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KOMATSU 830E-1AC DUMP TRUCK Operation & Maintenance Manual (SN:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT) – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT
- PUBLICATION NUMBER:CEAM025001
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Description
KOMATSU 830E-1AC DUMP TRUCK Operation & Maintenance Manual (SN:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT)
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 830E-1AC DUMP TRUCK Operation & Maintenance Manual (SN:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT)
- 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 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 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 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:A30589 & UP U.S.A. EPA TIER 4 COMPLIANT)
COVER ........................................................................ 0 FOREWORD...................................................................... 5 ALERTS PAGE................................................................... 6 TABLE OF CONTENTS............................................................. 7 TRUCK MODEL ILLUSTRATION...................................................... 19 ABOUT THIS MANUAL............................................................. 20 TORQUE TABLES AND CONVERSION CHARTS........................................... 21 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...... 22 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts..... 22 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws........ 23 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws.................... 24 GENERAL SAFETY................................................................ 31 Safety Rules.............................................................. 31 Truck Safety Features..................................................... 31 Clothing And Personal Items............................................... 31 Unauthorized Modification................................................. 31 Leaving The Operator’s Seat............................................... 31 Mounting And Dismounting.................................................. 32 Fire Extinguishers And First Aid Kits..................................... 32 Precautions For High Temperature Fluids................................... 32 Asbestos Dust Hazard Prevention........................................... 32 Fire Prevention For Fuel And Oil.......................................... 33 ROPS Precautions.......................................................... 33 Preventing Injury From Work Equipment..................................... 33 Precautions For Optional Attachments...................................... 33 Precautions When Starting The Machine..................................... 33 PRECAUTIONS FOR TRUCK OPERATION........................................... 34 Safety Is Thinking Ahead.............................................. 34 Safety At The Worksite................................................ 34 Fire Prevention....................................................... 34 Preparing For Operation............................................... 34 Ventilation For Enclosed Areas........................................ 34 Mirrors, Windows, And Lights.......................................... 35 In The Operator’s Cab - Before Starting The Engine.................... 35 Seat Belts............................................................ 35 OPERATING THE MACHINE..................................................... 35 Starting The Engine................................................... 35 Truck Operation - General............................................. 35 Traveling In The Truck................................................ 36 Precautions When Traveling In Reverse................................. 36 Traveling On Slopes................................................... 36 Ensuring Good Visibility.............................................. 37 Operating On Snow..................................................... 37 Avoid Damage To The Dump Body......................................... 37 Driving Near High Voltage Cables...................................... 37 When Loading The Truck................................................ 37 When Dumping.......................................................... 37 Working On Loose Ground............................................... 38 Parking The Machine................................................... 38 TOWING.................................................................... 38 WORKING NEAR BATTERIES.................................................... 39 Jump Starting With Booster Cables..................................... 40 Jump Starting With Receptacles........................................ 40 PRECAUTIONS FOR MAINTENANCE............................................... 41 BEFORE PERFORMING MAINTENANCE......................................... 41 Stopping The Engine Before Service................................ 41 Electrical Systems Isolation...................................... 41 Warning Tag....................................................... 43 Proper Tools...................................................... 43 Securing The Dump Body............................................ 43 DURING MAINTENANCE.................................................... 44 Personnel......................................................... 44 Attachments....................................................... 44 Working Under The Machine......................................... 44 Keeping The Machine Clean......................................... 44 Rules To Follow When Adding Fuel Or Oil........................... 44 Radiator Coolant Level............................................ 44 Use Of Lighting................................................... 45 Precautions With The Battery...................................... 45 Handling High Pressure Hoses...................................... 45 Precautions With High Pressure Oil................................ 45 Maintenance Near High Temperatures And High Pressures............. 45 Rotating Fan And Belts............................................ 45 Waste Materials................................................... 45 TIRES................................................................. 46 Handling Tires.................................................... 46 Tire Maintenance.................................................. 47 Storing Tires After Removal....................................... 47 ADDITIONAL JOB SITE RULES................................................. 48 WHEN REPAIRS ARE NECESSARY................................................ 49 SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK....................... 50 Preliminary Procedures before Welding or Performing Maintenance....... 50 Engine Shutdown Procedure before Welding or Performing Maintenance.... 50 CAPACITOR DISCHARGE SYSTEM................................................ 52 Necessary Tools....................................................... 52 Warnings And Cautions................................................. 53 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE.......................... 54 Preparation....................................................... 54 CAPACITOR CHARGE LIGHTS........................................... 56 FAILURE OF DISCHARGE SYSTEM........................................... 57 Measuring Dc Voltage On Capacitors................................ 57 MANUAL DISCHARGE OF CAPACITORS........................................ 58 SHORT ISOLATED CAPACITOR TERMINALS.................................... 60 WARNINGS AND CAUTIONS......................................................... 63 TRUCK OPERATION............................................................... 77 PREPARING FOR OPERATION................................................... 77 Safety Is Thinking Ahead.............................................. 77 WALK AROUND INSPECTION.................................................... 77 RETRACTABLE LADDER SYSTEM (If equipped)................................... 81 LADDER SYSTEM DESCRIPTION............................................. 81 LADDER SYSTEM OPERATION............................................... 82 Normal Operation.................................................. 82 GENERAL SAFETY........................................................ 82 IN-CAB CONTROL PANEL.................................................. 82 IN-CAB CONTROL PANEL FEATURES......................................... 83 Digital Display Screen............................................ 83 Command Buttons................................................... 83 USING THE IN-CAB CONTROL PANEL........................................ 84 Raising the Ladder................................................ 84 Lowering the Ladder............................................... 85 USING THE GROUND LEVEL CONTROL BOX.................................... 86 Raising the Ladder................................................ 86 Lowering the Ladder............................................... 86 Emergency Operation............................................... 87 ENGINE START-UP SAFETY PRACTICES.......................................... 88 AFTER ENGINE HAS STARTED.................................................. 89 PRE-SHIFT BRAKE CHECK..................................................... 90 Events................................................................ 90 OPERATION............................................................. 90 Description....................................................... 90 Brake Test Exit Criteria.......................................... 91 PERFORMING THE BRAKE TESTS............................................ 91 Setup............................................................. 91 Service Brake Test................................................ 92 Parking Brake Test................................................ 93 Retard System Test:............................................... 93 EMERGENCY STEERING SYSTEM................................................. 94 Operation............................................................. 94 Pre-Operation Testing................................................. 94 Additional Guidelines................................................. 95 CAMERA SYSTEM (Optional).................................................. 96 General............................................................... 96 Operation............................................................. 96 Camera Monitor........................................................ 98 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 99 MACHINE OPERATION ON THE HAUL ROAD........................................ 99 STARTING ON A GRADE WITH A LOADED TRUCK...................................100 PASSING...................................................................100 LOADING...................................................................101 DUMPING...................................................................101 Raising The Dump Body.................................................101 Lowering The Dump Body................................................102 SUDDEN LOSS OF ENGINE POWER...............................................103 FUEL DEPLETION............................................................103 SAFE PARKING PROCEDURES...................................................104 NORMAL ENGINE SHUTDOWN PROCEDURE..........................................104 DISABLED TRUCK CONNECTORS.................................................105 GENERAL...............................................................105 STEERING AND BRAKE SYSTEM.............................................105 Hookup............................................................105 HOIST SYSTEM..........................................................106 Hookup............................................................107 Dumping Procedure.................................................107 TOWING....................................................................108 Special Wiring Harness................................................108 Towing Procedure......................................................108 RESERVE ENGINE OIL SYSTEM (Optional)......................................111 Operation.............................................................111 LED Monitor Light.....................................................111 Changing Oil..........................................................111 OPERATOR CAB AND CONTROLS.....................................................113 STEERING WHEEL AND CONTROLS...............................................114 Horn Button...........................................................114 Tilt / Telescope Lever................................................114 Multi-Function Turn Signal Switch.....................................114 PEDALS....................................................................115 Service Brake Pedal...................................................115 Dynamic Retarding.....................................................115 Dynamic Retard Pedal..................................................115 Throttle/Accelerator Pedal............................................116 GRADE/SPEED RETARD CHART..................................................116 OVERHEAD PANEL AND DISPLAYS...............................................118 Radio Speakers........................................................118 Warning Alarm Buzzer..................................................118 Cab Radio.............................................................118 Warning Light Dimmer Control..........................................118 Status/Warning Indicator Light Panel..................................118 Air Cleaner Vacuum Gauges.............................................118 Windshield Wipers.....................................................118 Camera Monitor (Optional).............................................118 CENTER CONSOLE............................................................119 Directional Control Lever.............................................119 Override/Fault Reset Switch...........................................120 Engine Stop Switch....................................................120 L.H. Window Control Switch............................................120 R.H. Window Control Switch............................................120 Hoist Control Lever...................................................120 Raising The Dump Body.................................................120 Lowering The Dump Body................................................120 Retard Speed Control (RSC) Adjust Dial................................121 Retard Speed Control (RSC) Switch.....................................121 Data Store Button.....................................................122 KOMTRAX Plus Snapshot In Progress Light...............................122 Link Energized Light..................................................122 Service Engine Light..................................................122 DIAGNOSTIC PORTS......................................................122 KOMTRAX Plus Diagnostic Port..........................................122 Interface Module (IM) Diagnostic Port.................................122 Payload Meter Diagnostic Port.........................................122 Truck Control Interface (TCI) Diagnostic Port.........................122 Propulsion System Controller (PSC) Diagnostic Port....................123 Engine Diagnostic Port (CENSE)........................................123 Engine Diagnostic Port (QUANTUM)......................................123 OPERATOR’S SEAT (STANDARD SEAT)...........................................124 Seat Belts............................................................124 Adjustment............................................................124 PASSENGER SEAT (STANDARD SEAT)............................................125 Seat Belts............................................................125 Adjustment............................................................125 OPERATOR’S SEAT (OPTIONAL SEAT)...........................................126 Seat Belts............................................................126 Adjustment............................................................126 PASSENGER SEAT (OPTIONAL SEAT)............................................127 Seat Belts............................................................127 Adjustment............................................................127 HEATER / AIR CONDITIONER CONTROLS.........................................128 Fan Speed Control Knob................................................128 Temperature Control Knob..............................................128 Air Flow Directional Knob.............................................128 Heater/Air Conditioner Vents..........................................128 INSTRUMENT PANEL..........................................................129 Key Switch............................................................131 Starting..............................................................131 Grid Dryer (Optional).................................................131 Camera System (Optional)..............................................131 Rotating Beacon Light Switch (Optional)...............................131 Heated Mirror Switch (Optional).......................................131 Rest Switch...........................................................132 Wheel Brake Lock Control..............................................132 Hazard Warning Lights.................................................132 Cab/Air Conditioner Vents.............................................133 Engine Oil Pressure Gauge.............................................133 Right Turn Signal Indicator...........................................133 Tachometer............................................................133 High Beam Indicator...................................................133 Speedometer/Payload Meter Display.....................................133 Left Turn Signal Indicator............................................133 Water Temperature Gauge...............................................133 Lamp Test Switch......................................................134 Light Switch..........................................................134 Ladder Light Switch...................................................134 Manual Backup Switch..................................................134 Fog Lights (Optional).................................................134 Payload Meter Switch..................................................134 Panel Light Dimmer....................................................134 Hydraulic Oil Temperature Gauge.......................................135 Hourmeter.............................................................135 Fuel Level Gauge......................................................135 OVERHEAD STATUS / WARNING INDICATORS......................................136 Status / Warning Indicator Light Symbols..............................137 REAR AXLE LIGHT BAR.......................................................143 Backup Lights.........................................................143 Retard Lights.........................................................143 Brake Light...........................................................143 Backup Alarm..........................................................143 KOMTRAX PLUS..............................................................144 Operation.............................................................144 Interface Module......................................................146 Basic Precautions.....................................................146 KOMATSU WIRELESS BRIDGE (Optional)........................................147 General Information...................................................147 Communication Setup...................................................147 Switching to the KWB_SETUP Network....................................147 Setting the Computer Subnet Mask and IP Address.......................148 Properties............................................................148 Setting Up the KWB....................................................149 Adding Encryption.....................................................149 Final Computer Settings...............................................149 Data Downloading......................................................150 Resetting the KWB.....................................................150 KWB Lights............................................................150 FUSES AND CIRCUIT BREAKERS................................................151 CIRCUIT BREAKERS..........................................................153 LUBRICATION AND SERVICE.......................................................155 830E SERVICE CAPACITIES...................................................155 HYDRAULIC TANK SERVICE....................................................155 Adding Oil............................................................155 COOLANT LEVEL CHECK.......................................................156 RADIATOR FILLING PROCEDURE................................................156 Coolant Specifications................................................156 Unacceptable Practices................................................156 WHEEL MOTOR SERVICE.......................................................156 RESERVE ENGINE OIL SYSTEM (Optional)......................................157 Reserve Oil Tank Filling Procedure (Remote fill)......................157 Inline Screen.........................................................157 QUICK FILL SERVICE CENTER.................................................158 LUBRICATION CHART.........................................................159 10 HOUR (DAILY) INSPECTION................................................160 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................163 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................164 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................165 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................169 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................171 2500 HOUR MAINTENANCE CHECKS..............................................172 5000 HOUR MAINTENANCE CHECKS..............................................172 10,000 HOUR MAINTENANCE CHECKS............................................173 AUTOMATIC LUBRICATION SYSTEM..................................................175 GENERAL DESCRIPTION.......................................................175 SYSTEM COMPONENTS.........................................................177 Filter................................................................177 Hydraulic Motor and Pump..............................................177 Grease Reservoir......................................................177 Pressure Reducing Valve...............................................177 Flow Control Valve....................................................177 Solenoid Valve........................................................177 Vent Valve............................................................177 Lubrication Cycle Timer...............................................177 Over Pressure Cut Off Switch..........................................177 Grease Pressure Failure Switch........................................177 Injectors.............................................................177 Relief Valve (unloader valve).........................................177 SYSTEM OPERATION..........................................................178 Normal Operation......................................................178 GENERAL INSTRUCTIONS......................................................179 Lubricant Required For System.........................................179 System Priming........................................................179 Filter Assembly.......................................................179 LUBRICANT PUMP............................................................180 Pump Housing Oil Level................................................180 Pump Pressure Control.................................................180 INJECTORS (SL-1 Series “H”))..............................................181 Injector Specifications...............................................181 Injector Adjustment...................................................181 INJECTOR OPERATION........................................................182 PREVENTIVE MAINTENANCE PROCEDURES.........................................183 Daily Lubrication System Inspection...................................183 250 Hour Inspection...................................................183 1000 Hour Inspection..................................................183 SYSTEM CHECKOUT...........................................................184 Lubrication Controller Check..........................................184 Lubrication Controller Components.....................................184 Lubrication Controller Adjustment.....................................184 SYSTEM TROUBLESHOOTING CHART..............................................186 MAJOR COMPONENT DESCRIPTION...................................................189 Truck And Engine..........................................................189 Alternator (GTA-41).......................................................189 AC Induction Traction Motorized Wheels....................................189 Suspension................................................................189 Operator's Cab............................................................189 Power Steering............................................................189 Dynamic Retarding.........................................................189 Brake System..............................................................189 ENGINE....................................................................191 AC ELECTRIC DRIVE SYSTEM..................................................191 DYNAMIC RETARDING.........................................................191 BATTERY ELECTRIC SYSTEM...................................................191 SERVICE CAPACITIES........................................................191 HYDRAULIC SYSTEMS.........................................................191 SERVICE BRAKES............................................................191 DISC PARKING BRAKE........................................................191 STEERING..................................................................191 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS..............................192 TIRES.....................................................................192 WEIGHT DISTRIBUTION.......................................................192 OVERALL TRUCK DIMENSIONS (Empty with Standard Body)...................192 PAYLOAD METER III™............................................................193 INDEX.....................................................................193 Introduction..............................................................195 Data Summary..........................................................195 Data Gathering........................................................195 COMPONENT DESCRIPTION.....................................................196 System Diagram........................................................196 Suspension Pressure Sensors...........................................196 Inclinometer..........................................................196 Operator Display......................................................196 Operator Switch.......................................................197 Speed Input...........................................................197 Body-Up Switch........................................................197 Brake Lock Switch.....................................................197 Payload Meter.........................................................197 Communications Ports..................................................197 Key Switch Input......................................................198 Payload Meter Power...................................................198 Load Lights...........................................................198 Wiring and Termination................................................199 TCI Outputs...........................................................199 OPERATOR’S DISPLAY AND SWITCH.............................................200 Reading the Speedometer...............................................200 Reading the Load Display..............................................200 Using the Operator ID.................................................200 Using the Load and Ton Counter........................................200 Total Ton Counter.....................................................200 Total Load Counter....................................................201 Clearing the Counters.................................................201 Viewing Live Sensor Data..............................................201 Other Display Messages................................................201 PAYLOAD OPERATION & CALCULATION...........................................202 Haul Cycle States.....................................................202 Haul Cycle Description................................................202 Load Calculation......................................................203 Carry Back............................................................203 Measurement Accuracy..................................................203 SOURCES FOR PAYLOAD ERROR.................................................203 Payload Error.........................................................203 Loading Conditions....................................................204 Pressure Sensors......................................................204 Swingloads............................................................204 Speed and Distance....................................................204 HAUL CYCLE DATA...........................................................204 Haul Cycle Data.......................................................205 Haul Cycle Warning Flags..............................................206 Frame Torque Data.....................................................207 Sprung Weight Data....................................................207 Maximum Speed Data....................................................207 Alarm Records.........................................................207 Fault Code Data.......................................................208 PC SOFTWARE OVERVIEW......................................................209 PC Overview...........................................................209 System Configuration..................................................209 Installing the PLMIII Software........................................209 DOWNLOADING DATA..........................................................210 PLM III SYSTEM CONFIGURATION..............................................211 Starting Communications...............................................211 Displayed Payload Units...............................................211 Time Units............................................................211 Connection Menu.......................................................211 Connecting to the Payload Meter.......................................212 Configure the Payload Meter...........................................212 Setting the Date and Time.............................................212 Setting the Truck Type................................................213 Setting the Gauge Display Units.......................................213 Setting the Frame Serial Number.......................................213 Setting the Truck Number..............................................213 Setting the Komatsu Distributor.......................................213 Setting the Komatsu Customer..........................................213 Clean Truck Tare......................................................214 Inclinometer Calibration..............................................214 DATA ANALYSIS.............................................................215 Creating a Query......................................................215 Sorting on Truck Unit Number..........................................215 Sorting on Truck Type.................................................215 Sorting on Date Range.................................................216 Sorting on Time Range.................................................216 Payload Detail Screen.................................................217 Creating Reports......................................................217 Summary - one page report.............................................218 Detailed - multi-page report..........................................218 Creating Graphs.......................................................219 Exporting Data........................................................219 CSV Export............................................................219 Compressed............................................................220 Importing Data........................................................221 Deleting Haul Cycle Records...........................................221 Viewing Alarms........................................................222 Deleting Alarm Records................................................222 AM/FM RADIO...................................................................223 OPERATING INSTRUCTIONS....................................................223 GENERAL RADIO RECEIVER FUNCTIONS......................................223 Turning On the Power..............................................223 One-Hour Timer....................................................223 Adjusting the Volume..............................................224 Display...........................................................224 Radio Mode Displays...............................................224 CD Mode Displays..................................................224 MP3/USB/iPod Mode Displays........................................224 AUX Input Displays................................................225 CLOCK/ALARM Button................................................225 Front Auxiliary Mode..............................................225 Rear Auxiliary Mode...............................................225 Adjusting the Receiver Audio Settings.............................225 Adjusting the Receiver Menu Settings..............................226 USING THE RADIO.......................................................227 Finding a Station.................................................227 Setting the Presets...............................................227 USING THE CLOCK.......................................................228 Setting the Clock.................................................228 USING THE ALARM.......................................................228 Setting the Alarm.................................................228 Turning the Alarm Off.............................................229 Activating Snooze.................................................229 USING THE WEATHERBAND (USA Only)......................................229 USING THE COMPACT DISC PLAYER/USB.....................................230 Playing A Compact Disc............................................230 Button Functions..................................................230 PLAYING AN MP3 DISC/USB...............................................231 Root Directory....................................................231 Empty Directory or Folder.........................................231 No Folder.........................................................231 File Name Display.................................................231 PLAYING MP3 FILES.....................................................231 Button Functions..................................................231 USING AN iPOD®........................................................232 Playing an iPod...................................................232 Button Functions..................................................232 OPERATING TIPS........................................................233 Tips About The Audio System.......................................233 Understanding Radio Reception.....................................233 Care of The Compact Discs.........................................233 TROUBLESHOOTING.......................................................234
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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