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KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30339 — A30560) KOMATSU 830E-1AC – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30339 — A30560
- PUBLICATION NUMBER:CEAM022303
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KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30339 — A30560) KOMATSU 830E-1AC
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30339 — A30560) KOMATSU 830E-1AC – PDF DOWNLOAD:
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KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30339 — A30560) KOMATSU 830E-1AC
- This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
- All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E).
- The three numbers represent the basic truck model.
- The letter “M”, when present, designates a Mechanical drive system;
- The letter “E”, when present, designates an Electrical wheel motor drive system.
- The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30339 — A30560) KOMATSU 830E-1AC
1 INTRODUCTION.................................................................. 16 FOREWORD.................................................................... 16 ABOUT THIS MANUAL........................................................... 17 ALERTS...................................................................... 18 TRUCK MODEL ILLUSTRATION.................................................... 19 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 20 2 STANDARD CHARTS AND TABLES.................................................... 22 GENERAL INFORMATION......................................................... 22 EFFECT OF SPECIAL LUBRICANTS............................................ 22 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 22 STANDARD TIGHTENING TORQUES................................................. 23 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 23 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 24 SAE GRADE 9 CAP SCREWS.................................................. 25 T-BOLT CLAMPS........................................................... 25 SPLIT FLANGE CLAMPS..................................................... 26 FLARED TUBE AND HOSE FITTINGS........................................... 26 JIC 37° SWIVEL NUTS..................................................... 27 PIPE THREAD FITTINGS.................................................... 28 O-RING BOSS FITTINGS.................................................... 29 O-RING FACE SEAL FITTINGS............................................... 30 CONVERSION MULTIPLIERS...................................................... 31 METRIC TO ENGLISH....................................................... 31 ENGLISH TO METRIC....................................................... 32 TEMPERATURE CONVERSIONS................................................. 33 3 GENERAL SAFETY................................................................ 36 GENERAL SAFETY.............................................................. 36 Safety Rules............................................................ 36 Truck Safety Features................................................... 36 Clothing And Personal Items............................................. 36 Unauthorized Modification............................................... 36 Leaving The Operator’S Seat............................................. 36 Mounting And Dismounting................................................ 37 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 Rops Precautions........................................................ 38 Preventing Injury From Work Equipment................................... 38 Precautions For Optional Attachments.................................... 38 Precautions When Starting The Machine................................... 38 PRECAUTIONS FOR TRUCK OPERATION............................................. 39 Safety Is Thinking Ahead................................................ 39 Safety At The Worksite.................................................. 39 Preparing For Operation................................................. 39 Ventilation For Enclosed Areas.......................................... 39 Mirrors, Windows, And Lights............................................ 39 Before Starting The Engine.............................................. 39 Seat Belts.............................................................. 40 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 42 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 43 Avoid Damage To The Dump Body........................................... 43 Parking The Machine..................................................... 43 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING....................................................... 44 Fog Lights.......................................................... 44 Headlights.......................................................... 44 Brake Light......................................................... 44 Retard Light........................................................ 44 Clearance/Turn Signal Lights........................................ 45 Backup Lights....................................................... 45 Retard Lights....................................................... 45 Brake Lights........................................................ 45 Backup Alarm........................................................ 45 PRECAUTIONS FOR MAINTENANCE................................................. 46 BEFORE PERFORMING MAINTENANCE........................................... 46 Electrical System Isolation......................................... 46 Securing The Dump Body.............................................. 47 DURING MAINTENANCE...................................................... 48 Warning Tag......................................................... 48 Proper Tools........................................................ 48 Attachments......................................................... 48 Working Under The Machine........................................... 48 Keeping The Machine Clean........................................... 49 Adding Fuel Or Oil To The Machine................................... 49 Radiator Coolant Level.............................................. 49 Use Of Lighting..................................................... 49 Handling High Pressure Hoses........................................ 50 Precautions With High Pressure Oil.................................. 50 Maintenance Near High Temperatures and High Pressures............... 50 Rotating Fan And Belts.............................................. 50 Waste Materials..................................................... 50 Use of Tie-Off Anchor During Maintenance............................ 50 Battery Hazard Prevention........................................... 51 Jump Starting With Booster Cables................................... 51 Jump Starting With Receptacles...................................... 52 Handling Tires...................................................... 53 Tire Maintenance.................................................... 53 Storing Tires After Removal......................................... 53 WHEN REPAIRS ARE NECESSARY.................................................. 55 Observe The Following Precautions....................................... 55 SPECIAL PRECAUTIONS......................................................... 56 Preliminary Procedures Before Welding or Performing Maintenance......... 56 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 56 Discharging Control Cabinet Capacitors.................................. 57 4 WARNING AND CAUTIONS.......................................................... 60 GENERAL INFORMATION......................................................... 60 PIN PLATE................................................................... 60 GRADE SPEED CHART........................................................... 61 MACHINE SAFETY.............................................................. 61 KEY SWITCH.................................................................. 63 OIL FILL AND CHECK.......................................................... 64 HIGH PRESSURES.............................................................. 65 BATTERY AND ISOLATION BOX................................................... 67 HIGH VOLTAGE................................................................ 70 WELDING..................................................................... 72 LIFTING POINTS.............................................................. 73 EMERGENCY DUMPING........................................................... 74 AUTOMATIC LUBRICATION FILL.................................................. 75 POISON DANGER............................................................... 75 ROPS/FOPS................................................................... 76 TOWING...................................................................... 76 LUBRICATION CHART........................................................... 76 5 OPERATING INSTRUCTIONS........................................................ 78 PREPARING FOR OPERATION..................................................... 78 Safety Is Thinking Ahead................................................ 78 Walk Around Inspection.................................................. 78 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 83 GENERAL INFORMATION..................................................... 83 LADDER SYSTEM DESCRIPTION............................................... 83 LADDER SYSTEM OPERATION................................................. 83 In-Cab Control Panel.................................................... 84 Ground Level Control Box................................................ 86 Emergency Down Valve.................................................... 87 PRE-SHIFT BRAKE TEST........................................................ 89 OPERATION............................................................... 89 Service Brake Test...................................................... 90 Parking Brake Test...................................................... 91 Retard System Test...................................................... 91 Brake Test Exit Criteria................................................ 92 TRUCK OPERATION............................................................. 93 ENGINE START-UP SAFETY.................................................. 93 After Engine Has Started............................................ 93 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 94 Machine Operation On The Haul Road.................................. 95 Starting On A Grade With A Loaded Truck............................. 95 Retarding On A Grade................................................ 96 Passing............................................................. 97 Loading............................................................. 97 Dumping............................................................. 97 Lowering The Dump Body (When Dumping On Flat Ground)................ 98 Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush.... 98 SUDDEN LOSS OF ENGINE POWER............................................. 99 EMERGENCY STEERING SYSTEM............................................... 99 Operation........................................................... 99 Pre-Operation Testing...............................................100 Additional Guidelines...............................................100 FUEL DEPLETION..........................................................101 SAFE PARKING PROCEDURES.................................................101 NORMAL ENGINE SHUTDOWN PROCEDURE........................................101 DISABLED TRUCK CONNECTORS...................................................103 GENERAL INFORMATION.....................................................103 STEERING AND BRAKE SYSTEM...............................................103 Hookup..............................................................103 HOIST SYSTEM............................................................104 Hookup..............................................................104 Dumping Procedure...................................................104 TOWING......................................................................106 Towing Procedure........................................................106 SPECIAL WIRING HARNESS..................................................107 PAYLOAD METER III SYSTEM....................................................110 GENERAL INFORMATION.....................................................110 Data Summary........................................................110 Data Gathering......................................................110 COMPONENT DESCRIPTION...................................................110 Operator Display....................................................110 Operator Switch.....................................................110 Brake Lock Switch...................................................111 Payload Meter Module................................................111 Communications Ports................................................111 Load Lights.........................................................111 OPERATORS DISPLAY AND SWITCH............................................111 Reading the Load Display............................................111 Setting the Operator ID.............................................112 Load and Ton Counter................................................112 Viewing Live Sensor Data............................................112 Other Display Messages..............................................113 HAUL CYCLE WARNING FLAGS................................................113 Haul Cycle Data.....................................................113 Haul Cycle Warning Flags............................................115 PC SOFTWARE OVERVIEW....................................................116 SYSTEM CONFIGURATION....................................................117 Connecting to the Payload Meter.....................................117 Displayed Payload Units.............................................117 Connection Menu.....................................................117 Configure the Payload Meter.........................................118 Setting the Date and Time...........................................118 Setting the Truck Type and Serial Number............................119 Setting the Gauge Display Units.....................................119 Setting the Carryback Alarm Threshold...............................119 Setting the Truck Number............................................120 Setting the Komatsu Distributor.....................................120 Setting the Komatsu Customer........................................120 Clean Truck Tare Calibration........................................120 Inclinometer Calibration............................................121 DOWNLOADING PAYLOAD DATA................................................121 UPLOADING DATA..........................................................122 DATA ANALYSIS...........................................................123 Creating a Query....................................................123 Payload Detail Screen...............................................124 Creating Reports....................................................124 Creating Graphs.....................................................124 Exporting Data......................................................125 Importing Data......................................................126 Deleting Haul Cycle Records.........................................126 Viewing Alarms......................................................126 Deleting Alarm Records..............................................126 Patent Acknowledment................................................126 AUTOMATIC LUBRICATION SYSTEM................................................127 GENERAL INFORMATION.....................................................127 COMPONENT DESCRIPTION...................................................127 Filter..............................................................128 Hydraulic Motor and Pump............................................128 Grease Reservoir....................................................128 Pressure Reducing Valve.............................................128 Flow Control Valve..................................................129 Solenoid Valve......................................................129 Vent Valve..........................................................129 Lubrication Cycle Timer.............................................129 Pressure Cut Off Switch.............................................129 Injectors...........................................................130 Grease Pressure Failure Switch......................................130 Relief Valve (unloader valve).......................................131 SYSTEM OPERATION........................................................131 Filling The Reservoir...............................................131 Priming The Automatic Lubrication System............................132 PREVENTIVE MAINTENANCE PROCEDURES.......................................132 Daily Lubrication System Inspection.................................132 250 Hour Inspection.................................................133 1000 Hour Inspection................................................133 SYSTEM CHECKOUT.........................................................134 General Checks......................................................134 Lubrication Controller Components...................................134 RESERVE ENGINE OIL SYSTEM (Optional)........................................136 Operation...............................................................136 Changing Oil............................................................136 6 OPERATOR CAB AND CONTROLS.....................................................140 CAB INTERIOR................................................................140 STEERING WHEEL AND CONTROLS.................................................141 Horn Button.............................................................141 Tilt / Telescope Lever..................................................141 Multi-Function Turn Signal Switch.......................................141 Turn Signal Operation...................................................141 High Beam Headlight Operation...........................................141 Windshield Wiper Operation..............................................142 PEDALS......................................................................143 SERVICE BRAKE PEDAL.....................................................143 DYNAMIC RETARD PEDAL....................................................143 Dynamic Retarding.......................................................143 ACCELERATOR PEDAL.......................................................143 OVERHEAD PANEL AND DISPLAYS.................................................145 RADIO SPEAKERS..........................................................145 WARNING ALARM BUZZER....................................................145 CAB RADIO...............................................................145 WARNING LIGHT DIMMER CONTROL............................................145 STATUS/WARNING INDICATOR LIGHT PANEL....................................145 AIR CLEANER VACUUM GAUGES...............................................145 WINDSHIELD WIPERS.......................................................145 CENTER CONSOLE..............................................................146 DIRECTIONAL CONTROL LEVER...............................................146 OVERRIDE/FAULT RESET SWITCH.............................................146 ENGINE STOP SWITCH......................................................147 WINDOW CONTROL SWITCHES.................................................147 HOIST CONTROL LEVER.....................................................147 Raising The Dump Body...................................................147 Lowering The Dump Body..................................................147 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................147 RETARD SPEED CONTROL (RSC) SWITCH.......................................148 DATA STORE BUTTON.......................................................148 KOMTRAX Plus SNAPSHOT IN PROGRESS LIGHT.................................148 LINK ENERGIZED LIGHT....................................................148 SERVICE ENGINE LIGHT....................................................148 DIAGNOSTIC PORTS............................................................149 KOMTRAX Plus ...........................................................149 INTERFACE MODULE (IM)...................................................149 PAYLOAD METER...........................................................149 TRUCK CONTROL INTERFACE (TCI)...........................................149 PROPULSION SYSTEM CONTROLLER (PSC)......................................149 ENGINE (CENSE)..........................................................149 ENGINE (QUANTUM)........................................................149 OPERATOR’S SEAT (Standard)..................................................150 SEAT BELTS..............................................................150 ADJUSTMENT..............................................................150 PASSENGER SEAT (Standard)...................................................152 SEAT BELTS..............................................................152 ADJUSTMENT..............................................................152 HEATER / AIR CONDITIONER CONTROLS...........................................153 Fan Speed Control Knob..................................................153 Temperature Control Knob................................................153 Air Flow Directional Knob...............................................153 Heater/Air Conditioner Vents............................................153 INSTRUMENT PANEL ...........................................................154 CONTROL SYMBOLS.........................................................154 Key Switch..............................................................155 Rotating Beacon Light Switch (Optional).................................156 Heated Mirror Switch (Optional).........................................156 Rest Switch.............................................................156 Wheel Brake Lock Control Switch.........................................156 Hazard Warning Light Switch.............................................157 Cab/Air Conditioner Vents...............................................157 Engine Oil Pressure Gauge...............................................157 Right Turn Signal Indicator.............................................157 Tachometer..............................................................157 High Beam Indicator.....................................................157 Speedometer/Payload Meter Display.......................................157 Left Turn Signal Indicator..............................................157 Water Temperature Gauge.................................................158 Lamp Test Switch........................................................158 Light Switch............................................................158 Ladder Light Switch.....................................................158 Manual Backup Switch....................................................158 Fog Light Swich(Optional)...............................................158 Payload Meter Switch....................................................159 Panel Light Dimmer......................................................159 Hydraulic Oil Temperature Gauge.........................................159 Hourmeter...............................................................159 Fuel Level Gauge........................................................159 OVERHEAD STATUS/WARNING INDICATOR...........................................160 STATUS / WARNING INDICATOR LIGHT SYMBOLS................................161 High Hydraulic Oil Temperature......................................161 Low Steering Pressure...............................................162 Low Accumulator Precharge Pressure..................................162 Low Brake Pressure..................................................163 Low Hydraulic Tank Level............................................163 Automatic Lubrication System Pressure...............................163 Circuit Breaker Tripped.............................................163 Hydraulic Oil Filter Monitor........................................163 Low Fuel............................................................163 Parking Brake.......................................................163 Service Brake.......................................................164 Body Up.............................................................164 Dynamic Retarding...................................................164 Stop Engine.........................................................164 Cranking Motor Failure..............................................165 Manual Backup Lights................................................165 Engine Shutdown Timer...............................................165 Retard Speed Control (RSC) Indicator................................165 Check Engine........................................................165 No Power............................................................165 Propulsion System Warning...........................................166 Propulsion System Temperature.......................................166 System/Component Failure............................................166 Battery Charging System Failure.....................................166 No Propel...........................................................166 Propel System At Rest...............................................166 Propel System Not Ready.............................................167 Reduced Propulsion..................................................167 Retard At Continuous Level..........................................167 Brake Test Light (If Equipped)......................................167 Maintenance Monitor.................................................167 Brake Test Switch (If Equipped).....................................167 KOMTRAX Plus................................................................168 KOMTRAX Plus OPERATION..................................................168 Basic Precautions...................................................168 Interface Module....................................................169 DOWNLOADING KOMTRAX Plus DATA...........................................170 GENERAL INFORMATION.................................................170 KOMTRAX Plus DOWNLOADING PROCEDURE..................................170 Location of Downloaded Files........................................171 UPLOADING KOMTRAX Plus DATA.............................................171 ORBCOMM.................................................................173 KOMATSU WIRELESS BRIDGE (Optional)......................................173 General Information.................................................173 Communication Setup.................................................174 Switching to the KWB_SETUP Network..................................174 Setting the Computer Subnet Mask and IP Address.....................174 Setting Up the KWB..................................................175 Adding Encryption...................................................176 Final Computer Settings.............................................176 Downloading Data....................................................176 Resetting the KWB...................................................177 FUSES AND CIRCUIT BREAKERS..................................................178 FUSE BLOCK #1...........................................................178 FUSE BLOCK #2...........................................................179 FUSE BLOCK #3...........................................................179 FUSE BLOCK #4...........................................................180 FUSE HOLDERS............................................................180 CIRCUIT BREAKERS........................................................180 7 LUBRICATION AND SERVICE.......................................................182 GENERAL INFORMATION.........................................................182 HYDRAULIC SYSTEM SERVICE................................................182 Hydraulic Tank......................................................182 Hydraulic Filters...................................................183 Hydraulic Pump Drive Shaft..........................................183 WHEEL MOTOR SERVICE.....................................................183 COOLANT LEVEL SERVICE...................................................183 Radiator Filling Procedure..........................................184 Coolant Specifications..............................................184 Unacceptable Practices..............................................184 RESERVE ENGINE OIL SERVICE..............................................184 Reserve Oil Tank Filling Procedure (Remote Fill)....................185 CAB AIR FILTER SERVICE..................................................185 FUEL SYSTEM SERVICE.....................................................186 Fuel Tank Cleaning..................................................186 Fuel Filter Service.................................................186 INTAKE AIR CLEANER SERVICE..............................................186 FRONT WHEEL SERVICE.....................................................188 Oil Sampling........................................................188 FRONT ENGINE MOUNT TRUNION SERVICE......................................188 QUICK FILL SERVICE CENTER...............................................188 LUBRICATION CHART...........................................................190 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................191 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................193 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................194 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................195 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................197 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................199 EVERY 2500 HOUR MAINTENANCE.................................................200 EVERY 5000 HOUR MAINTENANCE.................................................201 EVERY 10,000 HOUR MAINTENANCE...............................................202 8 SPECIFICATIONS................................................................204 MAJOR COMPONENT DESCRIPTION.................................................204 Truck And Engine........................................................204 Alternator (GTA-41).....................................................204 AC Induction Traction Motorized Wheels..................................204 Suspension..............................................................204 Operator's Cab..........................................................204 Power Steering..........................................................204 Dynamic Retarding Gird..................................................204 Brake System............................................................204 SPECIFICATIONS..............................................................206 Engine..................................................................206 AC Electric Drive System................................................206 Dynamic Retarding.......................................................206 Battery Electric System.................................................206 Service Capacities......................................................206 Hydraulic Systems.......................................................206 Service Brakes..........................................................206 Parking Brake...........................................................206 Steering................................................................207 Standard Dump Body Capacities And Dimensions............................207 Tires...................................................................207 Weight Distribution.....................................................207 Overall Truck Dimensions................................................207 9 RADIO.........................................................................210 RADIO OPERATION.............................................................210 GENERAL RADIO RECEIVER FUNCTIONS........................................210 Turning On the Power....................................................210 One-Hour Timer..........................................................211 Finding a Station.......................................................211 Setting the Presets.....................................................211 Adjusting the Receiver Audio Settings...................................212 Display.................................................................212 Adjusting the Receiver Menu Settings....................................212 Front Auxiliary Mode....................................................213 Rear Auxiliary Mode.....................................................213 CLOCK.......................................................................214 Clock/Alarm Button......................................................214 Setting the Clock.......................................................214 Setting the Alarm.......................................................214 Turning the Alarm Off...................................................215 Activating Snooze.......................................................215 CD PLAYER...................................................................216 Playing A Compact Disc..................................................216 Playing an MP3 DISC.....................................................216 CD Mode Displays........................................................216 Button Functions........................................................216 MP3 PLAYER..................................................................218 Playing MP3 Files.......................................................218 MP3 Mode Displays.......................................................218 Button Functions........................................................219 iPod®.......................................................................220 Playing an iPod®........................................................220 iPod® Mode Displays.....................................................220 Button Functions........................................................220 WEATHERBAND (USA Only)......................................................222 TROUBLESHOOTING.............................................................223 Tips About The Audio System.............................................223 Understanding Radio Reception...........................................223 Care of The Compact Discs...............................................223
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