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Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual SN A30036 – A30071, A30079 – A30108 – PDF DOWNLOAD
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Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual
Book Code : CEAM018802
SERIAL NUMBERS:
A30036 – A30071,
A30079 – A30108
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Description
Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU 830E-AC DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 178
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 830E-AC DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30036 – A30071, A30079 – A30108 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual
FOREWORD:
- 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 should 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 should 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 G.V.W. (Gross Vehicle Weight) rating.The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter “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.
TABLE OF CONTENTS:
Komatsu 830E-Ac Dump Truck Operation & Maintenance Manual
COVER......................................................................... 1 WARNING....................................................................... 3 NON-OEM PARTS................................................................. 4 FOREWORD...................................................................... 5 ALERTS PAGE................................................................... 6 TABLE OF CONTENTS............................................................. 7 TRUCK MODEL ILLUSTRATION.................................................. 14 KOMATSU MODEL 830E-AC DUMP TRUCK.......................................... 14 ABOUT THIS MANUAL......................................................... 15 STANDARD CHARTS AND TABLES.................................................... 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...... 17 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE).......... 18 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts....... 18 GENERAL SAFETY................................................................ 23 Safety Rules.............................................................. 23 Truck Safety Features..................................................... 23 Clothing And Personal Items............................................... 23 Unauthorized Modification................................................. 23 Leaving The Operator’s Seat............................................... 23 Mounting And Dismounting.................................................. 24 Fire Extinguishers And First Aid Kits..................................... 24 Precautions For High Temperature Fluids................................... 24 Asbestos Dust Hazard Prevention........................................... 24 Fire Prevention For Fuel And Oil.......................................... 25 ROPS Precautions.......................................................... 25 Preventing Injury From Work Equipment..................................... 25 Precautions For Optional Attachments...................................... 25 Precautions When Starting The Machine..................................... 25 PRECAUTIONS FOR TRUCK OPERATION........................................... 26 Safety Is Thinking Ahead.............................................. 26 Safety At The Worksite................................................ 26 Fire Prevention....................................................... 26 Preparing For Operation............................................... 26 Ventilation For Enclosed Areas........................................ 26 Mirrors, Windows, And Lights.......................................... 27 In The Operator’s Cab - Before Starting The Engine.................... 27 Seat Belts............................................................ 27 OPERATING THE MACHINE..................................................... 27 Starting The Engine................................................... 27 Truck Operation - General............................................. 27 Traveling In The Truck................................................ 28 Precautions When Traveling In Reverse................................. 28 Traveling On Slopes................................................... 28 Ensuring Good Visibility.............................................. 29 Operating On Snow..................................................... 29 Avoid Damage To The Dump Body......................................... 29 Driving Near High Voltage Cables...................................... 29 When Loading The Truck................................................ 29 When Dumping.......................................................... 29 Working On Loose Ground............................................... 30 Parking The Machine................................................... 30 TOWING.................................................................... 30 WORKING NEAR BATTERIES.................................................... 31 Jump Starting With Booster Cables..................................... 32 Jump Starting With Receptacles........................................ 32 PRECAUTIONS FOR MAINTENANCE............................................... 33 BEFORE PERFORMING MAINTENANCE......................................... 33 Warning Tag....................................................... 33 Proper Tools...................................................... 33 Securing The Dump Body............................................ 33 DURING MAINTENANCE.................................................... 34 Personnel......................................................... 34 Attachments....................................................... 34 Working Under The Machine......................................... 34 Keeping The Machine Clean......................................... 34 Rules To Follow When Adding Fuel Or Oil........................... 34 Radiator Coolant Level............................................ 34 Use Of Lighting................................................... 34 Precautions With The Battery...................................... 35 Handling High Pressure Hoses...................................... 35 Precautions With High Pressure Oil................................ 35 Maintenance Near High Temperatures And High Pressures............. 35 Rotating Fan And Belts............................................ 35 Waste Materials................................................... 35 TIRES................................................................. 36 Handling Tires.................................................... 36 Tire Maintenance.................................................. 37 Storing Tires After Removal....................................... 37 ADDITIONAL JOB SITE RULES................................................. 38 WHEN REPAIRS ARE NECESSARY................................................ 39 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK........................ 40 Preliminary Procedures before Welding or Performing Maintenance....... 40 Engine Shutdown Procedure before Welding or Performing Maintenance.... 40 WARNINGS AND CAUTIONS......................................................... 43 TRUCK OPERATION............................................................... 55 PREPARING FOR OPERATION................................................... 55 Safety Is Thinking Ahead.............................................. 55 WALK AROUND INSPECTION.................................................... 55 ENGINE START-UP SAFETY PRACTICES.......................................... 59 AFTER ENGINE HAS STARTED.................................................. 60 EMERGENCY STEERING SYSTEM................................................. 61 Operation............................................................. 61 Pre-Operation Testing................................................. 61 Additional Guidelines................................................. 62 MACHINE OPERATION SAFETY PRECAUTIONS...................................... 62 MACHINE OPERATION ON THE HAUL ROAD........................................ 63 STARTING ON A GRADE WITH A LOADED TRUCK................................... 64 PASSING................................................................... 64 LOADING................................................................... 64 DUMPING................................................................... 64 Raising The Dump Body................................................. 64 Lowering The Dump Body................................................ 65 SUDDEN LOSS OF ENGINE POWER............................................... 66 FUEL DEPLETION............................................................ 67 SAFE PARKING PROCEDURES................................................... 67 NORMAL ENGINE SHUTDOWN PROCEDURE.......................................... 68 DELAYED ENGINE SHUTDOWN PROCEDURE......................................... 69 DISABLED TRUCK DUMPING PROCEDURE.......................................... 70 GENERAL............................................................... 70 STEERING AND BRAKE SYSTEM............................................. 70 Hookup............................................................ 70 HOIST SYSTEM.......................................................... 71 Hookup............................................................ 71 Dumping Procedure................................................. 71 TOWING.................................................................... 72 RESERVE ENGINE OIL SYSTEM (Optional)...................................... 73 OPERATOR CAB AND CONTROLS..................................................... 75 STEERING WHEEL AND CONTROLS............................................... 76 Horn Button........................................................... 76 Tilt / Telescope Lever................................................ 76 Multi-Function Turn Signal Switch..................................... 76 PEDALS.................................................................... 77 Service Brake Pedal................................................... 77 Dynamic Retarding..................................................... 77 Dynamic Retard Pedal.................................................. 77 Throttle/Accelerator Pedal............................................ 78 GRADE/SPEED RETARD CHART.................................................. 78 OVERHEAD PANEL AND DISPLAYS............................................... 80 CENTER CONSOLE............................................................ 81 Directional Control Lever............................................. 81 Override/Fault Reset Switch........................................... 82 Engine Stop Switch.................................................... 82 L.H. Window Control Switch............................................ 82 R.H. Window Control Switch............................................ 82 Hoist Control Lever................................................... 82 Raising The Dump Body................................................. 82 Lowering The Dump Body................................................ 82 Retard Speed Control (RSC) Adjust Dial................................ 83 Retard Speed Control (RSC) Switch..................................... 83 Data Store Button..................................................... 84 VHMS Snapshot In Progress Light....................................... 84 Link Energized Light.................................................. 84 Service Engine Light.................................................. 84 DIAGNOSTIC PORTS...................................................... 84 VHMS Diagnostic Port.................................................. 84 Interface Module (IM) Diagnostic Port................................. 84 Payload Meter Diagnostic Port......................................... 84 Truck Control Interface (TCI) Diagnostic Port......................... 84 Propulsion System Controller (PSC) Diagnostic Port.................... 84 Engine Diagnostic Port (CENSE)........................................ 84 Engine Diagnostic Port (QUANTUM)...................................... 84 OPERATOR’S SEAT........................................................... 85 Seat Belts............................................................ 85 Adjustment............................................................ 85 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS......................... 86 Fan Control Knob...................................................... 86 Temperature Control Knob.............................................. 86 Directional Control Knob.............................................. 86 Heater Vents.......................................................... 86 INSTRUMENT PANEL.......................................................... 87 Key Switch............................................................ 89 Starting.............................................................. 89 Engine Stop Switch with Five Minute Idle Timer Delay.................. 89 Rotating Beacon Light Switch (Optional)............................... 90 Heated Mirror Switch (Optional)....................................... 90 Rest Switch........................................................... 90 Wheel Brake Lock Control.............................................. 90 Hazard Warning Lights................................................. 90 Cab/Air Conditioner Vents............................................. 90 Engine Oil Pressure Gauge............................................. 91 Right Turn Signal Indicator........................................... 91 Tachometer............................................................ 91 High Beam Indicator................................................... 91 Speedometer/Payload Meter Display..................................... 91 Left Turn Signal Indicator............................................ 91 Water Temperature Gauge............................................... 91 Lamp Test Switch...................................................... 91 Light Switch.......................................................... 91 Ladder Light Switch................................................... 92 Manual Backup Switch.................................................. 92 Fog Lights (Optional)................................................. 92 Payload Meter Switch.................................................. 92 Panel Light Dimmer.................................................... 92 Hydraulic Oil Temperature Gauge....................................... 93 Hourmeter............................................................. 93 Fuel Level Gauge...................................................... 93 OVERHEAD STATUS / WARNING INDICATORS...................................... 94 Status / Warning Indicator Light Symbols.............................. 95 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...................................100 Operation.............................................................100 Interface Module......................................................101 Basic Precautions.....................................................101 CIRCUIT BREAKERS..........................................................104 LUBRICATION AND SERVICE.......................................................105 830E SERVICE CAPACITIES...................................................105 HYDRAULIC TANK SERVICE....................................................105 Adding Oil............................................................105 WHEEL MOTOR SERVICE.......................................................105 COOLANT LEVEL CHECK.......................................................106 RADIATOR FILLING PROCEDURE................................................106 RESERVE ENGINE OIL SYSTEM (Optional)......................................106 Reserve Oil Tank Filling Procedure (Remote fill)......................106 LUBRICATION CHART.........................................................107 10 HOUR (DAILY) INSPECTION................................................108 50 HOUR LUBRICATION AND MAINTENANCE CHECKS................................111 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................112 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................113 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................116 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)...................117 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.............................118 2500 HOUR MAINTENANCE CHECKS..............................................119 5000 HOUR MAINTENANCE CHECKS..............................................119 10,000 HOUR MAINTENANCE CHECKS............................................120 AUTOMATIC LUBRICATION SYSTEM..................................................121 GENERAL DESCRIPTION.......................................................121 SYSTEM COMPONENTS.........................................................123 Filter................................................................123 Hydraulic Motor and Pump..............................................123 Grease Reservoir......................................................123 Pressure Reducing Valve...............................................123 Pressure Gauge........................................................123 Flow Control Valve....................................................123 Solenoid Valve........................................................123 Vent Valve............................................................123 Lubrication Cycle Timer...............................................123 Over Pressure Cutoff Switch...........................................123 Grease Pressure Failure Switch........................................123 Injectors.............................................................123 Relief Valve (unloader valve).........................................123 SYSTEM OPERATION..........................................................124 GENERAL INSTRUCTIONS......................................................125 Required Lubricant....................................................125 System Priming........................................................125 Filter Assembly.......................................................125 LUBRICANT PUMP............................................................126 Pump Housing Oil Level................................................126 Pump Pressure Control.................................................126 INJECTORS (SL-1 Series “H”)...............................................127 Injector Specifications...............................................127 Injector Adjustment...................................................127 INJECTOR OPERATION........................................................128 PREVENTIVE MAINTENANCE PROCEDURES.........................................129 Daily Lubrication System Inspection...................................129 250 Hour Inspection...................................................129 1000 Hour Inspection..................................................129 SYSTEM CHECKOUT...........................................................130 Lubrication Controller Check..........................................130 Lubrication Controller Operation......................................130 Lubrication Controller Components.....................................130 Lubrication Controller Adjustment.....................................130 SYSTEM TROUBLESHOOTING CHART..............................................132 MAJOR COMPONENT DESCRIPTION...................................................135 PAYLOAD METER III™............................................................139 INDEX.....................................................................139 Introduction..............................................................141 Data Summary..........................................................141 Data Gathering........................................................141 COMPONENT DESCRIPTION.....................................................142 System Diagram........................................................142 Suspension Pressure Sensors...........................................142 Inclinometer..........................................................142 Operator Display......................................................142 Operator Switch.......................................................143 Speed Input...........................................................143 Body-Up Switch........................................................143 Brake Lock Switch.....................................................143 Payload Meter.........................................................143 Communications Ports..................................................143 Key Switch Input......................................................144 Payload Meter Power...................................................144 Load Lights...........................................................144 Wiring and Termination................................................145 TCI Outputs...........................................................145 OPERATOR’S DISPLAY AND SWITCH.............................................146 Reading the Speedometer...............................................146 Reading the Load Display..............................................146 Using the Operator ID.................................................146 Using the Load and Ton Counter........................................146 Total Ton Counter.....................................................146 Total Load Counter....................................................147 Clearing the Counters.................................................147 Viewing Live Sensor Data..............................................147 Other Display Messages................................................147 PAYLOAD OPERATION & CALCULATION...........................................148 Haul Cycle States.....................................................148 Haul Cycle Description................................................148 Load Calculation......................................................149 Carry Back............................................................149 Measurement Accuracy..................................................149 SOURCES FOR PAYLOAD ERROR.................................................149 Payload Error.........................................................149 Loading Conditions....................................................150 Pressure Sensors......................................................150 Swingloads............................................................150 Speed and Distance....................................................150 HAUL CYCLE DATA...........................................................150 Haul Cycle Data.......................................................151 Haul Cycle Warning Flags..............................................152 Frame Torque Data.....................................................153 Sprung Weight Data....................................................153 Maximum Speed Data....................................................153 Alarm Records.........................................................153 Fault Code Data.......................................................154 PC SOFTWARE OVERVIEW......................................................155 PC Overview...........................................................155 System Configuration..................................................155 Installing the PLMIII Software........................................155 DOWNLOADING DATA..........................................................156 PLM III SYSTEM CONFIGURATION..............................................157 Starting Communications...............................................157 Displayed Payload Units...............................................157 Time Units............................................................157 Connection Menu.......................................................157 Connecting to the Payload Meter.......................................158 Configure the Payload Meter...........................................158 Setting the Date and Time.............................................158 Setting the Truck Type................................................159 Setting the Gauge Display Units.......................................159 Setting the Frame Serial Number.......................................159 Setting the Truck Number..............................................159 Setting the Komatsu Distributor.......................................159 Setting the Komatsu Customer..........................................159 Clean Truck Tare......................................................160 Inclinometer Calibration..............................................160 DATA ANALYSIS.............................................................161 Creating a Query......................................................161 Sorting on Truck Unit Number..........................................161 Sorting on Truck Type.................................................161 Sorting on Date Range.................................................162 Sorting on Time Range.................................................162 Payload Detail Screen.................................................163 Creating Reports......................................................163 Summary - one page report.............................................164 Detailed - multi-page report..........................................164 Creating Graphs.......................................................165 Exporting Data........................................................165 CSV Export............................................................165 Compressed............................................................166 Importing Data........................................................167 Deleting Haul Cycle Records...........................................167 Viewing Alarms........................................................168 Deleting Alarm Records................................................168 RADIO / CASSETTE PLAYER.......................................................171 GENERAL RECEIVER FUNCTIONS................................................171 Turning The Power On And Off..........................................171 Display...............................................................171 Setting The Default Display...........................................171 Adjusting Display Brightness..........................................171 SETTING THE TIME..........................................................172 OPERATING THE RADIO.......................................................172 BAND..................................................................172 TUNE/SEEK.............................................................172 Manual Tuning.........................................................172 SEEK Mode.............................................................172 SCAN..................................................................172 AUTO..................................................................172 ADJUSTING THE RECEIVER SETTINGS...........................................173 PROGRAMMING PRESET STATIONS...............................................173 OPERATION OF THE WEATHERBAND (U.S.).......................................173 SATELLITE RADIO...........................................................174 Operating Satellite Radio.............................................174 Program Type Search (PTY).............................................174 CASSETTE PLAYER...........................................................175 Playing A Cassette....................................................175 Cassette Functions....................................................175 Programmable Eject Default............................................175 Bad Tape Detect.......................................................176 Cleaning The Cassette Player..........................................176
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