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Komatsu 830E Dump Truck Operation & Maintenance Manual CEAM15201 – PDF DOWNLOAD
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Komatsu 830E Dump Truck Operation & Maintenance Manual
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Description
Komatsu 830E Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Language : English
Pages : 156
Downloadable : Yes
File Type : PDF
Size: 2.56 MB
Book Code: CEAM015201
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL CEAM15201 – 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 WARNINGS.......................................................................................... 3 INTRODUCTION...................................................................................... 7 FOREWORD...................................................................................... 7 ALERTS PAGE................................................................................... 8 TRUCK MODEL ILLUSTRATION...................................................................... 16 ABOUT THIS MANUAL............................................................................. 17 TABLE OF CONTENTS................................................................................. 9 STANDARD CHARTS AND TABLES........................................................................ 19 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 VEHICLE HEALTH MONITORING SYSTEM (VHMS)....................................................... 85 Operation................................................................................. 85 Interface Module.......................................................................... 86 Basic Precautions......................................................................... 86 OPERATOR COMFORT.............................................................................. 87 OPERATOR SEAT............................................................................. 87 Adjustment............................................................................ 87 Seat Removal.......................................................................... 87 Seat Installation..................................................................... 88 LUBRICATION AND SERVICE........................................................................... 89 830E SERVICE CAPACITIES....................................................................... 89 HYDRAULIC TANK SERVICE........................................................................ 89 Adding Oil................................................................................ 89 COOLANT LEVEL CHECK........................................................................... 90 RADIATOR FILLING PROCEDURE.................................................................... 90 RESERVE ENGINE OIL SYSTEM (Optional).......................................................... 90 Reserve Oil Tank Filling Procedure (Remote fill).......................................... 90 LUBRICATION CHART............................................................................. 91 10 HOUR (DAILY) INSPECTION.................................................................... 92 10 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................ 92 LED Light Signals:.................................................................... 92 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................... 94 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 95 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 96 500 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................... 98 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS................................................. 99 2500 HOUR MAIN1TENANCE CHECKS.................................................................100 5000 HOUR MAINTENANCE CHECKS..................................................................100 10,000 HOUR MAINTENANCE CHECKS................................................................100 AUTOMATIC LUBRICATION SYSTEM......................................................................101 GENERAL DESCRIPTION...........................................................................101 SYSTEM COMPONENTS.............................................................................103 Filter ...................................................................................103 Hydraulic Motor and Pump .................................................................103 Grease Reservoir .........................................................................103 Pressure Reducing Valve...................................................................103 Flow Control Valve........................................................................103 Solenoid Valve ...........................................................................103 Vent Valve................................................................................103 Lubrication Cycle Timer...................................................................103 Delay Timer...............................................................................103 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]) .................................103 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])...............................103 Pressure Gauge............................................................................103 Injectors.................................................................................103 SYSTEM OPERATION..............................................................................104 Normal Operation:.........................................................................104 Pressure Failure Detection Circuits:......................................................105 INJECTOR OPERATION........................................................................106 System Priming............................................................................107 Filter Assembly...........................................................................107 LUBRICANT PUMP................................................................................108 Pump Housing Oil Level....................................................................108 Pump Pressure Control.....................................................................108 Pressure Control Valve Adjustment.........................................................108 INJECTORS (SL-1 Series “H”))..................................................................109 Injector Specifications...................................................................109 Injector Adjustment.......................................................................109 SYSTEM CHECKOUT...............................................................................110 Lubrication Cycle Timer Check.............................................................110 Lubrication Cycle Timer Adjustment........................................................110 SYSTEM TROUBLESHOOTING CHART..................................................................111 PREVENTATIVE MAINTENANCE PROCEDURES...........................................................113 Daily Lubrication System Inspection.......................................................113 250 Hour Inspection.......................................................................113 1000 Hour Inspection......................................................................113 TRUCK COMPONENT DESCRIPTION.......................................................................115 SPECIFICATIONS................................................................................117 PAYLOAD METER III.................................................................................119 OPERATION SECTION.............................................................................121 Introduction..............................................................................121 Data Summary..............................................................................121 Data Gathering............................................................................121 COMPONENT DESCRIPTION.........................................................................122 System Diagram............................................................................122 Suspension Pressure Sensors...............................................................122 Inclinometer..............................................................................122 Operator Display..........................................................................122 Operator Switch...........................................................................123 Speed Input...............................................................................123 Body-Up Switch............................................................................123 Brake Lock Switch.........................................................................123 Payload Meter.............................................................................123 Communications Ports......................................................................123 Keyswitch Input...........................................................................124 Payload Meter Power.......................................................................124 Load Lights...............................................................................124 Wiring and Termination....................................................................125 TCI Outputs...............................................................................125 OPERATOR’S DISPLAY AND SWITCH.................................................................126 Reading the Speedometer...................................................................126 Reading the Load Display..................................................................126 Using the Operator ID.....................................................................126 Using the Load and Ton Counter............................................................126 Total Ton Counter.........................................................................126 Total Load Counter........................................................................127 Clearing the Counters.....................................................................127 Viewing Live Sensor Data..................................................................127 Other Display Messages....................................................................127 PAYLOAD OPERATION & CALCULATION...............................................................128 Description of Haul Cycle States..........................................................128 Haul Cycle Description....................................................................128 Load Calculation..........................................................................129 Carry Back................................................................................129 Measurement Accuracy......................................................................129 SOURCES FOR PAYLOAD ERROR.....................................................................129 Payload Error.............................................................................129 Loading Conditions........................................................................130 Pressure Sensors..........................................................................130 Swingloads................................................................................130 Speed and Distance........................................................................130 HAUL CYCLE DATA...............................................................................130 Haul Cycle Data...........................................................................131 Haul Cycle Warning Flags..................................................................132 A: Continuous Loading.....................................................................132 B: Loading to Dumping Transition..........................................................132 C: No Final Load..........................................................................132 D: Maneuvering to Dumping Transition......................................................132 E: Average Load or Tare Used..............................................................132 F: Final Zone to Dumping Transition.......................................................132 H: False Body Up..........................................................................132 I: Body Up Signal Failed..................................................................132 J: Speed Sensor Failed....................................................................132 K: New Tare Not Calculated................................................................132 L: Incomplete Haul Cycle..................................................................132 M: Haul Cycle Too Long....................................................................133 N: Sensor Input Error.....................................................................133 Alarm Records.............................................................................133 Frame Torque Data.........................................................................133 Sprung Weight Data........................................................................134 Maximum Speed Data........................................................................134 PC SOFTWARE OVERVIEW..........................................................................134 PC Overview...............................................................................134 System Configuration......................................................................134 Installing the PLMIII Software............................................................134 DOWNLOADING DATA..............................................................................135 PLMIII SYSTEM CONFIGURATION...................................................................136 Starting Communications...................................................................136 Displayed Payload Units...................................................................136 Time Units................................................................................136 Connection Menu...........................................................................136 Connecting to the Payload Meter...........................................................137 Configure the Payload Meter...............................................................137 Setting the Date and Time.................................................................137 Setting the Truck Type....................................................................138 Setting the Gauge Display Units...........................................................138 Setting the Frame Serial Number...........................................................138 Setting the Truck Number..................................................................138 Setting the Komatsu Distributor...........................................................138 Setting the Komatsu Customer..............................................................138 Clean Truck Tare..........................................................................139 Inclinometer Calibration..................................................................139 DATA ANALYSIS.................................................................................140 Sorting on Truck Unit Number..............................................................140 Creating a Query..........................................................................140 Sorting on Truck Type.....................................................................140 Sorting on Date Range.....................................................................141 Sorting on Time Range.....................................................................141 Payload Detail Screen.....................................................................142 Creating Reports..........................................................................142 Summary - one page report.................................................................143 Detailed - multi-page report..............................................................143 Creating Graphs...........................................................................144 Exporting Data............................................................................144 CSV Export................................................................................144 Compressed................................................................................145 To export data in ZIP format:.............................................................146 Importing Data............................................................................146 Deleting Haul Cycle Records...............................................................146 Viewing Alarms............................................................................147 Deleting Alarm Records....................................................................147 RADIO, AM / FM STEREO CASSETTE....................................................................149 SETTING THE TIME..............................................................................149 GENERAL RECEIVER FUNCTIONS....................................................................149 Turning The Power On And Off..............................................................149 Display...................................................................................149 Setting The Default Display...............................................................150 Adjusting Display Brightness..............................................................150 OPERATING THE RADIO...........................................................................150 BAND......................................................................................150 TUNE/SEEK.................................................................................150 Manual Tuning.............................................................................150 SEEK Mode.................................................................................150 SCAN......................................................................................150 AUTO......................................................................................150 ADJUSTING THE RECEIVER SETTINGS...............................................................151 PROGRAMMING PRESET STATIONS...................................................................151 OPERATION OF THE WEATHERBAND (U.S.)...........................................................151 SATELLITE RADIO...............................................................................152 Operating Satellite Radio.................................................................152 Program Type Search (PTY).................................................................152 CASSETTE PLAYER...............................................................................153 Playing A Cassette........................................................................153 Cassette Functions........................................................................153 PROGRAMMABLE EJECT DEFAULT....................................................................153 Bad Tape Detect...........................................................................154 CASSETTE PLAYER CLEANING......................................................................154
IMAGES PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
