Komatsu 830E-5 Dump Truck Operation and Maintenance Manual (CEAM038901)

Komatsu 830E-5 Dump Truck Index:

OPERATION AND MAINTENANCE MANUAL 830E-5 DUMP TRUCK
Contents
INTRODUCTION
- WARNINGS
- Foreword
- Safety Alert Symbol and Signal Words
- Basic Machine Introduction
- Visibility
- Noise And Vibration
- Exhaust Gas Regulations
- Declaration of Conformity
- Komatsu Machine Operator Privacy Policy
- Product Information
SAFETY
- Safety Labels
  - Locations of Safety Labels
  - Illustrations of Safety Labels
- General Precautions Common to Operation and Maintenance
  - Precautions Before Starting Operation
  - Preparations for Safe Operation
  - Fire and Explosion Prevention
  - Precautions When Getting On or Off the Machine
  - Precautions for Cab and Working Around Machine
  - Precautions for Diesel Exhaust Fluid (DEF)
- Operation Precautions
  - Precautions at Jobsite
  - Precautions in Starting Engine
  - Precautions During Operation
- Maintenance Precautions
  - Precautions Before Inspection and Maintenance
  - Precautions During Inspection and Maintenance
- End of Service Life
OPERATION
- Visual Overview of Machine
  - Machine Components – Front And Rear Views
  - Machine Components – Inside Frame View
  - Machine Components – Left Side View
  - Machine Components – Right Side View
  - Exterior Lights
  - Cab Interior View
- Steering Wheel and Controls
- Pedals
- Center Console Controls
- Instrument Panel Switches
- Multi-function Operator Display
  - Instrument Panel Status Indicators
  - Instrument Panel Gauges and Meters
  - Digital Display Menus
- Heater and Air Conditioner Controls
- Seat Heater/Ventilation System (HVS)
- Retractable Ladder Operations
- Radio Operations
  - AM/FM RADIO / MP3 / USB / iPOD™ / AUX PLAYER
- KomVision
  - KomVision Monitor Panel
  - KomVision Monitor Display
  - KomVision Object Detection
- Cab Connectors
- Vehicle Information Display (VID) Panel
- KOMTRAX
- Payload Meter IV
  - Payload Meter IV Communication Module
  - Payload Lights/Scoreboard
  - Haul Cycle
  - Payload Calculations
  - Clean Truck Tare
  - Viewing and Downloading Data
- Battery Disconnect Switches
- Ground Level Engine Shutdown Switch
- Preparations Before Operating the Machine
  - Walk-Around Inspection
  - Pre-Shift Brake Tests
  - Emergency Steering Test
  - Adjusting the Mirrors
  - Adjusting the Cab Seat
  - KomVision Start-Up Inspection
- Starting the Engine
- Checks After Starting the Engine
- Operating the Machine
  - Traveling on a Haul Road
  - Initial Propulsion on a Grade
  - Assisted Brake Management (ABM)
  - Retarding on a Grade
  - Loading the Dump Body
  - Dumping the Load
- Shutting Down the Machine
- Hydraulic System Bleeddown Procedure
- Disabled Machine Operations
  - Stopping the Machine After Loss of Power
  - Dumping the Load From a Disabled Machine
  - Towing a Disabled Machine
  - Jump Starting a Disabled Machine
- Engine Emissions After-Treatment System Operations
MAINTENANCE
- Rules for Maintenance
- Recommended Fuel, Coolant, and Lubricant
- Oil Clinic Inspection
- Remote Fill Service Centers
- Torque Specifications
- Maintenance Schedule
  - Wheel Motor Maintenance Intervals
  - Engine Maintenance Intervals
  - Safety Critical Parts
  - Maintenance Schedule Table
- Maintenance Procedures as Required
  - Replace Engine Air Cleaner Filter Elements
  - Maintain Correct Hydraulic Oil Level
  - Maintain Correct Coolant Level
  - Replace Autolube Filter Element
  - Fuses, Diodes and Relays
- Maintenance For First 500 Hours
  - Initial 50 Hours Maintenance
  - Initial 100 Hours Maintenance
  - Initial 250 Hours Maintenance
  - Initial 500 Hours Maintenance
- Every 250 Hours Maintenance
  - Check Cab External Air Filter
  - Check HVAC Recirculation Air Filter
  - Lubricate Pump Driveshaft
  - Collect Wheel Motor Oil Sample
  - Collect Hydraulic Oil Sample
  - Check Automatic Lubrication (Autolube) System
  - Check Retractable Ladder
- Every 500 Hours Maintenance
  - Clean A/C Condenser
  - Check A/C Drain Hose
  - Lubricate Pedals
  - Clean Control Cabinet Interior
  - Check Tie Rod
  - Check Engine Air Intake Piping
  - Check Dump Body Up and Hoist Limit Switches
  - Replace Hydraulic Tank Breather Elements
  - Cooling System Service
  - Fuel System Service
  - Check Automatic Lubrication (Autolube) System Pump Oil Level
- Every 1000 Hours Maintenance
  - Change Hydraulic Oil
  - Replace Hydraulic Filter Elements
  - Replace DEF System Filters
  - Lubricate Retractable Ladder
  - Check Dump Body Pads
  - Check/Lubricate Hoist Lever
  - Check Cab Seat Suspension
- Every 2000 Hours Maintenance
  - Change Automatic Lubrication (Autolube) System Pump Oil
- Every 2500 Hours Maintenance
  - Change Front Wheel Hub Oil
  - Lubricate Electronic Fan Clutch
- Every 3000 Hours Maintenance
- Every 5000 Hours Maintenance
  - Check Engine Air Cleaner Vacuator Valves
  - Check Steering Wheel Retaining Nut
- EVERY 6000 HOUR MAINTENANCE
- Every 6500 Hours Maintenance
  - Lubricate Traction Alternator Bearing
SPECIFICATION
- Specifications: 830E-5
Index
- A
- B
- C
- D
- E
- F
- G
- H
- I
- J
- K
- L
- M
- N
- O
- P
- R
- S
- T
- U
- V
- W