is at
the middle of its stroke. To properly adjust, raise
the seat to its highest level. Then, lower the seat
approximately 51 mm (2 in.) to the middle of the
suspension stroke.
• Lumbar Support - Move lumbar support (3) to
adjust the lumbar support to the desired position.
1. Headrest 7. Backrest Recline • Armrest Tilt - Rotate armrest tilt (4) until the armrest
2. Seat Height Switch 8. Seat Cushion Fore is in desired position.
3. Lumbar Support and Aft • Seat Belt - The operator must always have seat
4. Armrest Tilt 9. Suspension belt (5) buckled and properly adjusted whenever the
5. Seat Belt Dampener truck is being operated.
6. Seat Tether 10. Seat Tilt
11. Fore and Aft • Tether - Tether belts (6) should be adjusted with the
12. Shoulder Height seat in the highest position and all the way forward.
Adjustment Knob With the seat in this position, adjust the tether belts
so they have some slack. This allows for a slight
Figure 6-6 OPERATOR SEAT CONTROLS extension when the seat deflects and rebounds.
The operator seat provides a fully adjustable • Backrest Recline - Lift backrest recline (7) to select
cushioned ride for driver comfort and easy operation. the desired backrest recline. Release the handle to
set the position.
Seat Belts And Tethers • Fore/Aft Location of Seat Cushion (if equipped)
• On both driver and passenger seats, check the seat - Lift and hold fore/aft (8) and move the seat cushion
belt fabric, buckle, all belt retractors and hardware to a comfortable position. Release the lever to lock
for damage or wear. Replace any worn or damaged the position adjustment.
parts immediately.
• Suspension Dampener - Adjust suspension
• Even if there are no signs of damage, replace both dampener (9) to obtain the desired stiffness of the
driver and passenger seat belts five years after seat adjustable shock absorber. Move the lever upward
belt manufacture, or every three years after start of to stiffen the absorbency of the shock. Move the
930E-4SE 6-11
OPERATOR SEAT (Standard) OPERATOR CAB AND CONTROLS
lever downward to soften the ride. Five detented Shoulder Height Adjustment Knob - Push knob
settings are available. (12) to move height adjuster up or down creating
a comfortable space between neck or shoulders.
NOTE: This seat contains a fixed rate shock absorber Release lever and gently tug belt to ensure adjuster
in addition to the adjustable shock absorber that is is locked in place.
controlled by the suspension dampener.
NOTE: The seat compressor must be allowed to
• Seat Cushion Tilt (if equipped) - Lift and hold
cool down for ten minutes for every one minute of
lever (10) and tilt the seat cushion to a comfortable
continuous operation. The compressor must not be
position. Release the lever to lock the position
operated continuously for more than three minutes.
adjustment.
• Fore/Aft Location of Seat - Lift and hold lever (11)
and move the seat to a comfortable height. Release
the lever to lock the fore/aft location.
6-12 930E-4SE
OPERATOR CAB AND CONTROLS PASSENGER SEAT (Standard)
PASSENGER SEAT • Even if there are no signs of damage, replace both

(Standard) E.5-0000051503 driver and passenger seat belts five years after seat
belt manufacture, or every three years after start of
use, whichever comes first. The passenger seat
belt date of manufacture label is sewn into the seat
Adjustment
in the seat. Refer to Figure 6-7 PASSENGER SEAT
• Fore/Aft Location of Seat Cushion (if equipped)
- Lift and hold fore/aft lever (1) and move the seat
cushion to a comfortable position. Release the lever
to lock the position adjustment.
• Seat Height - Pull up on seat height (2), then adjust
the height of the seat. When the desired height is
reached, release the lever.
• Weight Adjustment- Rotate weight adjustment (3)
1. Seat Cushion Fore 4. Fore and Aft until the weight indicator next to the knob is pointing
and Aft 5. Seat Tether to the weight of the person that will be riding in the
2. Seat Height seat. This will provide the most comfortable ride
3. Weight Adjustment setting.
• Fore/Aft Location of Seat - Lift and hold fore/aft
Figure 6-7 PASSENGER SEAT CONTROLS
lever (4) and move the seat to a comfortable height.
The passenger seat provides a fully adjustable Release the lever to lock the fore/aft location.
cushioned ride for driver comfort and easy operation.
• Seat Tether - Tether belts (5) should be adjusted
with the seat in the highest position and all the way
Seat Belts And Tethers forward. With the seat in this position, adjust the
• On both driver and passenger seats, check the seat tether belts so they have some slack. This allows
belt fabric, buckle, all belt retractors and hardware for a slight extension when the seat deflects and
for damage or wear. Replace any worn or damaged rebounds.
parts immediately.
930E-4SE 6-13
OPERATOR SEAT (Optional) OPERATOR CAB AND CONTROLS
OPERATOR SEAT use, whichever comes first. The passenger seat

(Optional) E.4-0000053881 belt date of manufacture label is sewn into the seat
Adjustment
in the seat. Refer to Figure 6-8 OPERATOR SEAT
• Headrest - The headrest (1) moves up, down, fore
or aft by adjusting headrest to desired position.
• Backrest Angle - Lift backrest adjustment handle
(2) to release and select the backrest angle.
Release the control handle to set.
• Seat Tether - Tether belts (3) should be adjusted
with the seat in the highest position and all the way
forward. With the seat in this position, adjust the
tether belts so they have some slack. This allows
for a slight extension when the seat deflects and
rebounds.
• Seat Belt - The operator must have seat belt (4)
buckled in place and properly adjusted whenever
vehicle is in motion.
• Air Lumbar Support - Each rocker switch (5)
controls an air pillow. One switch controls the lower
air pillow and the other switch controls the upper
air pillow. To inflate, press on top of the rocker
1. Headrest 7. Fore and Aft switch and hold for desired support, then release.
2. Backrest Angle 8. Seat Height To deflate, press on the bottom of the rocker switch
3. Seat Tether 9. Seat Cushion Fore and hold for desired support, then release. Adjust
4. Seat Belt and Aft each pillow for desired support.
5. Lumbar Support 10. Seat Tilt
6. Suspension 11. Armrest Tilt • Suspension Dampener - Press rocker switch (6)
Dampener on top to increase ride firmness. Press on lower
part of rocker switch to decrease ride firmness.
Figure 6-8 OPERATOR SEAT CONTROLS • Fore/Aft Location of Seat - Lift fore and aft lever
The operator seat provides a fully adjustable (7) and hold. Bend knees to move seat to a
cushioned ride for driver comfort and easy operation. comfortable position. Release the control lever to
lock the adjustment.
Seat Belts And Tethers • Seat Height - Press rocker switch (8) on top to
• On both driver and passenger seats, check the seat increase ride height. Press on lower part of rocker
belt fabric, buckle, all belt retractors and hardware switch to decrease ride height.
for damage or wear. Replace any worn or damaged • Fore/Aft Location of Seat Cushion - Lift and
parts immediately. hold lever (9) and move the seat cushion to a
• Even if there are no signs of damage, replace both comfortable position. Release the lever to lock the
driver and passenger seat belts five years after seat position adjustment.
6-14 930E-4SE
OPERATOR CAB AND CONTROLS OPERATOR SEAT (Optional)
• Seat Tilt - Lift seat slope lever (10) and hold to • Armrests - Rotate adjusting knob (11) until the
adjust the slope of the seat. Release the lever to armrest is in the desired position.
930E-4SE 6-15
PASSENGER SEAT (Optional) OPERATOR CAB AND CONTROLS
PASSENGER SEAT manufacture label is sewn into the shoulder harness

(Optional) B.4-0000054284 belt, near the retractor end.
Adjustment
in the seat. Refer to Figure 6-9 PASSENGER SEAT
• Headrest - The headrest (1) moves up, down, fore
or aft by adjusting it to the desired position.
• Seat Height - Press rocker switch (2) on top to
increase ride height. Press on lower part of rocker
switch to decrease ride height.
• Fore/Aft Location of Seat Cushion - Lift and
hold lever (3) and move the seat cushion to a
comfortable position. Release the lever to lock the
position adjustment.
• Seat Tilt - Lift seat slope lever (4) and hold to adjust
the slope of the seat. Release the lever to lock the
adjustment.
• Fore/Aft Location of Seat - Lift fore and aft lever
(5) and hold. Bend knees to move seat to a
comfortable position. Release the control lever to
• Suspension Dampener - Press rocker switch (6)
1. Headrest 6. Suspension
on top to increase ride firmness. Press on lower
2. Seat Height Dampener
part of rocker switch to decrease ride firmness.
3. Seat Cushion Fore 7. Lumbar Support
and Aft 8. Seat Belt • Air Lumbar Support - Each rocker switch (7)
4. Seat Tilt 9. Seat Tether controls an air pillow. One switch controls the lower
5. Fore and Aft 10. Backrest Angle air pillow and the other switch controls the upper
air pillow. To inflate, press on top of the rocker
Figure 6-9 PASSENGER SEAT CONTROLS switch and hold for desired support, then release.
The passenger seat provides a fully adjustable To deflate, press on the bottom of the rocker switch
cushioned ride for passenger comfort and easy and hold for desired support, then release. Adjust
operation. each pillow for desired support.
• Seat Belt - The operator must have seat belt (8)
Seat Belts And Tethers buckled in place and properly adjusted whenever
vehicle is in motion.
• On both driver and passenger seats, check the seat
belt fabric, buckle, all belt retractors and hardware • Seat Tether - Tether belts (9) should be adjusted
for damage or wear. Replace any worn or damaged with the seat in the highest position and all the way
parts immediately. forward. With the seat in this position, adjust the
tether belts so they have some slack. This allows
• Even if there are no signs of damage, replace both
for a slight extension when the seat deflects and
driver and passenger seat belts five years after seat
rebounds.
use, whichever comes first. The passenger seat • Backrest Angle - Lift backrest adjustment handle
belt date of manufacture label is sewn into the seat (10) to release and select the backrest angle.
belt near the buckle. The driver seat belt date of Release the control handle to set.
6-16 930E-4SE
OPERATOR CAB AND CONTROLS HEATER / AIR CONDITIONER CONTROLS
HEATER / AIR CONDITIONER selected by rotating the control knob clockwise to the
CONTROLS E.6-0000051502 desired position. OFF is in the full counter-clockwise
position. The control knob must be switched ON for
The heater/air conditioner compartment contains the air conditioner to function.
heater/air conditioner controls and some of the
heater/air conditioner components, such as the Temperature Control Knob
blower motor assembly and the heater coil. Optimum
cab air climate can be selected by using the following Temperature control knob (2) allows the operator to
controls in various combinations. select a comfortable air temperature.
The control knob determines the operation of the air
conditioning and heater modes.
Rotating the control knob counter-clockwise
(blue zone 3) will cause the A/C compressor to
operate and result in cooler air temperatures. Full
counter-clockwise position is the coldest air setting.
Rotating the control knob clockwise (red zone 4)
will affect coolant flow through the heater core and
result in warmer air temperatures. The full clockwise
position is the warmest heater setting.
Air Flow Directional Knob

Air flow directional knob (5) controls the direction of
airflow as follows:
Provides airflow to floor vents, only.
Provides airflow to upper vents and floor

vents.
(Blue Icon) Provides dehumidified air to
upper vents and floor vents.
Defrost - Provides dehumidified air to the
windshield.
1. Fan Speed Control 4. Red Zone
Knob 5. Air Flow Directional Defrost - Provides dehumidified air to the
2. Temperature Control Knob windshield as well as to floor vents.
Knob 6. Heater/Air
3. Blue Zone Conditioner Vents Heater/Air Conditioner Vents
Figure 6-10 HEATER / AIR CONDITIONER Heater/air conditioner vents (6) may be rotated 360°.
CONTROLS There are three vents in the heater/air conditioner
compartment, four vents across the top of the
Fan Speed Control Knob instrument panel, and one vent each in the RH and LH
Fan speed control knob (1, Figure 6-10 HEATER / AIR instrument panels. There are also an additional four
CONDITIONER CONTROLS, page 6-17) is provided vents under the instrument panel. Air flow through
to control the cab air fan motor. The fan motor is a the vents is controlled by manually opening, closing
3-speed motor (low, medium and high). Speeds are or turning the louvers.
930E-4SE 6-17
INSTRUMENT PANEL OPERATOR CAB AND CONTROLS
INSTRUMENT PANEL B.55-0000051679
1. Heater/Air Conditioner Vents 14. Not Used in This Application

2. Status Indicator Light Panel 15. Not Used in This Application
3. Hydraulic Oil Temperature Gauge 16. Key Switch
4. Coolant Temperature Gauge 17. Warning Light
5. Speedometer/Digital Display 18. Digital Display Contrast Buttons
6. Fuel Level Gauge 19. Turn Signal Indicators
7. Drive System Temperature Gauge 20. Panel Lights Dimmer Switch
8. Hazard Light Switch 21. Mode Switch #1
9. Brake Test Switch 22. Mode Switch #2
10. Wheel Brake Lock Switch 23. Fog Light Switch
11. AC Drive System Rest Switch 24. Backup Light Switch
12. Engine Warm Up Switch 25. Ladder Light Switch
13. Heated Mirrors 26. Headlight/Panel Illumination Switch
Figure 6-11 PANEL GAUGES, INDICATORS, AND CONTROLS
Control Symbols Most switches have two LED lights inside them, one
amber and one green in color. The amber is located in
The operator must understand the function and
the top portion of the switch and indicates that function
operation of each instrument and control. Many
has been activated. The green LED is located in the
control functions are identified with international
lower portion of the switch and indicates that function
symbols that the operator must learn to recognize
has not been activated.
immediately. This knowledge is essential for proper
and safe operation. • To activate a function, push on the top portion of
the switch. At this time, the amber LED will be
Items that are marked optional do not apply to every
illuminated, and the green LED will be OFF.
truck.
• To de-activate a function, push on the lower portion
The following symbols are general indicators and may of the switch. At this time, the green LED will be
appear in multiple locations and combinations on the illuminated, and the amber LED will be OFF.
instrument panel.
6-18 930E-4SE
OPERATOR CAB AND CONTROLS INSTRUMENT PANEL
NOTE: The green LED light in the hazard light switch, Hydraulic oil temperature
head light switch and the ladder light switch will gauge (3) indicates the
be illuminated when battery power is connected to oil temperature in the
the truck. The LED lights in the other switches will hydraulic tank. There are
illuminate when the key switch is turned to the ON two colored bands: green
position. and red.
This symbol when it Green indicates normal operation. As the needle

appears on an indicator approaches the red zone, minimum engine idle speed
or control identifies that will increase to help cool the oil. Red indicates high
this indicator or control is oil temperature in the hydraulic tank. Continued
NOT used. operation could damage components in the hydraulic
system. If this occurs, the operator should safely
stop the truck, move directional control lever to PARK
This symbol identifies and operate the engine at 1200 - 1500 rpm to reduce
a rotary control or system temperature.
switch. Rotate the
knob clockwise or Coolant Temperature Gauge
counterclockwise for Coolant temperature
functions. gauge (4) indicates
the temperature of the
This symbol identifies coolant in the engine
a switch used to test cooling system.
or check a function.
Press the switch on the
side near the symbol to The temperature range after engine warm-up and a
perform the test. truck operating under normal conditions should be 85°
to 97°C (185° to 207°F).
Heater / Air Conditioner Vents
Speedometer/Digital Display
Heater / Air Conditioner vents (1, Figure 6-11 PANEL
GAUGES, INDICATORS, AND CONTROLS, page Speedometer/digital display (5) displays the following
6-18) may be directed by the operator to provide the information:
most comfortable cabin air flow.
• The analog speedometer indicates the truck speed
in miles per hour (mph) or in kilometers per hour
Status Indicator Light Panel (kph).
Status indicator light panel (2) contains an array • The digital display shows payload meter
of indicator lights to provide the operator with information.
important status messages concerning selected truck
functions. Refer to Figure 6-12 STATUS INDICATOR • The digital display also shows warning messages
LIGHTS, page 6-23 for a detailed description of these and fault codes indicating abnormal operating
indicators. conditions and critical problems. See DIGITAL
DISPLAY OPERATION, page 6-26 for more
Hydraulic Oil Temperature Gauge information.
Fuel Level Gauge

• If temperature gauge does not move into the Fuel level gauge (6)
green range after a few minutes, and the red indicates how much
overhead indicator light does not go out, stop diesel fuel is in the fuel
the engine and notify maintenance personnel tank. When there is
immediately. only 10% of total fuel
tank capacity remaining,
the amber low fuel level
indicator on the gauge will
illuminate.
930E-4SE 6-19
Drive System Temperature Gauge When pulling into shovel or dump area, stop the truck
Drive system using the foot-operated service brake pedal. When
temperature gauge (7) truck is completely stopped and in loading position,
indicates the status of move the directional control lever to NETURAL, then
the highest measured apply the brake lock by pressing the top of the rocker
temperature range in the switch. To release the brake, press the bottom of the
drive system. rocker switch.
NOTE: The wheel brake lock will not function if the
Hazard Warning Light Switch directional control lever is in the PARK position.
Hazard warning light
switch (8) flashes all
the turn signal lights. • DO NOT use the wheel brake lock control
Pressing the top side switch to stop the truck unless the
of the rocker switch foot-operated treadle valve is inoperative.
activates these lights. Use of this switch applies rear service brakes
at a reduced, unmodulated pressure. DO
When these lights are on, a red LED light will be NOT use the brake lock for parking. With the
illuminated inside the switch. Pressing on the lower engine stopped, hydraulic pressure will bleed
side of the rocker switch turns these lights off, and a down, allowing the brakes to release.
green LED light will be illuminated.
Use at shovel and dump only to hold the truck in
Pre-Shift Brake Test Switch position.
Pre-shift brake test
switch (9) is used to NOTE: The wheel brake lock will not apply when the
initiate a brake test. directional control lever is placed in the PARK position,
Press on the momentary or when the key switch is OFF, or when the engine is
switch to enter the brake not running.
test mode. If certain
conditions are met, the Rest Switch
operator can enter a Rest switch (11) is a
brake test sequence. rocker switch with a
locking device. A safety
The amber light in the top of the switch is used to tab on the switch must
indicate when the truck is in brake test mode, and is be pushed to unlock the
referred to as the brake check light. When illuminated, switch before the top
a brake test is ready. When flashing, the brake test of the switch can be
is at the validation point, or the retard system test is depressed to activate the
finished. rest mode.
Wheel Brake Lock Control Switch When activated, an internal amber lamp will
Wheel brake lock switch illuminate. The switch should be activated to
(10) should be used deenergize the AC drive system whenever the engine
with engine running for is to be shutdown or parked for a length of time with
dumping and loading the engine running.
operations only. The The directional control lever must be in PARK or
brake lock switch NEUTRAL and the vehicle not moving to enable
actuates the hydraulic this function. This will allow the engine to continue
brake system which locks running while the AC drive system is de-energized.
the rear wheel service
brakes only.
6-20 930E-4SE
OPERATOR CAB AND CONTROLS INSTRUMENT PANEL
Key Switch
• Activation of the rest switch alone DOES NOT
completely ensure that the drive system is
safe to work on. Refer to the Safety chapter
for more information on servicing an AC
drive. Check all "link-on", or "link energized",
indicator lights to verify the AC drive system
is de-engergized before performing any
maintenance on the drive system. DO NOT
activate the rest switch while the truck is
moving! The truck may unintentionally enter
the “rest” mode after stopping.
Engine Warm Up (Optional)

Engine warm up switch
(12) is a rocker switch.
When in the ON position, Key switch (16) is a four-position (ACC, OFF, RUN,
this feature is used to START) switch. The ACC position is not currently
keep the engine warm in used.
cold conditions because
it puts a small amount of Starting
load on the engine.
When the switch is rotated one position clockwise, it
Settings in the GE config file also allows this switch is in the RUN position and all electrical circuits except
to control warming of the IGBTs in the control cabinet. START are activated.
When the inverters are turned off for traction duty, they 1. With the selector switch in PARK, rotate key
will be placed in warm-up mode. When a direction is switch fully clockwise to the START position,
selected, the inverters transition from Warm-up mode and hold this position until the engine starts.
to Traction mode. The START position is spring-loaded to return
This energy is created by passing a load through one to RUN when the key is released. If the engine
bank of the grid resistors in the retarding grid. is equipped with a prelube system, a noticeable
delay will occur before engine cranking begins.
Heated Mirror Switch (Optional) 2. After engine has started, place rest switch (4)
Heated mirror switch (13) in the OFF position, which will de-activate the
controls the operation of rest mode of operation. Refer to the discussion
the heated mirrors. of rest switch later in this chapter.
NOTE: The electric cranking motors have a 30
second time limit. If the 30 second limit is reached,
cranking will be prohibited for two minutes. After two
minutes, cranking will be allowed. If the 30 second
Rotating Beacon Light Switch (Optional) limit is reached seven consecutive times, the key
Rotating beacon light switch must be turned to the OFF position. This will
switch (14) controls the allow the interface module to power down and reset,
operation of the rotating which requires seven minutes to complete.
beacon light.
930E-4SE 6-21
Warning Light arrows are used to toggle through the different options
Red warning light (17) will and messages on the digital display. The OK position
come on to indicate that is used to acknowledge and clear warnings and faults
a truck function requires and set certain Payload Meter III settings.
immediate action by
Refer to DIGITAL DISPLAY OPERATION, page 6-26
the operator. Safely
for more information about using the digital display.
stop the truck and notify
maintenance personnel.
A warning message will
Fog Light Switch
appear on the digital Pressing the top of fog
display. light switch (23) turns the
lights on. Pressing the
Digital Display Contrast Buttons bottom of the switch turns
the lights off.
Cold ambient operating temperatures may affect
the contrast of the digital display. If necessary, use
buttons (18) to increase or decrease the contrast of
the digital display to make it easier to read. Backup Light Switch
Backup light switch (24)
Turn Signal Indicators allows the backup lights
Indicators (19) illuminate to be turned on for
to indicate that the right added visibility and safety
or left turn signals are when the directional
operating when the control lever is not in the
turn signal lever on the REVERSE position.
steering column is moved
upward or downward. Ladder Light Switch
Moving the lever to its Ladder light switch (25)
center position will turn turns the ladder lights and
the indicator off. deck lights on or off after
or before using ladder.
Panel Light Dimmer
Panel illumination light
dimmer switch (20) is
a rheostat which allows Pressing the top of the rocker switch turns the lights
the operator to vary on. Pressing the bottom of the switch turns the lights
the brightness of the off. Another switch is mounted at the front left of truck
instruments and panel near the base of ladder.
lights.
• Rotating the knob to the full clockwise position turns Headlight/Panel Illumination Light Switch
the panel lights on to the brightest condition. The instrument panel
lights, clearance lights,
• Rotating the knob counterclockwise continually and the headlights
dims the lights until OFF position is reached at full are controlled by this
counterclockwise rotation. three-position rocker type
switch (26).
Mode Switches
Mode switches (21)
OFF is selected by pressing the bottom of the switch.
and (22) are two-way
Press the top of the switch until it reaches the first
momentary rocker
position to select the panel lights, clearance lights and
switches. The
tail lights only. Press the top of the switch again until
it reaches the second position to select headlights,
panel lights, clearance lights and tail lights.
6-22 930E-4SE
OPERATOR CAB AND CONTROLS STATUS INDICATOR LIGHT PANEL
STATUS INDICATOR LIGHT

PANEL B.31-0000053883
1. Body Up 7. Not used in this application 13. Pantograph Energized

2. Parking Brake 8. Wheel Brake Lock 14. Pantograph Up
3. Propulsion System Not Ready 9. Traction Control 15. Service Brake
4. No Propel 10. Repair Monitor 16. Dynamic Retarding
5. Engine Warm Up 11. Retractable Ladder Down 17. No DC Link Voltage
6. Engine Shutdown Delay 12. Snapshot In Progress
Figure 6-12 STATUS INDICATOR LIGHTS
STATUS INDICATOR LIGHT If the directional control lever is in the PARK position
SYMBOLS B.3-0000053882 and the interface module (IM) detects any parking
brake abnormalities, this light will not illuminate. The
When illuminated, these amber (yellow) status lights red warning light on the dash will flash, the warning
alert the operator that the indicated truck function buzzer will sound intermittently and an error code will
requires some precaution. Refer to the following be displayed. If the red warning light and buzzer are
descriptions for explanations of the symbols. active, the operator must not leave the cab. Notify
maintenance personnel immediately.
Body Up
The body up indicator will Propel System Not Ready
illuminate when the body Propulsion system not
is not completely down on ready indicator will
the frame. The truck must illuminate during start-up
not be driven, other than much like the hour glass
to fully discharge the load icon on a computer
until body is down and the screen.
light is off.
This light indicates the Drive System CPU is in the
Parking Brake process of performing the self-diagnostics and set-up
The parking brake functions at start-up. Propulsion will not be available
indicator will illuminate at this time.
when the parking brake
is applied. The parking
brake is applied by
placing the directional
control lever in the PARK
position.
930E-4SE 6-23
STATUS INDICATOR LIGHT PANEL OPERATOR CAB AND CONTROLS
No Propel Wheel Brake Lock

The no propel indicator The wheel brake lock
will illuminate when the indicator will illuminate
rest switch is placed in the when the wheel brake
ON position. It will also lock is on.
illuminate when a fault
has occurred which has
eliminated the propulsion
capability. If this condition
occurs, the operator must
Traction Control OFF
safely stop the truck, The indicator will
move directional control illuminate when the
lever to PARK, shut down NO-Traction Control
the engine, and notify switch is turned ON or
maintenance personnel if a wheel speed sensor
immediately. malfunction occurs in the
Drive System. In either
case, Slip/Slide control
Engine Warm Up will be lost.
Engine warm up indicator
will illuminate when the Repair Monitor
engine warm up switch
The repair monitor
is turned on. In this
indicator will illuminate if a
state the Drive System
“repair” fault is detected,
will place a small load on
which must be corrected
the engine by running one
after the operator’s shift
Grid bank and both Grid
is done. These Faults
Blower motors. PROPEL
can be reviewed in the
IS NOT AVAILABLE in
Operator Text Display.
this mode.
Engine Shutdown Delay Retractable Ladder Down

When the key switch The retractable ladder
has been turned OFF, down indicator will
and certain conditions illuminate when the
have been met, this power ladder is not in
indicator light will the full up position. The
illuminate to indicate indicator will flash if the
that the shutdown timing park brake is released
sequence has started. without the ladder in the
The engine could operate full up position.
for up to three minutes.
Snapshot In Progress
• If the directional control lever is moved out of PARK, The indicator will
the engine will stop immediately. illuminate when the
• If the key switch is turned back ON, the engine stop KOMTRAX Plus system
sequence will be terminated, and the engine will is in the process of
remain running. recording a “snapshot”
of certain vehicle
Retarding Grid Dryer conditions.
This indicator light is not
used in this application.
6-24 930E-4SE
OPERATOR CAB AND CONTROLS STATUS INDICATOR LIGHT PANEL
Pantograph Energized Dynamic Retarding

This indicator light is not The dynamic retarding
used in this application. indicator will illuminate
whenever the Drive
System is in the Retard
mode, this can be due to
entry by; Retard Pedal
or automatic over speed
control or Speed Cruise
Pantograph Up Control is active and
This indicator light is not Retard mode is in control
used in this application. of the truck speed.
No DC Link Voltage
The no DC link voltage
indicator will illuminate
when the rest switch in
Service Brake ON, or whenever the DC
The service brakes are link in the control cabinet
applied, by either manual is not providing voltage to
or automatic means. the propulsion system.
930E-4SE 6-25
DIGITAL DISPLAY OPERATION OPERATOR CAB AND CONTROLS
DIGITAL DISPLAY
OPERATION C.6-0000051680
Toggling Through Main Level Screens
6-26 930E-4SE
OPERATOR CAB AND CONTROLS DIGITAL DISPLAY OPERATION
Toggling Through Warning Screens
930E-4SE 6-27
DIGITAL DISPLAY OPERATION OPERATOR CAB AND CONTROLS
Entering Payload Meter Data
6-28 930E-4SE
OPERATOR CAB AND CONTROLS KOMTRAX Plus
KOMTRAX Plus C.3-0000051569
KOMTRAX Plus OPERATION B.36-0000051740 • The KOMTRAX Plus system uses wireless
components that transmit via radio waves. It
Basic Precautions is necessary to conform to local laws when
• When using this truck, there is no particular need to using this system. Proper operation of the
operate the KOMTRAX Plus system. system is dependent on good reception.
Operating in tunnels, mountain ranges and
• Never disassemble, repair, or modify the
covered areas may prevent communication of
KOMTRAX Plus system. This may cause failure or
the system. Contact your Komatsu distributor
fire on the machine or this system.
before selling or exporting a truck equipped
• Do not touch the system when operating the with KOMTRAX Plus. It may be necessary
machine. to remove the system before transfer of
ownership. Contact your Komatsu distributor
• Do not pull on the wiring harnesses, connectors.
before installing equipment that may interfere
or sensors of this system. This may cause short
with the KOMTRAX Plus system. Komatsu
circuits or disconnections that lead to failure or fire
is not responsible for any failures that result
on the machine or this system.
from neglecting KOMTRAX Plus system
• Do not get water, dirt or oil on the system controllers. precautions and instructions.
• If there is any abnormality with the KOMTRAX
Plus system, please consult the servicing Komatsu This system uses KOMTRAX Plus controller
distributor. (2, Figure 6-14 KOMTRAX Plus COMPONENT
LOCATION, page 6-30) to gather data about the
operation of the truck from sensors and other
• DO NOT disassemble, repair, or modify controllers installed on the truck. The data stored
the KOMTRAX Plus system without proper in the KOMTRAX Plus controller is collected by
authorization. Changes to the system a laptop personal computer (PC) or transmitted
may cause machine failures and fire. DO directly by communications satellite (utilizing the
NOT touch the KOMTRAX Plus system Orbcomm controller). This data is then compiled
components during machine operation. DO at the Komatsu computer server. Based on this
NOT pull on KOMTRAX Plus system wiring information, the servicing Komatsu distributor will
harnesses, connectors, or sensors. This may suggest improvements and provide information aimed
cause short circuits or open circuits and lead at reducing machine repair costs and downtime.
to machine failure or fire. DO NOT allow water, When the data-store button (1, Figure 6-13 CENTER
dirt, or oil onto system components. CONSOLE, REAR VIEW, page 6-30) is pressed
on the back side of the center console, it will store
a “snapshot” of the Statex III drive system. It will
also trigger the KOMTRAX Plus system to store a
• Anyone with a pacemaker must remain “snapshot” of the truck operating system. A light on
a minimum of 22 cm (9 in.) from the the controller will stay illuminated while the KOMTRAX
communications antenna. Radio waves from Plus system is recording the “snapshot”, which lasts
the antenna can interfere with pacemaker for 7.5 minutes.
operation.
The KOMTRAX Plus system is turned on by the truck
key switch. Immediately after receiving 24V power
from the key switch, the KOMTRAX Plus controller
begins the power-up initialization sequence. This
sequence takes about three seconds, during which
time the red LED digits display a circular sequence of
flashing LED segments.
930E-4SE 6-29
KOMTRAX Plus OPERATOR CAB AND CONTROLS
1. Orbcomm Controller 2. KOMTRAX Plus

Controller
Figure 6-14 KOMTRAX Plus COMPONENT

LOCATION
Interface Module
1. Data Store Button
Interface module receives data from the sensors
Figure 6-13 CENTER CONSOLE, REAR VIEW installed on the truck and sends this information
to the KOMTRAX Plus controller. There is a small
During normal truck operation, the red LED digits on
green LED light on the face of the interface module
the KOMTRAX Plus controller will count from 00-99
controller. With the key switch ON, the light must be
continuously.
blinking. If the light is continuously illuminated, there
When the key switch is turned OFF, the KOMTRAX is a problem in the controller.
Plus controller will remain on while it finishes
processing internal data and saves the recent data DOWNLOADING KOMTRAX Plus
into permanent memory. When the data has been DATA D.52-0000051588
safely stored, the two digit LED display will turn
OFF. This process could take up to three minutes to General Information
complete. Downloading data requires a laptop PC running
Windows 95/98/2000/ME/XP/Vista/7 operating
systems, the VHMS Technical Analysis Toolbox
• If 24V power is disconnected (using the software, and a serial cable to connect the PC to
battery disconnect switches) from the the KOMTRAX Plus controller. Refer to the VHMS
KOMTRAX Plus controller before it has Technical Analysis Tool Box instruction manual for
completed its shut down procedure, the additional information about using this software.
KOMTRAX Plus controller will lose all data When a download to a laptop PC is performed,
gathered since the key switch was last turned certain files are generated to store data. KOMTRAX
ON. DO NOT disconnect battery power until Plus diagnostic port (1, Figure 6-15 KOMTRAX Plus
the KOMTRAX Plus controller has completed PORT (D.I.D. PANEL AT REAR OF CAB), page 6-31),
the shut down procedure and has turned the located on the D.I.D. panel at the rear of the operator
LED digits off. cab, is used to download data from the controller.
6-30 930E-4SE
KOMTRAX Plus Downloading Procedure 11. Verify that a manual snapshot (MFAO) has
been recorded. The display will show an item
named “Snapshot” with the code MFAO and
text “Manual Trigger”.
12. On the Download screen, click the [Select All]
button. All items will become checked.
13. Click the [Download] button. The download
may take one to ten minutes. Generally, if there
are several snapshots in the download items,
the download will take longer.
14. Click the [OK] button to complete the download.
15. Verify that the “Download Completed”
message is displayed. Click on [Exit].
1. KOMTRAX Plus Diagnostic Port 16. Select the [Machine History] option from the list
on the left side of the screen.
Figure 6-15 KOMTRAX Plus PORT (D.I.D. PANEL
AT REAR OF CAB) 17. Verify that the key ON/OFF and engine
ON/OFF records are recorded correctly.
NOTE: Always verify the full download has completed
before disconnecting the PC from the machine. 18. Exit any open windows on the PC.
1. Turn the key switch to the OFF position to stop 19. Verify a full download has been taken. Refer to
the engine. Location of Downloaded Files on Computer for
more detailed instructions.
2. Turn the key switch to the ON position, but DO
NOT start the engine. 20. Disconnect the KOMTRAX Plus cable from the
PC and from the machine.
3. Allow the KOMTRAX Plus controller to start up.
This will take about one minute. Verify the red 21. Turn the key switch to OFF.
LED display starts counting up.
Location Of Downloaded Files
4. Attach the KOMTRAX Plus serial cable to
KOMTRAX Plus diagnostic port (1), and the When a download using VHMS Technical Analysis
other end to the PC’s serial port. Tool Box is performed, several files are downloaded
onto the computer. They are organized in a specific
5. Double-click on the VHMS Technical Analysis
way so that they can be used by VHMS Technical
Tool Box icon on the PC's desktop.
Analysis Tool Box at a later time. This structure is
6. Enter the appropriate User Name and created automatically when the computer is used
Password and click the [OK] button. to perform the download from the KOMTRAX Plus
controller. The situation may arise where the files
7. Double-click on the [Download] icon.
need to be sent to someone, or someone gives these
8. Select the COM port in the Port No. drop-down files to you.
box and click the [Connection] button.
1. Open Windows Explorer by right-clicking on the
9. Verify that the date and time is correct for start button and choosing Explore.
current local date and time. Also verify that the
2. In the left frame, the computer's file structure
displayed service meter hours are equal to the
will be displayed. The right frame will show the
value entered previously.
details for the folder that is highlighted in the left
10. If this is the first time this PC has connected frame.
to the machine, you will need to download its
3. In the left frame, navigate to the download files.
definition file by clicking the [OK] button.
930E-4SE 6-31
KOMTRAX Plus OPERATOR CAB AND CONTROLS
The basic path is as follows: UPLOADING KOMTRAX Plus

• Desktop
DATA E.6-0000051586
After downloading, the KOMTRAX Plus data resides
• My Computer
on the PC that performed the download. In order to
• Local Disk (C:) make this data available to others, it must be sent
to an online database named WebCARE. Once the
• VHMS_Data
data has been uploaded (ftp'd) to WebCARE, it is
• Model accessible to anyone with an internet connection and
an ID and password.
• Serial Number
• Date VHMS Technical Analysis Tool Box is used to perform
the ftp upload. Perform an ftp upload as soon as the
• Check Number person who performed the download can obtain an
internet connection. All downloads must be uploaded
NOTE: The date folder is named in the format
to WebCARE.
“YYYYMMDD”.
1. Double-click on the VHMS Technical Analysis
Tool Boxicon on the PC's desktop.
2. Enter the appropriate user name and password
and click the [OK] button.
3. Double click the [FTP] icon.

4. At the ftp Client Login window, enter the ftp
User ID and Password.
a. User ID = komatsu
b. Password = vhms
Figure 6-16 FILE LOCATION 5. The target directory must be set to the PC's
The screenshot shows the location of where the hard drive (usually drive C:\).
KOMTRAX Plus download files reside on a computer.
a. Double-click the VHMS_Data folder to drop
The Check Number folder is named in the format
down the model folders.
CHK000#. Each time a download is taken, it is placed
in one of these folders. The first download will be in b. Double-click the appropriate model folder
the CHK0001 folder. If a second download is taken to drop down the serial number folders.
on the same day, will be in the CHK0002 folder, etc.
c. Double-click the appropriate serial number
Once the appropriate folder is selected, the contents folder to drop down the date folders.
will be shown in the right frame. These files can then
d. Double-click the appropriate date folder to
be e-mailed or copied to a disk.
drop down the check number folders.
If someone provides KOMTRAX Plus download
files through e-mail or on a disk, the same folder
organization must be created in order to view them in
VHMS Technical Analysis Tool Box.
6-32 930E-4SE
e. Double-click the appropriate check number 8. Click the [Yes] button to verify that you want to
folder to display its contents in the files upload the data to WebCARE.
window.
9. If the sending file was uploaded successfully,

the file will appear in the OK window. If the
sending file was not uploaded successfully, the
file will appear in the “NG” (No Good) window.
Ensure the PC has an internet connection.
6. Some models will automatically create a

sending file during the download process.
Others need to have the sending file created at
this time. A sending file is just a compressed
version of all the other downloaded files. If
there is already a sending file in the Send File
window, you do not need to perform this step.
If there is not a sending file in the Send File
window, click the [Make Sending File] button.
NOTE: The compressed sending file will look similar
to this file name, and will always end with a “.K”. 10. Click the [OK] button, then the [Exit] button.
P_830E_-_A30761_1105208857.K Close all other open windows.
7. After selecting the correct file to send, click the
[Send (FTP)] button.
930E-4SE 6-33
ORBCOMM OPERATOR CAB AND CONTROLS
ORBCOMM D.27-0000051585 coaxial cable is routed through the inside of the cab
to protect it from damage. If the antenna or coaxial
cable is damaged, replace the parts.
• ORBCOMM a two-way radio communication
device. Wireless signals from the system
can interfere with other wireless signals
in the area. This interference can cause
a malfunction in a blast zone resulting
in an unintended detonation. Know the
locations of blast zones in the area and
keep a safe distance to avoid unintentional
blasts. If the machine is operating within
a distance of 12m (40 ft) of a blast zone,
disconnect the ORBCOMM harness. Failure
to do so could result in serious injury or
death. This warning does not supersede
requirements or regulations of the area or
country where this machine is in operation.
The following specifications are provided to
ensure compliance with all of the applicable
requirements or regulations: Transmit power:
5-10 Watts Operating Frequency Range: 148
- 150 MHz
1. ORBCOMM Antenna 2. Magnetic Base
The ORBCOMM Controller transmits data through
antenna (1, Figure 6-17 ORBCOMM ANTENNA, Figure 6-17 ORBCOMM ANTENNA
page 6-34) mounted on top of the cab. The antenna
6-34 930E-4SE
OPERATOR CAB AND CONTROLS KOMATSU WIRELESS BRIDGE (KWB)
KOMATSU WIRELESS BRIDGE

(KWB) A.8-0000073739
General Information
The Komatsu Wireless Bridge (KWB) provides access
to two networks; one directly to the KOMTRAX Plus
controller, and one directly to the Ethernet switch
to enable all features for wireless access. These
systems allow maintenance and service personnel to
download data and access controllers on the truck
wirelessly without actually getting on the truck.
Each truck is equipped with two wireless bridge
antennas located on the LH deck handrail. See
Figure 6-18 KWB ANTENNA LOCATION, page 6-35
for locations.
1. PicoStation M2 3. CAT 5E network cable

Access Point to POE Port
2. Power over Ethernet 4. Service Laptop
(POE) Adapter
Figure 6-19 KWB TOOLS

NOTE: PicoStation M2 devices act as Access Points
for each network. One PicoStation M2 is required for
1. Antenna for Truck_Net SSID
each network.
2. Antenna for KWB_Connect SSID
Figure 6-18 KWB ANTENNA LOCATION VHMS DOWNLOADS A.1-0000073736
The KWB_Connect Bullet M2 is configured as a bridge General Information

and provides access to KOMTRAX Plus controller
VHMS downloads are accomplished by connecting
downloads via the VHMS Auto Download Tool.
the service laptop wirelessly to the KWB_Connect
The TRUCK_NET Bullet M2 is configured as a router SSID and opening the VHMS Auto Download tool.
and allows access to controllers connected to the The software used to automatically download data
Ethernet switch. This includes PLM IV and the GE from a KOMTRAX Plus controller is obtained from
drive system. Diagnostic information, alarm codes, your Komatsu distributor.
and haul cycle data can be downloaded wirelessly.
Installing this software will create an icon called
This data can also be downloaded directly by “VHMS Auto Download Tool”. Any KWB_Connect
connecting a service laptop to the Ethernet switch. Bullet M2 that is properly setup, connected to a
See Figure 6-19 KWB TOOLS, page 6-35 for powering KOMTRAX Plus controller and within range of the
the PicoStation M2 access point. Access Point (AP), will automatically download all
data from the KOMTRAX Plus controller.
The “VHMS Auto Download Tool” software will not
download from KOMTRAX Plus controllers that have
not had the vehicle data setup (this is a consideration
only when replacing or installing a KOMTRAX Plus
controller for the first time).
930E-4SE 6-35
KOMATSU WIRELESS BRIDGE (KWB) OPERATOR CAB AND CONTROLS
Any KWB_Connect Bullet M2 not connected to a

KOMTRAX Plus controller will not show up in the list
of available download sources.
The “VHMS Auto Download Tool” software will only
download data once every 20 hours, however, it is
possible to force a download by right clicking on a
connected vehicle in the “Download History” section
and selecting “Download ON.”
VHMS Downloading Procedure

1. Disconnect from any Wired Ethernet
connection and confirm IP settings for
the wired and wireless LAN connection
are set for Automatic when downloading
wirelessly through the Access Point (AP). (See
CHANGING A LAPTOP'S IP ADDRESS, page
6-36 for more information)
2. If the KWB_Connect Access Point is already Figure 6-21 FORCE DOWNLOAD
powered on, connect to the KWB_Connect ONBOARD CONTROLLER
SSID. Otherwise, use the provided POE ACCESS A.5-0000073735
adapter to power the KWB_Connect Access
Point. (See CONNECTING TO A WIRELESS Each truck is equipped with controllers on board
NETWORK, page 6-37 for instructions on that are connected to the Ethernet switch. These
connecting to the KWB_Connect SSID) controllers are accessed either through a wireless or
wired connection.
3. Ensure a truck with a KWB_Connect BULLET
M2 is within range and the truck is powered on.
Wireless Access
4. Open the “VHMS Auto Download Tool”
Wireless access to the TRUCK_NET SSID allow
NOTE: If this is the first time the tool has been used, maintenance and service personnel the ability to
the defaults are the following: communicate with controllers connected to the
Ethernet switch without actually getting on the truck.
• User name: user
• Password: 1 CHANGING A LAPTOP'S IP
ADDRESS A.2-0000073738
The following instructions are for Windows 7 ™.
1. Click Start > Control Panel
2. Open the Network and Sharing Center
• If settings are displayed by icons click
“Network and Sharing Center”
• If settings are displayed by category click
“View network status and tasks”
3. Click “Change Adapter settings” in the left-hand
pane
Figure 6-20 LOGIN SCREEN
4. Right click on the adapter that needs to be
5. Confirm that a truck is present in the configured
“Connecting Unit” section.
• For WIRELESS CONNECTIONS use
6. To force a download, right click on a vehicle in Wireless Network Connection
the download history that is also shown as a
connected unit, and then select download ON. • For WIRED LAN CONNECTIONS use Local
Area Connection
6-36 930E-4SE
OPERATOR CAB AND CONTROLS KOMATSU WIRELESS BRIDGE (KWB)
5. Click “Properties” • Click OK

• Click OK/Close
Figure 6-23 AUTOMATIC IP CONFIGURATION

Figure 6-22 ETHERNET ADAPTER PROPERTIES CONNECTING TO A WIRELESS
6. Select “Internet Protocol Version 4 (TCP/IPV4)” NETWORK A.2-0000073737
(See Figure 6-22 ETHERNET ADAPTER The following instructions are for Windows 7 ™.
PROPERTIES, page 6-37)
1. Click on the network icon in the system tray
7. Click “Properties”
2. Connect to the desired SSID:
8. FOR AUTOMATIC IP SETTINGS (See Figure
6-23 AUTOMATIC IP CONFIGURATION, page • For KWB_Connect, click on “KWB_Connect”
6-37): (See Figure 6-24 CONNECTING TO
KWB_CONNECT, page 6-38).
• Select Obtain an IP address automatically
radio button • For TRUCK_NET, click on “TRUCK_NET”
(See Figure 6-25 CONNECTING TO
• Select Obtain DNS server address TRUCK_NET, page 6-38).
automatically radio button
930E-4SE 6-37
KOMATSU WIRELESS BRIDGE (KWB) OPERATOR CAB AND CONTROLS
Figure 6-24 CONNECTING TO KWB_CONNECT Figure 6-25 CONNECTING TO TRUCK_NET

3. Click on the “Connect” button.
4. Accept any requests from the network (it may
be listed as unsecure).
NOTE: The connection status will be shown as
“Limited.”
6-38 930E-4SE
OPERATOR CAB AND CONTROLS FUSES AND CIRCUIT BREAKERS
FUSES AND CIRCUIT VEHICLE ELECTRICAL CENTER

BREAKERS E.30-0000051583 89 A.7-0000070603
Before replacing a fuse, determine the cause of Vehicle Electrical Center 89 is located inside the
failure. Repair as necessary. Always replace a fuse auxiliary control cabinet.
with one of specified amperage. Never replace a fuse
with one of greater amperage.
Figure 6-26 VEHICLE ELECTRICAL CENTER 89

VEHICLE ELECTRICAL CENTER 89
LOCATION AMPS DEVICE(S) PROTECTED
F2 25 Back-Up Lamps
F3 15 Back-Up Horn
F4 15 Left Low Beam Headlights
F5 15 Right Low Beam Headlights
F6 25 High Beam Headlights
F8 15 Marker & Tail Lights
F9 10 Brake Light
F10 20 Ladder Lights
F11 15 Turn Signal Hazard
F12 10 Steering Bleed Down
F13 10 Retard Lamps
F20 10 Auto Lube
F42 5 IM & Fuel Sensor
F43 1 Direction Selector Switch
Display Mode Switch, Camera Switch and Switch
F44 5
LED Lights
930E-4SE 6-39
FUSES AND CIRCUIT BREAKERS OPERATOR CAB AND CONTROLS

F45 15 GE Drive Control & Feedback
F53 20 Heated Mirror
F56 10 Operator Seat
F57 10 Pre-Shift Brake Test
F61 1 Left Rear Wheel Speed
F62 15 Fog Lamp
F63 15 Seat Belt Alarm
F64 5 Headlight Switch
SP1 1 Spare
SP2 1 Spare
SP3 1 Spare
SP4 5 Spare
SP5 10 Spare
SP6 15 Spare
SP7 20 Spare
SP8 25 Spare
D14 3 Back-Up Diode 1
D15 3 Back-Up Diode 2
R3 Back-Up Horn Micro Relay
R8 Marker & Tail Light Micro Relay
R9 Brake Light Micro Relay
R11 Left Turn Micro Relay
R12 Right Turn Micro Relay
R13 Turn Signal Hazard Flasher Relay
R14 Steering Bleed Down Micro Relay
R15 Retard Lamps Micro Relay
R29 Auto Lube Micro Relay
R39 Heated Mirror Micro Relay
R40 Fog Lamp Micro Relay
R41 Seat Belt Alarm Micro Relay
6-40 930E-4SE
VEHICLE ELECTRICAL CENTER

90 A.5-0000070602
Vehicle Electrical Center 90 is located inside the

F14 5 Payload Lamps
F15 5 Park Brake Status
F17 5 Payload Meter
F18 15 Ground Level Shutdown Switch
F19 10 Park Brake Control
F46 5 Payload Meter Key Switch Power
F47 5 KOMTRAX Plus 2 Key Switch Power
F48 5 Modular Mining Conn Key Switch Power
SP1 1 Spare
SP2 1 Spare
SP3 1 Spare
SP4 5 Spare
SP5 10 Spare
SP6 15 Spare
SP7 20 Spare
SP8 25 Spare
D1 3 Key Switch Run Diode
D2 3 Shift Selector Reverse Diode
930E-4SE 6-41

D3 3 Shift Selector Neutral Diode
D4 3 Shift Selector Forward Diode
D5 3 Park Brake Diode
D6 3 Truck Moving Diode
D7 3 Brake Lock Diode
D8 3 Park Brake Latch Diode
D9 3 GE True Forward Signal Diode
D10 3 GE True Reverse Signal Diode
D11 3 GE Propel System At Rest Diode
D12 3 GE Propel System Not Ready Diode
D13 3 Forward, Neutral, Reverse Signal Diode
D14 3 Engine Running Diode
R16 Payload Red Lamp Relay
R17 Payload Amber Lamp Relay
R18 Payload Green Lamp Relay
R19 Engine Interlock Relay
R20 Timed Engine Shutdown Relay
R21 Engine Running Relay
R22 Park Brake Request Relay
R23 Park Brake Release Relay
R24 Park Brake Switch Relay
R25 Truck Moving Relay
R26 Park Brake Latch Relay
R27 GE Interface Relay
R28 Park Brake Status Relay
6-42 930E-4SE
VEHICLE ELECTRICAL CENTER

91 A.5-0000071904
Vehicle Electrical Center 91 is located inside the

F21 10 Ether Start
F22 20 Op-Cab Communication Radio 12V
F23 10 Entertainment Radio 12V
F24 10 A/C Compressor
F25 10 Shutter Control
F26 15 Electronic Gauge Display Un-Switched
F27 10 IM Un-Switched # 1
F28 10 IM Un-Switched # 2
F29 10 KOMTRAX Plus & Orbcomm
F30 20 Modular Mining Un-Switched
F31 15 Engine Oil Reserve Pump Motor
F32 15 Engine Oil Reserve Controller
F33 15 Vehicle Horn / Service Lamps
F34 15 Engine Service Lamps / Hydraulic Mod Lamp
F35 15 Ladder & Hazard Lamp Control Switch
F36 20 Engine Un-Switched Power Fuse #1
930E-4SE 6-43

F40 20 Op-Cab Communication Radio 24V
F41 5 Op-Cab Fire Suppression
F49 15 Operator Cab HVAC Key Switch
F50 10 Windshield Wipers
F51 10 Hoist Limit Switch
F52 5 Turn Signal Switch
F54 5 Electronic Gauge Display Key Switch
F55 5 Aux Box Dome Lamps
F56 20 Electric Window - Left
F58 20 ORS Heated Hose PWR
F59 5 Hydraulic Ladder
F60 51 MM PXT Display
F62 20 Electric Window - Right
F63 20 Auxiliary Power Port 12V
SP1 5 Spare
SP2 5 Spare
SP3 10 Spare
SP4 10 Spare
SP5 15 Spare
SP6 15 Spare
SP7 20 Spare
SP8 20 Spare
D13 3 Turn Signal Switch Diode
D14 3 Key Switch Power Or Diode
D15 3 GE Control Power Or Diode
R30 Starter Enable Relay
R34 GE Payload 70% Signal Relay
R35 GE Payload 100% Signal Relay
R36 Ether Start Relay
R37 Entertainment Radio Relay
6-44 930E-4SE

R38 A/C Compressor Relay
R39 Shutter Control Relay
CIRCUIT BREAKERS C.17-0000051607
The following circuit breaker is located on the LH wall

inside the Auxiliary Control Cabinet
CIRCUIT BREAKERS
LOCATION AMPS DEVICE(S) PROTECTED CIRCUIT
CB60 50 24VDC to 12VDC Converter 11B5
930E-4SE 6-45
6-46 930E-4SE
LUBRICATION AND SERVICE
930E-4SE 7-1
GENERAL INFORMATION LUBRICATION AND SERVICE
Service Capacities
GENERAL U.S.
INFORMATION E.45-0000051606 System Liters
Gallons
Recommended preventive maintenance will Wheel Motors (each side) 95 25
contribute to the long life and dependability of the truck
and its components. The use of proper lubricants and Front Wheel Hub (each side) 68 18
the performance of checks and adjustments at the Fuel Tank (Diesel Fuel Only) 5300 1400
recommended intervals is most important.
Retractable Ladder System
8 2
Refer to LUBRICATION CHART, page 7-10 for (If Equipped)
lubricant requirements. For detailed service
requirements for specific components, refer to the HYDRAULIC SYSTEM
service manual section for that component.
SERVICE C.71-0000051605
Refer to the manufacturer's service manual when
servicing any components of the drive system.
Hydraulic Tank
There are two sight gauges on the side of the
Refer to the engine manufacturer's service manual
hydraulic tank. With the engine stopped, key switch
when servicing the engine or any of its components.
OFF, hydraulic system bled down and body down, oil
The service intervals presented here are in hours should be visible in the top sight gauge. If hydraulic
of operation. These intervals are recommended in oil is not visible in the top sight gauge, follow Adding
lieu of an oil analysis program which may determine Oil instructions below.
different intervals. However, if the truck is being
Adding Oil
operated under extreme conditions, some or all, of the
intervals may need to be shortened and the service Keep the system open to the atmosphere only as
performed more frequently. long as absolutely necessary to lessen the chances
of system contamination.
This truck is equipped with an automatic lubrication
system. The initial setup for this system provides Service the tank with clean Type C-4 hydraulic oil only.
for nominal amounts of lubricant to be delivered to All oil being put into the hydraulic tank must be filtered
each serviced point. The lubrication injectors can be through filters rated at three microns.
adjusted to vary the amount of lubricant delivered. In
addition, the timer for lubrication intervals is normally 1. Ensure that the engine is stopped, key switch
adjustable. Refer to AUTOMATIC LUBRICATION is OFF, hydraulic accumulators depressurized,
SYSTEM, page 5-85 for adjustments to these devices. and body is down.
2. Remove fill cap (2, Figure 7-1 HYDRAULIC
Service Capacities TANK SERVICE, page 7-3) and add hydraulic
U.S. oil until the oil level is visible in the center of the
System Liters top sight gauge.
Gallons
Crankcase (including 3. Install the fill cap.
4 oil filters) (Komatsu 341 90 4. Start the engine. Raise and lower the dump
SSDA18V170 Engine) body three times.
Cooling System (Komatsu
799 211 5. Check the hydraulic oil level again with the
SSDA18V170 Engine)
engine stopped, key switch OFF, hydraulic
Hydraulic System (Refer accumulators depressurized, and body down.
to HYDRAULIC SYSTEM 1325 350
6. Repeat steps 1 - 5 until the oil level is
SERVICE, page 7-2)
maintained in the center of the top sight gauge.
7-2 930E-4SE
LUBRICATION AND SERVICE GENERAL INFORMATION
Replace filter elements after the initial 50, 100, 250

and 500 hours of operation; then at each 1000 hours
of operation thereafter. Torque for hoist filter is 20 N·m
(15 ft lb) and the steering filter torque is 99 N·m (73 ft
lb). Check oil level. Add oil as necessary. (Lube Key
B).
Hydraulic Pump Drive Shaft
1. Sight Gauges 2. Fill Cap
Figure 7-1 HYDRAULIC TANK SERVICE 1. Drive Shaft Grease Fittings
Figure 7-4 DRIVE SHAFT LUBRICATION POINTS

Add one or two applications of grease to each drive
shaft grease fitting (1, Figure 7-4 DRIVE SHAFT
LUBRICATION POINTS, page 7-3). Non - moly
grease only. Check that each bearing of the U-joint
assembly is receiving grease. Replace bearings if
any wear is detected.
WHEEL MOTOR SERVICE C.3-0000051604
Due to differences in gear ratio and component

1. Hydraulic Tank Breathers evolution/design, wheel motor service intervals may
be unit number and/or mine specific. Because of
Figure 7-2 HYDRAULIC TANK BREATHERS the wide variety of factors involved, it is necessary
Hydraulic tank breathers (1, Figure 7-2 HYDRAULIC to consult your area Komatsu representative for
TANK BREATHERS, page 7-3) need to be replaced all wheel motor service intervals and instructions.
every 500 hours. General intervals for oil service and sampling are
listed in the interval charts.
Hydraulic Filters
COOLANT LEVEL SERVICE H.35-0000051603
Inspect the coolant sight gauge. If coolant cannot be

seen in the sight gauge, it is necessary to add coolant
to the system before truck operation. Refer to the
procedure below for the proper filling instructions.
1. Hoist 2. Steering
Figure 7-3 HYDRAULIC FILTERS
930E-4SE 7-3
Coolant Specifications
For ambient temperatures of -32° C (-25° F) and
above, use a standard 50/50 anti-freeze-to-water
mixture.
For arctic climates with ambient temperatures
between -32° C (-25° F) and -54° C (-65° F), use a
60/40 anti-freeze-to-water mixture.
NOTE: Do not use propylene glycol coolant in arctic
climates. Only use ethylene glycol coolants.
NOTE: Coolant must meet Cummins Engineering
Standard 14603.
Unacceptable Practices
• Use of high-silicate anti-freeze.
1. Sight Gauge 2. Radiator Cap • Under concentration or over concentration of
Extended Service Additive (SCA).
Figure 7-5 Radiator (Cooling System) • Use of anti-freezes/coolants that are not fully
formulated for extended service intervals.
Radiator Filling Procedure
• Use of sealing additives (stop-leak) in the cooling
system.
• The cooling system is pressurized due to
• Use of soluble oils in the cooling system.
thermal expansion of coolant. DO NOT
remove the radiator cap while the engine and • Use of poor-quality water. See the engine
coolant are hot. Severe burns may result. manufacturer’s specifications for water quality
requirements.
1. With the engine and coolant at ambient • Use of anti-freeze, Extended Service Additive
temperature, remove the radiator cap. (SCA) or coolant filter(s) that do not meet the
engine manufacturer’s specifications.
NOTE: If coolant is added using the quick fill service
center, the radiator cap MUST be removed prior to • Use of Treated Water coolant.
adding coolant.
• Use of coolants with less than 40 percent antifreeze.
2. Fill the radiator with the proper coolant mixture
(as specified by the engine manufacturer) until RESERVE ENGINE OIL
coolant is visible in the sight gauge. SERVICE A.5-0000071903
3. Install the radiator cap. The reserve oil tank for the engine is designed to add
4. Operate the engine for five minutes. Check the more oil capacity to the engine to reduce the frequent
coolant level. servicing of the engine oil. The engine oil level must
still be checked every shift using the dipstick. If engine
5. If coolant is not visible in the sight gauge, oil level is not correct, check for proper operation of the
repeat Steps 1 through 4. Any excess coolant reserve oil system. Never add oil to the engine unless
will be discharged through the vent hose it has been drained.
after the engine reaches normal operating
temperature. If the engine oil has been drained from the oil pan, the
new oil must be added to the engine oil pan before
Engine coolant must always be visible in the sight starting. DO NOT use the oil in the reserve tank to
gauge before truck operation. fill an empty engine with oil. After an oil change, both
the engine and reserve tank must be full of oil before
starting the engine.
7-4 930E-4SE
For trucks operating in cold weather applications with

a minimum ambient temperature of -30°C (-22°F), a
heated suction line is installed between the reserve oil
pump and engine oil pan. Engine oil becomes more
viscous in lower temperatures, causing the pumps
to work harder and wear more quickly. Heating the
oil keeps the oil less viscous, thus maintaining the
corresponding flow rate at the inlet of the reserve
pump.
An optional heated return line is available for trucks
operating in cold weather applications with a minimum
ambient temperature beyond -30°C (-22°F).
LED Monitor Lights

After engine startup, allow the pumping unit to run
for 5 minutes before operating the truck. Green LED,
Figure 7-6 PUMPING UNIT, page 7-5, should remain 1. Pump 1 3. Green LED
solid and red LED (4) should be off. This verifies that 2. Pump 2 4. Red LED
the system is working properly, pumps 1 and 2 are
synchronized and pumping oil, and the engine oil level Figure 7-6 PUMPING UNIT
is correct. Sight Gauge
If the green LED is flashing, the pump is receiving Oil should always be visible in the bottom sight gauge.
air from the engine oil pan (the oil level is below the If not, add oil to the reserve oil tank until oil is visible
withdrawal point of the pickup tube). The reserve oil in the top sight gauge.
pump should return oil back to the engine oil pan,
continuously adjusting the oil level until air is no longer • Never add oil to the engine unless it has been
drawn by the reserve oil pump. completely drained.
Over a period of time, both signals (solid / flashing • If the engine oil has been drained from the oil pan,
LED lights) should be observed. This verifies that the new oil must be added to the oil pan. DO NOT
system is operating properly and the engine oil level use the oil in the reserve oil tank to fill an empty
is correct. engine oil pan.
A solid red LED signal indicates that the pump is not After an oil change, both the engine and reserve oil
able to return oil to the engine oil pan because the tank must be full of oil before starting the engine.
pump is not working properly, the line is frozen, or the
reserve tank is empty. Shut down the engine and allow Reserve Oil Tank Filling Procedure
adequate time for the oil to drain into the engine oil (Remote Fill)
pan. Check the oil level. It should be between the 1. Remove the reserve oil fill cap to prevent it from
normal marks, not above the high static mark. dislodging during remote fill.
2. Connect the pressure supply hose from the
new oil supply to the quick coupler on the truck.
Open the valve on the supply hose to apply
pressure.
3. Pull out on power button (1, Figure 7-7
CONTROL PANEL, page 7-6) to turn on the
auto fill system.
4. Press and release start button (2). If the oil
reserve tank is not full, the float will be in a
low position and the relay in the auto fill control
(AFC) box will close. This will cause the fill
valve to open. Yellow light (4) should illuminate
and the filling process will begin.
930E-4SE 7-5
5. When the tank is full, the float will be in a CAB AIR FILTER SERVICE D.4-0000051602
high position. The relay in the AFC box will
open and the filling process will terminate.
Yellow light (4) will turn off and red light (3) will
illuminate.
6. Close the oil supply valve in the fill hose.
7. Press and hold start button (2) for 2 - 3 seconds
to relieve oil pressure in the line.
8. Disconnect the new oil supply hose.
9. Push power button (1) to turn off the auto fill
system.
1. Cab Filter Element 2. Filter Cover
Figure 7-8 CAB AIR FILTER LOCATION
1. Power Button 3. Red Light (Full)

2. Start Button 4. Yellow Light (Valve
Open)
Figure 7-7 CONTROL PANEL

Inline Screen 1. HVAC Recirculation Filter Element
There is an inline screen located at the inlet of the Figure 7-9 HVAC RECIRCULATION FILTER
fill valve. This screen does not require periodic LOCATION
maintenance, but it can be cleaned by removing the 1. Clean both filter elements (1, Figure 7-8
screen and back flushing. CAB AIR FILTER LOCATION, page 7-6 and
Figure 7-9 HVAC RECIRCULATION FILTER
LOCATION, page 7-6) with mild soap and
water.
2. Rinse completely clean and air dry with a
maximum of 275 kPa (40 psi).
3. Reinstall the filters.
7-6 930E-4SE
FUEL SYSTEM SERVICE G.74-0000051601 Remove breather (1, Figure 7-11 FUEL TANK
BREATHER, page 7-7) and clean in solvent. Dry with
Fuel Tank Cleaning pressurized air and reinstall.
Fuel Filter Service
1. Fuel Tank Drain
Figure 7-10 FUEL TANK

Open fuel tank drain (1, Figure 7-10 FUEL TANK,
page 7-7) to drain water and sediment from the fuel 1. Water Drain Valves
tank. The fuel tank is provided with a drain and a
cleaning port in the side that allows steam or solvent Figure 7-12 WATER SEPARATOR DRAIN
to be utilized in cleaning tanks that have accumulated Open water drain valves (1, Figure 7-12 WATER
foreign material. SEPARATOR DRAIN, page 7-7) to remove water
It is not necessary to remove the tank from the truck for from the fuel/water separators daily.
cleaning of sediment, however rust and scale on the
walls and baffles may require complete tank removal. INTAKE AIR CLEANER
Prior to a cleaning procedure of this type, all vents, fuel SERVICE E.5-0000051600
gauge, and hose connections should be removed and
temporarily sealed. After all scale, rust, and foreign
material has been removed, the temporary plugs can • The engine must be turned off before
be removed. A small amount of light oil must be servicing the air cleaner assemblies or
sprayed into the tank to prevent rust if the tank is to opening the engine air intake system. Never
remain out of service. All openings should be sealed start the engine with the filter elements
for rust prevention. removed. Serious engine damage can result.
During operation or after the engine has been turned

off, observe the air filter restriction gauges mounted on
the overhead panel in the cab. When a gauge shows
maximum restriction, filter service is required.
1. Fuel Tank Breather
Figure 7-11 FUEL TANK BREATHER
930E-4SE 7-7
To service the intake air cleaner system, perform the remove it with a stiff brush. If heavy plugging
following: with fibrous material occurs, remove the
section and clean it with compressed air or
water no hotter than 72° C (160° F).
NOTE: Never clean DonacloneTMtubes with
compressed air unless both the primary and safety
filters are installed in the air cleaner.
3. Change the filter. If the new filter is not to be
installed immediately, be sure to cover the inlet
to prevent contamination.
NOTE: Before installing the new filter, inspect it for
shipping damage and gasket integrity. If there is
damage, DO NOT install the filter.
4. Check all engine intake air plumbing, hoses
and clamps. All connections must be air tight
1. Dust Cup 2. Vacuator™ Valve to prevent dirt from entering. If there are holes
or damage, replace immediately.
Figure 7-13 DUST CUP LOCATION
1. Inspect and empty dust cups (1, Figure 7-13
DUST CUP LOCATION, page 7-8). Never
allow the dust level to build up to the tube
(precleaner) chamber.
NOTE: On dust cups with the VacuatorTMvalve, dust
cup service is minimal; just check the valve to see
that it is not inverted, damaged or plugged. If it is
damaged, replace it immediately.
1. Filter Vacuum Gauge 2. Reset Button
Figure 7-14 VACUUM GAUGES

5. After the filters have been serviced, reset
air cleaner vacuum gauges (1, Figure 7-14
VACUUM GAUGES, page 7-8) in the cab
by pressing reset button (2) on the face of
the gauge. Refer to the Shop Manual, for
more detailed instructions about the intake air
cleaner system.
QUICK FILL SERVICE CENTER F.1-0000051637

The service center can be located on either side of the
2. Check tubes for plugging. Generally tubes are machine and is used to fill system fluids. The table
self cleaning. Under special circumstances shows the maximum recommended fill pressures for
plugging can occur. If tubes carry light dust, the service center.
7-8 930E-4SE
NOTE: Ensure that capscrews (5) are parallel to the

ground as shown, the gap between clamps (3) is
aligned with the slot in tie rod structure (1) and the
anti-rotation retainer is on the bottom of the rod end.
NOTE: Some slight movement of the capscrew heads
may be observed during the first couple of checks due
to torque tolerance.
6. Reapply torque to each capscrew until the
specified torque is maintained.
7. Apply an upwards force to each end of the tie
1. Hydraulic Oil 3. Engine Oil rod assembly near rod end threads. Look for
2. Radiator Coolant 4. Grease lateral movement between the tie rod ends and
tie rod structure.
Figure 7-15 SERVICE CENTER
If lateral movement is detected, visually inspect
MAXIMUM FILL PRESSURES the internal and external threads on both ends.
Replace parts that have damaged threads.
Fill System kPa psi
Use new capscrews and locknuts where thread
Engine damage to the tie rod end and tie rod structure
345 50
Crankcase is observed.
Reserve Tank 862 125 8. Ensure that sufficient grease is being supplied
Hydraulic Tank 345 50 by the auto lube system to the spherical
bearings of the tie rod and steering cylinders.
Coolant 345 50
Grease 10 342 1,500
Fuel 103 15
TIE ROD INSPECTION AND TORQUE

PROCEDURE A.37-0000061684
1. When inspecting this area or making
adjustments, turn off the engine and make sure
that the key switch is in the OFF position.
2. After the engine has been turned off, allow at
least 90 seconds for the accumulators to bleed
down.
3. Turn the steering wheel to the left and to the
right to ensure that the steering accumulator
pressure has been bled down. 1. Tie Rod 4. Locknut
2. Rod End Threads 5. Capscrew
4. Block the front and back of the rear wheels. 3. Clamp 6. Flat Washer
5. For the four capscrew clamp style tie rod
assembly tighten locknuts (4, Figure 7-16 Figure 7-16 FOUR CAPSCREW CLAMP STYLE
FOUR CAPSCREW CLAMP STYLE TIE ROD TIE ROD ASSEMBLY
ASSEMBLY, page 7-9) to 1017 ± 102 N·m (750
± 75 ft lb).
930E-4SE 7-9
LUBRICATION CHART LUBRICATION AND SERVICE
LUBRICATION CHART A.4-0000073435
7-10 930E-4SE
INITIAL 50 HOUR LUBRICATION AND
LUBRICATION AND SERVICE MAINTENANCE INSPECTION
INITIAL 50 HOUR LUBRICATION
AND MAINTENANCE
INSPECTION B.5-0000060941
NOTE: These checks are required only after the initial
50 hours of operation, such as the commissioning
of a new truck, or after a new or rebuilt component
installation.
INITIAL 50 HOUR SERVICE INSPECTION

Item Task
HYDRAULIC SYSTEM Replace filter elements only after the initial 50, 100, 250 and 500 hours of
FILTERS operation; then at each 1000 hours of operation thereafter.
Replace the fuel filters. Refer to the engine operation and maintenance manual
FUEL FILTERS
for filter replacement instructions.
Check to ensure the wheel nut torque on all wheels is 2 326 ± 136 N·m (1,715
WHEELS
± 100 ft lb).
930E-4SE 7-11
INITIAL 100 HOUR LUBRICATION AND
MAINTENANCE INSPECTION LUBRICATION AND SERVICE
INITIAL 100 HOUR LUBRICATION
AND MAINTENANCE
INSPECTION A.3-0000075975
NOTE: These checks are required only after the initial
100 hours of operation (such as: the commissioning
of a new truck, or after a new or rebuilt component
installation).
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION

Item Task
HYDRAULIC SYSTEM Replace filter elements only after the initial 100, 250 and 500 hours of
FILTERS operation; then at each 1000 hours of operation thereafter.
7-12 930E-4SE
EVERY 250 HOUR LUBRICATION AND
LUBRICATION AND SERVICE MAINTENANCE
EVERY 250 HOUR LUBRICATION
AND MAINTENANCE A.2-0000076177
NOTE: The 10 hour lubrication and maintenance
checks must also be performed at this time. “Lube
Key” references are to the lubrication chart.
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE (includes after rebuilds)
Item Task
Replace filter elements only after the initial 50, 100, 250, and 500 hours of
HYDRAULIC SYSTEM
operation; then at each 1000 hours of operation thereafter.
EVERY 250 HOUR LUBRICATION AND MAINTENANCE

Item Task
• Add one or two applications of grease to each grease fitting on the pump
drive shaft. Non — moly grease only.
Refer to HYDRAULIC SYSTEM SERVICE, page 7-2 for detailed
HYDRAULIC SYSTEM
instructions.
NOTE: Oil change interval can be extended to 2,500 hours if oil is sampled
at every 250 hour intervals and no abnormalities are detected.
Use a flashlight and a mirror on a long rod to inspect all inner and outer
REAR WHEEL MOUNTING wheel mounting nuts and studs. Check for loose, damaged or missing
hardware.
Under normal operating conditions, clean every 250 hours. In extremely

CAB AIR FILTER dusty conditions, service as frequently as required. Refer to CAB AIR
FILTER SERVICE, page 7-6 for detailed instructions.
Remove the magnetic plugs from the front wheel hub covers and check for
FRONT WHEEL HUB
debris. Clean the plugs and perform any necessary repairs.
WHEEL MOTOR OIL Take an oil sample of the wheel motor oil. Refer to the shop manual for oil
SAMPLING sampling instructions.
BATTERIES Check the electrolyte level and add water if necessary.
• Check operation of the switches.

BODY-UP & HOIST LIMIT
SWITCHES • Clean the sensing areas of any dirt accumulation and inspect the wiring for
any signs of damage.
AC DRIVE BELT Check the belt for wear or damage.

• Check all grease hoses from the injectors to the lubrication points.
• Check all grease supply line hoses from the pump to the injectors.
• Check the grease reservoir level.
AUTOMATIC LUBE SYSTEM
• Inspect all bearing points for a bead of lubricant around the bearing seal.
• Perform system checkout. Refer to the Shop Manual for detailed
instructions.
930E-4SE 7-13
MAINTENANCE LUBRICATION AND SERVICE

Item Task
RETRACTABLE LADDER Check the ladder system for:
SYSTEM (If Equipped)
• Loose or missing hardware.
• Bent or misaligned structures.
• Foreign materials such as dirt, mud, etc., that could affect proper operation
of ladder.
• Damaged wiring and harnesses.
• Power pack box free of moisture and is properly sealed.
• System voltage of 21VDC (off) to 30VDC max (operating).
• Adverse noise conditions.
• Proper movement in a vertical plane (viewed from front of ladder); the
ladder must move up and down central to the actuator box.
• Range of functions, including remote switches and park-brake interlock.
Check the pads, shims and mounting hardware for wear and proper
DUMP BODY PADS
tightening.
7-14 930E-4SE
EVERY 500 HOUR LUBRICATION
AND MAINTENANCE A.5-0000075973
NOTE: Maintenance requirements for every 10 and
250 hour Lubrication and Maintenance Checks must
also be performed at this time. “Lube Key” references
are to the lubrication chart.
INITIAL 500 HOUR MAINTENANCE (Includes after rebuild)

Item Task
WHEEL MOTOR Change or filter the gear case oil.

Item Task
• Remove the breather elements for the motorized wheels. Clean or replace
the elements.
• (Initial 500 hours only) change or filter wheel motor gear oil only after initial
WHEEL MOTORS
500 hours or operation. Wheel motor gear oil must be filtered or changed
every 2500 hours of operation thereafter.
Refer to the Shop Manual, Section 10 for oil sampling information.
• Replace filter elements. Check the oil level. Add oil as necessary. (Lube
Key “B”).
HYDRAULIC SYSTEM
• Replace the breather elements. Refer to HYDRAULIC SYSTEM SERVICE,
page 7-2 for detailed instructions.
Check for proper piston extension (front and rear). Refer to the Shop Manual
HYDRAIR® SUSPENSION for more information on proper suspension extension and maintenance
procedures.
Lubricate the treadle roller and hinge pins with lubricating oil. Lift the boot
THROTTLE AND BRAKE
from the mounting plate and apply a few drops of lubricating oil between
PEDAL
the mounting plate and the plunger.
• Clean the air conditioner recirculation filter. Refer to CAB AIR FILTER
SERVICE, page 7-6 for more information.
HVAC • Ensure the air conditioner cab drains are clear of any obstructions.
• Wash the air conditioner condenser with a low pressure hose. Check for any
obstructions to airflow, clean as required.
• Wash the radiator fins with a low pressure hose. Check for any obstructions
to airflow, clean as required.
• Inspect the radiator stabilizers (upper radiator stabilizers, lower radiator
stabilizers and shroud bumpers) for damage and tightness. Fix as required.
• Check for proper coolant mixture. Add coolant as required.
COOLING SYSTEM • Change coolant filters.
• Check cooling system hoses for damage and signs of deterioration.
• Check the torque on the cooling fan mounting capscrews: 237 N·m (175 ft
lb).
Refer to the engine maintenance manual for coolant filter replacement
instructions and proper coolant mixture instructions.
930E-4SE 7-15
Item Task
• Wash the fuel cooler (if equipped), located on the front RH side of the
radiator, with a low pressure hose. Check for any obstructions to airflow,
clean as required.
FUEL SYSTEM • Change the fuel filters (fuel separators). Refer to the engine Operation &
Maintenance manual for specific filter replacement instructions.
• Drain water and sediment from the fuel tank. Refer to FUEL SYSTEM
SERVICE, page 7-7 for detailed instructions.
PARKING BRAKE Refer to the Shop Manual for the recommended inspections.
FRAME AND AXLE BOX Wash the truck, clean all of the weld joints, and visually inspect the entire
INSPECTION frame and axle box for cracking or damage.
Using a laptop PC with the VHMS Technical Analysis Tool Box program,
KOMTRAX Plus DATA perform a data download from the KOMTRAX Plus controller. Send the data
DOWNLOAD to WebCARE using the FTP feature. Refer to the Shop Manual, Section 30
for more detailed instructions.
• Change the engine oil. (Lube Key “A”).
• Replace engine oil filters.
• Check belt tension and the condition of each accessory belt. Refer to
the engine Operation & Maintenance manual for specific adjustment
instructions.
NOTE: If the engine is equipped with the Centinel™oil system and/or the
ENGINE Eliminator™filter system, engine oil and filter change intervals are extended
beyond 500 hours. Take an engine oil sample for analysis.
NOTE: When installing spin-on filter elements, follow the instructions of the
filter manufacturer. The tightening instructions are normally printed on the
outside of the filter. Do not use a wrench or strap to tighten filter elements.
Refer to the engine Operation & Maintenance manual for complete

specifications regarding engine lube oil specifications.
Check all mounting hardware, joints and connections. Ensure that there are
AIR INTAKE PIPING
no air leaks and all hardware is properly tightened.
HOIST ACTUATOR
Check operation. Clean, lubricate, and adjust as necessary.
LINKAGE
Check all steering and brake accumulator pre-charge pressures. Refer to
ACCUMULATOR the Shop Manual for details.
PRECHARGE
NOTE: Pre-shift Inspection is necessary.
• Check the torque on the pin retaining nuts located on the steering linkage -
1017 N·m (750 ft lb).
STEERING LINKAGE
NOTE: Interval is dependent on Lube system operation, bearing wear and if
there is a Functional Autolube System.
7-16 930E-4SE

Item Task
TIE ROD Refer to TIE ROD INSPECTION AND TORQUE PROCEDURE, page 7-9.
• Vacuum the dust and debris from inside the control cabinet.
• Do not use compressed air. Compressed air causes dust particles and
contaminants to be blown across the surface of the electrical cards, eroding
the varnish and driving the particles into the electrical and mechanical
CONTROL CABINET
components of the system.
• Wear the appropriate Personal Protective Equipment (PPE). A clean,
soft-bristle brush can be used in areas such as the ST transformer coils, if
needed.
930E-4SE 7-17
EVERY 1000 HOURS LUBRICATION AND
EVERY 1000 HOURS LUBRICATION
AND MAINTENANCE F.42-0000051631
NOTE: Maintenance for every 10, 250, and 500 hour
Lubrication and Maintenance Checks must also be
performed at this time. “Lube Key” references are to
the lubrication chart.
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE

Item Task
• Drain the hydraulic tank and clean the inlet strainer.
• Replace the filter elements.
HYDRAULIC SYSTEM • Refill the tank with new oil. (Lube Key “B”).
NOTE: Oil change interval can be extended to 2,500 hours if oil is sampled at
every 250 hour intervals and no abnormalities are detected.
• Clean the cooling system with a quality cleaning agent.
• Flush the system with water.
COOLING SYSTEM
• Refill the system with anti-freeze and water solution.
• Check the Coolant Specifications, page 7-4 in this chapter.
Service the fuel tank breather. Refer to FUEL SYSTEM SERVICE, page 7-7
FUEL SYSTEM
for more detailed instructions.
OPERATOR'S SEAT Apply grease to the slide rails. (Lube Key “D”).
AUTOMATIC BRAKE Ensure the brakes are automatically applied when brake pressure decreases
APPLICATION below the specified limit. Refer to the Shop Manual for more details.
AUTOMATIC LUBE Check pump housing oil level using the dipstick on top of the pump unit. If
SYSTEM necessary, add SAE 10W-30 motor oil.
• Add grease to each bearing grease fitting. Ensure that each bearing is
RETRACTABLE LADDER receiving grease.
• Add grease to the cylinder.
• Clean and check centrifuge.
ELIMINATOR FILTER
(If Equipped) Refer to engine manufacturer’s Operation & Maintenance Manual. (Service
interval is dependent on duty cycle, oil quality, etc.)
Use the front and rear brake wear indicators included in the truck’s tool group
BRAKE DISC
to check for brake disc wear. Refer to the shop manual for instructions.
7-18 930E-4SE
LUBRICATION AND SERVICE EVERY 4000 HOUR MAINTENANCE
EVERY 4000 HOUR

MAINTENANCE A.5-0000071716
NOTE: Maintenance for every 10, 250, 500 & 1,000
hour Lubrication and Maintenance Checks must also
be performed at this time.
EVERY 4000 HOUR MAINTENANCE
Item Task
Remove the oil strainer screen and wash thoroughly in high flash point
solvent until all accumulated sludge has been removed. Blow the screen dry
RESERVE ENGINE OIL
with compressed air or leave in a well ventilated place until all the solvent
has evaporated. Inspect the screen for damage and replace if necessary.
Re-install the screen.
930E-4SE 7-19
EVERY 5000 HOUR MAINTENANCE LUBRICATION AND SERVICE
EVERY 5000 HOUR

MAINTENANCE E.47-0000051629
NOTE: Maintenance for every 10, 250, 500, 1,000 &
2,500 hour Lubrication and Maintenance Checks must
also be performed at this time. “Lube Key” references
are to the lubrication chart.
Item Task
AIR CLEANERS
RETRACTABLE LADDER • Drain, flush and re-fill the hydraulic oil reservoir.
SYSTEM (If Equipped) • Replace oil filter screen.
Check that the torque on the steering wheel retainer nut is 81 ± 7 N•m (60 ± 5
STEERING WHEEL
ft lb). If tightening is necessary, add Loctite® Threadlocker Blue 242 to the
RETAINER NUT
nut, then use a torque wrench to tighten the nut to 81 ± 7 N·m (60 ± 5 ft lb).
7-20 930E-4SE
LUBRICATION AND SERVICE EVERY 18000 HOUR MAINTENANCE
EVERY 18000 HOUR

MAINTENANCE A.15-0000071968
NOTE: Maintenance for every 250, 500, 1000,
2500, 3000, 5000 and 6500 hour Lubrication and
Maintenance Checks must also be performed at this
time. “Lube Key” references are to the lubrication
chart.
Item Task
Even if there are no signs of damage, replace both driver and passenger
SEAT BELTS AND
seat belts five years after seat belt manufacture, or every three years after
TETHERS
start of use, whichever comes first.
930E-4SE 7-21
EVERY 18000 HOUR MAINTENANCE LUBRICATION AND SERVICE
7-22 930E-4SE
SPECIFICATIONS
930E-4SE 8-1
MAJOR COMPONENT DESCRIPTION SPECIFICATIONS
Operator's Cab D.34-0000051642
MAJOR COMPONENT The operator cab has been engineered for operator
DESCRIPTION C.3-0000051647 comfort and to allow for efficient and safe operation
of the truck. The cab provides wide visibility,
Truck and Engine A.2-0000061081 with an integral 4-post ROPS/FOPS structure,
The 930E-4SE dump truck is an off-highway, rear and an advanced analog operator environment.
dump truck with AC electric drive. The gross vehicle It includes a tinted safety-glass windshield and
weight is 505 611 kg (1,114,670 lbs). The engine is a power-operated side windows, a deluxe interior with
Komatsu SSDA18V170 rated at 2 611 kW (3,500 HP). a fully adjustable seat with lumbar support, a fully
adjustable tilt/telescope steering wheel, controls
Traction Alternator D.19-0000051645
mounted within easy reach of the operator, and a
digital/analog instrument panel which provides the
The diesel engine drives an in-line alternator at engine operator with all instruments and gauges which
speed. The alternator produces AC current which is are necessary to control and/or monitor the truck's
rectified to DC within the main control cabinet. operating systems.
Cooling air for the control / power group and wheel
motors, as well as the alternator itself, is provided by Power Steering D.1-0000051641
a fan mounted on the alternator shaft. The truck is equipped with a full time power steering
system which provides positive steering control
Main Control Cabinet A.2-0000060880 with minimum operator effort. The system includes
nitrogen-charged accumulators which automatically
Each phase module contains paired positive and
provide emergency power if the steering hydraulic
negative semiconductor switches referred to as
pressure is reduced below an established minimum.
insulated gate bipolar transistors (IGBT). The IGBTs
cycle on and off at varying frequencies to create an
AC power signal from the DC supply. Dynamic Retarding Grid E.32-0000051640
The dynamic retarding grid is used to slow the truck

The AC power signal produced by each inverter
during normal operation or control speed coming
is a variable-voltage, variable-frequency (VVVF)
down a grade. The dynamic retarding ability of the
signal. Frequency and voltage are changed to suit
electric system is controlled by the operator through
the operating conditions.
the activation of the retarder pedal (or by operating
a lever on the steering column) in the operator’s cab
AC Induction Traction Motorized and by setting the speed control. Dynamic Retarding
Wheels C.3-0000051644 is automatically activated if the truck speed goes to a
The alternator output supplies electrical energy to the preset overspeed setting.
two wheel motors attached to the rear axle housing.
The motorized wheels use three-phase AC induction Brake System B.18-0000060879
motors with full-wave AC power.
Service brakes at each wheel are oil-cooled multiple
The two wheel motors convert electrical energy back disc brakes applied by an all-hydraulic actuation
to mechanical energy through built-in gear trains system. Depressing the brake pedal actuates both
within the wheel motor assembly. The direction of the front and rear brakes after first applying the retarder.
wheel motors is controlled by a forward or reverse All wheel brakes will be applied automatically if the
hand selector switch located on the center console. brake system pressure decreases below a preset
minimum.
Suspension D.3-0000051643
The parking brake is a dry disc type, mounted inboard
Hydrair II® suspension cylinders located at each on each rear wheel motor, and is spring-applied and
wheel provide a smooth and comfortable ride for the hydraulically-released with wheel speed application
operator and dampens shock loads to the chassis protection (will not apply with truck moving).
during loading and operation.
8-2 930E-4SE
SPECIFICATIONS SPECIFICATIONS
SPECIFICATIONS D.3-0000051658
Engine B.9-0000061080
Komatsu SSDA18V170
No. of Cylinders................................................................................................................................................. 18
Operating Cycle....................................................................................................................................... 4-Stroke
Rated Brake HP............................................................................................. 2 610 kW (3,500 HP) at 1900 RPM
Flywheel HP .................................................................................................. 2 495 kW (3,346 HP) at 1900 RPM
AC Electric Drive System A.2-0000061079
(AC/DC Current)
Alternator ...................................................................................................................... General Electric GTA - 39
Dual Impeller, In-Line Blower.........................................................................................453 m³/ min (16,000 cfm)
Motorized Wheels.....................................................................................GDY106 AC Induction Traction Motors
Standard Gear Ratio* ................................................................................................................................ 32.62:1
Maximum Speed.....................................................................................................................64.5 km/h (40 mph)
*Wheel motor application depends upon GVW, haul road grade and length, rolling resistance, and other
parameters. Komatsu and GE must analyze each job condition to ensure proper application.
Dynamic Retarding A.2-0000061078
Electric Dynamic Retarding .................................................................................................................... Standard

Maximum Rating.................................................................................................................. 4 026 kW (5,400 HP)
Continuous* ......................................................................................................................... 2 909 kW (3,900 HP)
*Continuously rated high-density blown grids with retard at engine idle and retard in reverse propulsion.
Battery Electric System G.19-0000051654
Batteries ............................ 4 x 8D 1400 CCA, 12 volt, in series/parallel, bumper mounted with isolation station
Alternator ...................................................................................................................24 Volt, 250 Ampere Output
Lighting ....................................................................................................................................................... 24 Volt
Cranking Motors (2).................................................................................................................................... 24 Volt
Service Capacities B.9-0000061077
Crankcase (including lube oil filters)................................................................................................ 341 L / 90 gal

Cooling System ............................................................................................................................. 799 L / 211 gal
Hydraulic System........................................................................................................................ 1 325 L / 350 gal
Wheel Motor Gear Box (per wheel) ................................................................................................... 95 L / 25 gal
Hydraulic Systems B.20-0000060889
Hoist and Brake Cooling Pump ....................................................................................................... Tandem Gear

Rating .................................................................931 L/min (246 gpm) at 1900 RPM and 18 616 kPa (2,700 psi)
Steering/Brake Pump ................................................................................... Variable Displacement Piston Pump
Rating ...................................................................246 L/min (65 gpm) at 1900 RPM and 22 063 kPa (3,200 psi)
Relief Pressure-Hoist.........................................................................................................17 237 kPa (2,500 psi)
Relief Pressure-Steering/Brake .........................................................................................27 579 kPa (4,000 psi)
Hoist Cylinders (2) .................................................................................................................... 3-Stage Hydraulic
Tank (Vertical/Cylindrical) ........................................................................................................... Non-Pressurized
Tank Capacity ....................................................................................................................947 liters (250 gallons)
Filtration.................................................................................................................... In-line replaceable elements
Suction....................................................................................................................... Single, Full Flow, 100 Mesh
Hoist and Steering Filters (Dual In-Line, High Pressure)....................................................... Beta 12 Rating =200
930E-4SE 8-3
Service Brakes B.12-0000060895
Hydraulic actuated, oil-cooled multiple discs on each wheel.
Total Friction Area / Brake ................................................................................................97 019 cm² (15,038 in²)

Maximum Apply Pressure..................................................................................................17 238 kPa (2,500 psi)
Steering B.11-0000060901
Twin hydraulic cylinders with accumulator assist to provide constant rate steering. Emergency power steering
automatically provided by accumulators.
Turning Circle (SAE)............................................................................................................... 29.7 m (97 ft. 7 in.)
Standard Dump Body Capacities and Dimensions B.2-0000060897
Capacity
Heaped @ 2:1 (SAE).................................................................................................................. 211 m3 (276 yd3)
Struck ......................................................................................................................................... 171 m3 (224 yd3)
Width (Inside) ......................................................................................................................... 8.15 m (26 ft. 9 in.)
Depth ........................................................................................................................................ 3.2 m (10 ft. 7 in.)
Loading Height ......................................................................................................................6.98 m (22 ft. 11 in.)
Dumping Angle .................................................................................................................................................45°
NOTE: Optional capacity dump bodies are available.
Tires B.3-0000060898
Radial Tires (standard) ......................................................................................................................... 56/80 R63

Radial Tires (standard) ..........................................................................................................................................
Rock Service, Deep Tread ......................................................................................................................Tubeless
Rims, standard 5 piece............................................................................................... Rated to 827 kPa (120 psi)
Weight Distribution A.2-0000061076
Empty Vehicle
Front Axle (48.5%)........................................................................................................... 104 460 kg (230,293 lb)
Rear Axle (51.5%) ........................................................................................................... 110 848 kg (244,377 lb)
Total (with 50% Fuel) ....................................................................................................... 215 308 kg (474,670 lb)
Standard Komatsu Body...................................................................................................... 30 362 kg (66,936 lb)
Standard Tire Weight........................................................................................................... 26 127 kg (57,600 lb)
Loaded Vehicle
Front Axle (32.8%)........................................................................................................... 165 958 kg (365,871 lb)
Rear Axle (67.2%) ........................................................................................................... 339 653 kg (748,799 lb)
Total ...............................................................................................................................505 611 kg (1,114,670 lb)
Nominal Payload* ............................................................................................................ 290 302 kg (640,000 lb)

*Nominal payload is defined by Komatsu America Corporation’s payload policy documentation. In general,
the nominal payload must be adjusted for the specific vehicle configuration and site application. The figures
above are provided for basic product description purposes. Please contact your Komatsu distributor for specific
application requirements.
Overall Truck Dimensions B.18-0000060851
(Empty With Standard Body)
Length .................................................................................................................................... 15.6 m (51 ft. 2 in.)

Width ...................................................................................................................................... 8.69 m (28 ft. 6 in.)
Height with Canopy ................................................................................................................ 7.37 m (24 ft. 2 in.)
8-4 930E-4SE
Height with Dump Body Up .................................................................................................. 14.02 m (46 ft. 0 in.)
930E-4SE 8-5
8-6 930E-4SE
RADIO
930E-4SE 9-1
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX
PLAYER RADIO
AM/FM RADIO / CD / MP3 / USB /
iPOD™ / AUX PLAYER A.2-0000073292
1. Phone/Bluetooth Button 10. SCAN/ASCN (Scan/Autoscan) Button

2. Digital Display 11. PREV (Previous) Button
3. CD Slot 12. DISP (Display) Button
4. Volume Knob/OK Button 13. ESC (Escape) Button/Preset 6 Button
5. SRC/PWR (Source/Power) Button 14. Random Button/Preset 5 Button
6. NEXT Button 15. Repeat Button/Preset 4 Button
7. Eject Button 16. Clock/Alarm Button/Preset 3 Button
8. USB Connection Port 17. Browse Button/Preset 2 Button
9. Auxiliary Jack Port 18. Play/Pause Button/Preset 1 Button
Figure 9-1 AM/FM RADIO / CD PLAYER
Phone/Bluetooth Button A.5-0000073230 • CD-Rs (MP3 and unprotected WMA formats).

The Phone/Bluetooth button (1, Figure 9-1 AM/FM • CD-RWs (MP3 and unprotected WMA formats).
RADIO / CD PLAYER, page 9-2) is used to pair a
Bluetooth enabled device to the receiver. Paired Volume Knob/OK Button A.3-0000073226
devices can be used to play music, podcasts or
audiobooks through the cab’s stereo system. The Volume Knob/OK Button (4) is used to control the
volume of the receiver and to access the Audio Control
NOTE: The receiver can be paired to a phone, but and User menus.
hands-free calling is not supported.
The volume is raised by turning the Volume Knob/OK
Button clockwise, and lowered by turning the Volume
Digital Display A.2-0000073228
Knob/OK Button counterclockwise.
The Digital Display (2) displays information about
Press the Volume Knob/OK Button for less than three
the radio, such as radio frequency band (AM, FM,
seconds to access the Audio Control menu. Press the
WX), radio station frequency, source type, and track
Volume Knob/OK Button for more than three seconds
information. The Digital Display also displays menu
to access the User menu.
information and any error messages that may occur
while operating the radio. While in the Audio Control and User menus, the
Volume Knob/OK Button is used to select options and
CD Slot A.3-0000073227 make changes.
The CD Slot (3) is used to add or remove CDs to the
receiver. The receiver is able to play:
• Most audio CDs.
9-2 930E-4SE
AM/FM RADIO / CD / MP3 / USB / iPOD™
RADIO / AUX PLAYER
SRC/PWR (Source/Power) Auxiliary Jack Port A.2-0000073221
Button A.3-0000073225 The Auxiliary Jack Port (9) is used to connect an iPod
The SRC/PWR (Source/Power) button (5) is used to or USB MP3 player to the receiver using a standard
turn the receiver on and off and to change the audio 3.5mm (0.125 in) stereo cable.
source. The audio source cycles in the following
order: SCAN/ASCN (Scan/Autoscan)
• FM1 (first six preset FM stations)
Button A.2-0000073240
The SCAN/ASCN Button (10) is used to scan radio
• FM2 (second six preset FM stations)
stations, CD tracks, and MP3/WMA files and folders.
• AM The SCAN/ASCN Button is also used to automatically
scan for the strongest radio stations available.
• Weatherband/WX (USA Only)
• CD When using a USB, iPod or the CD player, this button
is used to scan through all playable files on the
• USB/iPod selected device. Press the SCAN/ASCN Button to
• Front Auxiliary skip to the next file. The file plays for eight seconds,
then the receiver skips to the next file.
• Rear Auxiliary
Pressing and holding the SCAN/ASCN Button starts
• Bluetooth at the first file on the selected device instead of at the
To turn the receiver off, press and hold the SRC/PWR currently playing file. The file plays for eight seconds,
button. To turn the receiver on or to switch the audio then the receiver skips to the next file.
source, press the SRC/PWR button.
PREV (Previous) Button A.4-0000073239
NOTE: With the key switch OFF, receiver can still
be turned on by pressing the SRC/PWR button. The PREV (Previous) Button (11) is used to select the
The receiver stays on until the SRC/PWR button is prior track or station. It can also be used to skip audio
pressed and held again, or until one hour elapses, files or rewind to the beginning of the current track.
whichever comes first. There are two radio playback configurations for the
PREV Button, SEEK and Fast Reverse (FR), which
NEXT Button A.4-0000073224 are set through the User menu.
The NEXT Button (6) is used to select the next track
or station. It can also be used to skip audio files or fast DISP (Display) Button A.2-0000073238
forward through the current track. The DISP (Display) Button (12) is used to change
There are two radio playback configurations for the the source display view. Pressing the DISP Button
NEXT Button, SEEK and Fast Forward (FF), which are for more than three seconds shows the clock for a
set through the User menu. short time. With the key switch OFF, press the DISP
Button to turn on the radio and show the clock for a
few seconds.
Eject Button A.2-0000073223
The Eject Button (7) is used to eject a CD from the ESC (Escape) Button A.2-0000073237
receiver.
The ESC (Escape) Button (13) is used to exit the
current menu and return to the previous menu.
USB Connection Port A.2-0000073222
The USB Connection Port (8) is used to connect an RDM (Random) Button A.2-0000073236
iPod, USB mass storage device or USB MP3 player
to the receiver. The RDM (Random) Button (14) is used to play the
tracks in shuffle mode. The receiver will play songs
The USB Connection Port also provides up to 1 amp in random from the currently available list. The RDM
of power. Any device that requires less than 1 amp icon illuminates on the Digital Display (2) when active.
of power will be charged while connected to the USB Press again to stop shuffle mode.
Connection Port.
When using a USB, iPod or the CD player, this button
plays files on the available device in shuffle mode.
Pressing the RDM Button again stops shuffle.
930E-4SE 9-3
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX
PLAYER RADIO
RPT (Repeat) Button A.2-0000073235 Browse Button A.2-0000073233
The RPT (Repeat) Button (15) is used to set the track The Browse Button (17) is used to navigate on USB
currently playing on repeat. The RPT icon illuminates sticks, CD MP3 discs, and iPods and select a specific
on the digital display (2) when active. Press the RPT song or play context.
Button again to cancel repeat play.
When using a USB, iPod or the CD player, this button
Play/Pause Button A.2-0000073232
sets the file currently playing on repeat. Pressing the The Play/Pause Button (18) is used to pause or
RPT Button again cancels repeat play. unpause current media.
Clock/Alarm Button A.2-0000073234 Preset Buttons A.2-0000073231
The Clock/Alarm Button (16) is used to turn off an The Preset Buttons (13-18) are used to set and access
alarm set from the Audio Control menu. preset stations 1 thru 6 for each frequency band (FM1,
FM2, AM, and WX).
9-4 930E-4SE
RADIO GENERAL FEATURES
GENERAL FEATURES A.2-0000073250 Bluetooth Pairing A.2-0000073248
Audio Sources A.2-0000073249 The receiver can be paired to a Bluetooth-enabled

device, such as an iPod or phone. Paired devices
The receiver is capable of playing AM, FM, and can be used to play music, podcasts or audiobooks
WX (USA only) radio stations. Audio can also be through the cab’s stereo system.
played from an iPod or other MP3 player, a mass
storage USB device, and from audio and MP3 CDs. NOTE: The receiver can be paired to a phone, but
Music from an iPod or other MP3 player or a mass hands-free calling is not supported.
storage USB device can be access through a wireless
A list of supported devices is located in the following
Bluetooth connection, a USB port, or a 3.5mm (0.125
web page:
in) audio jack.
http://www.panapacific.com/support
NOTE: It is not recommended to connect a device to
the receiver through more than one connection at a Other devices may be connected and played but
time, as the device may not function correctly (e.g., functionality cannot be guaranteed.
connecting an MP3 player through both the USB and
audio-jack, or connecting a Bluetooth-enabled iPod You can connect up to 10 devices to the radio; the
through Bluetooth pairing and the USB, at the same radio will connect to the first available paired device,
time). starting from the last paired/connected device.
930E-4SE 9-5
RADIO OPERATION RADIO
RADIO OPERATION A.2-0000073247 The receiver starts at the current radio

frequency and begins searching for the next
Tuning A.2-0000073246 tunable station. When a station is found, the
The radio has two tuning configurations, MANUAL receiver stays on the station for eight seconds,
and AUTO, which are set through the User menu. and then continues on to find the next available
frequency.
If tuning is set to MANUAL, the radio will:
NOTE: If a tunable station is not found the radio will
1. perform manual tuning when the NEXT or display “NO STATION FOUND”.
PREV buttons are short pressed.
3. Press the SCAN/ASCN button again to stop the
2. perform seek tuning when the NEXT or PREV scan.
buttons are long pressed.
The receiver stops scanning and stays tuned
If tuning is set to AUTO, the radio will: to the station that was playing when the SCAN/
ASCN button was pressed.
1. perform seek tuning when the NEXT or PREV
buttons are short pressed.
Performing an Autoscan A.2-0000073243
2. perform manual tuning when the NEXT or
PREV buttons are long pressed. 1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1,
Manual tuning increases the frequency by one step FM2, AM or WX).
(0.2 MHz in FM mode, 10kHz in AM mode, and 25
The desired frequency band is shown on the
kHz in WX mode). Seek tuning finds the next tunable
left hand side of the display.
station.
2. Press and hold the SCAN/ASCN button (10)
NOTE: If a tunable station is not found the radio will
until the receiver beeps.
display “NO STATION FOUND”.
The autoscan begins and the “AUTO SCAN”
Scanning A.2-0000073245 icon blinks on the Digital Display (2).
The receiver is capable of two bands of scanning; When the autoscan finishes the receiver tunes
regular scan and autoscan. the radio to the station stored in Preset 1. The
“AUTO SCAN” icon will stay illuminated while
The regular scan cycles through all radio frequencies the mode is active.
and stops when a tunable station is found.
3. Press any of the six Preset buttons (13-18) to
The autoscan finds and temporarily stores the access the six stations stored by the autoscan.
strongest six stations found on the current frequency
band. These presets are stored in the six Preset 4. To exit autoscan mode, perform any of the
buttons (13-18) until the radio is turned off or the following actions:
source is changed. a. Press and hold the SCAN/ASCN button.
NOTE: Autoscan does not store the frequencies on b. Press the SRC/PWR button.
the presets in numerical order; they are stored based
on the order in which they were found and on the c. Turn power off to the radio.
quality of the frequency. The “AUTO SCAN” icon de-illuminates on the
display and the presets are set back to their
Performing a Regular Scan A.2-0000073244 prior stations.
1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1, Station Presets A.2-0000073260
FM2, AM or WX). The receiver is capable of storing six AM preset
The desired frequency band is shown on the stations, twelve FM preset stations (FM1 and FM2),
left hand side of the display. and six WX preset stations. The preset stations are
accessed by pressing one of the six Preset buttons
2. Press but do not hold the SCAN/ASCN button (13-18).
(10).
9-6 930E-4SE
RADIO RADIO OPERATION
Storing Radio Station Presets A.2-0000073259 Tuning Radio Station Presets A.3-0000073258
1. Press the SRC/PWR Button (6) to access the 1. Press the SRC/PWR Button (5) to access the
radio to the desired frequency band (FM1, radio to the desired frequency band (FM1,
FM2, AM or WX). FM2, AM or WX).
The desired frequency band is shown on the The desired frequency band is shown on the
left hand side of the display. left hand side of the Digital Display (2).
2. Tune the radio to the desired frequency. 2. Press and release the desired Preset Button
(13-18).
3. Press and hold the desired Preset button
(13-18) until the radio produces a beep. The receiver tunes to the frequency stored by
the Preset Button that was pressed.
The frequency is stored in the receiver's
memory.
930E-4SE 9-7
CD OPERATION RADIO
CD OPERATION A.2-0000073257 Playing a CD A.2-0000073229
Using the CD Player A.2-0000073256 Use the following procedure to play a CD:
The CD player in the receiver is able to play: 1. Press the SRC/PWR Button (5) to select CD.
• Most audio CDs. CD is shown on the Digital Display (2).
• CD-Rs (MP3 and unprotected WMA formats). 2. Insert the CD into the CD Slot (3), label side up.
• CD-RWs (MP3 and unprotected WMA formats). The CD player pulls the CD into the receiver
and the CD begins playing.
NOTE: When playing any CD, CD-R, or CD-RW, the
sound quality can be reduced due to disc quality, the The receiver shows the track number, Song,
method of recording, the quality of the music that has Artist, elapsed time, and Album information on
been recorded, or the way the disc has been handled. the Digital Display, when available.
3. Use the NEXT Button (6), SCAN/ASCN Button
(10), PREV (Previous) Button (11), RDM
• Do not use damaged or warped CDs in the (Random) Button (14), RPT (Repeat) Button
CD player. Damaged CDs can cause skipping, (15), and Play/Pause Button (18) to control the
difficulty in finding tracks, and/or difficulty in track being played as needed. Refer to the
loading and ejecting the CD. description and operation of each button for
more information.
To avoid damage to the CD player:
Ejecting a CD A.2-0000073255
• Do not use scratched or damaged CDs.
To eject a CD, press the Eject Button (7). The CD is
• Do not apply labels to CDs, as the labels can get ejected partially from the CD Slot (3).
caught in the player. Use a marking pen to label the
top of the CD. NOTE: If the CD is not removed within a short period
of time, the CD is automatically pulled back into the
• Insert only one CD at a time. player.
• Keep the loading slot free of foreign materials,
liquids, and debris.
9-8 930E-4SE
RADIO IPOD OPERATION
IPOD OPERATION A.2-0000073254 Accessing iPod Menus A.2-0000073251
iPod Support A.2-0000073253 The receiver can access various menus on a

connected iPod, allowing the user to control what files
The receiver supports the following iPod Models: to play. Each menu contains a list of items that can be
• iPod Classic (6th generation) played, depending on which menu is being accessed.
• iPod Nano (6G) The following menus are available from a connected
iPod:
• iPod Touch (4G)
• Playlists
• iPhone (3G, 3GS, 4, and 4S)
• Artists
NOTE: Other iPods may be played, but functionality
is not guaranteed. • Albums
There may be problems with the operation and • Genres

function of an iPod in the following situations: • Podcasts
• When connecting an iPod with a version of the • Songs
firmware installed that is more recent than receiver
supports. • Composers
• When connecting an iPod with firmware installed • Audio Books

from other providers. NOTE: If the iPod is an unsupported model, it can
When an iPod is connected to the USB port, the iPod still be listened to in the vehicle by connecting to
battery recharges automatically while the vehicle is the Auxiliary Jack Port (9) using a standard 3.5mm
on. When the vehicle is turned off, the iPod shuts off (0.125 in) stereo cable. Refer to the Auxiliary Device
and stops charging. Operation section for more information.
To access an iPod menu from the receiver, perform
Connecting an iPod A.2-0000073252 the following steps:
1. Connect one end of the standard iPod USB 1. Press the Browse button (17) while an iPod is
cable to the iPod's dock connector. connected through the USB Connection Port
2. Connect the other end of the cable to the USB (7).
Connection Port (8). 2. Use the NEXT Button (6) and PREV button (11)
The receiver switches the source to USB/iPod to navigate through the different menus.
and starts playing the music on the iPod The menus available are shown one at a time
through the stereo. on the Digital Display (2).
The receiver shows the track number, song, 3. Press the Volume Knob/OK Button (4) to select
artist, elapsed time, and Album information on the menu shown on the Digital Display.
the Digital Display (2), when available.
4. Use the NEXT Button (6) and PREV button (11)
NOTE: If the iPod is an unsupported model, it can to navigate through the selected list.
still be listened to in the vehicle by connecting to
the Auxiliary Jack Port (9) using a standard 3.5mm The items available through the selected menu
(0.125 in) stereo cable. Refer to the Auxiliary Device are shown one at a time on the Digital Display
Operation section for more information. (2).
5. Press the Volume Knob/OK Button (4) to select
the item shown on the Digital Display.
The selected list or item begins playing.
930E-4SE 9-9
USB DEVICE OPERATION RADIO
USB DEVICE OPERATION A.2-0000073270 the top level of the drive. The receiver can read up to
four levels of sub-folders in each top level folder, for a
Supported USB Devices A.2-0000073269 total of five levels.
The receiver is capable of playing files from a USB The receiver can also only see the first 255 files in
MP3 player or a USB mass storage device. The each folder, and is capable of reading a maximum
receiver is only capable of playing from devices that of 1,000 files on the device. Files and folders above
are formatted using FAT16, FAT32, NTFS, or HFS+. these numbers cannot be accessed.
Other drive formats cannot be accessed.
To access different folders on a USB MP3 Player,
NOTE: The receiver can access portable hard drives USB mass storage device, or an MP3 CD, perform
that use only USB power, but are not supported. the following steps:
Supported File Types A.4-0000073268 1. Press the SRC/PWR Button (5) to set the
receiver to the desired file source (USB or CD).
The receiver is capable of playing unprotected MP3
and WMA files. The receiver can also access M3U 2. Press the Browse Button (17) to access the CD
and PLS playlist file types, allowing users to make MP3/USB Music menu.
playlists and play them back through the receiver. 3. Press the PREV (Previous) Button (11) and
MP3 files must meet the following requirements to be NEXT Button (6) or rotate the Volume Knob/
played: OK Button (4) to select Folder Mode.
Bit Rate: 32, 40, 48, 56, 64, 80, 96, 112, 124, 160, 4. Press the Volume Knob/OK Button (4).
192, 224, 256, or 320 kbps 5. Press the PREV (Previous) Button (11) and
Sampling Frequency: 32, 44.1 or 48 kHz NEXT Button (6) or rotate the Volume Knob/
OK Button (4) to move through the available
WMA Files must meet the following requirements to folders.
be played:
NOTE: The receiver does not display empty folders or
Version: 1, 2, 7, 8, 9 or 9.1 folders that contain only other folders.
Bit Rate: 32 to 320 kbps 6. Press the Volume Knob/OK Button (4) to
access the folder shown on the Digital Display
Sampling Frequency: 32 to 48 kHz (2).
Connecting a USB Device A.2-0000073267 The receiver plays the first valid track in the
selected folder.
1. For devices without a USB connector, connect
one end of the USB cable to the MP3 player or 7. Use the NEXT Button (6), SCAN/ASCN Button
USB storage device. (10), PREV (Previous) Button (11), RDM
(Random) Button (14), RPT (Repeat) Button
2. Connect the other end of the cable to the USB (15), and Play/Pause Button (18) to control the
Connection Port (8). track being played as needed. Refer to the
3. For devices with a USB connector, connect the description and operation of each button for
USB MP3 player or USB storage device to the more information.
USB Connection Port (8).
Accessing USB Playlists A.2-0000073265
The receiver switches the source to USB/iPod
and starts playing the music on the USB device The receiver is capable of playing M3U and PLS
through the stereo. playlists stored on a USB MP3 Player, USB mass
storage device, or on an MP3 CD.
The receiver shows the track number, song,
artist, elapsed time, and Album information on To access playlists on a USB MP3 Player, USB
the Digital Display (2), when available. mass storage device, or on an MP3 CD, perform the
following steps:
Accessing USB Folders A.2-0000073266
1. Press the SRC/PWR Button (5) to set the
Separate folders can be accessed on a USB MP3 receiver to the desired file source (USB or CD)
Player, USB mass storage device, or on an MP3 CD.
2. Press the Browse Button (17) to access the CD
The receiver is limited to reading the first 8 folders on
MP3/USB Music menu.
9-10 930E-4SE
RADIO USB DEVICE OPERATION
3. Press the PREV (Previous) Button (11) and To start a scan, perform the following steps:
NEXT Button (6) or rotate the Volume Knob/
1. Press the SRC/PWR Button (5) to access the
OK Button (4) to select Playlist Mode.
radio to the desired file source (USB or CD).
4. Press the Volume Knob/OK Button (4).
2. To perform a scan of the currently access folder
The first playlist available is shown on the or playlist, Press the SCAN/ASCN Button (10).
Digital Display (2).
The receiver starts at the file currently playing.
5. Press the PREV (Previous) Button and NEXT The receiver stays on the file for eight seconds,
Button or rotate the Volume Knob/ OK Button and then continues on to find the next available
to move through the available playlists. file.
6. Press the Volume Knob/OK Button to access 3. To perform a scan of the entire device being
the playlist shown on the Digital Display. accessed, press and hold the SCAN/ASCN
Button until the receiver beeps.
The receiver plays the first valid track in the
selected playlist. The receiver starts at the first track available on
the entire device file. The receiver stays on the
7. Use the NEXT Button, SCAN/ASCN Button
file for eight seconds, and then continues on to
(10), PREV (Previous) Button, RDM (Random)
find the next available file.
Button (14), RPT (Repeat) Button (15),
and Play/Pause Button (18) to control the 4. Press the SCAN/ASCN button again to stop the
track being played as needed. Refer to the scan.
description and operation of each button for
The receiver stops scanning and stays tuned
more information.
to the song that was playing when the SCAN/
ASCN button was pressed.
Scanning a USB Device A.2-0000073264
The receiver can scan files on a USB MP3 Player,

USB mass storage device, or on an MP3 CD. The
receiver can scan the currently accessed folder or
playlist, or can scan the entire device being accessed.
930E-4SE 9-11
AUXILIARY DEVICE OPERATION RADIO
AUXILIARY DEVICE NOTE: The rear auxiliary source is always available,

OPERATION A.2-0000073263 but the front auxiliary source is only available if an item
is connected through the Auxiliary Jack Port.
The receiver has two auxiliary connections, the
Auxiliary Jack Port (9) in the front and one in the rear. NOTE: Devices connected through the auxiliary
The connections allow other devices to be connected ports cannot be controlled through the receiver. The
through the receiver to use the speaker system, receiver can only be used to change the source to
such as iPods or MP3 payers that are not supported and from the auxiliary ports and to adjust the volume.
through a USB connection.
Devices can be connected to the receiver using
a standard 3.5mm (0.125 in) stereo cable. Both
auxiliary connections are accessed by pressing the
Source/Power Button (5).
9-12 930E-4SE
RADIO BLUETOOTH OPERATION
BLUETOOTH OPERATION A.2-0000073262 The Bluetooth Menu is shown on the Digital

Display (2).
Bluetooth Menu A.2-0000073261
3. Rotate the Volume Knob/OK Button (4) until the
The Bluetooth Menu is used to perform functions Digital Display shows “ADD PHONE”.
related to using the Bluetooth system, such as
enabling and disabling Bluetooth functionality, 4. Press the Volume Knob/OK Button.
adding and removing devices, and connecting or The Digital Display shows “ADDING PH” and
disconnecting a previously added device. the Bluetooth icon blinks.
The Bluetooth Menu is accessed by pressing the 5. On the device being connected to the receiver,
Phone/Bluetooth button (1) for more than 3 seconds. look for a Bluetooth-enabled device named
The Volume Knob/OK Button (4) is used to navigate “Delphi500 Radio.”
through the Bluetooth Menu.
6. Use the device to connect to the receiver.
Enabling/Disabling Bluetooth A.2-0000073280
When appropriate, use the four-digit PIN
“0000” to complete the connection.
To enable or disable Bluetooth on the receiver:
Refer to the device’s manual for more
1. Press the Phone/Bluetooth button (1) for more information on pairing the device.
than 3 seconds.
When the device is successfully paired with
The Bluetooth Menu is shown on the Digital the receiver, the Digital Display shows “PH
Display (2). CONNECTED” and then the name of the
connected device. The Phone icon illuminates
2. Rotate the Volume Knob/OK Button (4) until
on the Digital Display as well.
the Digital Display shows “BT Disable” or “BT
Enable”, depending on which option is needed. NOTE: The receiver will attempt to find a device to pair
3. Press the Volume Knob/OK Button to enable or to for three minutes after the add phone procedure
disable the Bluetooth. is started. If no Bluetooth-Enabled device is found
during the paring process, the Digital Display will show
If Bluetooth is disabled, any currently “NO PH FOUND” the Phone and arrows icons will
connected Bluetooth devices are disconnected de-illuminate.
from the receiver.
7. Press the ESC Button (13) to exit the Bluetooth
If Bluetooth is enabled, the receiver attempts to menu.
reconnect with any previously paired Bluetooth
devices. The receiver attempts to reconnect Deleting Previously Paired
with each devices in order three times before Devices A.2-0000073278
moving to the next device. The Phone Icon
illuminates and arrow icons blink on the Digital Use the following procedure to delete one or all
Display while reconnection is being attempted. previously paired devices
4. Press the ESC Button (13) to exit the Bluetooth 1. Press the Phone/Bluetooth button (1) for more
menu. than 3 seconds.
The Bluetooth menu is shown on the Digital
Pairing a Bluetooth Device A.2-0000073279 Display (2).
To pair a device to the receiver: 2. Rotate the Volume Knob/OK Button (4) until the
1. Verify Bluetooth is enabled on the receiver and Digital Display shows “DELETE PH”.
the device. The Bluetooth Menu is shown on the Digital
Refer to Enabling/Disabling Bluetooth for Display (2).
information on enabling Bluetooth on the 3. Press the Volume Knob/OK Button.
receiver.
A list of all previously connected devices are
Refer to the device’s manual for more shown one at a time on the Digital Display.
information on enabling Bluetooth on the
device. 4. Rotate the Volume Knob/OK Button until the
device to be deleted is shown. Alternately,
2. Press the Phone/Bluetooth button (1) for more
than 3 seconds.
930E-4SE 9-13
BLUETOOTH OPERATION RADIO
select “DELETE ALL” to delete all paired The Digital Display shows CONNECTING
devices stored in the receiver. while attempting to connect to the device.
When the device is successfully connected
The Digital Display shows “ADDING PH” and
with the receiver, the Digital Display shows
the Bluetooth icon blinks.
“PH CONNECTED” and then the name of the
5. Press the Volume Knob/OK Button. connected device. The Phone Icon illuminates
on the Digital Display as well.
The Digital Display shows “PH DELETED” and
the device(s) can no longer be connected to the 6. Press the ESC Button (13) to exit the Bluetooth
receiver. menu.
menu. Disconnecting a Device A.2-0000073276
Use the following procedure to disconnect a device

Connecting a Device A.2-0000073277 currently connected to the receiver.
Use the following procedure to connect a previously 1. Press the Phone/Bluetooth button (1) for more
paired device. than 3 seconds.
1. Press the Phone/Bluetooth button (1) for more The Bluetooth menu is shown on the Digital
than 3 seconds. Display (2).
The Bluetooth menu is shown on the Digital 2. Rotate the Volume Knob/OK Button (4) until the
Display (2). Digital Display shows “DISCONNECT PH”.
2. Rotate the Volume Knob/OK Button (4) until the 3. Press the Volume Knob/OK Button.
Digital Display shows “CONNECT PH”.
The Digital Display shows “DISCONNECT
3. Press the Volume Knob/OK Button. PH” for a short time. Once the device
is disconnected the radio will display
A list of all previously connected devices are
DISCONNECTED and then the device’s name.
shown one at a time on the Digital Display.
The Phone icon de-illuminates on the Digital
4. Rotate the Volume Knob/OK Button (4) until the Display as well.
Digital Display shows the name of the device
being connected.
menu.
5. Press the Volume Knob/OK Button.
9-14 930E-4SE
RADIO RECEIVER SYSTEM SETTINGS
RECEIVER SYSTEM 4. FADE

SETTINGS A.2-0000073275 5. BALANCE
The receiver contains two menus of user-adjustable 6. AUTO EQ
settings:
• Audio Control Menu Bass
• User Menu The bass is used to adjust the level of the bass
sounds. The levels range from -6 to +6. The Digital
Display (2) shows “BASS” and its current setting
AUDIO CONTROL MENU A.2-0000073274
when selected.
The Audio Control menu is used to adjust the bass,
middle, treble, fade, and balance and to set the Middle
equalizer (EQ) automatically. The Audio Control
menu is also used to set the clock time and format The middle is used to adjust the level of the mid-range
and to set alarms. sounds. The levels range from -6 to +6. The Digital
Display shows “MIDDLE” and its current setting when
The Audio Control menu is accessed by pressing selected.
the Volume Knob/OK Button (4) for less than three
seconds when the receiver is not already in another Treble
menu.
The treble is used to adjust the level of the treble
sounds. The levels range from -6 to +6. The Digital
Adjusting Audio Settings
Display shows “TREBLE” and its current setting when
1. Press the Volume Knob/OK Button (4) for less selected.
than two seconds when the receiver is not
already in another menu. Fade
The Digital Display shows “BASS” and the The fade is used to adjust the amount of sound going
current bass setting. to the front and rear speakers. The amount of sound
2. Rotate the Volume Knob/OK Button to find the ranges from F15 to R15. The Digital Display shows
desired option. “FADE” and its current setting when selected.
3. Once the desired option is shown, press the NOTE: Fade is not available in systems with only two
Volume Knob/OK Button to select that option. speakers or when the receiver is set to two channel
configuration.
4. Rotate the Volume Knob/OK Button to change
the currently displayed audio option. Balance
5. Once the option is changed to the desired The balance is used to adjust the amount of sounds
setting, press the Volume Knob/OK Button to going to the left and right speakers. The amount of
exit from the option and return to the Audio sound ranges from L15 to R15. The Digital Display
Control menu. shows “BALANCE” and its current setting when
6. Continue using the Volume Knob/OK Button to selected.
make changes to other options, as needed.
Auto EQ
7. Once all desired settings have been adjusted,
press the ESC Button (13) to exit the Audio The auto EQ is used to adjust the stereo equalizer
Control menu. (EQ) automatically to best match the selected audio
style. The Auto EQ Options are:
Audio Adjustment Options 1. Pop
The following options are available from the Audio 2. Rock
Control menu.
3. Country
1. BASS
4. News
2. MIDDLE
5. Jazz
3. TREBLE
6. Classical
930E-4SE 9-15
RECEIVER SYSTEM SETTINGS RADIO
7. Manual 2. Rotate the Volume Knob/OK Button until

“ALARM” is shown on the Digital Display.
The Digital Display shows “EQ” and its current setting Press the Volume Knob/OK Button to enter the
when selected. Alarm submenu.
Adjusting the Clock 3. Rotate the Volume Knob/OK Button until

“ALARM ON” is shown on the Digital Display.
1. Press the Volume Knob/OK Button (4) for less Press the Volume Knob/OK Button.
already in another menu. The current time is shown on the Digital Display
and the hours digit(s) begin to flash. The Alarm
The Digital Display (2) shows “BASS” and the icon also illuminates on the Digital Display.
current bass setting.
4. Rotate the Volume Knob/OK Button to adjust
2. Rotate the Volume Knob/OK Button until the hour shown. Press the Volume Knob/OK
“CLOCK” is shown on the Digital Display. Button to set the hour.
Press the Volume Knob/OK Button to enter the
Clock submenu. The minutes digits begin to flash on the Digital
Display.
3. Rotate the knob to change the clock format, if
desired. 5. Rotate the Volume Knob/OK Button to adjust
the minutes shown. Press the Volume
The time can be displayed in 12-hour and 24- Knob/OK Button to set the minutes.
hour format.
“SET TONE” is shown on the Digital Display.
4. Press the Volume Knob/OK Button to set the
clock format. 6. Rotate the Volume Knob/OK Button to change
between “SET TONE” and “SET MUSIC”.
The hour digit(s) begin to flash on the Digital Press the Volume Knob/OK Button to set the
Display. sound option.
5. Rotate the Volume Knob/OK Button to adjust “SET TONE” is used to play an alarm tone
the hour shown. Press the Volume Knob/OK through the speaker system. “SET MUSIC”
Button to set the hour. plays the last accessed audio source (radio,
The minutes digits begin to flash on the Digital CD player, etc.).
Display. 7. If “SET TONE” was selected, rotate the Volume
6. Rotate the Volume Knob/OK Button to adjust Knob/OK Button to select the volume level for
the minutes shown. Press the Volume the tone alarm.
Knob/OK Button to set the minutes. The tone alarm has three available option: low,
The time is now set and the receiver exits the mid, and high.
Clock submenu. 8. If “SET MUSIC” was selected, rotate the
7. Press the ESC Button (13) to exit the Audio Volume Knob/OK Button to select the volume
Control menu. level for the music alarm.
The music alarm can be set from 1 (lowest
Setting an Alarm possible volume level) to 30 (highest possible
The receiver can be used to set an alarm. The alarm volume level).
will play either and audio tone or audio from the last 9. Press the Volume Knob/OK Button to set the
accessed audio source (radio, CD player, etc.) at the alarm sound level.
selected time.
The alarm is now set and the receiver exits the
Use the following procedure to set an alarm. Alarm submenu.
1. Press the Volume Knob/OK Button (4) for less 10. Press the ESC Button (13) to exit the Audio
than two seconds when the receiver is not Control menu.
already in another menu.
The Digital Display (2) shows “BASS” and the
9-16 930E-4SE
RADIO RECEIVER SYSTEM SETTINGS
Canceling an Alarm The User menu is accessed by pressing the Volume

Knob/OK Button (4) for more than three seconds when
A previously set alarm can be canceled before the
the receiver is not already in another menu.
alarm is activated. Use the following procedure to
cancel and alarm.
Adjusting User Settings
1. Press the Volume Knob/OK Button (4) for less
1. Press the Volume Knob/OK Button (4) for less
The Digital Display (2) shows “BASS” and the
2. Rotate the Volume Knob/OK Button to find the
desired option.
2. Rotate the Volume Knob/OK Button until
3. Once the desired option is shown, press the
“ALARM” is shown on the Digital Display.
Volume Knob/OK Button to select that option.
Press the Volume Knob/OK Button to enter the
Alarm submenu. 4. Rotate the Volume Knob/OK Button to change
the currently displayed audio option.
3. Rotate the Volume Knob/OK Button until
“ALARM OFF” is shown on the Digital Display. 5. Once the option is changed to the desired
Press the Volume Knob/OK Button. setting, press the Volume Knob/OK Button to
exit from the option and return to the Audio
The alarm is now canceled and the receiver
Control menu.
exits the Alarm submenu.
6. Continue using the Volume Knob/OK Button to
4. Press the ESC Button (13) to exit the Audio
make changes to other options, as needed.
Control menu.
7. Once all desired settings have been adjusted,
Turning off or Snoozing an Activated press the ESC Button (13) to exit the User
Alarm menu.
When an alarm is set up, the alarm is triggered when User Adjustment Options
the time set for the alarm is reached. The receiver will
play an audio tone or music source, as directed when The following settings can be adjusted from the User
the alarm was set. menu.
An active alarm can be either turned off or postponed. 1. Speakers

To turn an active alarm off, press the Clock/ Alarm 2. Seek Sensitivity
Button (16).
3. Tune Configuration
To postpone an alarm, press any button on the
receiver except for the Clock/Alarm Button. The alarm 4. Playback Configuration
sound turns off, but will activate again nine minutes 5. Brightness
later. When the alarm activates again, the alarm can
be postponed again or turned off. 6. HUE Adjustment
NOTE: If no buttons are pressed, the alarm continues Speakers

to sound for 63 minutes and then automatically shuts
off. The speaker setting adjusts the number of audio
channels being used. There are two options available,
USER MENU A.2-0000073281 “2CH” (two channel) and “4CH” (four channel). Two
channel uses only the front speakers, while four
The User menu is used to adjust speaker channel uses the front and rear speakers. The Digital
configuration, sensitivity of radio frequency seeking, Display (2) shows “SPEAKERS” when this option is
tuning configuration, audio playback configuration, selected.
and the brightness and color setting of the Digital
Display (2).
930E-4SE 9-17
RECEIVER SYSTEM SETTINGS RADIO
Seek Sensitivity • skip to the start of the current file (if the current file
has been playing for longer than ten seconds) when
The seek sensitivity setting controls the sensitivity of
the PREV Button is short pressed.
the seek function when in any of the radio tuner modes
(FM1, FM2, AM and WX). A higher seek sensitivity • fast forward or reverse through the current file when
level typically finds more stations, but those stations the NEXT or PREV buttons are long pressed. The
may have weaker signals. A lower seek sensitivity fast forward or reverse is stopped when the NEXT
typically finds stations but those are the stations with or PREV Button is released.
the strongest signals in the area. The seek sensitivity
If playback is set to FAST F/F, the radio will:
can be set from -2 (lowest sensitivity) to +2 (highest
sensitivity). The Digital Display shows “SEEK SEN” • fast forward or reverse through the current file when
and the current sensitivity level when this option is the NEXT or PREV buttons are short pressed. The
selected. fast forward or reverse is stopped when the NEXT
or PREV Button pressed again.
Tune Configuration
• skip to the start of the next file when the NEXT
The tune configuration setting controls how the NEXT Button is long pressed.
Button (6) and PREV Button (11) function when in
• skip to the start of the previous file (if the current file
any of the radio tuner modes (FM1, FM2, AM and
has been playing for less than seconds) when the
WX). There are two options available, “MANUAL” and
PREV Button is long pressed.
“AUTO”.
• skip to the start of the current file (if the current file
If tuning is set to MANUAL, the radio will:
has been playing for longer than ten seconds) when
• perform manual tuning when the NEXT or PREV the PREV Button is long pressed.
buttons are short pressed.
The Digital Display shows “PLBK CFG” and the
• perform seek tuning when the NEXT or PREV current playback configuration when this option is
buttons are long pressed. selected.
If tuning is set to AUTO, the radio will:
Brightness
• perform seek tuning when the NEXT or PREV The brightness setting controls the brightness level of
buttons are short pressed. the Digital Display. This value can be adjusted from
• perform manual tuning when the NEXT or PREV -10 (very dim) to +10 (very bright). The Digital Display
buttons are long pressed. shows “DIMMING” and the current brightness value
when this option is selected.
The Digital Display shows “TUNE CFG” and the
current tuning configuration when this option is
HUE Adjustment
selected.
The HUE adjustment setting changes the color of the
Playback Configuration light in the Digital Display. Depending on the receiver
model, the following color options are available:
The playback configuration setting controls how the
NEXT Button and PREV Button function when playing • AMBER or GREEN
audio from the CD, USB/iPod, or Bluetooth source • RED or BLUE
modes. There are two options available, “SEEK” and
“FAST F/F”. NOTE: This option is only available on receiver
models equipped with a dual color system.
If playback is set to SEEK, the radio will:
The Digital Display shows “HUE ADJ” and the
• skip to the start of the next file when the NEXT currently selected color when this option is selected.
Button is short pressed.
• skip to the start of the previous file (if the current file
has been playing for less than seconds) when the
PREV Button is short pressed.
9-18 930E-4SE
RADIO TROUBLESHOOTING
TROUBLESHOOTING A.2-0000073291
Radio Troubleshooting A.3-0000073180
Problem Possible Cause Solution

Unable to tune into any radio Vehicle is in a weak signal area. Increase the seek sensitivity (refer
stations to the User Menu section for more
information).
CD Player Troubleshooting A.4-0000073179

“Disc Error” is shown on the The disc has an invalid or unknown Try burning the CD again with
Digital Display (2) or CD Player format. correctly formatted files.
Automatically Ejects CD
The disc is very hot. Try the disc again when the
temperature returns to normal.
The road is very rough. Try the disc again when the road
is smoother.
The disc is bent. Do not use CD in the CD player.
Continued use may cause damage
to CD player.
The air is very humid. Try the disc again later.
The disc is dirty, scratched, or wet. Carefully clean the CD and try
again.
The disc is inserted upside down. Eject the CD and try again the
correct direction.
There was a problem while burning Try burning the CD again.
the disc.
The label is caught in the CD Completely remove the label and
player. try again. Use a marker to label
CDs.
If problem continues, try another known good CD. If error message
continues, contact your dealer.
CD Player Not Functioning Temperature of the receiver is -20° Allow the vehicle’s interior
to 55°C (-4° to 131°F). temperature to adjust to within
normal operating parameters.
CD Insertion is not possible A CD is already on the CD player. Eject and remove CD before
attempting to insert new CD.
930E-4SE 9-19
TROUBLESHOOTING RADIO
iPod Troubleshooting A.3-0000073178

iPod does not play or there is no The iPod has not been recognized. Verify that the iPod is supported.
sound
• If the iPod is supported, reset the
The iPod does not respond to iPod and re-connect again (refer
commands from the receiver to the iPod Operation section for
UNSUPPORTED is shown on the iPod connected to receiver is not more information).
Digital Display supported. • If the iPod is not supported, use
the Auxiliary Jack Port (9) to
connect the iPod to the receiver.
NO MUSIC is shown on the Digital There are not any playable files in 1. Check to see if there are
Display the iPod. files on the iPod.
2. If there are files, then
files may not be playable.
Replace files and try again.
iPod Not Functioning Temperature of the receiver is -20° Allow the vehicle’s interior
to 55°C (-4° to 131°F). temperature to adjust to within
normal operating parameters.
USB Troubleshooting A.3-0000073177

UNSUPPORTED is shown on the USB device was not connected as Disconnect the device and try
Digital Display a mass storage device. again.
USB device connected has an 1. Check device’s file format
unsupported file format structure. structure.
2. If possible, re-format device
and try again. Refer to USB
Operation section for more
details.
Device is damaged 1. Verify device is working
properly.
2. If device is not damaged,
disconnect the device and
try again.
NO MUSIC is shown on the Digital There are not any playable files on 1. Check to see if there are
Display the USB. files on the USB device.
2. If there are files, then
files may not be playable.
Replace files and try again.
Refer to USB Operation
section for more details.
9-20 930E-4SE
RADIO TROUBLESHOOTING
Bluetooth Troubleshooting A.3-0000073176

Receiver does not recognize Device needs to be paired to Refer to the Bluetooth Operation
Bluetooth-enabled device receiver. section for details on pairing a
device. If device is already paired
with the receiver, delete the device
and pair it again.
Device is not turned on. Verify device is on.
Bluetooth is not enabled on Verify both receiver and device
receiver and/or device. have Bluetooth enabled. Refer to
the Bluetooth Operation section
for details on enabling Bluetooth.
Device is out of range. Move the device closer to the
receiver.
Device not communicating with Receiver may be connected to Verify receiver is connected to
receiver different Bluetooth device. correct device. Refer to the
Bluetooth Operation section for
details on connecting Bluetooth
devices.
Device requires receiver’s Refer to device’s manual for
passkey or passkey was entered information on entering a passkey.
incorrectly. Refer to the Bluetooth Operation
section for information on pairing a
device and for the correct passkey.
Device is close to other devices Move the device away from other
using radio frequencies (e.g. devices that use radio frequencies.
microwave oven, cordless phones,
802.11 wireless network)
Device’s music cannot be heard Device needs to be paired to Refer to the Bluetooth Operation
receiver. section for details on pairing a
device. If device is already paired
with the receiver, delete the device
and pair it again.
Device needs to be connected to Refer to the Bluetooth Operation
receiver. section for details on connecting
a device.
Receiver is not set to use Bluetooth Press the PWR/SRC Button (5) to
source. change the source to Bluetooth.
Volume on receiver is too low. Rotate the Volume Knob/OK
Button (4) to adjust the receiver’s
volume.
Device is paused. Verify device is not paused and try
again.
Device does not have any music Verify device has music files and
files. try again.
930E-4SE 9-21

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CEAM031503

Operation & Maintenance

SERIAL NUMBERS 930E-4SE A31937 and up

Copyright 2018 Komatsu

Unsafe use of this machine may cause serious injury or death.

WARNING: Breathing diesel engine exhaust exposes you to

WARNING: This product can expose you to chemicals including

ABOUT THIS MANUAL F.2-0000051237

This material is proprietary to Komatsu America

It is the policy of the company to improve

Because of continuous research and

California Proposition 65 Warnings

The ALERT symbol is used with the following signal words:

NON-OEM PARTS IN CRITICAL SYSTEMS C.3-0000051235

SOFTWARE LICENSE INFORMATION A.3-0000074884

Suggested Sources For Rust Preventive

STANDARD TIGHTENING Table 2-1

Example: M20 x 2.25

SAE Grade 5 And Grade 8 Capscrews

1/4-20 9.5 7 0.97 13.6 10 1.38

SAE Grade 9 Capscrews Standard Tightening Torque for SAE Hex

Tightening Torque For T-Bolt Type Hose

1. Shank Diameter (in) — Threads per inch

Split Flange Clamps

Flared Tube And Hose Fittings

Tightening Torque For Flared Tube And Hose Fittings

JIC 37° Swivel Nuts

Pipe Thread Fittings

With With Without Without

O-Ring Boss Fittings

O-Ring Face Seal Fittings

Fahrenheit Celsius Fahrenheit Celsius Fahrenheit

121 250 2 482 63 145 293 4 40 104

Know what to do in the event of a fire and keep phone

Precautions For High Temperature Fluids

2. Wait for the oil temperature to cool down. ROPS Precautions

PRECAUTIONS FOR TRUCK Mirrors, Windows, And Lights

Emergency Exit from Operator’s Cab

Emergency Egress Ladders

1. Emergency Egress Latch

Figure 3-1 EMERGENCY EGRESS GATE

Traveling In Reverse Minimum Safe

Driving near high-voltage cables can cause electric

Dumping The Machine

EXTERIOR LIGHTING D.89-0000054339

1. Fog Lights 5. Ladder Lights

Figure 3-2 FRONT LIGHTS

Fog Lights Mirror Mounted Backup Lights

Brake Lights Clearance/Turn Signal Lights

1. Backup Lights 4. Backup Alarm

Figure 3-3 REAR AXLE LIGHT BAR

Brake Lights Backup Lamp

1. Engine Shutdown Switch 4. Starter Disconnect Switch 7. LED Lights (On)

Figure 3-4 ISOLATION BOX ASSEMBLY (COVERS REMOVED)

• To avoid serious personal injury or death,

Proper jack point locations must be used. The jacks

1. Rear Body Ear 3. Body Retention Sling

Figure 3-5 BODY RETENTION SLING

DURING MAINTENANCE G.31-0000051281 Keeping The Machine Clean

If water gets into the electrical system, there is danger

Always chock the tires of the machine securely. Never

Radiator Coolant Level Maintenance Near High Temperatures

Always put fluids drained from your machine in