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Komatsu 830E Dump Truck Operation & Maintenance Manual A30733 & UP – PDF DOWNLOAD
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Komatsu 830E Dump Truck Operation & Maintenance Manual
Book Code: CEAM015001
SERIAL NUMBERS A30733 & UP
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Description
Komatsu 830E Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
Language : English
Pages : 154
Downloadable : Yes
File Type : PDF
Size: 2.54 MB
Book Code: CEAM015001
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL A30733 & UP – PDF DOWNLOAD:
DESCRIPTION:
Komatsu 830E Dump Truck Operation & Maintenance Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information 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 the truck or performing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. 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. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
- All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used.
- Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- A product identification plate is located on the frame in front of the right side front wheel. It 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. 960E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system.
- The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (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 maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW. The result is the allowable payload.
TABLE OF CONTENTS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
MAIN MENU......................................................................................... 0 COVER............................................................................................. 1 INTRODUCTION...................................................................................... 7 FOREWORD...................................................................................... 7 ALERTS PAGE................................................................................... 8 TRUCK MODEL ILLUSTRATION...................................................................... 16 ABOUT THIS MANUAL............................................................................. 17 WARNINGS...................................................................................... 3 STANDARD CHARTS AND TABLES.................................................................... 19 TABLE OF CONTENTS................................................................................. 9 GENERAL SAFETY.................................................................................... 25 Safety Rules.................................................................................. 25 Safety Features............................................................................... 25 Clothing And Personal Items................................................................... 25 Unauthorized Modification..................................................................... 25 Leaving The Operator's Seat................................................................... 26 Mounting And Dismounting...................................................................... 26 Fire Prevention For Fuel And Oil.............................................................. 26 Precautions With High Temperature Fluids...................................................... 27 Asbestos Dust Hazard Prevention............................................................... 27 Prevention Of Injury By Work Equipment........................................................ 27 Fire Extinguisher And First Aid Kit........................................................... 27 Precautions When Using Rops................................................................... 28 Precautions For Attachments................................................................... 28 Precautions For Starting Machine.............................................................. 28 PRECAUTIONS DURING OPERATION.................................................................. 29 Safety Is Thinking Ahead.................................................................. 29 Safety At The Worksite.................................................................... 29 Fire Prevention........................................................................... 29 Preparing For Operation................................................................... 29 Ventilation In Enclosed Areas............................................................. 29 In Operator's Cab - Before Starting The Engine............................................ 30 Mirrors, Windows, And Lights.............................................................. 30 OPERATING THE MACHINE..................................................................... 30 When Starting The Engine.............................................................. 30 Truck Operation - General............................................................. 30 Check When Traveling In Reverse....................................................... 31 Traveling............................................................................. 31 Traveling On Slopes................................................................... 32 Ensure Good Visibility................................................................ 32 Operate Carefully On Snow............................................................. 32 Avoid Damage To Dump Body............................................................. 32 Driving Near High-voltage Cables...................................................... 32 When Dumping.......................................................................... 33 Working On Loose Ground............................................................... 33 When Loading.......................................................................... 33 Parking The Machine................................................................... 33 TOWING.................................................................................... 33 WORKING NEAR BATTERIES.................................................................... 34 Battery Hazard Prevention............................................................. 34 Starting With Booster Cables.......................................................... 34 PRECAUTIONS FOR MAINTENANCE............................................................... 35 BEFORE PERFORMING MAINTENANCE......................................................... 35 Warning Tag....................................................................... 35 Proper Tools...................................................................... 35 Stopping The Engine Before Service................................................ 35 Securing The Dump Body............................................................ 35 DURING MAINTENANCE.................................................................... 36 Personnel......................................................................... 36 Attachments....................................................................... 36 Work Under The Machine............................................................ 36 Keep The Machine Clean............................................................ 36 Rules To Follow When Adding Fuel Or Oil........................................... 36 Radiator Water Level.............................................................. 37 Use Of Lighting................................................................... 37 Precautions With The Battery...................................................... 37 Handling High-pressure Hoses...................................................... 37 Precautions With High Pressure Oil................................................ 37 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 38 Rotating Fan And Belts............................................................ 38 Waste Materials................................................................... 38 TIRES................................................................................. 39 Handling Tires.................................................................... 39 Storing Tires After Removal....................................................... 39 ADDITIONAL JOB SITE RULES................................................................. 40 WHEN REPAIRS ARE NECESSARY................................................................ 41 WARNINGS AND CAUTIONS............................................................................. 43 OPERATING INSTRUCTIONS............................................................................ 51 PREPARING FOR OPERATION....................................................................... 51 Safety Is Thinking Ahead.................................................................. 51 At The Truck - Ground Level Walk Around Inspection........................................ 51 ENGINE START-UP SAFETY PRACTICES.............................................................. 54 AFTER ENGINE HAS STARTED...................................................................... 55 MACHINE OPERATION SAFETY PRECAUTIONS.......................................................... 55 LOADING....................................................................................... 56 HAULING....................................................................................... 56 PASSING....................................................................................... 56 DUMPING....................................................................................... 57 To Raise Body:............................................................................ 57 To Lower Body: When dumping over a berm or into a crusher:................................ 57 To Lower Body: When dumping on flat ground:............................................... 58 TOWING........................................................................................ 58 SUDDEN LOSS OF ENGINE POWER................................................................... 59 SAFE PARKING PROCEDURES....................................................................... 59 ENGINE SHUTDOWN PROCEDURE..................................................................... 59 DELAYED ENGINE SHUTDOWN PROCEDURE............................................................. 60 RESERVE ENGINE OIL SYSTEM (Optional).......................................................... 61 Operation................................................................................. 61 LED Monitor Light......................................................................... 61 Changing Oil.............................................................................. 61 OPERATOR CAB AND CONTROLS......................................................................... 63 STEERING WHEEL AND CONTROLS................................................................... 64 Horn Button............................................................................... 64 Tilt / Telescope Lever.................................................................... 64 Multi-function Turn Signal Switch......................................................... 64 Turn Signal Operation..................................................................... 64 High Beam Headlight Operation............................................................. 64 Windshieldindshield Wiper Operation....................................................... 64 PEDALS........................................................................................ 65 Service Brake Pedal....................................................................... 65 Dynamic Retarder Pedal.................................................................... 65 Optional - Dual Function / Single Pedal................................................... 65 Throttle Pedal............................................................................ 65 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS............................................. 66 Defroster Vent Control Switch............................................................. 66 Heat Vent Control Switch.................................................................. 66 Temperature Control Knob.................................................................. 66 Fan Control Knob.......................................................................... 66 Heater/air Conditioner Selector Switch.................................................... 66 Heater/air Conditioner Vents.............................................................. 66 OVERHEAD PANEL AND DISPLAY.................................................................... 67 Grade/speed Warning Chart................................................................. 67 Radio Speakers............................................................................ 67 Warning Alarm Buzzer...................................................................... 67 Cab Radio................................................................................. 67 Warning Lights Dimmer Control............................................................. 67 Status / Warning Indicator Light Panel.................................................... 67 Windshield Wipers......................................................................... 67 Air Cleaner Vacuum Gauges................................................................. 68 CENTER CONSOLE................................................................................ 68 F-n-r Selector Switch..................................................................... 68 Hoist Control Lever....................................................................... 69 To Raise Body:............................................................................ 69 To Lower Body:............................................................................ 69 Ash Tray.................................................................................. 69 Lighter................................................................................... 69 L.h. Window Control Switch................................................................ 69 R.h. Window Control Switch................................................................ 69 Engine Shutdown Switch.................................................................... 69 Override Switch........................................................................... 70 Retard Speed Control (RSC) Off/on Switch.................................................. 70 Retard Speed Control (RSC) Adjust Dial.................................................... 70 Statex III Propulsion System Diagnostic Connector......................................... 71 Komatsu Engine Quantum Connector.......................................................... 71 Komatsu Engine Cense Connector............................................................ 71 Unused Connector.......................................................................... 71 Modular Mining Port Conector.............................................................. 71 Data Store Button......................................................................... 71 Passenger Seat............................................................................ 71 Service Engine Light (Blue)............................................................... 71 Payload Meter............................................................................. 71 INSTRUMENT PANEL AND INDICATOR LIGHTS......................................................... 72 CONTROL SYMBOLS........................................................................... 72 INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS............................................... 73 Key Switch................................................................................ 74 Starting.................................................................................. 74 Engine Shutdown Switch With Timer Delay (Optional)........................................ 74 Fog Lights (Optional)..................................................................... 75 Ladder Light Switch....................................................................... 75 Manual Backup Switch...................................................................... 75 Panel Illumination Lights................................................................. 75 Cab Air Conditioner / Heater Vents........................................................ 75 Engine Cold Weather Starting Aid (Optional)............................................... 75 Rotating Beacon Light Switch (Optional)................................................... 75 Heated Mirror Switch (Optional)........................................................... 75 Wheel Brake Lock Control.................................................................. 76 Parking Brake Control..................................................................... 76 Tachometer................................................................................ 76 Right Turn Signal Indicator............................................................... 77 High Beam Indicator....................................................................... 77 Left Turn Signal Indicator................................................................ 77 Speedometer / Payload Meter............................................................... 77 Voltmeter................................................................................. 77 Engine Oil Pressure Gauge................................................................. 77 Water Temperature Gauge................................................................... 77 Fuel Gauge................................................................................ 77 Hourmeter................................................................................. 78 Headlight Switch.......................................................................... 78 Panel Light Dimmer........................................................................ 78 Payload Meter Switch...................................................................... 78 INDICATOR LIGHT SYMBOLS................................................................... 80 Hazard Warning Lights................................................................. 84 Lamp Test Switch...................................................................... 84 OPERATOR COMFORT.............................................................................. 85 OPERATOR SEAT............................................................................. 85 Adjustment............................................................................ 85 Seat Removal.......................................................................... 85 Seat Installation..................................................................... 86 LUBRICATION AND SERVICE........................................................................... 87 830E SERVICE CAPACITIES....................................................................... 87 HYDRAULIC TANK SERVICE........................................................................ 87 Adding Oil................................................................................ 87 COOLANT LEVEL CHECK........................................................................... 88 RADIATOR FILLING PROCEDURE.................................................................... 88 RESERVE ENGINE OIL SYSTEM (Optional).......................................................... 88 Reserve Oil Tank Filling Procedure (Remote fill).......................................... 88 LUBRICATION CHART............................................................................. 89 10 HOUR (DAILY) INSPECTION.................................................................... 90 10 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 90 LED Light Signals:.................................................................... 90 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 92 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 93 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 94 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 96 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS................................................. 97 2500 HOUR MAIN1TENANCE CHECKS................................................................. 98 5000 HOUR MAINTENANCE CHECKS.................................................................. 98 10,000 HOUR MAINTENANCE CHECKS................................................................ 98 AUTOMATIC LUBRICATION SYSTEM...................................................................... 99 GENERAL DESCRIPTION........................................................................... 99 SYSTEM COMPONENTS.............................................................................101 Filter ...................................................................................101 Hydraulic Motor and Pump .................................................................101 Grease Reservoir .........................................................................101 Pressure Reducing Valve...................................................................101 Flow Control Valve........................................................................101 Solenoid Valve ...........................................................................101 Vent Valve................................................................................101 Lubrication Cycle Timer...................................................................101 Delay Timer...............................................................................101 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]) .................................101 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])...............................101 Pressure Gauge............................................................................101 Injectors.................................................................................101 SYSTEM OPERATION..............................................................................102 Normal Operation:.........................................................................102 Pressure Failure Detection Circuits:......................................................103 INJECTOR OPERATION........................................................................104 System Priming............................................................................105 Filter Assembly...........................................................................105 LUBRICANT PUMP................................................................................106 Pump Housing Oil Level....................................................................106 Pump Pressure Control.....................................................................106 Pressure Control Valve Adjustment.........................................................106 INJECTORS (SL-1 Series “H”))..................................................................107 Injector Specifications...................................................................107 Injector Adjustment.......................................................................107 SYSTEM CHECKOUT...............................................................................108 Lubrication Cycle Timer Check.............................................................108 Lubrication Cycle Timer Adjustment........................................................108 SYSTEM TROUBLESHOOTING CHART..................................................................109 PREVENTATIVE MAINTENANCE PROCEDURES...........................................................111 Daily Lubrication System Inspection.......................................................111 250 Hour Inspection.......................................................................111 1000 Hour Inspection......................................................................111 TRUCK COMPONENT DESCRIPTION.......................................................................113 SPECIFICATIONS................................................................................115 PAYLOAD METER III.................................................................................117 OPERATION SECTION.............................................................................119 Introduction..............................................................................119 Data Summary..............................................................................119 Data Gathering............................................................................119 COMPONENT DESCRIPTION.........................................................................120 System Diagram............................................................................120 Suspension Pressure Sensors...............................................................120 Inclinometer..............................................................................120 Operator Display..........................................................................120 Operator Switch...........................................................................121 Speed Input...............................................................................121 Body-Up Switch............................................................................121 Brake Lock Switch.........................................................................121 Payload Meter.............................................................................121 Communications Ports......................................................................121 Keyswitch Input...........................................................................122 Payload Meter Power.......................................................................122 Load Lights...............................................................................122 Wiring and Termination....................................................................123 TCI Outputs...............................................................................123 OPERATOR’S DISPLAY AND SWITCH.................................................................124 Reading the Speedometer...................................................................124 Reading the Load Display..................................................................124 Using the Operator ID.....................................................................124 Using the Load and Ton Counter............................................................124 Total Ton Counter.........................................................................124 Total Load Counter........................................................................125 Clearing the Counters.....................................................................125 Viewing Live Sensor Data..................................................................125 Other Display Messages....................................................................125 PAYLOAD OPERATION & CALCULATION...............................................................126 Description of Haul Cycle States..........................................................126 Haul Cycle Description....................................................................126 Load Calculation..........................................................................127 Carry Back................................................................................127 Measurement Accuracy......................................................................127 SOURCES FOR PAYLOAD ERROR.....................................................................127 Payload Error.............................................................................127 Loading Conditions........................................................................128 Pressure Sensors..........................................................................128 Swingloads................................................................................128 Speed and Distance........................................................................128 HAUL CYCLE DATA...............................................................................128 Haul Cycle Data...........................................................................129 Haul Cycle Warning Flags..................................................................130 A: Continuous Loading.....................................................................130 B: Loading to Dumping Transition..........................................................130 C: No Final Load..........................................................................130 D: Maneuvering to Dumping Transition......................................................130 E: Average Load or Tare Used..............................................................130 F: Final Zone to Dumping Transition.......................................................130 H: False Body Up..........................................................................130 I: Body Up Signal Failed..................................................................130 J: Speed Sensor Failed....................................................................130 K: New Tare Not Calculated................................................................130 L: Incomplete Haul Cycle..................................................................130 M: Haul Cycle Too Long....................................................................131 N: Sensor Input Error.....................................................................131 Alarm Records.............................................................................131 Frame Torque Data.........................................................................131 Sprung Weight Data........................................................................132 Maximum Speed Data........................................................................132 PC SOFTWARE OVERVIEW..........................................................................132 PC Overview...............................................................................132 System Configuration......................................................................132 Installing the PLMIII Software............................................................132 DOWNLOADING DATA..............................................................................133 PLMIII SYSTEM CONFIGURATION...................................................................134 Starting Communications...................................................................134 Displayed Payload Units...................................................................134 Time Units................................................................................134 Connection Menu...........................................................................134 Connecting to the Payload Meter...........................................................135 Configure the Payload Meter...............................................................135 Setting the Date and Time.................................................................135 Setting the Truck Type....................................................................136 Setting the Gauge Display Units...........................................................136 Setting the Frame Serial Number...........................................................136 Setting the Truck Number..................................................................136 Setting the Komatsu Distributor...........................................................136 Setting the Komatsu Customer..............................................................136 Clean Truck Tare..........................................................................137 Inclinometer Calibration..................................................................137 DATA ANALYSIS.................................................................................138 Sorting on Truck Unit Number..............................................................138 Creating a Query..........................................................................138 Sorting on Truck Type.....................................................................138 Sorting on Date Range.....................................................................139 Sorting on Time Range.....................................................................139 Payload Detail Screen.....................................................................140 Creating Reports..........................................................................140 Summary - one page report.................................................................141 Detailed - multi-page report..............................................................141 Creating Graphs...........................................................................142 Exporting Data............................................................................142 CSV Export................................................................................142 Compressed................................................................................143 To export data in ZIP format:.............................................................144 Importing Data............................................................................144 Deleting Haul Cycle Records...............................................................144 Viewing Alarms............................................................................145 Deleting Alarm Records....................................................................145 RADIO, AM / FM STEREO CASSETTE....................................................................147 SETTING THE TIME..............................................................................147 GENERAL RECEIVER FUNCTIONS....................................................................147 Turning The Power On And Off..............................................................147 Display...................................................................................147 Setting The Default Display...............................................................148 Adjusting Display Brightness..............................................................148 OPERATING THE RADIO...........................................................................148 BAND......................................................................................148 TUNE/SEEK.................................................................................148 Manual Tuning.............................................................................148 SEEK Mode.................................................................................148 SCAN......................................................................................148 AUTO......................................................................................148 ADJUSTING THE RECEIVER SETTINGS...............................................................149 PROGRAMMING PRESET STATIONS...................................................................149 OPERATION OF THE WEATHERBAND (U.S.)...........................................................149 SATELLITE RADIO...............................................................................150 Operating Satellite Radio.................................................................150 Program Type Search (PTY).................................................................150 CASSETTE PLAYER...............................................................................151 Playing A Cassette........................................................................151 Cassette Functions........................................................................151 PROGRAMMABLE EJECT DEFAULT....................................................................151 Bad Tape Detect...........................................................................152 CASSETTE PLAYER CLEANING......................................................................152
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