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KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30210 – A30239) KOMATSU 830E-1AC
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- KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- PUBLICATION NUMBER:CEAM020801
- SERIAL NUMBER:A30210 – A30239
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Description
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30210 – A30239) KOMATSU 830E-1AC
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30210 – A30239) KOMATSU 830E-1AC:
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DESCRIPTION:
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30210 – A30239) KOMATSU 830E-1AC
- This manual is written for use by the operator and/or the service technician. It 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 must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions must be understood and followed when operating or repairing the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The Komatsu truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter E, when present, designates an electrical wheel motor drive system. - The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW). GVW is total weight: the empty vehicle weight + the fuel and lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30210 – A30239) KOMATSU 830E-1AC
COVER......................................................................... 1 FOREWORD...................................................................... 5 ALERTS PAGE............................................................... 6 TABLE OF CONTENTS............................................................. 7 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................................................... 36 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 ENGINE START-UP SAFETY PRACTICES.......................................... 63 AFTER ENGINE HAS STARTED.................................................. 64 EMERGENCY STEERING SYSTEM................................................. 65 Operation............................................................. 65 Pre-Operation Testing................................................. 65 Additional Guidelines................................................. 66 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 66 MACHINE OPERATION ON THE HAUL ROAD........................................ 67 STARTING ON A GRADE WITH A LOADED TRUCK................................... 68 PASSING................................................................... 68 LOADING................................................................... 68 DUMPING................................................................... 68 Raising The Dump Body................................................. 68 Lowering The Dump Body................................................ 69 SUDDEN LOSS OF ENGINE POWER............................................... 70 FUEL DEPLETION............................................................ 71 SAFE PARKING PROCEDURES................................................... 71 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 72 DISABLED TRUCK CONNECTORS................................................. 73 GENERAL............................................................... 73 STEERING AND BRAKE SYSTEM............................................. 73 Hookup............................................................ 73 HOIST SYSTEM.......................................................... 74 Hookup............................................................ 74 Dumping Procedure................................................. 74 TOWING.................................................................... 75 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 76 Operation............................................................. 76 LED Monitor Light..................................................... 76 Changing Oil.......................................................... 76 OPERATOR CAB AND CONTROLS..................................................... 77 STEERING WHEEL AND CONTROLS............................................... 78 Horn Button........................................................... 78 Tilt / Telescope Lever................................................ 78 Multi-Function Turn Signal Switch..................................... 78 PEDALS.................................................................... 79 Service Brake Pedal................................................... 79 Dynamic Retarding..................................................... 79 Dynamic Retard Pedal.................................................. 79 Throttle/Accelerator Pedal............................................ 80 GRADE/SPEED RETARD CHART.................................................. 80 OVERHEAD PANEL AND DISPLAYS............................................... 82 Radio Speakers........................................................ 82 Warning Alarm Buzzer.................................................. 82 Cab Radio............................................................. 82 Warning Light Dimmer Control.......................................... 82 Status/Warning Indicator Light Panel.................................. 82 Air Cleaner Vacuum Gauges............................................. 82 Windshield Wipers..................................................... 82 CENTER CONSOLE............................................................ 83 Directional Control Lever............................................. 83 Override/Fault Reset Switch........................................... 84 Engine Stop Switch.................................................... 84 L.H. Window Control Switch............................................ 84 R.H. Window Control Switch............................................ 84 Hoist Control Lever................................................... 84 Raising The Dump Body................................................. 84 Lowering The Dump Body................................................ 84 Retard Speed Control (RSC) Adjust Dial................................ 85 Retard Speed Control (RSC) Switch..................................... 85 Data Store Button..................................................... 86 VHMS Snapshot In Progress Light....................................... 86 Link Energized Light.................................................. 86 Service Engine Light.................................................. 86 DIAGNOSTIC PORTS...................................................... 86 VHMS Diagnostic Port.................................................. 86 Interface Module (IM) Diagnostic Port................................. 86 Payload Meter Diagnostic Port......................................... 86 Truck Control Interface (TCI) Diagnostic Port......................... 86 Propulsion System Controller (PSC) Diagnostic Port.................... 86 Engine Diagnostic Port (CENSE)........................................ 86 Engine Diagnostic Port (QUANTUM)...................................... 86 OPERATOR’S SEAT........................................................... 87 Adjustment............................................................ 87 HEATER / AIR CONDITIONER CONTROLS......................................... 88 Fan Speed Control Knob................................................ 88 Temperature Control Knob.............................................. 88 Air Flow Directional Knob............................................. 88 Heater/Air Conditioner Vents.......................................... 88 INSTRUMENT PANEL.......................................................... 89 Key Switch............................................................ 91 Starting.............................................................. 91 Rotating Beacon Light Switch (Optional)............................... 91 Heated Mirror Switch (Optional)....................................... 91 Rest Switch........................................................... 91 Wheel Brake Lock Control.............................................. 92 Hazard Warning Lights................................................. 92 Cab/Air Conditioner Vents............................................. 92 Engine Oil Pressure Gauge............................................. 92 Right Turn Signal Indicator........................................... 92 Tachometer............................................................ 92 High Beam Indicator................................................... 93 Speedometer/Payload Meter Display..................................... 93 Left Turn Signal Indicator............................................ 93 Water Temperature Gauge............................................... 93 Lamp Test Switch...................................................... 93 Light Switch.......................................................... 93 Ladder Light Switch................................................... 93 Manual Backup Switch.................................................. 94 Fog Lights (Optional)................................................. 94 Payload Meter Switch.................................................. 94 Panel Light Dimmer.................................................... 94 Hydraulic Oil Temperature Gauge....................................... 94 Hourmeter............................................................. 95 Fuel Level Gauge...................................................... 95 OVERHEAD STATUS / WARNING INDICATORS...................................... 96 Status / Warning Indicator Light Symbols.............................. 97 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...................................102 Operation.............................................................102 Interface Module......................................................103 Basic Precautions.....................................................104 CIRCUIT BREAKERS..........................................................107 LUBRICATION AND SERVICE.......................................................109 830E SERVICE CAPACITIES...................................................109 HYDRAULIC TANK SERVICE....................................................109 Adding Oil............................................................109 WHEEL MOTOR SERVICE.......................................................109 COOLANT LEVEL CHECK.......................................................110 RADIATOR FILLING PROCEDURE................................................110 RESERVE ENGINE OIL SYSTEM (Optional)......................................110 Reserve Oil Tank Filling Procedure (Remote fill)......................110 LUBRICATION CHART.........................................................111 10 HOUR (DAILY) INSPECTION................................................112 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................115 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................116 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................117 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................120 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)...................121 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................122 2500 HOUR MAINTENANCE CHECKS..............................................123 5000 HOUR MAINTENANCE CHECKS..............................................123 10,000 HOUR MAINTENANCE CHECKS............................................124 AUTOMATIC LUBRICATION SYSTEM..................................................125 GENERAL DESCRIPTION.......................................................125 SYSTEM COMPONENTS.........................................................127 Filter................................................................127 Hydraulic Motor and Pump..............................................127 Grease Reservoir......................................................127 Pressure Reducing Valve...............................................127 Flow Control Valve....................................................127 Solenoid Valve........................................................127 Vent Valve............................................................127 Lubrication Cycle Timer...............................................127 Pump Cutoff Pressure Switch...........................................127 Grease Pressure Failure Switch........................................127 Pressure Gauge........................................................127 Injectors.............................................................127 SYSTEM OPERATION..........................................................128 Normal Operation......................................................128 GENERAL INSTRUCTIONS......................................................129 Lubricant Required For System.........................................129 System Priming........................................................129 Filter Assembly.......................................................129 LUBRICANT PUMP............................................................130 Pump Housing Oil Level................................................130 Pump Pressure Control.................................................130 Pressure Control Valve Adjustment.....................................130 Flow Control Valve Adjustment.........................................130 INJECTORS (SL-1 Series “H”))..............................................131 Injector Specifications...............................................131 Injector Adjustment...................................................131 PREVENTIVE MAINTENANCE PROCEDURES.........................................133 Daily Lubrication System Inspection...................................133 250 Hour Inspection...................................................133 1000 Hour Inspection..................................................133 SYSTEM CHECKOUT...........................................................134 Lubrication Controller Check..........................................134 Lubrication Controller Operation......................................134 Lubrication Controller Components.....................................134 Lubrication Controller Adjustment.....................................134 SYSTEM TROUBLESHOOTING CHART..............................................136 INJECTOR OPERATION........................................................132 MAJOR COMPONENT DESCRIPTION...................................................139 PAYLOAD METER III™............................................................143 INDEX.....................................................................143 Introduction..............................................................145 Data Summary..........................................................145 Data Gathering........................................................145 COMPONENT DESCRIPTION.....................................................146 System Diagram........................................................146 Suspension Pressure Sensors...........................................146 Inclinometer..........................................................146 Operator Display......................................................146 Operator Switch.......................................................147 Speed Input...........................................................147 Body-Up Switch........................................................147 Brake Lock Switch.....................................................147 Payload Meter.........................................................147 Communications Ports..................................................147 Key Switch Input......................................................148 Payload Meter Power...................................................148 Load Lights...........................................................148 Wiring and Termination................................................149 TCI Outputs...........................................................149 OPERATOR’S DISPLAY AND SWITCH.............................................150 Reading the Speedometer...............................................150 Reading the Load Display..............................................150 Using the Operator ID.................................................150 Using the Load and Ton Counter........................................150 Total Ton Counter.....................................................150 Total Load Counter....................................................151 Clearing the Counters.................................................151 Viewing Live Sensor Data..............................................151 Other Display Messages................................................151 PAYLOAD OPERATION & CALCULATION...........................................152 Haul Cycle States.....................................................152 Haul Cycle Description................................................152 Load Calculation......................................................153 Carry Back............................................................153 Measurement Accuracy..................................................153 SOURCES FOR PAYLOAD ERROR.................................................153 Payload Error.........................................................153 Loading Conditions....................................................154 Pressure Sensors......................................................154 Swingloads............................................................154 Speed and Distance....................................................154 HAUL CYCLE DATA...........................................................154 Haul Cycle Data.......................................................155 Haul Cycle Warning Flags..............................................156 Frame Torque Data.....................................................157 Sprung Weight Data....................................................157 Maximum Speed Data....................................................157 Alarm Records.........................................................157 Fault Code Data.......................................................158 PC SOFTWARE OVERVIEW......................................................159 PC Overview...........................................................159 System Configuration..................................................159 Installing the PLMIII Software........................................159 DOWNLOADING DATA..........................................................160 PLM III SYSTEM CONFIGURATION..............................................161 Starting Communications...............................................161 Displayed Payload Units...............................................161 Time Units............................................................161 Connection Menu.......................................................161 Connecting to the Payload Meter.......................................162 Configure the Payload Meter...........................................162 Setting the Date and Time.............................................162 Setting the Truck Type................................................163 Setting the Gauge Display Units.......................................163 Setting the Frame Serial Number.......................................163 Setting the Truck Number..............................................163 Setting the Komatsu Distributor.......................................163 Setting the Komatsu Customer..........................................163 Clean Truck Tare......................................................164 Inclinometer Calibration..............................................164 DATA ANALYSIS.............................................................165 Creating a Query......................................................165 Sorting on Truck Unit Number..........................................165 Sorting on Truck Type.................................................165 Sorting on Date Range.................................................166 Sorting on Time Range.................................................166 Payload Detail Screen.................................................167 Creating Reports......................................................167 Summary - one page report.............................................168 Detailed - multi-page report..........................................168 Creating Graphs.......................................................169 Exporting Data........................................................169 CSV Export............................................................169 Compressed............................................................170 Importing Data........................................................171 Deleting Haul Cycle Records...........................................171 Viewing Alarms........................................................172 Deleting Alarm Records................................................172 AM/FM RADIO / CD PLAYER.......................................................175 OPERATING INSTRUCTIONS....................................................175 GENERAL RADIO RECEIVER FUNCTIONS..........................................175 Turning On the Power..................................................175 One-Hour Timer........................................................175 Display...............................................................176 Setting a Default Display.............................................176 Adjusting the Brightness of the Display...............................176 Auxiliary Mode........................................................176 Adjusting the Receiver Settings.......................................176 USING THE CLOCK...........................................................177 Setting the Clock.....................................................177 USING THE ALARM...........................................................177 Setting the Alarm.....................................................177 Turning the Alarm Off.................................................177 Activating Snooze.....................................................177 Setting Alarm Volume..................................................177 USING THE RADIO...........................................................178 Finding a Station.....................................................178 Setting the Presets...................................................179 SATELLITE RADIO SERVICE (Optional)........................................179 Activating Satellite Radio (Optional).................................179 USING THE WEATHERBAND.....................................................180 USING THE COMPACT DISC PLAYER.............................................180 Playing a Compact Disc................................................180 Button Functions......................................................180 PLAYING AN MP3 DISC.......................................................181 MP3 Format Compatibility..............................................181 Root Directory........................................................181 Empty Directory or Folder.............................................181 No Folder.............................................................181 File Name Display.....................................................181 Pre-Programmed Playlists..............................................182 Playing MP3 Files.....................................................182 Button Functions......................................................182 TROUBLESHOOTING...........................................................183
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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