Komatsu 830E-5 Dump Truck Operation & Maintenance Manual CEAM032209 – PDF DOWNLOAD

Description

Komatsu 830E-5 Dump Truck Operation & Maintenance Manual CEAM032209 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 830E-5 Dump Truck Operation & Maintenance Manual CEAM032209 – PDF DOWNLOAD

Contents 3
INTRODUCTION 7
Foreword 8
Safety Alert Symbol and Signal Words 9
Basic Machine Introduction 10
Visibility 11
Noise And Vibration 14
Exhaust Gas Regulations 16
Declaration of Conformity 17
Komatsu Machine Operator Privacy Policy 18
Product Information 21
SAFETY 25
Safety Labels 26
Locations of Safety Labels 27
Illustrations of Safety Labels 30
General Precautions Common to Operation and Maintenance 44
Preparations for Safe Operation 44
Fire and Explosion Prevention 45
Precautions When Getting On or Off the Machine 46
Precautions for Cab and Working Around Machine 48
Precautions for Diesel Exhaust Fluid (DEF) 49
Operation Precautions 52
Precautions at Jobsite 52
Precautions in Starting Engine 53
Precautions During Operation 54
Maintenance Precautions 57
Precautions Before Inspection and Maintenance 57
Precautions During Inspection and Maintenance 60
OPERATION 67
Visual Overview of Machine 68
Machine Components – Front And Rear Views 68
Machine Components – Inside Frame View 69
Machine Components – Left Side View 70
Machine Components – Right Side View 71
Exterior Lights 72
Cab Interior View 74
Steering Wheel and Controls 75
Pedals 77
Center Console Controls 78
Instrument Panel Gauges 83
Instrument Panel Indicator Lamps 86
Instrument Panel Switches 92
Heater and Air Conditioner Controls 96
Seat Heater/Ventilation System (HVS) 100
Retractable Ladder Operations 101
Radio Operations 103
AM/FM RADIO / MP3 / USB / iPOD™ / AUX PLAYER 103
USB Connection Port 103
Phone/Bluetooth Button 103
Digital Display 104
DISP (Display) Button 104
SRC/PWR/ESC (Source/Power/Escape) Button 104
Volume Knob/OK Button 104
NEXT Button 104
PREV (Previous) Button 104
Preset Buttons 105
RDM (Random) Button 105
RPT (Repeat) Button 105
Mute/Play/Pause Button 105
Browse Button 105
SCAN/ASCN (Scan/Autoscan) Button 105
Auxiliary Jack Port 106
KomVision 107
KomVision Monitor Panel 108
KomVision Monitor Display 110
KomVision Object Detection 114
Cab Connectors 117
Vehicle Information Display (VID) Panel 118
Digital Display Operations 119
Digital Display Menus 120
KOMTRAX 126
Payload Meter IV 128
Payload Meter IV Communication Module 129
Payload Lights/Scoreboard 129
Haul Cycle 130
Payload Calculations 132
Clean Truck Tare 133
Viewing and Downloading Data 134
Battery Disconnect Switches 137
Ground Level Shutdown Switch 138
Preparations Before Operating the Machine 139
Walk-Around Inspection 139
Zone 1: In Front of Left Front Tire 140
Zone 2: Behind Left Front Tire 141
Zone 3: In Front of Left Rear Tires 141
Zone 4: Rear of Truck 142
Zone 5: In Front of Right Rear Tires 142
Zone 6: Behind Right Front Tire 143
Zone 7: In Front of Right Front Tire 143
Zone 8: Front of Truck 143
Zone 9: Decks and Cab 144
Pre-Shift Brake Tests 145
Emergency Steering Test 148
Adjusting the Mirrors 150
Adjusting the Cab Seat 151
Seat Adjustment Controls, Earlier Models 152
Seat Adjustment Controls, Later Models 156
KomVision Start-Up Inspection 159
Starting the Engine 161
Checks After Starting the Engine 162
Operating the Machine 163
Traveling on a Haul Road 163
Initial Propulsion on a Grade 163
Retarding on a Grade 164
Dynamic Retarding Operation 164
Loading the Dump Body 164
Overload Speed Limit Function 164
Dumping the Load 165
Shutting Down the Machine 167
Disabled Machine Operations 168
Stopping the Machine After Loss of Power 168
Dumping the Load From a Disabled Machine 168
Towing a Disabled Machine 169
Enabling the Steering and Braking Circuits 170
Releasing the Parking Brake 171
Towing Procedure 171
Jump Starting a Disabled Machine 172
Engine Emissions After-Treatment System Operations 174
MAINTENANCE 177
Rules for Maintenance 178
Recommended Fuel, Coolant, and Lubricant 179
Oil Clinic Inspection 180
Remote Fill Service Centers 181
Torque Specifications 182
Maintenance Schedule 189
Wheel Motor Maintenance Intervals 189
Engine Maintenance Intervals 189
Safety Critical Parts 189
Maintenance Schedule Table 190
Maintenance Procedures as Required 192
Replace Engine Air Cleaner Filter Elements 192
Maintain Correct Hydraulic Oil Level 193
Maintain Correct Coolant Level 194
Replace Autolube Filter Element 196
Fuses, Diodes and Relays 196
Maintenance For First 500 Hours 207
Initial 50 Hours Maintenance 207
Initial 100 Hours Maintenance 207
Initial 250 Hours Maintenance 207
Initial 500 Hours Maintenance 207
Every 250 Hours Maintenance 208
Clean Cab External Air Filter 209
Lubricate Pump Driveshaft 209
Collect Wheel Motor Oil Sample 209
Collect Hydraulic Oil Sample 210
Check Automatic Lubrication (Autolube) System 211
Check Retractable Ladder 212
Every 500 Hours Maintenance 213
Clean HVAC Recirculation Air Filter 214
Clean A/C Condenser 214
Check A/C Drain Hose 214
Lubricate Pedals 215
Clean Control Cabinet Interior 215
Check Tie Rod 215
Check Engine Air Intake Piping 216
Check Dump Body Up and Hoist Limit Switches 216
Replace Hydraulic Tank Breather Elements 217
Cooling System Service 217
Fuel System Service 218
Check Automatic Lubrication (Autolube) System Pump Oil Level 220
Every 1000 Hours Maintenance 221
Change Hydraulic Oil 221
Replace Hydraulic Filter Elements 222
Replace DEF System Filters 224
Lubricate Retractable Ladder 224
Check Dump Body Pads 225
Check/Lubricate Hoist Lever 225
Check Cab Seat Suspension 225
Every 2000 Hours Maintenance 226
Change Automatic Lubrication (Autolube) System Pump Oil 226
Every 2500 Hours Maintenance 227
Change Front Wheel Hub Oil 227
Lubricate Electronic Fan Clutch 227
Every 3000 Hours Maintenance 229
Every 5000 Hours Maintenance 230
Check Engine Air Cleaner Vacuator Valves 230
Check Steering Wheel Retaining Nut 231
Every 6500 Hours Maintenance 232
Lubricate Traction Alternator Bearing 232
SPECIFICATION 235
Specifications: 830E-5 236
Index 239

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DESCRIPTION:

Komatsu 830E-5 Dump Truck Operation & Maintenance Manual CEAM032209 – PDF DOWNLOAD

SERIAL NUMBER 830E-5 A50005 and up
ENGINE 16V160

FOREWORD:

• The operation and maintenance manual explains the operation, methods of inspection and maintenance for this
  machine that must be obeyed to use this machine safely. Most accidents are caused by the failure to follow
  fundamental safety rules for the operation and maintenance of machines.
• The precautions in this manual must be followed at all times. Accidents can be prevented by knowing conditions
  ahead of time that may cause a hazard when performing operation and maintenance.
  Komatsu cannot predict every circumstance that might involve a potential hazard when the machine is used.
• Therefore, the safety messages in this manual and on the machine may not include all possible safety
  precautions. If you carry out any operation, inspection or maintenance under conditions not described in this
  manual, understand it is your responsibility to take the necessary precautions to ensure safety. In no event
  should you or others engage in prohibited uses or actions described in this manual.

SAFETY ALERT SYMBOL AND SIGNAL WORDS:

• The precautions and warnings included in this manual as well as the safety signs attached to the machine
  must always be observed. These enable you to use the machine safely and prevent injury to operators, service
  personnel and bystanders.
• Identify important safety messages in the manual and on machine labels with the safety alert symbol
  (Exclamation point in triangle), followed by key signal words.
• The safety alert symbol (Exclamation point in triangle) identifies important safety messages on machines, in
  manuals and elsewhere. When you see this symbol, be alert to the risk of personal injury or death. Follow
  the instructions in the safety message. The following signal words are used to inform you there is a potentially
  hazardous situation that may lead to personal injury or damage to the machine.

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V