Komatsu 830E-AC Dump Truck Operation and Maintenance Manual (CEAM016303)

📘 Show Index

Komatsu 830E-AC Dump Truck Index:

COVER
WARNING
NON-OEM PARTS
FOREWORD
ALERTS PAGE
TABLE OF CONTENTS
- TRUCK MODEL ILLUSTRATION
- KOMATSU MODEL 830E-AC DUMP TRUCK
- ABOUT THIS MANUAL
STANDARD CHARTS AND TABLES
- EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
- STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)
- STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts
GENERAL SAFETY
- Safety Rules
- Truck Safety Features
- Clothing And Personal Items
- Unauthorized Modification
- Leaving The Operator’s Seat
- Mounting And Dismounting
- Fire Extinguishers And First Aid Kits
- Precautions For High Temperature Fluids
- Asbestos Dust Hazard Prevention
- Fire Prevention For Fuel And Oil
- ROPS Precautions
- Preventing Injury From Work Equipment
- Precautions For Optional Attachments
- Precautions When Starting The Machine
- PRECAUTIONS FOR TRUCK OPERATION
  - Safety Is Thinking Ahead
  - Safety At The Worksite
  - Fire Prevention
  - Preparing For Operation
  - Ventilation For Enclosed Areas
  - Mirrors, Windows, And Lights
  - In The Operator’s Cab – Before Starting The Engine
  - Seat Belts
- OPERATING THE MACHINE
  - Starting The Engine
  - Truck Operation – General
  - Traveling In The Truck
  - Precautions When Traveling In Reverse
  - Traveling On Slopes
  - Ensuring Good Visibility
  - Operating On Snow
  - Avoid Damage To The Dump Body
  - Driving Near High Voltage Cables
  - When Loading The Truck
  - When Dumping
  - Working On Loose Ground
  - Parking The Machine
- TOWING
- WORKING NEAR BATTERIES
  - Jump Starting With Booster Cables
  - Jump Starting With Receptacles
- PRECAUTIONS FOR MAINTENANCE
  - BEFORE PERFORMING MAINTENANCE
  - DURING MAINTENANCE
  - TIRES
- ADDITIONAL JOB SITE RULES
- WHEN REPAIRS ARE NECESSARY
- SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK
  - Preliminary Procedures before Welding or Performing Maintenance
  - Engine Shutdown Procedure before Welding or Performing Maintenance
WARNINGS AND CAUTIONS
TRUCK OPERATION
- PREPARING FOR OPERATION
  - Safety Is Thinking Ahead
- WALK AROUND INSPECTION
- ENGINE START-UP SAFETY PRACTICES
- AFTER ENGINE HAS STARTED
- EMERGENCY STEERING SYSTEM
  - Operation
  - Pre-Operation Testing
  - Additional Guidelines
- MACHINE OPERATION SAFETY PRECAUTIONS
- MACHINE OPERATION ON THE HAUL ROAD
- STARTING ON A GRADE WITH A LOADED TRUCK
- PASSING
- LOADING
- DUMPING
  - Raising The Dump Body
  - Lowering The Dump Body
- SUDDEN LOSS OF ENGINE POWER
- FUEL DEPLETION
- SAFE PARKING PROCEDURES
- NORMAL ENGINE SHUTDOWN PROCEDURE
- DELAYED ENGINE SHUTDOWN PROCEDURE
- DISABLED TRUCK DUMPING PROCEDURE
  - GENERAL
  - STEERING AND BRAKE SYSTEM
  - HOIST SYSTEM
- TOWING
- RESERVE ENGINE OIL SYSTEM (Optional)
OPERATOR CAB AND CONTROLS
- STEERING WHEEL AND CONTROLS
  - Horn Button
  - Tilt / Telescope Lever
  - Multi-Function Turn Signal Switch
- PEDALS
  - Service Brake Pedal
  - Dynamic Retarding
  - Dynamic Retard Pedal
  - Throttle/Accelerator Pedal
- GRADE/SPEED RETARD CHART
- OVERHEAD PANEL AND DISPLAYS
- CENTER CONSOLE
  - Directional Control Lever
  - Override/Fault Reset Switch
  - Engine Stop Switch
  - L.H. Window Control Switch
  - R.H. Window Control Switch
  - Hoist Control Lever
  - Raising The Dump Body
  - Lowering The Dump Body
  - Retard Speed Control (RSC) Adjust Dial
  - Retard Speed Control (RSC) Switch
  - Data Store Button
  - VHMS Snapshot In Progress Light
  - Link Energized Light
  - Service Engine Light
  - DIAGNOSTIC PORTS
  - VHMS Diagnostic Port
  - Interface Module (IM) Diagnostic Port
  - Payload Meter Diagnostic Port
  - Truck Control Interface (TCI) Diagnostic Port
  - Propulsion System Controller (PSC) Diagnostic Port
  - Engine Diagnostic Port (CENSE)
  - Engine Diagnostic Port (QUANTUM)
- OPERATOR’S SEAT
  - Seat Belts
  - Adjustment
- HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS
  - Fan Control Knob
  - Temperature Control Knob
  - Directional Control Knob
  - Heater Vents
- INSTRUMENT PANEL
  - Key Switch
  - Starting
  - Engine Stop Switch with Five Minute Idle Timer Delay
  - Rotating Beacon Light Switch (Optional)
  - Heated Mirror Switch (Optional)
  - Rest Switch
  - Wheel Brake Lock Control
  - Hazard Warning Lights
  - Cab/Air Conditioner Vents
  - Engine Oil Pressure Gauge
  - Right Turn Signal Indicator
  - Tachometer
  - High Beam Indicator
  - Speedometer/Payload Meter Display
  - Left Turn Signal Indicator
  - Water Temperature Gauge
  - Lamp Test Switch
  - Light Switch
  - Ladder Light Switch
  - Manual Backup Switch
  - Fog Lights (Optional)
  - Payload Meter Switch
  - Panel Light Dimmer
  - Hydraulic Oil Temperature Gauge
  - Hourmeter
  - Fuel Level Gauge
- OVERHEAD STATUS / WARNING INDICATORS
  - Status / Warning Indicator Light Symbols
- VEHICLE HEALTH MONITORING SYSTEM (VHMS)
  - Operation
  - Interface Module
  - Basic Precautions
- CIRCUIT BREAKERS
LUBRICATION AND SERVICE
- 830E SERVICE CAPACITIES
- HYDRAULIC TANK SERVICE
  - Adding Oil
- WHEEL MOTOR SERVICE
- COOLANT LEVEL CHECK
- RADIATOR FILLING PROCEDURE
- RESERVE ENGINE OIL SYSTEM (Optional)
  - Reserve Oil Tank Filling Procedure (Remote fill)
- LUBRICATION CHART
- 10 HOUR (DAILY) INSPECTION
- 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 500 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)
- 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
- 2500 HOUR MAINTENANCE CHECKS
- 5000 HOUR MAINTENANCE CHECKS
- 10,000 HOUR MAINTENANCE CHECKS
AUTOMATIC LUBRICATION SYSTEM
- GENERAL DESCRIPTION
- SYSTEM COMPONENTS
  - Filter
  - Hydraulic Motor and Pump
  - Grease Reservoir
  - Pressure Reducing Valve
  - Pressure Gauge
  - Flow Control Valve
  - Solenoid Valve
  - Vent Valve
  - Lubrication Cycle Timer
  - Over Pressure Cutoff Switch
  - Grease Pressure Failure Switch
  - Injectors
  - Relief Valve (unloader valve)
- SYSTEM OPERATION
- GENERAL INSTRUCTIONS
  - Required Lubricant
  - System Priming
  - Filter Assembly
- LUBRICANT PUMP
  - Pump Housing Oil Level
  - Pump Pressure Control
- INJECTORS (SL-1 Series “H”)
  - Injector Specifications
  - Injector Adjustment
- INJECTOR OPERATION
- PREVENTIVE MAINTENANCE PROCEDURES
  - Daily Lubrication System Inspection
  - 250 Hour Inspection
  - 1000 Hour Inspection
- SYSTEM CHECKOUT
  - Lubrication Controller Check
  - Lubrication Controller Operation
  - Lubrication Controller Components
  - Lubrication Controller Adjustment
- SYSTEM TROUBLESHOOTING CHART
MAJOR COMPONENT DESCRIPTION
PAYLOAD METER III™
- INDEX
- Introduction
  - Data Summary
  - Data Gathering
- COMPONENT DESCRIPTION
  - System Diagram
  - Suspension Pressure Sensors
  - Inclinometer
  - Operator Display
  - Operator Switch
  - Speed Input
  - Body-Up Switch
  - Brake Lock Switch
  - Payload Meter
  - Communications Ports
  - Key Switch Input
  - Payload Meter Power
  - Load Lights
  - Wiring and Termination
  - TCI Outputs
- OPERATOR’S DISPLAY AND SWITCH
  - Reading the Speedometer
  - Reading the Load Display
  - Using the Operator ID
  - Using the Load and Ton Counter
  - Total Ton Counter
  - Total Load Counter
  - Clearing the Counters
  - Viewing Live Sensor Data
  - Other Display Messages
- PAYLOAD OPERATION & CALCULATION
  - Haul Cycle States
  - Haul Cycle Description
  - Load Calculation
  - Carry Back
  - Measurement Accuracy
- SOURCES FOR PAYLOAD ERROR
  - Payload Error
  - Loading Conditions
  - Pressure Sensors
  - Swingloads
  - Speed and Distance
- HAUL CYCLE DATA
  - Haul Cycle Data
  - Haul Cycle Warning Flags
  - Frame Torque Data
  - Sprung Weight Data
  - Maximum Speed Data
  - Alarm Records
  - Fault Code Data
- PC SOFTWARE OVERVIEW
  - PC Overview
  - System Configuration
  - Installing the PLMIII Software
- DOWNLOADING DATA
- PLM III SYSTEM CONFIGURATION
  - Starting Communications
  - Displayed Payload Units
  - Time Units
  - Connection Menu
  - Connecting to the Payload Meter
  - Configure the Payload Meter
  - Setting the Date and Time
  - Setting the Truck Type
  - Setting the Gauge Display Units
  - Setting the Frame Serial Number
  - Setting the Truck Number
  - Setting the Komatsu Distributor
  - Setting the Komatsu Customer
  - Clean Truck Tare
  - Inclinometer Calibration
- DATA ANALYSIS
  - Creating a Query
  - Sorting on Truck Unit Number
  - Sorting on Truck Type
  - Sorting on Date Range
  - Sorting on Time Range
  - Payload Detail Screen
  - Creating Reports
  - Summary – one page report
  - Detailed – multi-page report
  - Creating Graphs
  - Exporting Data
  - CSV Export
  - Compressed
  - Importing Data
  - Deleting Haul Cycle Records
  - Viewing Alarms
  - Deleting Alarm Records
RADIO / CASSETTE PLAYER
- GENERAL RECEIVER FUNCTIONS
  - Turning The Power On And Off
  - Display
  - Setting The Default Display
  - Adjusting Display Brightness
- SETTING THE TIME
- OPERATING THE RADIO
  - BAND
  - TUNE/SEEK
  - Manual Tuning
  - SEEK Mode
  - SCAN
  - AUTO
- ADJUSTING THE RECEIVER SETTINGS
- PROGRAMMING PRESET STATIONS
- OPERATION OF THE WEATHERBAND (U.S.)
- SATELLITE RADIO
  - Operating Satellite Radio
  - Program Type Search (PTY)
- CASSETTE PLAYER
  - Playing A Cassette
  - Cassette Functions
  - Programmable Eject Default
  - Bad Tape Detect
  - Cleaning The Cassette Player