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Komatsu 830E Dump Truck Operation & Maintenance Manual SN A30650-A30661, A30663-A30676 – PDF DOWNLOAD
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Komatsu 830E Dump Truck Operation & Maintenance Manual
Book Code : CEAM010400
SERIAL SUFFIX:
A30650 thru A30661,
A30663 thru A30676
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Description
Komatsu 830E Dump Truck Operation & Maintenance Manual
FILE DETAILS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
Model Specification: KOMATSU 830E DUMP TRUCK
Language: English
File Format: PDF
Total Pages: 144
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL SN A30650-A30661, A30663-A30676 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E Dump Truck Operation & Maintenance Manual
FOREWORD:
This Manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when operating or accomplishing repairs on the truck.
- The first section is an Introduction to the manual and contains a Table of Contents to locate specific areas of interest. Other sections include Safety, Operation, Maintenance, Specifications, and Optional Equipment. The illustrations used in this manual are TYPICAL of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 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.
TABLE OF CONTENTS:
Komatsu 830E Dump Truck Operation & Maintenance Manual
MAIN MENU..................................................... 0 COVER......................................................... 1 INTRODUCTION.................................................. 5 FOREWORD.................................................. 5 ALERTS PAGE............................................... 6 TABLE OF CONTENTS......................................... 7 TRUCK MODEL ILLUSTRATION.................................. 10 ABOUT THIS MANUAL......................................... 11 STANDARD CHARTS AND TABLES................................ 13 SAFETY........................................................ 19 GENERAL SAFETY............................................ 19 PRECAUTIONS DURING OPERATION.............................. 23 OPERATING THE MACHINE................................. 24 TOWING................................................ 27 BATTERY............................................... 28 PRECAUTIONS FOR MAINTENANCE............................... 29 BEFORE CARRYING OUT MAINTENANCE....................... 29 DURING MAINTENANCE.................................... 30 TIRES................................................. 33 ADDITIONAL JOB SITE RULES............................. 34 WHEN REPAIRS ARE NECESSARY............................ 35 WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS......... 37 OPERATION..................................................... 43 OPERATING INSTRUCTIONS.................................... 43 PREPARING FOR OPERATION............................... 43 SAFETY IS THINKING AHEAD.............................. 43 AT THE TRUCK - GROUND LEVEL WALK-AROUND INSPECTION.... 43 WALK-AROUND INSPECTION - ILLUSTRATION................. 44 ENGINE START-UP SAFETY PRACTICES.......................... 46 AFTER ENGINE HAS STARTED.................................. 47 MACHINE OPERATION SAFETY PRECAUTIONS...................... 47 LOADING................................................... 48 HAULING................................................... 48 PASSING................................................... 48 DUMPING................................................... 49 TOWING.................................................... 50 SUDDEN LOSS OF ENGINE POWER............................... 51 SAFE PARKING PROCEDURES................................... 51 ENGINE SHUTDOWN PROCEDURE................................. 51 DELAYED ENGINE SHUTDOWN PROCEDURE......................... 52 OPERATOR CAB AND CONTROLS................................. 53 STEERING WHEEL AND CONTROLS........................... 54 SERVICE BRAKE PEDAL................................... 55 DYNAMIC RETARDER PEDAL................................ 55 THROTTLE PEDAL........................................ 55 HEATER / AIR CONDITIONER VENTS........................ 55 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..... 56 CENTER CONSOLE........................................ 58 INSTRUMENT PANEL AND INDICATOR LIGHTS..................... 62 CONTROL SYMBOLS....................................... 62 INSTRUMENT PANEL.......................................... 63 PANEL GAUGES, INDICATORS, AND CONTROLS.................... 64 OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL........... 69 INDICATOR LIGHT SYMBOLS................................... 70 HAZARD WARNING LIGHTS................................. 74 LAMP TEST SWITCH...................................... 74 OPERATOR SEAT............................................. 75 MAINTENANCE................................................... 77 LUBRICATION AND SERVICE................................... 77 LUBRICATION CHART..................................... 78 10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS.... 79 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............ 81 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........... 82 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........... 83 500 HOUR LUBRICATION AND MAINTENANCE CHECKS........... 85 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......... 86 2500 HOUR LUBRICATION AND MAINTENANCE CHECKS.......... 87 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.......... 88 10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS........ 88 LINCOLN AUTOMATIC LUBRICATION SYSTEM...................... 89 GENERAL DESCRIPTION................................... 89 SYSTEM COMPONENTS..................................... 91 SYSTEM OPERATION.................................. 92 INJECTOR OPERATION................................ 94 GENERAL INSTRUCTIONS.................................. 95 LUBRICATION REQUIRED.............................. 95 SYSTEM PRIMING.................................... 95 FILTER ASSEMBLY................................... 95 LUBRICANT PUMP........................................ 96 SYSTEM CHECKOUT....................................... 98 24 VDC SOLID STATE TIMER CHECK.................... 98 SYSTEM TROUBLESHOOTING CHART.......................... 99 PREVENTATIVE MAINTENANCE PROCEDURES...................102 SPECIFICATIONS................................................103 MAJOR COMPONENT DESCRIPTION...............................103 SPECIFICATIONS............................................105 PAYLOAD METER III.............................................107 INDEX.....................................................107 OPERATION SECTION.........................................109 INTRODUCTION..............................................109 DATA SUMMARY..............................................109 DATA GATHERING............................................109 COMPONENT DESCRIPTION.....................................110 SYSTEM DIAGRAM........................................110 SUSPENSION PRESSURE SENSORS...........................110 INCLINOMETER..........................................110 OPERATOR DISPLAY......................................110 OPERATOR SWITCH.......................................111 SPEED INPUT...........................................111 BODY-UP SWITCH........................................111 BRAKE LOCK SWITCH.....................................111 PAYLOAD METER.........................................111 COMMUNICATION PORTS...................................111 KEYSWITCH INPUT.......................................112 PAYLOAD METER POWER...................................112 LOAD LIGHTS...........................................112 WIRING AND TERMINATION................................113 TCI OUTPUTS...........................................113 OPERATOR DISPLAY AND SWITCH...............................114 READING THE SPEEDOMETER...............................114 READING THE LOAD DISPLAY..............................114 USING THE OPERATOR ID.................................114 USING THE LOAD AND TON COUNTER........................114 TOTAL TON COUNTER.................................114 TOTAL LOAD COUNTER................................115 CLEARING THE COUNTERS.............................115 VIEWING LIVE SENSOR DATA..............................115 OTHER DISPLAY MESSAGES................................115 PAYLOAD OPERATION & CALCULATION...........................116 DESCRIPTION OF HAUL CYCLE STATES......................116 STATES OR STAGES OF A TYPICAL HAUL CYCLE..........116 HAULCYCLE DESCRIPTION.............................116 LOAD CALCULATION......................................117 CARRY BACK............................................117 MEASUREMENT ACCURACY..................................117 SOURCES FOR PAYLOAD ERROR.............................117 PAYLOAD ERROR.....................................117 LOADING CONDITIONS................................118 PRESSURE SENSORS..................................118 SWING LOADS.......................................118 SPEED AND DISTANCE................................118 HAUL CYCLE DATA...........................................118 HAUL CYCLE DATA.......................................119 HAUL CYCLE WARNING FLAGS..............................120 ALARM RECORDS.........................................121 FRAME TORQUE DATA.....................................121 SPRUNG WEIGHT DATA....................................122 MAXIMUM SPEED DATA....................................122 PC SOFTWARE OVERVIEW......................................122 PC OVERVIEW...........................................122 SYSTEM CONFIGURATION..................................122 INSTALLING THE PAYLOAD METER III SOFTWARE.............122 DOWNLOADING DATA..........................................123 PLM III SYSTEM CONFIGURATION..............................124 STARTING COMMUNICATIONS...............................124 DISPLAYED PAYLOAD UNITS...........................124 TIME UNITS........................................124 CONNECTION MENU.......................................124 CONNECTING TO THE PAYLOAD METER.......................125 CONFIGURE THE PAYLOAD METER...........................125 SETTING THE DATE AND TIME.........................125 SETTING THE TRUCK TYPE............................126 SETTING THE GAUGE DISPLAY UNITS...................126 SETTING THE FRAME SERIAL NUMBER...................126 SETTING THE TRUCK NUMBER..........................126 SETTING THE KMS DISTRIBUTOR.......................126 SETTING THE KMS CUSTOMER..........................126 CLEAN TRUCK TARE......................................127 INCLINOMETER CALIBRATION..............................127 DATA ANALYSIS.............................................128 CREATING A QUERY......................................128 SORTING ON TRUCK UNIT NUMBER......................128 SORTING ON TRUCK TYPE.............................128 SORTING ON DATE RANGE.............................129 SORTING ON TIME RANGE.............................129 PAYLOAD DETAIL SCREEN.................................130 CREATING REPORTS......................................130 SUMMARY - ONE PAGE REPORT.........................131 DETAILED - MULTI PAGE REPORT......................131 CREATING GRAPHS.......................................132 EXPORTING DATA........................................132 CSV EXPORT........................................132 COMPRESSED........................................133 IMPORTING DATA........................................134 DELETING HAUL CYCLE RECORDS...........................134 VIEWING ALARMS........................................135 DELETING ALARM RECORDS................................135 CAB RADIO ....................................................137
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