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KOMATSU 830E-1AC Dump Truck Operation & Maintenance Manual (SN:A40851 & UP) KOMATSU 830E-1AC – PDF DOWNLOAD
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- KOMATSU 830E-1AC Dump Truck Operation & Maintenance Manual
- SERIAL NUMBER:A40851 & UP
- PUBLICATION NUMBER:CEAM027001
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Description
KOMATSU 830E-1AC Dump Truck Operation & Maintenance Manual (SN:A40851 & UP) KOMATSU 830E-1AC
KOMATSU 830E-1AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A40851 & UP) KOMATSU 830E-1AC – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 830E-1AC Dump Truck Operation & Maintenance Manual (SN:A40851 & UP) 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:A40851 & UP) KOMATSU 830E-1AC
1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 WARNINGS.................................................................... 16 CALIFORNIA PROPOSITION 65 WARNINGS...................................... 16 ALERTS...................................................................... 17 TRUCK MODEL ILLUSTRATION.................................................... 18 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 19 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................................................ 36 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 ROPS Precautions........................................................ 37 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.............................................................. 39 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 41 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 42 Avoid Damage To The Dump Body........................................... 42 Safe Parking Of 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........................................ 44 Backup Lights....................................................... 45 Retard Lights....................................................... 45 Brake Lights........................................................ 45 Backup Alarm........................................................ 45 HID Backup Light.................................................... 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........................................ 49 Precautions With High Pressure Oil.................................. 49 Maintenance Near High Temperatures and High Pressures............... 50 Rotating Fan and Belts.............................................. 50 Waste Materials..................................................... 50 Use of Tie-Off Anchor During Maintenance............................ 50 Handling Tires...................................................... 50 Tire Maintenance.................................................... 51 Storing Tires After Removal......................................... 51 BATTERY HAZARD PREVENTION........................................... 51 Jump Starting With Booster Cables............................... 52 Jump Starting With Receptacles.................................. 53 WHEN REPAIRS ARE NECESSARY.................................................. 54 Observe The Following Precautions....................................... 54 SPECIAL PRECAUTIONS......................................................... 55 Preliminary Procedures Before Welding or Performing Maintenance......... 55 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 55 Before welding on the machine, obey the following guidelines:........... 55 Discharging Control Cabinet Capacitors.................................. 56 4 WARNING AND CAUTIONS.......................................................... 58 GENERAL INFORMATION......................................................... 58 PIN PLATE................................................................... 58 GRADE SPEED CHART........................................................... 59 MACHINE SAFETY.............................................................. 59 KEY SWITCH.................................................................. 61 OIL FILL AND CHECK.......................................................... 61 HIGH PRESSURES.............................................................. 62 BATTERY AND ISOLATION BOX................................................... 65 HIGH VOLTAGE................................................................ 68 WELDING..................................................................... 71 LIFTING POINTS.............................................................. 72 EMERGENCY DUMPING........................................................... 73 AUTOMATIC LUBRICATION FILL.................................................. 73 ROPS/FOPS................................................................... 73 TOWING...................................................................... 74 LUBRICATION CHART........................................................... 74 5 OPERATING INSTRUCTIONS........................................................ 76 PREPARING FOR OPERATION..................................................... 76 Safety Is Thinking Ahead................................................ 76 Walk Around Inspection.................................................. 76 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 81 GENERAL INFORMATION..................................................... 81 LADDER SYSTEM DESCRIPTION............................................... 81 LADDER SYSTEM OPERATION................................................. 81 In-Cab Control Panel.................................................... 82 Ground Level Control Box................................................ 84 Emergency Down Valve.................................................... 84 PRE-SHIFT BRAKE TEST........................................................ 85 OPERATION............................................................... 85 Service Brake Test...................................................... 86 Parking Brake Test...................................................... 86 Retard System Test...................................................... 87 Brake Test Exit Criteria................................................ 87 TRUCK OPERATION............................................................. 88 ENGINE START-UP SAFETY.................................................. 88 After Engine Has Started............................................ 88 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 89 Machine Operation on the Haul Road.................................. 89 Starting on a Grade With a Loaded Truck............................. 90 Retarding on a Grade................................................ 90 Passing............................................................. 91 Loading............................................................. 91 Overload Speed Limit Function....................................... 92 Dumping............................................................. 92 Lowering the Dump Body (When Dumping on Flat Ground)................ 93 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 93 SUDDEN LOSS OF ENGINE POWER............................................. 94 EMERGENCY STEERING SYSTEM............................................... 94 Operation........................................................... 94 Pre-Operation Testing............................................... 95 Additional Guidelines............................................... 95 CAMERA SYSTEM (Optional)................................................ 96 General............................................................. 96 Operation........................................................... 96 Camera Monitor...................................................... 97 Camera Selection.................................................... 97 Auto Backlight Control/Day/Night Settings........................... 97 Contrast Adjustment................................................. 97 Brightness Adjustment............................................... 97 Saturation Adjustment............................................... 97 Single Scan / Return................................................ 97 Minus............................................................... 97 Plus................................................................ 97 Enter............................................................... 97 FUEL DEPLETION.......................................................... 98 SAFE PARKING PROCEDURES................................................. 98 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 98 DISABLED TRUCK CONNECTORS...................................................100 GENERAL INFORMATION.....................................................100 STEERING AND BRAKE SYSTEM...............................................100 Hookup..............................................................100 HOIST SYSTEM............................................................101 Hookup..............................................................101 Dumping Procedure...................................................102 TOWING......................................................................103 SPECIAL WIRING HARNESS..................................................103 TOWING PROCEDURE........................................................103 PAYLOAD METER III SYSTEM....................................................105 GENERAL INFORMATION.....................................................105 Data Summary........................................................105 Data Gathering......................................................105 COMPONENT DESCRIPTION...................................................105 Operator Display....................................................105 Operator Switches...................................................105 Brake Lock Switch...................................................106 Payload Meter Module................................................106 Communications Ports................................................106 Load Lights.........................................................106 OPERATOR’S DISPLAY AND SWITCH...........................................106 Reading the Load Display............................................106 Setting the Operator ID.............................................107 Load and Ton Counter................................................107 Viewing Live Sensor Data............................................107 Other Display Messages..............................................108 HAUL CYCLE WARNING FLAGS................................................108 Haul Cycle Data.....................................................108 Haul Cycle Warning Flags............................................110 PC SOFTWARE OVERVIEW....................................................111 SYSTEM CONFIGURATION....................................................111 Connecting to the Payload Meter.....................................111 Displayed Payload Units.............................................112 Connection Menu.....................................................112 Configure the Payload Meter.........................................112 Setting the Date and Time...........................................112 Setting the Truck Type and Serial Number............................113 Setting the Gauge Display Units.....................................113 Setting the Carryback Alarm Threshold...............................113 Setting the Truck Number............................................114 Setting the Komatsu Distributor.....................................114 Setting the Komatsu Customer........................................114 Clean Truck Tare Calibration........................................114 Inclinometer Calibration............................................115 DOWNLOADING PAYLOAD DATA................................................115 UPLOADING DATA..........................................................116 DATA ANALYSIS...........................................................117 Creating a Query....................................................117 Payload Detail Screen...............................................118 Creating Reports....................................................118 Creating Graphs.....................................................118 Exporting Data......................................................119 Importing Data......................................................119 Deleting Haul Cycle Records.........................................119 Viewing Alarms......................................................120 Deleting Alarm Records..............................................120 Patent Acknowledgment...............................................120 AUTOMATIC LUBRICATION SYSTEM................................................121 GENERAL INFORMATION.....................................................121 COMPONENT DESCRIPTION...................................................121 Filter..............................................................122 Hydraulic Motor and Pump............................................122 Grease Reservoir....................................................122 Pressure Reducing Valve.............................................122 Flow Control Valve..................................................122 Solenoid Valve......................................................123 Vent Valve..........................................................123 Interface Module....................................................123 Pressure Cut Off Switch.............................................123 Injectors...........................................................124 Grease Pressure Failure Switch......................................125 Relief Valve (unloader valve).......................................125 SYSTEM OPERATION........................................................125 Filling The Reservoir...............................................125 Priming The Automatic Lubrication System............................126 PREVENTIVE MAINTENANCE PROCEDURES.......................................126 Daily Lubrication System Inspection.................................126 250 Hour Inspection.................................................127 1000 Hour Inspection................................................127 SYSTEM CHECKOUT.........................................................127 General Checks......................................................127 Lubrication Cycle Operation.........................................128 RESERVE ENGINE OIL SYSTEM...................................................129 Operation...............................................................129 Changing Oil............................................................129 6 OPERATOR CAB AND CONTROLS.....................................................132 CAB INTERIOR................................................................132 STEERING WHEEL AND CONTROLS.................................................133 Horn Button.............................................................133 Tilt / Telescope Lever..................................................133 Multi-Function Turn Signal Switch.......................................133 Turn Signal Operation...................................................133 High Beam Headlight Operation...........................................133 Windshield Wiper Operation..............................................133 PEDALS......................................................................134 SERVICE BRAKE PEDAL.....................................................134 DYNAMIC RETARD PEDAL....................................................134 Dynamic Retarding.......................................................134 ACCELERATOR PEDAL.......................................................134 OVERHEAD PANEL AND DISPLAYS.................................................135 RADIO SPEAKERS..........................................................135 WARNING ALARM BUZZER....................................................135 CAB RADIO...............................................................135 AIR CLEANER VACUUM GAUGES...............................................135 CAMERA MONITOR (OPTIONAL)...............................................135 CENTER CONSOLE..............................................................136 DIRECTIONAL CONTROL LEVER...............................................136 OVERRIDE/FAULT RESET SWITCH.............................................136 ENGINE STOP SWITCH......................................................136 WINDOW CONTROL SWITCHES.................................................137 HOIST CONTROL LEVER.....................................................137 Raising The Dump Body...................................................137 Lowering The Dump Body..................................................137 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................137 RETARD SPEED CONTROL (RSC) SWITCH.......................................138 DATA STORE BUTTON.......................................................138 12V AUXILIARY POWER OUTLETS.............................................138 FIRE SUPPRESSION CONTROL OUTLET.........................................138 COMMUNICATION RADIO OUTLET..............................................138 DIAGNOSTIC PORTS............................................................139 KOMTRAX Plus ...........................................................139 INTERFACE MODULE (IM)...................................................139 PAYLOAD METER...........................................................139 DRIVE SYSTEM OR MODULAR MINING..........................................139 DRIVE SYSTEM CONTROLLER (DSC)...........................................139 ENGINE (CENSE)..........................................................139 ENGINE (QUANTUM)........................................................139 OPERATOR SEAT (Standard)....................................................140 SEAT BELTS..............................................................140 ADJUSTMENT..............................................................140 PASSENGER SEAT (Standard)...................................................142 SEAT BELTS..............................................................142 ADJUSTMENT..............................................................142 OPERATOR SEAT (Optional)....................................................143 SEAT BELTS..............................................................143 ADJUSTMENT..............................................................143 PASSENGER SEAT (Optional)...................................................144 SEAT BELTS..............................................................144 ADJUSTMENT..............................................................144 HEATER / AIR CONDITIONER CONTROLS...........................................145 Fan Speed Control Knob..................................................145 Temperature Control Knob................................................145 Air Flow Directional Knob...............................................145 Heater/Air Conditioner Vents............................................145 INSTRUMENT PANEL ...........................................................146 CONTROL SYMBOLS.........................................................146 Cab/Air Conditioner Vents...............................................147 Status Indicator Light Panel............................................147 Hydraulic Oil Temperature Gauge.........................................147 Coolant Temperature Gauge...............................................147 Speedometer/Digital Display.............................................147 Fuel Level Gauge........................................................147 Drive System Temperature Gauge..........................................148 Hazard Warning Light Switch.............................................148 Pre-Shift Brake Test Switch.............................................148 Wheel Brake Lock Control Switch.........................................148 Rest Switch.............................................................148 Engine Warm Up..........................................................149 Heated Mirror Switch (Optional).........................................149 Rotating Beacon Light Switch (Optional).................................149 Camera System (Optional)................................................149 Key Switch..............................................................149 Warning Light...........................................................150 Digital Display Contrast Buttons........................................150 Turn Signal Indicators..................................................150 Panel Light Dimmer......................................................150 Mode Switches...........................................................150 Fog Light Swich.........................................................150 Backup Light Switch.....................................................150 Ladder Light Switch.....................................................150 Headlight/Panel Illumination Light Switch...............................150 STATUS INDICATOR LIGHT PANEL................................................152 STATUS INDICATOR LIGHT SYMBOLS..........................................152 Body Up.............................................................152 Parking Brake.......................................................152 Propel System Not Ready.............................................152 No Propel...........................................................153 Engine Warm Up......................................................153 Engine Shutdown Delay...............................................153 Not used............................................................153 Wheel Brake Lock....................................................153 Traction Control....................................................153 Repair Monitor......................................................153 Retractable Ladder Down.............................................153 Snapshot In Progress................................................153 Pantograph Energized................................................153 Pantograph Up.......................................................154 Service Brake.......................................................154 Dynamic Retarding...................................................154 No DC Link Voltage..................................................154 DIGITAL DISPLAY OPERATION...................................................155 Toggling Through Main Level Screens.....................................155 Toggling Through Warning Screens........................................156 Entering Payload Meter Data.............................................157 KOMTRAX Plus................................................................158 KOMTRAX Plus OPERATION..................................................158 Basic Precautions...................................................158 Interface Module....................................................159 DOWNLOADING KOMTRAX Plus DATA...........................................160 GENERAL INFORMATION.................................................160 KOMTRAX Plus DOWNLOADING PROCEDURE..................................160 Location of Downloaded Files........................................161 UPLOADING KOMTRAX Plus DATA.............................................161 ORBCOMM.................................................................163 KOMATSU WIRELESS BRIDGE (Optional)......................................163 General Information.................................................163 Communication Setup.................................................164 Switching to the KWB_SETUP Network..................................164 Setting the Computer Subnet Mask and IP Address.....................164 Setting Up the KWB..................................................165 Adding Encryption...................................................165 Final Computer Settings.............................................166 Downloading Data....................................................166 Resetting the KWB...................................................166 FUSES AND CIRCUIT BREAKERS..................................................168 VEHICLE ELECTRICAL CENTER 89............................................168 VEHICLE ELECTRICAL CENTER 90............................................170 VEHICLE ELECTRICAL CENTER 91............................................172 CIRCUIT BREAKERS........................................................174 7 LUBRICATION AND SERVICE.......................................................176 GENERAL INFORMATION.........................................................176 HYDRAULIC SYSTEM SERVICE................................................176 Hydraulic Tank......................................................176 Hydraulic Filters...................................................177 Hydraulic Pump Drive Shaft..........................................177 WHEEL MOTOR SERVICE.....................................................177 COOLANT LEVEL SERVICE...................................................177 Radiator Filling Procedure..........................................178 Coolant Specifications..............................................178 Unacceptable Practices..............................................178 RESERVE ENGINE OIL SERVICE..............................................178 Reserve Oil Tank Filling Procedure (Remote Fill)....................179 Inline Screen.......................................................179 CAB AIR FILTER SERVICE..................................................179 FUEL SYSTEM SERVICE.....................................................180 Fuel Tank Cleaning..................................................180 Fuel Filter Service.................................................180 INTAKE AIR CLEANER SERVICE..............................................181 FRONT WHEEL SERVICE.....................................................182 Oil Sampling........................................................182 FRONT ENGINE MOUNT TRUNION SERVICE......................................182 QUICK FILL SERVICE CENTER...............................................182 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................183 LUBRICATION CHART...........................................................185 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................186 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................188 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................189 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................190 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................192 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................194 EVERY 2500 HOUR MAINTENANCE.................................................195 EVERY 5000 HOUR MAINTENANCE.................................................196 8 SPECIFICATIONS................................................................198 MAJOR COMPONENT DESCRIPTION.................................................198 Truck And Engine........................................................198 Traction Alternator.....................................................198 Main Control Cabinet....................................................198 AC Induction Traction Motorized Wheels..................................198 Suspension..............................................................198 Operator's Cab..........................................................198 Power Steering..........................................................198 Dynamic Retarding Grid..................................................198 Brake System............................................................198 SPECIFICATIONS..............................................................199 Engine..................................................................199 AC Electric Drive System................................................199 Dynamic Retarding.......................................................199 Battery Electric System.................................................199 Service Capacities......................................................199 Hydraulic Systems.......................................................199 Service Brakes..........................................................200 Parking Brake...........................................................200 Steering................................................................200 Standard Dump Body Capacities And Dimensions............................200 Tires...................................................................200 Weight Distribution.....................................................200 Overall Truck Dimensions................................................201 9 RADIO.........................................................................204 RADIO OPERATION.............................................................204 GENERAL RADIO RECEIVER FUNCTIONS........................................204 Turning On the Power....................................................204 One-Hour Timer..........................................................204 Finding a Station.......................................................204 Setting the Presets.....................................................205 Adjusting the Receiver Audio Settings...................................205 Display.................................................................206 Adjusting the Receiver Menu Settings....................................206 Front Auxiliary Mode....................................................206 Rear Auxiliary Mode.....................................................206 CLOCK.......................................................................207 Clock/Alarm Button......................................................207 Setting the Clock.......................................................207 Setting the Alarm.......................................................207 Turning the Alarm Off...................................................208 Activating Snooze.......................................................208 CD PLAYER...................................................................209 Playing a Compact Disc..................................................209 Playing an MP3 DISC.....................................................209 CD Mode Displays........................................................209 Button Functions........................................................209 MP3 PLAYER..................................................................211 Playing MP3 Files.......................................................211 MP3 Mode Displays.......................................................211 Button Functions........................................................211 iPod®.......................................................................213 Playing an iPod®........................................................213 iPod® Mode Displays.....................................................213 Button Functions........................................................213 WEATHERBAND (USA Only)......................................................215 TROUBLESHOOTING.............................................................216 Tips About the Audio System.............................................216 Understanding Radio Reception...........................................216 Care of the Compact Discs...............................................216
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