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Komatsu 830E 1AC Dump Truck Operation & Maintenance Manual SN A30461 & up Tier II – PDF DOWNLOAD
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Komatsu 830E 1AC Dump Truck Operation & Maintenance Manual
Book Code : CEAM024100
SERIAL NUMBERS A30461 & UP Tier II
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Description
Komatsu 830E 1AC Dump Truck Operation & Maintenance 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.
KOMATSU 830E 1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30461 & UP TIER II – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu 830E 1AC Dump Truck Operation & Maintenance Manual
COVER............................................................................. 1 WARNING........................................................................... 3 NON-OEM PARTS..................................................................... 4 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.................................................................... 27 Safety Rules.................................................................. 27 Truck Safety Features......................................................... 27 Clothing And Personal Items................................................... 27 Unauthorized Modification..................................................... 27 Leaving The Operator’s Seat................................................... 27 Mounting And Dismounting...................................................... 28 Fire Extinguishers And First Aid Kits......................................... 28 Precautions For High Temperature Fluids....................................... 28 Asbestos Dust Hazard Prevention............................................... 28 Fire Prevention For Fuel And Oil.............................................. 29 ROPS Precautions.............................................................. 29 Preventing Injury From Work Equipment......................................... 29 Precautions For Optional Attachments.......................................... 29 Precautions When Starting The Machine......................................... 29 PRECAUTIONS FOR TRUCK OPERATION............................................... 30 Safety Is Thinking Ahead.................................................. 30 Safety At The Worksite.................................................... 30 Fire Prevention........................................................... 30 Preparing For Operation................................................... 30 Ventilation For Enclosed Areas............................................ 30 Mirrors, Windows, And Lights.............................................. 31 In The Operator’s Cab - Before Starting The Engine........................ 31 Seat Belts................................................................ 31 OPERATING THE MACHINE......................................................... 31 Starting The Engine....................................................... 31 Truck Operation - General................................................. 31 Traveling In The Truck.................................................... 32 Precautions When Traveling In Reverse..................................... 32 Traveling On Slopes....................................................... 32 Ensuring Good Visibility.................................................. 33 Operating On Snow......................................................... 33 Avoid Damage To The Dump Body............................................. 33 Driving Near High Voltage Cables.......................................... 33 When Loading The Truck.................................................... 33 When Dumping.............................................................. 33 Working On Loose Ground................................................... 34 Parking The Machine....................................................... 34 TOWING........................................................................ 34 WORKING NEAR BATTERIES........................................................ 35 Jump Starting With Booster Cables......................................... 36 Jump Starting With Receptacles............................................ 36 PRECAUTIONS FOR MAINTENANCE................................................... 37 BEFORE PERFORMING MAINTENANCE............................................. 37 Stopping The Engine Before Service.................................... 37 Electrical Systems Isolation.......................................... 37 Warning Tag........................................................... 39 Proper Tools.......................................................... 39 Securing The Dump Body................................................ 39 DURING MAINTENANCE........................................................ 40 Personnel............................................................. 40 Attachments........................................................... 40 Working Under The Machine............................................. 40 Keeping The Machine Clean............................................. 40 Rules To Follow When Adding Fuel Or Oil............................... 40 Radiator Coolant Level................................................ 40 Use Of Lighting....................................................... 41 Precautions With The Battery.......................................... 41 Handling High Pressure Hoses.......................................... 41 Precautions With High Pressure Oil.................................... 41 Maintenance Near High Temperatures And High Pressures................. 41 Rotating Fan And Belts................................................ 41 Waste Materials....................................................... 41 TIRES..................................................................... 42 Handling Tires........................................................ 42 Tire Maintenance...................................................... 43 Storing Tires After Removal........................................... 43 ADDITIONAL JOB SITE RULES................................................. 44 WHEN REPAIRS ARE NECESSARY................................................ 45 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK....................... 46 Preliminary Procedures before Welding or Performing Maintenance....... 46 Engine Shutdown Procedure before Welding or Performing Maintenance.... 46 WARNINGS AND CAUTIONS............................................................. 49 TRUCK OPERATION................................................................... 63 PREPARING FOR OPERATION....................................................... 63 Safety Is Thinking Ahead.................................................. 63 WALK AROUND INSPECTION........................................................ 63 RETRACTABLE LADDER SYSTEM (If equipped)....................................... 67 LADDER SYSTEM DESCRIPTION................................................. 67 LADDER SYSTEM OPERATION................................................... 68 Normal Operation...................................................... 68 GENERAL SAFETY............................................................ 68 IN-CAB CONTROL PANEL...................................................... 68 IN-CAB CONTROL PANEL FEATURES............................................. 69 Digital Display Screen................................................ 69 Command Buttons....................................................... 69 USING THE IN-CAB CONTROL PANEL............................................ 70 Raising the Ladder.................................................... 70 Lowering the Ladder................................................... 71 USING THE GROUND LEVEL CONTROL BOX........................................ 72 Raising the Ladder.................................................... 72 Lowering the Ladder................................................... 72 Emergency Operation................................................... 73 ENGINE START-UP SAFETY PRACTICES.......................................... 74 AFTER ENGINE HAS STARTED.................................................. 75 PRE-SHIFT BRAKE CHECK (if equipped)........................................... 76 Events.................................................................... 76 OPERATION................................................................. 76 Description........................................................... 76 Brake Test Exit Criteria.............................................. 77 PERFORMING THE BRAKE TESTS................................................ 77 Setup................................................................. 77 Service Brake Test.................................................... 78 Parking Brake Test.................................................... 79 Retard System Test:................................................... 79 EMERGENCY STEERING SYSTEM..................................................... 80 Operation................................................................. 80 Pre-Operation Testing..................................................... 80 Additional Guidelines..................................................... 81 MACHINE OPERATION SAFETY PRECAUTIONS.......................................... 81 MACHINE OPERATION ON THE HAUL ROAD............................................ 82 STARTING ON A GRADE WITH A LOADED TRUCK....................................... 83 PASSING....................................................................... 83 LOADING....................................................................... 83 DUMPING....................................................................... 83 Raising The Dump Body..................................................... 83 Lowering The Dump Body.................................................... 84 SUDDEN LOSS OF ENGINE POWER................................................... 85 FUEL DEPLETION................................................................ 86 SAFE PARKING PROCEDURES....................................................... 86 NORMAL ENGINE SHUTDOWN PROCEDURE.............................................. 87 DISABLED TRUCK CONNECTORS..................................................... 88 GENERAL................................................................... 88 STEERING AND BRAKE SYSTEM................................................. 88 Hookup................................................................ 88 HOIST SYSTEM.............................................................. 89 Hookup................................................................ 89 Dumping Procedure..................................................... 89 TOWING.................................................................... 91 Special Wiring Harness................................................ 91 Towing Procedure...................................................... 91 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 94 Operation............................................................. 94 LED Monitor Light..................................................... 94 Changing Oil.......................................................... 94 OPERATOR CAB AND CONTROLS......................................................... 95 STEERING WHEEL AND CONTROLS................................................... 96 Horn Button............................................................... 96 Tilt / Telescope Lever.................................................... 96 Multi-Function Turn Signal Switch......................................... 96 PEDALS........................................................................ 97 Service Brake Pedal....................................................... 97 Dynamic Retarding......................................................... 97 Dynamic Retard Pedal...................................................... 97 Throttle/Accelerator Pedal................................................ 98 GRADE/SPEED RETARD CHART...................................................... 98 OVERHEAD PANEL AND DISPLAYS...................................................100 Radio Speakers............................................................100 Warning Alarm Buzzer......................................................100 Cab Radio.................................................................100 Warning Light Dimmer Control..............................................100 Status/Warning Indicator Light Panel......................................100 Air Cleaner Vacuum Gauges.................................................100 Windshield Wipers.........................................................100 CENTER CONSOLE................................................................101 Directional Control Lever.................................................101 Override/Fault Reset Switch...............................................102 Engine Stop Switch........................................................102 L.H. Window Control Switch................................................102 R.H. Window Control Switch................................................102 Hoist Control Lever.......................................................102 Raising The Dump Body.....................................................102 Lowering The Dump Body....................................................102 Retard Speed Control (RSC) Adjust Dial....................................103 Retard Speed Control (RSC) Switch.........................................103 Data Store Button.........................................................104 VHMS Snapshot In Progress Light...........................................104 Link Energized Light......................................................104 Service Engine Light......................................................104 DIAGNOSTIC PORTS..........................................................104 VHMS Diagnostic Port......................................................104 Interface Module (IM) Diagnostic Port.....................................104 Payload Meter Diagnostic Port.............................................104 Truck Control Interface (TCI) Diagnostic Port.............................104 Propulsion System Controller (PSC) Diagnostic Port........................104 Engine Diagnostic Port (CENSE)............................................104 Engine Diagnostic Port (QUANTUM)..........................................104 OPERATOR’S SEAT...............................................................105 Seat Belts................................................................105 Adjustment................................................................105 HEATER / AIR CONDITIONER CONTROLS.............................................106 Fan Speed Control Knob....................................................106 Temperature Control Knob..................................................106 Air Flow Directional Knob.................................................106 Heater/Air Conditioner Vents..............................................106 INSTRUMENT PANEL..............................................................107 Key Switch................................................................109 Starting..................................................................109 Rotating Beacon Light Switch (Optional)...................................109 Heated Mirror Switch (Optional)...........................................109 Rest Switch...............................................................109 Wheel Brake Lock Control..................................................110 Hazard Warning Lights.....................................................110 Cab/Air Conditioner Vents.................................................110 Engine Oil Pressure Gauge.................................................110 Right Turn Signal Indicator...............................................110 Tachometer................................................................110 High Beam Indicator.......................................................111 Speedometer/Payload Meter Display.........................................111 Left Turn Signal Indicator................................................111 Water Temperature Gauge...................................................111 Lamp Test Switch..........................................................111 Light Switch..............................................................111 Ladder Light Switch.......................................................111 Manual Backup Switch......................................................112 Fog Lights (Optional).....................................................112 Payload Meter Switch......................................................112 Panel Light Dimmer........................................................112 Hydraulic Oil Temperature Gauge...........................................112 Hourmeter.................................................................113 Fuel Level Gauge..........................................................113 OVERHEAD STATUS / WARNING INDICATORS..........................................114 Status / Warning Indicator Light Symbols..................................115 VEHICLE HEALTH MONITORING SYSTEM (VHMS).......................................121 Operation.................................................................121 Interface Module..........................................................122 Basic Precautions.........................................................122 CIRCUIT BREAKERS..............................................................125 LUBRICATION AND SERVICE...........................................................127 830E SERVICE CAPACITIES.......................................................127 HYDRAULIC TANK SERVICE........................................................127 Adding Oil................................................................127 WHEEL MOTOR SERVICE...........................................................128 COOLANT LEVEL CHECK...........................................................128 RADIATOR FILLING PROCEDURE....................................................128 RESERVE ENGINE OIL SYSTEM (Optional)..........................................128 Reserve Oil Tank Filling Procedure (Remote fill)..........................129 LUBRICATION CHART.............................................................130 10 HOUR (DAILY) INSPECTION....................................................131 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................134 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................135 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................136 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................140 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued).......................141 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.................................142 2500 HOUR MAINTENANCE CHECKS..................................................143 5000 HOUR MAINTENANCE CHECKS..................................................143 5000 HOUR MAINTENANCE CHECKS (Continued)......................................144 10,000 HOUR MAINTENANCE CHECKS................................................144 AUTOMATIC LUBRICATION SYSTEM......................................................145 GENERAL DESCRIPTION...........................................................145 SYSTEM COMPONENTS.............................................................147 Filter....................................................................147 Hydraulic Motor and Pump..................................................147 Grease Reservoir..........................................................147 Pressure Reducing Valve...................................................147 Flow Control Valve........................................................147 Solenoid Valve............................................................147 Vent Valve................................................................147 Lubrication Cycle Timer...................................................147 Over Pressure Cut Off Switch..............................................147 Grease Pressure Failure Switch............................................147 Injectors.................................................................147 Relief Valve (unloader valve).............................................147 SYSTEM OPERATION..............................................................148 Normal Operation..........................................................148 GENERAL INSTRUCTIONS..........................................................149 Lubricant Required For System.............................................149 System Priming............................................................149 Filter Assembly...........................................................149 LUBRICANT PUMP................................................................150 Pump Housing Oil Level....................................................150 Pump Pressure Control.....................................................150 INJECTORS (SL-1 Series “H”))..................................................151 Injector Specifications...................................................151 Injector Adjustment.......................................................151 PREVENTIVE MAINTENANCE PROCEDURES.............................................153 Daily Lubrication System Inspection.......................................153 250 Hour Inspection.......................................................153 1000 Hour Inspection......................................................153 SYSTEM CHECKOUT...............................................................154 Lubrication Controller Check..............................................154 Lubrication Controller Components.........................................154 Lubrication Controller Adjustment.........................................154 SYSTEM TROUBLESHOOTING CHART..................................................156 INJECTOR OPERATION............................................................152 MAJOR COMPONENT DESCRIPTION.......................................................159 PAYLOAD METER III™................................................................163 INDEX.........................................................................163 Introduction..................................................................165 Data Summary..............................................................165 Data Gathering............................................................165 COMPONENT DESCRIPTION.........................................................166 System Diagram............................................................166 Suspension Pressure Sensors...............................................166 Inclinometer..............................................................166 Operator Display..........................................................166 Operator Switch...........................................................167 Speed Input...............................................................167 Body-Up Switch............................................................167 Brake Lock Switch.........................................................167 Payload Meter.............................................................167 Communications Ports......................................................167 Key Switch Input..........................................................168 Payload Meter Power.......................................................168 Load Lights...............................................................168 Wiring and Termination....................................................169 TCI Outputs...............................................................169 OPERATOR’S DISPLAY AND SWITCH.................................................170 Reading the Speedometer...................................................170 Reading the Load Display..................................................170 Using the Operator ID.....................................................170 Using the Load and Ton Counter............................................170 Total Ton Counter.........................................................170 Total Load Counter........................................................171 Clearing the Counters.....................................................171 Viewing Live Sensor Data..................................................171 Other Display Messages....................................................171 PAYLOAD OPERATION & CALCULATION...............................................172 Haul Cycle States.........................................................172 Haul Cycle Description....................................................172 Load Calculation..........................................................173 Carry Back................................................................173 Measurement Accuracy......................................................173 SOURCES FOR PAYLOAD ERROR.....................................................173 Payload Error.............................................................173 Loading Conditions........................................................174 Pressure Sensors..........................................................174 Swingloads................................................................174 Speed and Distance........................................................174 HAUL CYCLE DATA...............................................................174 Haul Cycle Data...........................................................175 Haul Cycle Warning Flags..................................................176 Frame Torque Data.........................................................177 Sprung Weight Data........................................................177 Maximum Speed Data........................................................177 Alarm Records.............................................................177 Fault Code Data...........................................................178 PC SOFTWARE OVERVIEW..........................................................179 PC Overview...............................................................179 System Configuration......................................................179 Installing the PLMIII Software............................................179 DOWNLOADING DATA..............................................................180 PLM III SYSTEM CONFIGURATION..................................................181 Starting Communications...................................................181 Displayed Payload Units...................................................181 Time Units................................................................181 Connection Menu...........................................................181 Connecting to the Payload Meter...........................................182 Configure the Payload Meter...............................................182 Setting the Date and Time.................................................182 Setting the Truck Type....................................................183 Setting the Gauge Display Units...........................................183 Setting the Frame Serial Number...........................................183 Setting the Truck Number..................................................183 Setting the Komatsu Distributor...........................................183 Setting the Komatsu Customer..............................................183 Clean Truck Tare..........................................................184 Inclinometer Calibration..................................................184 DATA ANALYSIS.................................................................185 Creating a Query..........................................................185 Sorting on Truck Unit Number..............................................185 Sorting on Truck Type.....................................................185 Sorting on Date Range.....................................................186 Sorting on Time Range.....................................................186 Payload Detail Screen.....................................................187 Creating Reports..........................................................187 Summary - one page report.................................................188 Detailed - multi-page report..............................................188 Creating Graphs...........................................................189 Exporting Data............................................................189 CSV Export................................................................189 Compressed................................................................190 Importing Data............................................................191 Deleting Haul Cycle Records...............................................191 Viewing Alarms............................................................192 Deleting Alarm Records....................................................192 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER.................................195 OPERATING INSTRUCTIONS........................................................195 GENERAL RADIO RECEIVER FUNCTIONS..........................................195 Turning On the Power..................................................195 One-Hour Timer........................................................195 Adjusting the Volume..................................................196 Display...............................................................196 Radio Mode Displays...................................................196 CD Mode Displays......................................................196 MP3/USB/iPod Mode Displays............................................196 AUX Input Displays....................................................197 CLOCK/ALARM Button....................................................197 Front Auxiliary Mode..................................................197 Rear Auxiliary Mode...................................................197 Adjusting the Receiver Audio Settings.................................197 Adjusting the Receiver Menu Settings..................................198 USING THE RADIO...........................................................199 Finding a Station.....................................................199 Setting the Presets...................................................199 USING THE CLOCK...........................................................200 Setting the Clock.....................................................200 USING THE ALARM...........................................................200 Setting the Alarm.....................................................200 Turning the Alarm Off.................................................201 Activating Snooze.....................................................201 USING THE WEATHERBAND (USA Only)..........................................201 USING THE COMPACT DISC PLAYER/USB.........................................202 Playing A Compact Disc................................................202 Button Functions......................................................202 PLAYING AN MP3 DISC/USB...................................................203 Root Directory........................................................203 Empty Directory or Folder.............................................203 No Folder.............................................................203 File Name Display.....................................................203 PLAYING MP3 FILES.........................................................203 Button Functions......................................................203 USING AN iPOD®............................................................204 Playing an iPod.......................................................204 Button Functions......................................................204 OPERATING TIPS............................................................205 Tips About The Audio System...........................................205 Understanding Radio Reception.........................................205 Care of The Compact Discs.............................................205 TROUBLESHOOTING...........................................................206
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