Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30816 & UP) KOMATSU 830E – PDF DOWNLOAD
Original price was: $51.95.$26.95Current price is: $26.95.
- KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30816 & UP
- PUBLICATION NUMBER:CEAM016800
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30816 & UP) KOMATSU 830E
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30816 & UP) KOMATSU 830E – PDF DOWNLOAD:
IMAGE PREVIEW:
DESCRIPTION:
KOMATSU 830E DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30816 & UP) KOMATSU 830E
- 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 (SN:A30816 & UP) KOMATSU 830E
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 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values.................. 19 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)...................... 20 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts................... 20 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 TRUCK OPERATION........................................................................... 51 PREPARING FOR OPERATION............................................................... 51 Safety Is Thinking Ahead.......................................................... 51 WALK AROUND INSPECTION................................................................ 51 ENGINE START-UP SAFETY PRACTICES...................................................... 54 AFTER ENGINE HAS STARTED.............................................................. 55 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 55 HAULING............................................................................... 56 STARTING ON A GRADE WITH A LOADED TRUCK............................................... 56 PASSING............................................................................... 57 LOADING............................................................................... 57 DUMPING............................................................................... 57 To Raise Body:.................................................................... 57 To Lower Body: When dumping over a berm or into a crusher:........................ 58 To Lower Body: When dumping on flat ground:....................................... 58 SUDDEN LOSS OF ENGINE POWER........................................................... 59 SAFE PARKING PROCEDURES............................................................... 59 ENGINE SHUTDOWN PROCEDURE............................................................. 59 DELAYED ENGINE SHUTDOWN PROCEDURE..................................................... 60 EMERGENCY STEERING SYSTEM............................................................. 61 Operation......................................................................... 61 Testing........................................................................... 61 DISABLED TRUCK DUMPING PROCEDURE...................................................... 62 Hookup............................................................................ 62 Raising the Body.................................................................. 62 Lowering the Body................................................................. 62 TOWING................................................................................ 63 RESERVE ENGINE OIL SYSTEM (Optional).................................................. 64 Operation......................................................................... 64 LED Monitor Light................................................................. 64 Changing Oil...................................................................... 64 OPERATOR CAB AND CONTROLS................................................................. 65 STEERING WHEEL AND CONTROLS........................................................... 66 Horn Button....................................................................... 66 Tilt / Telescope Lever............................................................ 66 Multi-function Turn Signal Switch................................................. 66 Turn Signal Operation............................................................. 66 High Beam Headlight Operation..................................................... 66 Windshield Wiper Operation........................................................ 66 PEDALS................................................................................ 67 Service Brake Pedal............................................................... 67 Dynamic Retarder Pedal............................................................ 67 Optional - Dual Function / Single Pedal........................................... 67 Throttle Pedal.................................................................... 67 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS..................................... 68 Defroster Vent Control Switch..................................................... 68 Heat Vent Control Switch.......................................................... 68 Temperature Control Knob.......................................................... 68 Fan Control Knob.................................................................. 68 Heater/air Conditioner Selector Switch............................................ 68 Heater/air Conditioner Vents...................................................... 68 OVERHEAD PANEL AND DISPLAY............................................................ 69 Grade/speed Warning Chart......................................................... 69 Radio Speakers.................................................................... 69 Warning Alarm Buzzer.............................................................. 69 Cab Radio......................................................................... 69 Warning Lights Dimmer Control..................................................... 69 Status / Warning Indicator Light Panel............................................ 69 Windshield Wipers................................................................. 69 Air Cleaner Vacuum Gauges......................................................... 70 CENTER CONSOLE........................................................................ 70 F-N-R Selector Switch............................................................. 70 Hoist Control Lever............................................................... 71 To Raise Body:.................................................................... 71 To Lower Body:.................................................................... 71 Ash Tray.......................................................................... 71 Lighter........................................................................... 71 L.h. Window Control Switch........................................................ 71 R.h. Window Control Switch........................................................ 71 Engine Shutdown Switch............................................................ 71 Override Switch................................................................... 72 Retard Speed Control (RSC) Off/on Switch.......................................... 72 Retard Speed Control (RSC) Adjust Dial............................................ 72 Statex III Propulsion System Diagnostic Connector................................. 73 Komatsu Engine Quantum Connector.................................................. 73 Komatsu Engine Cense Connector.................................................... 73 Unused Connector.................................................................. 73 Modular Mining Port Conector...................................................... 73 Data Store Button................................................................. 73 Passenger Seat.................................................................... 73 Service Engine Light (Blue)....................................................... 73 Payload Meter..................................................................... 73 INSTRUMENT PANEL AND INDICATOR LIGHTS................................................. 74 CONTROL SYMBOLS................................................................... 74 INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS....................................... 75 Key Switch........................................................................ 76 Starting.......................................................................... 76 Engine Shutdown Switch With Timer Delay (Optional)................................ 76 Fog Lights (Optional)............................................................. 77 Ladder Light Switch............................................................... 77 Manual Backup Switch.............................................................. 77 Panel Illumination Lights......................................................... 77 Cab Air Conditioner / Heater Vents................................................ 77 Engine Cold Weather Starting Aid (Optional)....................................... 77 Rotating Beacon Light Switch (Optional)........................................... 77 Heated Mirror Switch (Optional)................................................... 77 Wheel Brake Lock Control.......................................................... 78 Parking Brake Control............................................................. 78 Tachometer........................................................................ 78 Right Turn Signal Indicator....................................................... 79 High Beam Indicator............................................................... 79 Left Turn Signal Indicator........................................................ 79 Speedometer / Payload Meter....................................................... 79 Voltmeter......................................................................... 79 Engine Oil Pressure Gauge......................................................... 79 Water Temperature Gauge........................................................... 79 Fuel Gauge........................................................................ 79 Hourmeter......................................................................... 80 Headlight Switch.................................................................. 80 Panel Light Dimmer................................................................ 80 Payload Meter Switch.............................................................. 80 INDICATOR LIGHT SYMBOLS........................................................... 82 Hazard Warning Lights......................................................... 86 Lamp Test Switch.............................................................. 86 VEHICLE HEALTH MONITORING SYSTEM (VHMS)............................................... 87 Operation......................................................................... 87 Interface Module.................................................................. 88 Basic Precautions................................................................. 88 OPERATOR COMFORT...................................................................... 89 OPERATOR SEAT..................................................................... 89 Adjustment.................................................................... 89 Seat Removal.................................................................. 89 Seat Installation............................................................. 90 LUBRICATION AND SERVICE................................................................... 91 830E SERVICE CAPACITIES............................................................... 91 HYDRAULIC TANK SERVICE................................................................ 91 Adding Oil........................................................................ 91 WHEEL MOTOR SERVICE................................................................... 91 COOLANT LEVEL CHECK................................................................... 92 RADIATOR FILLING PROCEDURE............................................................ 92 RESERVE ENGINE OIL SYSTEM (Optional).................................................. 92 Reserve Oil Tank Filling Procedure (Remote fill).................................. 92 LUBRICATION CHART..................................................................... 93 10 HOUR (DAILY) INSPECTION............................................................ 94 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................ 97 100 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................... 98 250 HOUR LUBRICATION AND MAINTENANCE CHECKS........................................... 99 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................102 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS.........................................104 2500 HOUR MAINTENANCE CHECKS..........................................................105 5000 HOUR MAINTENANCE CHECKS..........................................................105 10,000 HOUR MAINTENANCE CHECKS........................................................106 AUTOMATIC LUBRICATION SYSTEM..............................................................107 GENERAL DESCRIPTION...................................................................107 SYSTEM COMPONENTS.....................................................................109 Filter............................................................................109 Hydraulic Motor and Pump..........................................................109 Grease Reservoir..................................................................109 Pressure Reducing Valve...........................................................109 Flow Control Valve................................................................109 Solenoid Valve....................................................................109 Vent Valve........................................................................109 Lubrication Cycle Timer...........................................................109 Delay Timer.......................................................................109 Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])..........................109 Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa]).......................109 Pressure Gauge....................................................................109 Injectors.........................................................................109 SYSTEM OPERATION......................................................................110 Normal Operation:.................................................................110 Pressure Failure Detection Circuits:..............................................111 INJECTOR OPERATION................................................................112 System Priming....................................................................113 Filter Assembly...................................................................113 LUBRICANT PUMP........................................................................114 Pump Housing Oil Level............................................................114 Pump Pressure Control.............................................................114 Pressure Control Valve Adjustment.................................................114 INJECTORS (SL-1 Series “H”))..........................................................115 Injector Specifications...........................................................115 Injector Adjustment...............................................................115 SYSTEM CHECKOUT.......................................................................116 Lubrication Cycle Timer Check.....................................................116 Lubrication Cycle Timer Adjustment................................................116 SYSTEM TROUBLESHOOTING CHART..........................................................117 PREVENTATIVE MAINTENANCE PROCEDURES...................................................119 Daily Lubrication System Inspection...............................................119 250 Hour Inspection...............................................................119 1000 Hour Inspection..............................................................119 TRUCK COMPONENT DESCRIPTION...............................................................121 SPECIFICATIONS........................................................................123 PAYLOAD METER III™........................................................................125 INDEX.................................................................................125 Introduction..........................................................................127 Data Summary......................................................................127 Data Gathering....................................................................127 COMPONENT DESCRIPTION.................................................................128 System Diagram....................................................................128 Suspension Pressure Sensors.......................................................128 Inclinometer......................................................................128 Operator Display..................................................................128 Operator Switch...................................................................129 Speed Input.......................................................................129 Body-Up Switch....................................................................129 Brake Lock Switch.................................................................129 Payload Meter.....................................................................129 Communications Ports..............................................................129 Keyswitch Input...................................................................130 Payload Meter Power...............................................................130 Load Lights.......................................................................130 Wiring and Termination............................................................131 TCI Outputs.......................................................................131 OPERATOR’S DISPLAY AND SWITCH.........................................................132 Reading the Speedometer...........................................................132 Reading the Load Display..........................................................132 Using the Operator ID.............................................................132 Using the Load and Ton Counter....................................................132 Total Ton Counter.................................................................132 Total Load Counter................................................................133 Clearing the Counters.............................................................133 Viewing Live Sensor Data..........................................................133 Other Display Messages............................................................133 PAYLOAD OPERATION & CALCULATION.......................................................134 Description of Haul Cycle States..................................................134 Haul Cycle Description............................................................134 Load Calculation..................................................................135 Carry Back........................................................................135 Measurement Accuracy..............................................................135 SOURCES FOR PAYLOAD ERROR.............................................................135 Payload Error.....................................................................135 Loading Conditions................................................................136 Pressure Sensors..................................................................136 Swingloads........................................................................136 Speed and Distance................................................................136 HAUL CYCLE DATA.......................................................................136 Haul Cycle Data...................................................................137 Haul Cycle Warning Flags..........................................................138 M: Haul Cycle Too Long............................................................139 N: Sensor Input Error.............................................................139 Frame Torque Data.................................................................139 Sprung Weight Data................................................................139 Maximum Speed Data................................................................139 Alarm Records.....................................................................139 Fault Code Data...................................................................140 PC SOFTWARE OVERVIEW..................................................................141 PC Overview.......................................................................141 System Configuration..............................................................141 Installing the PLMIII Software....................................................141 DOWNLOADING DATA......................................................................142 PLM III SYSTEM CONFIGURATION..........................................................143 Starting Communications...........................................................143 Displayed Payload Units...........................................................143 Time Units........................................................................143 Connection Menu...................................................................143 Connecting to the Payload Meter...................................................144 Configure the Payload Meter.......................................................144 Setting the Date and Time.........................................................144 Setting the Truck Type............................................................145 Setting the Gauge Display Units...................................................145 Setting the Frame Serial Number...................................................145 Setting the Truck Number..........................................................145 Setting the Komatsu Distributor...................................................145 Setting the Komatsu Customer......................................................145 Clean Truck Tare..................................................................146 Inclinometer Calibration..........................................................146 DATA ANALYSIS.........................................................................147 Creating a Query..................................................................147 Sorting on Truck Unit Number......................................................147 Sorting on Truck Type.............................................................147 Sorting on Date Range.............................................................148 Sorting on Time Range.............................................................148 Payload Detail Screen.............................................................149 Creating Reports..................................................................149 Summary - one page report.........................................................150 Detailed - multi-page report......................................................150 Creating Graphs...................................................................151 Exporting Data....................................................................151 CSV Export........................................................................151 Compressed........................................................................152 Importing Data....................................................................153 Deleting Haul Cycle Records.......................................................153 Viewing Alarms....................................................................154 Deleting Alarm Records............................................................154 RADIO / CASSETTE PLAYER...................................................................157 GENERAL RECEIVER FUNCTIONS............................................................157 Turning The Power On And Off......................................................157 Display...........................................................................157 Setting The Default Display.......................................................157 Adjusting Display Brightness......................................................157 SETTING THE TIME......................................................................158 OPERATING THE RADIO...................................................................158 BAND..............................................................................158 TUNE/SEEK.........................................................................158 Manual Tuning.....................................................................158 SEEK Mode.........................................................................158 SCAN..............................................................................158 AUTO..............................................................................158 ADJUSTING THE RECEIVER SETTINGS.......................................................159 PROGRAMMING PRESET STATIONS...........................................................159 OPERATION OF THE WEATHERBAND (U.S.)...................................................159 SATELLITE RADIO.......................................................................160 Operating Satellite Radio.........................................................160 Program Type Search (PTY).........................................................160 CASSETTE PLAYER.......................................................................161 Playing A Cassette................................................................161 Cassette Functions................................................................161 Progrommable Eject Default........................................................161 Bad Tape Detect...................................................................162 Cleaning The Cassette Player......................................................162
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
