KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX A30625 Thru A30649) – PDF DOWNLOAD

Description

KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX A30625 Thru A30649)

KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX A30625 THRU A30649) – PDF DOWNLOAD:

Image Preview:

Description:

KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX A30625 Thru A30649)

• 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. 830E). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical wheelmotor drive system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The 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 total maximum Gross Vehicle Weight (GVW) and this means the TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.

Table of Contents:

KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SERIAL SUFFIX A30625 Thru A30649)

MAIN MENU........................................................................................  0
COVER............................................................................................  1
INTRODUCTION.....................................................................................  6
	FOREWARD.....................................................................................  6
	ALERTS PAGE - DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL....  7
	TABLE OF CONTENTS............................................................................  8
	TRUCK MODEL ILLUSTRATION..................................................................... 11
	ABOUT THIS MANUAL............................................................................ 12
	STANDARD CHARTS AND TABLES................................................................... 14
SAFETY........................................................................................... 20
	GENERAL SAFETY............................................................................... 20
	PRECAUTIONS DURING OPERATION................................................................. 24
		OPERATING MACHINE........................................................................ 25
		TOWING................................................................................... 28
		BATTERY.................................................................................. 29
	PRECAUTIONS FOR MAINTENANCE.................................................................. 30
		BEFORE CARRYING OUT MAINTENANCE.......................................................... 30
		DURING MAINTENANCE....................................................................... 31
		TIRES.................................................................................... 34
		ADDITIONAL JOB SITE RULES................................................................ 35
		WHEN REPAIRS ARE NECESSARY............................................................... 36
	WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS.............................................. 38
OPERATION........................................................................................ 44
	OPERATING INSTRUCTIONS....................................................................... 44
		PREPARING FOR OPERATION.................................................................. 44
		SAFETY IS THINKING AHEAD................................................................. 44
		AT THE TRUCK - GROUND LEVEL WALK - AROUND INSPECTION..................................... 44
		WALK - AROUND INSPECTION - ILLUSTRATION.................................................. 45
	ENGINE START-UP SAFETY PRACTICES............................................................. 47
	AFTER ENGINE HAS STARTED..................................................................... 48
	MACHINE OPERATION SAFETY PRECAUTIONS......................................................... 48
	LOADING...................................................................................... 49
	HAULING...................................................................................... 49
	PASSING...................................................................................... 49
	DUMPING...................................................................................... 50
	TOWING....................................................................................... 51
	SAFE PARKING PROCEDURES...................................................................... 52
	ENGINE SHUTDOWN PROCEDURE.................................................................... 52
	DELAYED ENGINE SHUTDOWN PROCEDURE............................................................ 53
	OPERATOR CAB AND CONTROLS.................................................................... 54
	STEERING WHEEL AND CONTROLS.................................................................. 55
	SERVICE BRAKE PEDAL ......................................................................... 56
	THROTTLE PEDAL............................................................................... 56
	HEATER/AIR CONDITIONER VENTS................................................................. 56
	HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS.............................................. 57
	CENTER CONSOLE............................................................................... 59
	OPERATOR SEAT................................................................................ 63
	INSTRUMENT PANEL AND INDICATORS, AND CONTROLS ............................................... 64
		CONTROLS SYMBOLS......................................................................... 64
	INSTRUMENT PANEL (3-6)....................................................................... 64
	PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-28, FIGURE 3-6)................ 66
	OVERHEAD STAUTUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7).................................. 71
	INDICATOR LIGHT SYMBOLS - REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)................ 72
		HAZARD WARNINGS LIGHTS (7)............................................................... 78
		LAMP TEST SWITCH (8)..................................................................... 78
MAINTENANCE...................................................................................... 80
	LUBRICATION AND SERVICE...................................................................... 80
		LUBRICATION CHART........................................................................ 81
		10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS....................................... 82
		50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................... 84
		100 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 85
		250 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 86
		500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 88
		1000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 89
		2500 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 90
		5000 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 91
	LINCOLN AUTOMATIC LUBRICATION SYSTEM......................................................... 92
		GENERAL DESCRIPTION...................................................................... 92
		SYSTEM COMPONENTS........................................................................ 94
			SYSTEM OPERATION..................................................................... 95
			INJECTOR OPERATION................................................................... 97
		GENERAL INSTRUCTIONS..................................................................... 98
			LUBRICANT  REQUIRED.................................................................. 98
			SYSTEM PRIMING....................................................................... 98
			FILTER ASSEMBLY...................................................................... 98
		LUBRICANT PUMP........................................................................... 99
		SYSTEM CHECKOUT..........................................................................101
			24 VDC SOLID STATE TIMER CHECK.......................................................101
		SYSTEM TROUBLESHOOTING CHART.............................................................102
		PREVENTATIVE MAINTENANCE PROCEDURES......................................................105
SPECIFICATIONS...................................................................................106
	MAJOR COMPONENT DESCRIPTION..................................................................106
	SPECIFICATIONS...............................................................................108
OPTIONAL EQUIPMENT...............................................................................110
	PAYLOAD METER II INDEX.......................................................................110
		GENERAL INFORMATION......................................................................112
		LIGHTS, SWITCHES, AND COMPONENTS.........................................................113
		TIPS FOR OPERATION.......................................................................114
		EXTERNAL DISPLAY LIGHTS..................................................................114
		THEORY OF OPERATION......................................................................115
			BASIC DESCRIPTION....................................................................115
			LINKAGE FACTOR.......................................................................115
			BRAKE LOCK...........................................................................116
			SOURCES OF ERROR.....................................................................116
			TYPICAL DATA FROM SERVICE CHECK MODE.................................................116
			EXAMPLE CALCULATION OF PAYLOAD.......................................................117
			CALCULATION OF THE CALIBRATION LOAD..................................................117
		TYPES OF DATA STORED.....................................................................118
			CYCLE DATA...........................................................................118
			ENGINE ON/OFF DATA...................................................................119
			FAULT CODES AND WARNING DATA.........................................................119
			ENGINE OPERATION.....................................................................120
			TOTAL PAYLOAD AND TOTAL NUMBER OF CYLES..............................................120
			OTHER DATA...........................................................................120
		OPERATOR FUNCTIONS.......................................................................121
			USING THE OPERATOR LOAD COUNTER......................................................121
				DESCRIPTION......................................................................121
				VIEWING THE OPERATOR LOAD COUNTER................................................121
				CLEARING THE OPERATOR LOAD COUNTER...............................................121
			DIMMING THE LIGHTS ON THE DISPLAY....................................................121
		INTITIAL SETUP OF PAYLOAD METER..........................................................122
			SWITCH SETTINGS......................................................................122
			CHECKING THE OPERATOR CHECK MODE.....................................................122
			CHECKING THE SERVICE CHECK MODE......................................................123
				SETTING "UP:00"..................................................................123
				SETTING "PL:00"..................................................................123
			CHECKING THE Gt SETTING..............................................................123
			CHECKING THE INCLINOMETER SETTINGS...................................................123
			CALIBRATING A TRUCK..................................................................124
		DISPLAYS AT START-UP.....................................................................125
		SETUP AND MAINTENANCE....................................................................126
			SETTING THE SPEED LIMIT..............................................................126
			SETTING THE OPTION CODE..............................................................126
			SETTING THE MACHINE I.D..............................................................126
			SETTING THE OPERATOR I.D.............................................................127
			SETTING THE TIME AND DATE............................................................127
		DOWNLOAD OF PAYLOAD AND FAULT CODES......................................................127
		DISPLAY OF FAULT CODES...................................................................128
		CHARTS OF ERROR CODES AND OTHER INFORMATION..............................................129
		SERVICE CHECK MODE.......................................................................131
			MONITORING INPUT SIGNALS ............................................................131
			UP FACTOR - PAYLOAD CALCULATION GAIN.................................................132
			PL MODE - LOAD CALCULATION...........................................................132
		FINAL GEAR RATIO SELECTION...............................................................133
		BATTERY REPLACEMENT PROCEDURE............................................................134
			REPLACING THE BATTERY................................................................134
			AFTER REPLACING THE BATTERY..........................................................135
		SUSPENSION PRESSURE SENSOR...............................................................135
			REMOVAL..............................................................................135
			INSTALLATION.........................................................................136
		INCLINOMETER.............................................................................136
			REMOVAL..............................................................................136
			INSTALLATION.........................................................................136
		SCOREBOARD...............................................................................137
			DESCRIPTION..........................................................................137
			MAKING CONNECTIONS...................................................................137
			WIRING DIAGRAM.......................................................................138
			NORMAL OPERATION OF THE SCOREBOARD...................................................139
		PAYLOAD METER BACK PANEL.................................................................139
			CONNECTIONS (AMP PIN IDENTIFICATION).................................................140
		PAYLOAD CIRCUIT NUMBERS..................................................................141
		PAYLOAD METER II RE-INTIALIZATION PROCEDURE..............................................142
	CAB RADIO (AM/FM STERO CASSETTE).............................................................144

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]