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Komatsu 830E-1AC Dump Truck Operation & Maintenance Manual SN A30240-A30338 – PDF DOWNLOAD
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Komatsu 830E-1AC Dump Truck Operation & Maintenance Manual
SERIAL NUMBERS A30240 – A30338
Book Code : CEAM021501
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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
** Requirements: Adobe PDF Reader & WinZip.
** ZOOM IN/OUT: YES
** INSTANT DELIVERY: YES
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30240-A30338 – 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 FOREWORD...................................................................... 5 ALERTS PAGE............................................................... 6 TABLE OF CONTENTS............................................................. 7 TRUCK MODEL ILLUSTRATION...................................................... 15 ABOUT THIS MANUAL............................................................. 16 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 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 Electrical Systems Isolation...................................... 33 Warning Tag....................................................... 35 Proper Tools...................................................... 35 Securing The Dump Body............................................ 35 DURING MAINTENANCE.................................................... 36 Personnel......................................................... 36 Attachments....................................................... 36 Working Under The Machine......................................... 36 Keeping The Machine Clean......................................... 36 Rules To Follow When Adding Fuel Or Oil........................... 36 Radiator Coolant Level............................................ 36 Use Of Lighting................................................... 37 Precautions With The Battery...................................... 37 Handling High Pressure Hoses...................................... 37 Precautions With High Pressure Oil................................ 37 Maintenance Near High Temperatures And High Pressures............. 37 Rotating Fan And Belts............................................ 37 Waste Materials................................................... 37 TIRES................................................................. 38 Handling Tires.................................................... 38 Tire Maintenance.................................................. 39 Storing Tires After Removal....................................... 39 ADDITIONAL JOB SITE RULES................................................. 40 WHEN REPAIRS ARE NECESSARY................................................ 41 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK....................... 42 Preliminary Procedures before Welding or Performing Maintenance....... 42 Engine Shutdown Procedure before Welding or Performing Maintenance.... 42 WARNINGS AND CAUTIONS......................................................... 45 TRUCK OPERATION............................................................... 59 PREPARING FOR OPERATION................................................... 59 Safety Is Thinking Ahead.............................................. 59 WALK AROUND INSPECTION.................................................... 59 RETRACTABLE LADDER SYSTEM (If equipped)................................... 63 LADDER SYSTEM DESCRIPTION............................................. 63 LADDER SYSTEM OPERATION............................................... 64 Normal Operation.................................................. 64 GENERAL SAFETY........................................................ 64 IN-CAB CONTROL PANEL.................................................. 64 IN-CAB CONTROL PANEL FEATURES......................................... 65 Digital Display Screen............................................ 65 Command Buttons................................................... 65 USING THE IN-CAB CONTROL PANEL........................................ 66 Raising the Ladder................................................ 66 Lowering the Ladder............................................... 67 USING THE GROUND LEVEL CONTROL BOX.................................... 68 Raising the Ladder................................................ 68 Lowering the Ladder............................................... 68 Emergency Operation............................................... 69 ENGINE START-UP SAFETY PRACTICES.......................................... 70 AFTER ENGINE HAS STARTED.................................................. 71 PRE-SHIFT BRAKE CHECK (if equipped)....................................... 72 Events................................................................ 72 OPERATION............................................................. 72 Description....................................................... 72 Brake Test Exit Criteria.......................................... 73 PERFORMING THE BRAKE TESTS............................................ 73 Setup............................................................. 73 Service Brake Test................................................ 74 Parking Brake Test................................................ 75 Retard System Test:............................................... 75 EMERGENCY STEERING SYSTEM................................................. 76 Operation............................................................. 76 Pre-Operation Testing................................................. 76 Additional Guidelines................................................. 77 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 77 MACHINE OPERATION ON THE HAUL ROAD........................................ 78 STARTING ON A GRADE WITH A LOADED TRUCK................................... 79 PASSING................................................................... 79 LOADING................................................................... 79 DUMPING................................................................... 79 Raising The Dump Body................................................. 79 Lowering The Dump Body................................................ 80 SUDDEN LOSS OF ENGINE POWER............................................... 81 FUEL DEPLETION............................................................ 82 SAFE PARKING PROCEDURES................................................... 82 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 83 DISABLED TRUCK CONNECTORS................................................. 84 GENERAL............................................................... 84 STEERING AND BRAKE SYSTEM............................................. 84 Hookup............................................................ 84 HOIST SYSTEM.......................................................... 85 Hookup............................................................ 85 Dumping Procedure................................................. 85 TOWING.................................................................... 87 Special Wiring Harness................................................ 87 Towing Procedure...................................................... 87 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 90 Operation............................................................. 90 LED Monitor Light..................................................... 90 Changing Oil.......................................................... 90 OPERATOR CAB AND CONTROLS..................................................... 91 STEERING WHEEL AND CONTROLS............................................... 92 Horn Button........................................................... 92 Tilt / Telescope Lever................................................ 92 Multi-Function Turn Signal Switch..................................... 92 PEDALS.................................................................... 93 Service Brake Pedal................................................... 93 Dynamic Retarding..................................................... 93 Dynamic Retard Pedal.................................................. 93 Throttle/Accelerator Pedal............................................ 94 GRADE/SPEED RETARD CHART.................................................. 94 OVERHEAD PANEL AND DISPLAYS............................................... 96 Radio Speakers........................................................ 96 Warning Alarm Buzzer.................................................. 96 Cab Radio............................................................. 96 Warning Light Dimmer Control.......................................... 96 Status/Warning Indicator Light Panel.................................. 96 Air Cleaner Vacuum Gauges............................................. 96 Windshield Wipers..................................................... 96 CENTER CONSOLE............................................................ 97 Directional Control Lever............................................. 97 Override/Fault Reset Switch........................................... 98 Engine Stop Switch.................................................... 98 L.H. Window Control Switch............................................ 98 R.H. Window Control Switch............................................ 98 Hoist Control Lever................................................... 98 Raising The Dump Body................................................. 98 Lowering The Dump Body................................................ 98 Retard Speed Control (RSC) Adjust Dial................................ 99 Retard Speed Control (RSC) Switch..................................... 99 Data Store Button.....................................................100 VHMS Snapshot In Progress Light.......................................100 Link Energized Light..................................................100 Service Engine Light..................................................100 DIAGNOSTIC PORTS......................................................100 VHMS Diagnostic Port..................................................100 Interface Module (IM) Diagnostic Port.................................100 Payload Meter Diagnostic Port.........................................100 Truck Control Interface (TCI) Diagnostic Port.........................100 Propulsion System Controller (PSC) Diagnostic Port....................100 Engine Diagnostic Port (CENSE)........................................100 Engine Diagnostic Port (QUANTUM)......................................100 OPERATOR’S SEAT...........................................................101 Adjustment............................................................101 HEATER / AIR CONDITIONER CONTROLS.........................................102 Fan Speed Control Knob................................................102 Temperature Control Knob..............................................102 Air Flow Directional Knob.............................................102 Heater/Air Conditioner Vents..........................................102 INSTRUMENT PANEL..........................................................103 Key Switch............................................................105 Starting..............................................................105 Rotating Beacon Light Switch (Optional)...............................105 Heated Mirror Switch (Optional).......................................105 Rest Switch...........................................................105 Wheel Brake Lock Control..............................................106 Hazard Warning Lights.................................................106 Cab/Air Conditioner Vents.............................................106 Engine Oil Pressure Gauge.............................................106 Right Turn Signal Indicator...........................................106 Tachometer............................................................106 High Beam Indicator...................................................107 Speedometer/Payload Meter Display.....................................107 Left Turn Signal Indicator............................................107 Water Temperature Gauge...............................................107 Lamp Test Switch......................................................107 Light Switch..........................................................107 Ladder Light Switch...................................................107 Manual Backup Switch..................................................108 Fog Lights (Optional).................................................108 Payload Meter Switch..................................................108 Panel Light Dimmer....................................................108 Hydraulic Oil Temperature Gauge.......................................108 Hourmeter.............................................................109 Fuel Level Gauge......................................................109 OVERHEAD STATUS / WARNING INDICATORS......................................110 Status / Warning Indicator Light Symbols..............................111 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...................................117 Operation.............................................................117 Interface Module......................................................118 Basic Precautions.....................................................118 CIRCUIT BREAKERS..........................................................121 LUBRICATION AND SERVICE.......................................................123 830E SERVICE CAPACITIES...................................................123 HYDRAULIC TANK SERVICE....................................................123 Adding Oil............................................................123 WHEEL MOTOR SERVICE.......................................................124 COOLANT LEVEL CHECK.......................................................124 RADIATOR FILLING PROCEDURE................................................124 RESERVE ENGINE OIL SYSTEM (Optional)......................................124 Reserve Oil Tank Filling Procedure (Remote fill)......................125 LUBRICATION CHART.........................................................126 10 HOUR (DAILY) INSPECTION................................................127 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................130 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................131 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................132 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................136 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................138 2500 HOUR MAINTENANCE CHECKS..............................................139 5000 HOUR MAINTENANCE CHECKS..............................................139 10,000 HOUR MAINTENANCE CHECKS............................................140 AUTOMATIC LUBRICATION SYSTEM..................................................141 GENERAL DESCRIPTION.......................................................141 SYSTEM COMPONENTS.........................................................143 Filter................................................................143 Hydraulic Motor and Pump..............................................143 Grease Reservoir......................................................143 Pressure Reducing Valve...............................................143 Flow Control Valve....................................................143 Solenoid Valve........................................................143 Vent Valve............................................................143 Lubrication Cycle Timer...............................................143 Over Pressure Cut Off Switch..........................................143 Grease Pressure Failure Switch........................................143 Injectors.............................................................143 Relief Valve (unloader valve).........................................143 SYSTEM OPERATION..........................................................144 Normal Operation......................................................144 GENERAL INSTRUCTIONS......................................................145 Lubricant Required For System.........................................145 System Priming........................................................145 Filter Assembly.......................................................145 LUBRICANT PUMP............................................................146 Pump Housing Oil Level................................................146 Pump Pressure Control.................................................146 INJECTORS (SL-1 Series “H”))..............................................147 Injector Specifications...............................................147 Injector Adjustment...................................................147 INJECTOR OPERATION....................................................148 PREVENTIVE MAINTENANCE PROCEDURES.........................................149 Daily Lubrication System Inspection...................................149 250 Hour Inspection...................................................149 1000 Hour Inspection..................................................149 SYSTEM CHECKOUT...........................................................150 Lubrication Controller Check..........................................150 Lubrication Controller Components.....................................150 Lubrication Controller Adjustment.....................................150 SYSTEM TROUBLESHOOTING CHART..............................................152 MAJOR COMPONENT DESCRIPTION...................................................155 PAYLOAD METER III™............................................................159 INDEX.....................................................................159 Introduction..............................................................161 Data Summary..........................................................161 Data Gathering........................................................161 COMPONENT DESCRIPTION.....................................................162 System Diagram........................................................162 Suspension Pressure Sensors...........................................162 Inclinometer..........................................................162 Operator Display......................................................162 Operator Switch.......................................................163 Speed Input...........................................................163 Body-Up Switch........................................................163 Brake Lock Switch.....................................................163 Payload Meter.........................................................163 Communications Ports..................................................163 Key Switch Input......................................................164 Payload Meter Power...................................................164 Load Lights...........................................................164 Wiring and Termination................................................165 TCI Outputs...........................................................165 OPERATOR’S DISPLAY AND SWITCH.............................................166 Reading the Speedometer...............................................166 Reading the Load Display..............................................166 Using the Operator ID.................................................166 Using the Load and Ton Counter........................................166 Total Ton Counter.....................................................166 Total Load Counter....................................................167 Clearing the Counters.................................................167 Viewing Live Sensor Data..............................................167 Other Display Messages................................................167 PAYLOAD OPERATION & CALCULATION...........................................168 Haul Cycle States.....................................................168 Haul Cycle Description................................................168 Load Calculation......................................................169 Carry Back............................................................169 Measurement Accuracy..................................................169 SOURCES FOR PAYLOAD ERROR.................................................169 Payload Error.........................................................169 Loading Conditions....................................................170 Pressure Sensors......................................................170 Swingloads............................................................170 Speed and Distance....................................................170 HAUL CYCLE DATA...........................................................170 Haul Cycle Data.......................................................171 Haul Cycle Warning Flags..............................................172 Frame Torque Data.....................................................173 Sprung Weight Data....................................................173 Maximum Speed Data....................................................173 Alarm Records.........................................................173 Fault Code Data.......................................................174 PC SOFTWARE OVERVIEW......................................................175 PC Overview...........................................................175 System Configuration..................................................175 Installing the PLMIII Software........................................175 DOWNLOADING DATA..........................................................176 PLM III SYSTEM CONFIGURATION..............................................177 Starting Communications...............................................177 Displayed Payload Units...............................................177 Time Units............................................................177 Connection Menu.......................................................177 Connecting to the Payload Meter.......................................178 Configure the Payload Meter...........................................178 Setting the Date and Time.............................................178 Setting the Truck Type................................................179 Setting the Gauge Display Units.......................................179 Setting the Frame Serial Number.......................................179 Setting the Truck Number..............................................179 Setting the Komatsu Distributor.......................................179 Setting the Komatsu Customer..........................................179 Clean Truck Tare......................................................180 Inclinometer Calibration..............................................180 DATA ANALYSIS.............................................................181 Creating a Query......................................................181 Sorting on Truck Unit Number..........................................181 Sorting on Truck Type.................................................181 Sorting on Date Range.................................................182 Sorting on Time Range.................................................182 Payload Detail Screen.................................................183 Creating Reports......................................................183 Summary - one page report.............................................184 Detailed - multi-page report..........................................184 Creating Graphs.......................................................185 Exporting Data........................................................185 CSV Export............................................................185 Compressed............................................................186 Importing Data........................................................187 Deleting Haul Cycle Records...........................................187 Viewing Alarms........................................................188 Deleting Alarm Records................................................188 AM/FM RADIO / CD PLAYER.......................................................191 OPERATING INSTRUCTIONS....................................................191 GENERAL RADIO RECEIVER FUNCTIONS......................................191 Turning On the Power..............................................191 One-Hour Timer....................................................191 Display...........................................................192 Setting a Default Display.........................................192 Adjusting the Brightness of the Display...........................192 Auxiliary Mode....................................................192 Adjusting the Receiver Settings...................................192 USING THE CLOCK.......................................................193 Setting the Clock.................................................193 USING THE ALARM.......................................................193 Setting the Alarm.................................................193 Turning the Alarm Off.............................................193 Activating Snooze.................................................193 Setting Alarm Volume..............................................193 USING THE RADIO.......................................................194 Finding a Station.................................................194 Setting the Presets...............................................195 SATELLITE RADIO SERVICE (Optional)....................................195 Activating Satellite Radio (Optional).............................195 USING THE WEATHERBAND.................................................196 USING THE COMPACT DISC PLAYER.........................................196 Playing a Compact Disc............................................196 Button Functions..................................................196 PLAYING AN MP3 DISC...................................................197 MP3 Format Compatibility..........................................197 Root Directory....................................................197 Empty Directory or Folder.........................................197 No Folder.........................................................197 File Name Display.................................................197 Pre-Programmed Playlists..........................................198 Playing MP3 Files.................................................198 Button Functions..................................................198 TROUBLESHOOTING.......................................................199
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
