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Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual SN A30113 & Up – PDF DOWNLOAD
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Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual
Book Code : CEAM019302
SERIAL NUMBERS:
A30113 & UP
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Description
Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU 830E-1AC DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 184
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30113 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual
FOREWORD:
- This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should 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 accomplishing repairs on the truck. The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest.
- Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. 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 G.V.W. (Gross Vehicle Weight) rating.The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E).
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.
TABLE OF CONTENTS:
Komatsu 830E-1Ac Dump Truck Operation & Maintenance Manual
COVER......................................................................... 1 WARNING....................................................................... 3 WARNING NON-OEM PARTS......................................................... 4 FOREWORD...................................................................... 5 ALERTS PAGE............................................................... 6 TABLE OF CONTENTS............................................................. 7 TRUCK MODEL ILLUSTRATION.................................................. 14 ABOUT THIS MANUAL......................................................... 14 STANDARD CHARTS AND TABLES.................................................... 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...... 17 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE).......... 18 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts....... 18 GENERAL SAFETY................................................................ 23 Safety Rules.............................................................. 23 Truck Safety Features..................................................... 23 Clothing And Personal Items............................................... 23 Unauthorized Modification................................................. 23 Leaving The Operator’s Seat............................................... 23 Mounting And Dismounting.................................................. 24 Fire Extinguishers And First Aid Kits..................................... 24 Precautions For High Temperature Fluids................................... 24 Asbestos Dust Hazard Prevention........................................... 24 Fire Prevention For Fuel And Oil.......................................... 25 ROPS Precautions.......................................................... 25 Preventing Injury From Work Equipment..................................... 25 Precautions For Optional Attachments...................................... 25 Precautions When Starting The Machine..................................... 25 PRECAUTIONS FOR TRUCK OPERATION........................................... 26 Safety Is Thinking Ahead.............................................. 26 Safety At The Worksite................................................ 26 Fire Prevention....................................................... 26 Preparing For Operation............................................... 26 Ventilation For Enclosed Areas........................................ 26 Mirrors, Windows, And Lights.......................................... 27 In The Operator’s Cab - Before Starting The Engine.................... 27 Seat Belts............................................................ 27 OPERATING THE MACHINE..................................................... 27 Starting The Engine................................................... 27 Truck Operation - General............................................. 27 Traveling In The Truck................................................ 28 Precautions When Traveling In Reverse................................. 28 Traveling On Slopes................................................... 28 Ensuring Good Visibility.............................................. 29 Operating On Snow..................................................... 29 Avoid Damage To The Dump Body......................................... 29 Driving Near High Voltage Cables...................................... 29 When Loading The Truck................................................ 29 When Dumping.......................................................... 29 Working On Loose Ground............................................... 30 Parking The Machine................................................... 30 TOWING.................................................................... 30 WORKING NEAR BATTERIES.................................................... 31 Jump Starting With Booster Cables..................................... 32 Jump Starting With Receptacles........................................ 32 PRECAUTIONS FOR MAINTENANCE............................................... 33 BEFORE PERFORMING MAINTENANCE......................................... 33 Stopping The Engine Before Service................................ 33 Warning Tag....................................................... 33 Proper Tools...................................................... 33 Securing The Dump Body............................................ 33 DURING MAINTENANCE.................................................... 34 Personnel......................................................... 34 Attachments....................................................... 34 Working Under The Machine......................................... 34 Keeping The Machine Clean......................................... 34 Rules To Follow When Adding Fuel Or Oil........................... 34 Radiator Coolant Level............................................ 34 Use Of Lighting................................................... 34 Precautions With The Battery...................................... 35 Handling High Pressure Hoses...................................... 35 Precautions With High Pressure Oil................................ 35 Maintenance Near High Temperatures And High Pressures............. 35 Rotating Fan And Belts............................................ 35 Waste Materials................................................... 35 TIRES..................................................................... 36 Handling Tires........................................................ 36 Tire Maintenance...................................................... 37 Storing Tires After Removal........................................... 37 ADDITIONAL JOB SITE RULES................................................. 38 WHEN REPAIRS ARE NECESSARY................................................ 39 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK........................ 40 Preliminary Procedures before Welding or Performing Maintenance....... 40 Engine Shutdown Procedure before Welding or Performing Maintenance.... 40 WARNINGS AND CAUTIONS......................................................... 43 TRUCK OPERATION............................................................... 55 PREPARIN G FOR OPERATION.................................................. 55 Safety Is Thinking Ahead.............................................. 55 WALK AROUND INSPECTION.................................................... 55 ENGINE START-UP SAFETY PRACTICES.......................................... 59 AFTER ENGINE HAS STARTED.................................................. 60 EMERGENCY STEERING SYSTEM................................................. 61 Operation............................................................. 61 Pre-Operation Testing................................................. 61 Additional Guidelines................................................. 62 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 62 MACHINE OPERATION ON THE HAUL ROAD........................................ 63 STARTING ON A GRADE WITH A LOADED TRUCK................................... 64 PASSING................................................................... 64 LOADING................................................................... 64 DUMPING................................................................... 64 Raising The Dump Body................................................. 64 Lowering The Dump Body................................................ 65 SUDDEN LOSS OF ENGINE POWER............................................... 66 FUEL DEPLETION............................................................ 67 SAFE PARKING PROCEDURES................................................... 67 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 68 DISABLED TRUCK CONNECTIONS................................................ 69 GENERAL............................................................... 69 STEERING AND BRAKE SYSTEM............................................. 69 Hookup............................................................ 69 HOIST SYSTEM.......................................................... 70 Hookup............................................................ 70 Dumping Procedure................................................. 70 TOWING.................................................................... 71 Special Wiring Harness................................................ 71 Towing Procedure...................................................... 72 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 74 Operation............................................................. 74 OPERATOR CAB AND CONTROLS..................................................... 75 STEERING WHEEL AND CONTROLS............................................... 76 Horn Button........................................................... 76 Tilt / Telescope Lever................................................ 76 Multi-Function Turn Signal Switch..................................... 76 PEDALS.................................................................... 77 Service Brake Pedal................................................... 77 Dynamic Retarding..................................................... 77 Dynamic Retard Pedal.................................................. 77 Throttle/Accelerator Pedal............................................ 78 GRADE/SPEED RETARD CHART.................................................. 78 OVERHEAD PANEL AND DISPLAYS............................................... 80 CENTER CONSOLE............................................................ 81 Directional Control Lever............................................. 81 Override/Fault Reset Switch........................................... 82 Engine Stop Switch.................................................... 82 L.H. Window Control Switch............................................ 82 R.H. Window Control Switch............................................ 82 Hoist Control Lever................................................... 82 Raising The Dump Body................................................. 82 Lowering The Dump Body................................................ 82 Retard Speed Control (RSC) Adjust Dial................................ 83 Retard Speed Control (RSC) Switch..................................... 83 Data Store Button..................................................... 84 VHMS Snapshot In Progress Light....................................... 84 Link Energized Light.................................................. 84 Service Engine Light.................................................. 84 DIAGNOSTIC PORTS...................................................... 84 VHMS Diagnostic Port.................................................. 84 Interface Module (IM) Diagnostic Port................................. 84 Payload Meter Diagnostic Port......................................... 84 Truck Control Interface (TCI) Diagnostic Port......................... 84 Propulsion System Controller (PSC) Diagnostic Port.................... 84 Engine Diagnostic Port (CENSE)........................................ 84 Engine Diagnostic Port (QUANTUM)...................................... 84 OPERATOR’S SEAT........................................................... 85 Seat Belts............................................................ 85 Adjustment............................................................ 85 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................... 86 Fan Control Knob...................................................... 86 Temperature Control Knob.............................................. 86 Directional Control Knob.............................................. 86 Heater Vents.......................................................... 86 INSTRUMENT PANEL.......................................................... 87 Key Switch............................................................ 89 Starting.............................................................. 89 Rotating Beacon Light Switch (Optional)............................... 89 Heated Mirror Switch (Optional)....................................... 89 Rest Switch........................................................... 89 Wheel Brake Lock Control.............................................. 90 Hazard Warning Lights................................................. 90 Cab/Air Conditioner Vents............................................. 90 Engine Oil Pressure Gauge............................................. 90 Right Turn Signal Indicator........................................... 90 Tachometer............................................................ 90 High Beam Indicator................................................... 91 Speedometer/Payload Meter Display..................................... 91 Left Turn Signal Indicator............................................ 91 Water Temperature Gauge............................................... 91 Lamp Test Switch...................................................... 91 Light Switch.......................................................... 91 Ladder Light Switch................................................... 91 Manual Backup Switch.................................................. 92 Fog Lights (Optional)................................................. 92 Payload Meter Switch.................................................. 92 Panel Light Dimmer.................................................... 92 Hydraulic Oil Temperature Gauge....................................... 92 Hourmeter............................................................. 93 Fuel Level Gauge...................................................... 93 OVERHEAD STATUS / WARNING INDICATORS...................................... 94 Status / Warning Indicator Light Symbols.............................. 95 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...................................100 Operation.............................................................100 Interface Module......................................................101 Basic Precautions.....................................................102 FUSE BLOCKS...............................................................103 CIRCUIT BREAKERS..........................................................105 LUBRICATION AND SERVICE.......................................................107 830E SERVICE CAPACITIES...................................................107 HYDRAULIC TANK SERVICE....................................................107 Adding Oil............................................................107 WHEEL MOTOR SERVICE.......................................................107 COOLANT LEVEL CHECK.......................................................108 RADIATOR FILLING PROCEDURE................................................108 RESERVE ENGINE OIL SYSTEM (Optional)......................................108 Reserve Oil Tank Filling Procedure (Remote fill)......................108 LUBRICATION CHART.........................................................109 10 HOUR (DAILY) INSPECTION................................................110 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................113 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................114 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................115 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................118 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)...................119 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................120 2500 HOUR MAINTENANCE CHECKS..............................................121 5000 HOUR MAINTENANCE CHECKS..............................................121 10,000 HOUR MAINTENANCE CHECKS............................................122 AUTOMATIC LUBRICATION SYSTEM..................................................123 GENERAL DESCRIPTION.......................................................123 SYSTEM COMPONENTS.........................................................125 Filter................................................................125 Hydraulic Motor and Pump..............................................125 Grease Reservoir......................................................125 Pressure Reducing Valve...............................................125 Pressure Gauge........................................................125 Flow Control Valve....................................................125 Solenoid Valve........................................................125 Vent Valve............................................................125 Lubrication Cycle Timer...............................................125 Over Pressure Cutoff Switch...........................................125 Grease Pressure Failure Switch........................................125 Injectors.............................................................125 Relief Valve (unloader valve).........................................125 SYSTEM OPERATION..........................................................126 GENERAL INSTRUCTIONS......................................................127 Required Lubricant....................................................127 System Priming........................................................127 Filter Assembly.......................................................127 LUBRICANT PUMP............................................................128 Pump Housing Oil Level................................................128 Pump Pressure Control.................................................128 INJECTORS (SL-1 Series “H”)...............................................129 Injector Specifications...............................................129 Injector Adjustment...................................................129 INJECTOR OPERATION........................................................130 PREVENTIVE MAINTENANCE PROCEDURES.........................................131 Daily Lubrication System Inspection...................................131 250 Hour Inspection...................................................131 1000 Hour Inspection..................................................131 SYSTEM CHECKOUT...........................................................132 Lubrication Controller Check..........................................132 Lubrication Controller Operation......................................132 Lubrication Controller Components.....................................132 Lubrication Controller Adjustment.....................................132 SYSTEM TROUBLESHOOTING CHART..............................................134 MAJOR COMPONENT DESCRIPTION...................................................137 PAYLOAD METER III™............................................................141 INDEX.....................................................................141 Introduction..............................................................143 Data Summary..........................................................143 Data Gathering........................................................143 COMPONENT DESCRIPTION.....................................................144 System Diagram........................................................144 Suspension Pressure Sensors...........................................144 Inclinometer..........................................................144 Operator Display......................................................144 Operator Switch.......................................................145 Speed Input...........................................................145 Body-Up Switch........................................................145 Brake Lock Switch.....................................................145 Payload Meter.........................................................145 Communications Ports..................................................145 Key Switch Input......................................................146 Payload Meter Power...................................................146 Load Lights...........................................................146 Wiring and Termination................................................147 TCI Outputs...........................................................147 OPERATOR’S DISPLAY AND SWITCH.............................................148 Reading the Speedometer...............................................148 Reading the Load Display..............................................148 Using the Operator ID.................................................148 Using the Load and Ton Counter........................................148 Total Ton Counter.....................................................148 Total Load Counter....................................................149 Clearing the Counters.................................................149 Viewing Live Sensor Data..............................................149 Other Display Messages................................................149 PAYLOAD OPERATION & CALCULATION...........................................150 Haul Cycle States.....................................................150 Haul Cycle Description................................................150 Load Calculation......................................................151 Carry Back............................................................151 Measurement Accuracy..................................................151 SOURCES FOR PAYLOAD ERROR.................................................151 Payload Error.........................................................151 Loading Conditions....................................................152 Pressure Sensors......................................................152 Swingloads............................................................152 Speed and Distance....................................................152 HAUL CYCLE DATA...........................................................152 Haul Cycle Data.......................................................153 Haul Cycle Warning Flags..............................................154 Frame Torque Data.....................................................155 Sprung Weight Data....................................................155 Maximum Speed Data....................................................155 Alarm Records.........................................................155 Fault Code Data.......................................................156 PC SOFTWARE OVERVIEW......................................................157 PC Overview...........................................................157 System Configuration..................................................157 Installing the PLMIII Software........................................157 DOWNLOADING DATA..........................................................158 PLM III SYSTEM CONFIGURATION..............................................159 Starting Communications...............................................159 Displayed Payload Units...............................................159 Time Units............................................................159 Connection Menu.......................................................159 Connecting to the Payload Meter.......................................160 Configure the Payload Meter...........................................160 Setting the Date and Time.............................................160 Setting the Truck Type................................................161 Setting the Gauge Display Units.......................................161 Setting the Frame Serial Number.......................................161 Setting the Truck Number..............................................161 Setting the Komatsu Distributor.......................................161 Setting the Komatsu Customer..........................................161 Clean Truck Tare......................................................162 Inclinometer Calibration..............................................162 DATA ANALYSIS.............................................................163 Creating a Query......................................................163 Sorting on Truck Unit Number..........................................163 Sorting on Truck Type.................................................163 Sorting on Date Range.................................................164 Sorting on Time Range.................................................164 Payload Detail Screen.................................................165 Creating Reports......................................................165 Summary - one page report.............................................166 Detailed - multi-page report..........................................166 Creating Graphs.......................................................167 Exporting Data........................................................167 CSV Export............................................................167 Compressed............................................................168 Importing Data........................................................169 Deleting Haul Cycle Records...........................................169 Viewing Alarms........................................................170 Deleting Alarm Records................................................170 AM/FM RADIO / CD PLAYER.......................................................173 OPERATING INSTRUCTIONS....................................................173 GENERAL RADIO RECEIVER FUNCTIONS......................................173 Turning On the Power..............................................173 One-Hour Timer....................................................173 Display...........................................................174 Setting a Default Display.........................................174 Adjusting the Brightness of the Display...........................174 Auxiliary Mode....................................................174 Adjusting the Receiver Settings...................................174 USING THE CLOCK.......................................................175 Setting the Clock.................................................175 USING THE ALARM.......................................................175 Setting the Alarm.................................................175 Turning the Alarm Off.............................................175 Activating Snooze.................................................175 Setting Alarm Volume..............................................175 USING THE RADIO.......................................................176 Finding a Station.................................................176 Setting the Presets...............................................177 SATELLITE RADIO SERVICE (Optional)....................................177 Activating Satellite Radio (Optional).............................177 USING THE WEATHERBAND.................................................178 USING THE COMPACT DISC PLAYER.........................................178 Playing a Compact Disc............................................178 Button Functions..................................................178 PLAYING AN MP3 DISC...................................................179 MP3 Format Compatibility..........................................179 Root Directory....................................................179 Empty Directory or Folder.........................................179 No Folder.........................................................179 File Name Display.................................................179 Pre-Programmed Playlists..........................................180 Playing MP3 Files.................................................180 Button Functions..................................................180 TROUBLESHOOTING.......................................................181
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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