Complete Operator’s manual for Komatsu Dump Trucks 830E, with all the shop information to maintain & operate the trucks.
Total Pages: 5,305 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM006200 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM010400 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM010600 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM011500 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM013204 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM013400 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM015001 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM015201 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM016303 – Dump Truck 830E-AC Operation & Maintenance Manual.pdf
CEAM016800 – Dump Truck 830E Operation & Maintenance Manual.pdf
CEAM018802 – Dump Truck 830E-AC Operation & Maintenance Manual.pdf
CEAM018903 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM019102 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM019302 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM019903 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM020101 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM020801 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM021501 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM022303 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM024100 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM024403 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM025001 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM026901 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM027001 – Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEBM010501 – Dump Truck 830E Operation & Maintenance Manual.pdf
DG621 – Dump Truck 830E Operator Handbook.pdf
DG723 – Dump Truck 830E Operation & Maintenance Manual.pdf
TABLE OF CONTENTS
INTRODUCTION ___________________________________________________________________ SECTION 1
Foreword . . . 1-1
ALERTS Page – a description of the DANGER, WARNING, and CAUTION symbols used in this manual. . . 1-2
TABLE OF CONTENTS . . . 1-3
Truck Model Illustration . . . 1-6
About This Manual . . . 1-7
STANDARD CHARTS and TABLES. . . 1-9
SAFETY _________________________________________________________________________ SECTION 2
Safety records of most organizations will show that the greatest percentage of accidents are caused by unsafe acts
of persons. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to
the proper authority. These safety rules are provided as a guide for the operator. However, local conditions and
regulations may add many more to this list.
GENERAL SAFETY . . . 2-1
PRECAUTIONS DURING OPERATION . . . 2-5
Operating The Machine . . . 2-6
Towing . . . 2-9
Battery . . . 2-10
PRECAUTIONS FOR MAINTENANCE . . . 2-11
Before Carrying Out Maintenance . . . 2-11
During Maintenance . . . 2-12
Tires . . . 2-15
Additional Job Site Rules . . . 2-16
WHEN REPAIRS ARE NECESSARY . . . 2-17
WARNING, CAUTION, and Instruction Plates / Decals . . . 2-19 thru 2-26
OPERATION _____________________________________________________________________ SECTION 3
This portion of the manual covers Identification, location, and operation of the controls, switches, and indicators in
the Operator’s Cab and use / function of these controls, switches, and indicators.
OPERATING INSTRUCTIONS
Preparing For Operation . . . 3-1
Safety Is Thinking Ahead . . . 3-1
At The Truck – Ground Level Walk-Around Inspection . . . 3-1
Walk-Around Inspection – Illustration . . . 3-2
ENGINE START-UP SAFETY PRACTICES . . . 3-4
AFTER ENGINE HAS STARTED . . . 3-5
MACHINE OPERATION SAFETY PRECAUTIONS . . . 3-5
LOADING . . . 3-6
HAULING . . . 3-6
PASSING . . . 3-6
DUMPING . . . 3-7
OPERATION (Continued) ___________________________________________________________ SECTION 3
TOWING . . .3-8
SUDDEN LOSS OF ENGINE POWER . . .3-9
SAFE PARKING PROCEDURES . . .3-9
ENGINE SHUTDOWN PROCEDURE . . .3-9
DELAYED ENGINE SHUTDOWN PROCEDURE . . .3-10
RESERVE ENGINE OIL SYSTEM . . . 3-11
OPERATOR CAB and CONTROLS . . .3-13
STEERING WHEEL AND CONTROLS. . .3-14
SERVICE BRAKE PEDAL. . .3-15
DYNAMIC RETARDER PEDAL. . .3-15
THROTTLE PEDAL. . .3-15
HEATER / AIR CONDITIONER VENTS . . .3-15
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS. . .3-16
CENTER CONSOLE . . .3-18
INSTRUMENT PANEL AND INDICATOR LIGHTS . . .3-22
Control Symbols . . .3-22
INSTRUMENT PANEL (Figure 3-6) . . .3-23
PANEL GAUGES, INDICATORS, AND CONTROLS (Discussion of items 1 – 28, Figure 3-6) . . .3-24
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL (Figure 3-7) . . .3-29
INDICATOR LIGHT SYMBOLS – Refer to Figure 3-7 by rows (A-E) and columns (1 – 6). . .3-30
Hazard Warning Lights (7) . . .3-34
Lamp Test Switch (8) . . .3-34
OPERATOR SEAT . . .3-35
MAINTENANCE __________________________________________________________________ SECTION 4
This portion of the manual pertains mainly to the periodic Lubrication and Service required to keep the truck oper-
ating at its design potential. Routine lubrication and maintenance procedures are provided in this section. For
major repairs, refer to the appropriate section in the Truck Shop Manual. Refer to the engine manufacturer’s ser-
vice manual when servicing the engine.
LUBRICATION AND SERVICE . . .4-1
Hydraulic Tank . . .4-1
Coolant Level Check . . .4-2
Reserve Engine Oil System . . .4-2
Lubrication Chart . . .4-3
10 HOUR (DAILY) Lubrication And Maintenance Checks . . .4-4
50 HOUR Lubrication And Maintenance Checks . . .4-6
100 HOUR Lubrication And Maintenance Checks . . .4-7
250 HOUR Lubrication And Maintenance Checks . . .4-8
500 HOUR Lubrication And Maintenance Checks . . .4-10
1000 HOUR Lubrication And Maintenance Checks . . . 4-11
MAINTENANCE (Continued) ________________________________________________________ SECTION 4
2500 HOUR Lubrication And Maintenance Checks . . . 4-12
5000 HOUR Lubrication And Maintenance Checks . . . 4-12
10000 HOUR Lubrication And Maintenance Checks . . . 4-12
LINCOLN AUTOMATIC LUBRICATION SYSTEM . . . 4-13
General Description . . . 4-13
System Components . . . 4-15
System Operation . . . 4-16
Injector Operation . . . 4-18
General Instructions . . . 4-19
Lubricant Required . . . 4-19
System Priming . . . 4-19
Filter Assembly . . . 4-19
Lubricant Pump . . . 4-20
System Checkout . . . 4-22
Lubrication Cycle Timer Check . . . 4-22
System Troubleshooting Chart . . . 4-23
Preventative Maintenance Procedures. . . 4-25
SPECIFICATIONS __________________________________________________________________ SECTION 5
This portion of the manual covers major component descriptions and truck specifications.
Major Component Description . . . 5-1
Specifications . . . 5-3
OPTIONAL EQUIPMENT ____________________________________________________________ SECTION 6
This portion of the manual covers operation/maintenance of OPTIONAL EQUIPMENT.
PAYLOAD METER III INDEX . . . 6-1
CAB RADIO (AM/FM STEREO CASSETTE) . . . 7-1
CEAM006200 – Dump Truck 830E Operation & Maintenance Manual…2
COVER…2
INTRODUCTION…7
FOREWARD…7
ALERTS PAGE – DESCRIPTION OF THE DANGER, WARNING, AND CAUTION SYMBOLS USED IN THIS MANUAL…8
TABLE OF CONTENTS…9
TRUCK MODEL ILLUSTRATION…12
ABOUT THIS MANUAL…13
STANDARD CHARTS AND TABLES…15
SAFETY…21
GENERAL SAFETY…21
PRECAUTIONS DURING OPERATION…25
OPERATING MACHINE…26
TOWING…29
BATTERY…30
PRECAUTIONS FOR MAINTENANCE…31
BEFORE CARRYING OUT MAINTENANCE…31
DURING MAINTENANCE…32
TIRES…35
ADDITIONAL JOB SITE RULES…36
WHEN REPAIRS ARE NECESSARY…37
WARNING, CAUTION, AND INSTRUCTION PLATES/DECALS…39
OPERATION…45
OPERATING INSTRUCTIONS…45
PREPARING FOR OPERATION…45
SAFETY IS THINKING AHEAD…45
AT THE TRUCK – GROUND LEVEL WALK – AROUND INSPECTION…45
WALK – AROUND INSPECTION – ILLUSTRATION…46
ENGINE START-UP SAFETY PRACTICES…48
AFTER ENGINE HAS STARTED…49
MACHINE OPERATION SAFETY PRECAUTIONS…49
LOADING…50
HAULING…50
PASSING…50
DUMPING…51
TOWING…52
SAFE PARKING PROCEDURES…53
ENGINE SHUTDOWN PROCEDURE…53
DELAYED ENGINE SHUTDOWN PROCEDURE…54
OPERATOR CAB AND CONTROLS…55
STEERING WHEEL AND CONTROLS…56
SERVICE BRAKE PEDAL …57
THROTTLE PEDAL…57
HEATER/AIR CONDITIONER VENTS…57
HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS…58
CENTER CONSOLE…60
OPERATOR SEAT…64
INSTRUMENT PANEL AND INDICATORS, AND CONTROLS …65
CONTROLS SYMBOLS…65
INSTRUMENT PANEL (3-6)…65
PANEL GAUGES, INDICATORS, AND CONTROLS (DISCUSSION OF ITEMS 1-28, FIGURE 3-6)…67
OVERHEAD STAUTUS/WARNING INDICATOR LIGHT PANEL (FIGURE 3-7)…72
INDICATOR LIGHT SYMBOLS – REFER TO FIGURE 3-7 BY ROWS (A-E) AND COLUMNS (1-6)…73
HAZARD WARNINGS LIGHTS (7)…79
LAMP TEST SWITCH (8)…79
MAINTENANCE…81
LUBRICATION AND SERVICE…81
LUBRICATION CHART…82
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…83
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…85
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…86
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…87
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…89
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…90
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…91
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…92
LINCOLN AUTOMATIC LUBRICATION SYSTEM…93
GENERAL DESCRIPTION…93
SYSTEM COMPONENTS…95
SYSTEM OPERATION…96
INJECTOR OPERATION…98
GENERAL INSTRUCTIONS…99
LUBRICANT REQUIRED…99
SYSTEM PRIMING…99
FILTER ASSEMBLY…99
LUBRICANT PUMP…100
SYSTEM CHECKOUT…102
24 VDC SOLID STATE TIMER CHECK…102
SYSTEM TROUBLESHOOTING CHART…103
PREVENTATIVE MAINTENANCE PROCEDURES…106
SPECIFICATIONS…107
MAJOR COMPONENT DESCRIPTION…107
SPECIFICATIONS…109
OPTIONAL EQUIPMENT…111
PAYLOAD METER II INDEX…111
GENERAL INFORMATION…113
LIGHTS, SWITCHES, AND COMPONENTS…114
TIPS FOR OPERATION…115
EXTERNAL DISPLAY LIGHTS…115
THEORY OF OPERATION…116
BASIC DESCRIPTION…116
LINKAGE FACTOR…116
BRAKE LOCK…117
SOURCES OF ERROR…117
TYPICAL DATA FROM SERVICE CHECK MODE…117
EXAMPLE CALCULATION OF PAYLOAD…118
CALCULATION OF THE CALIBRATION LOAD…118
TYPES OF DATA STORED…119
CYCLE DATA…119
ENGINE ON/OFF DATA…120
FAULT CODES AND WARNING DATA…120
ENGINE OPERATION…121
TOTAL PAYLOAD AND TOTAL NUMBER OF CYLES…121
OTHER DATA…121
OPERATOR FUNCTIONS…122
USING THE OPERATOR LOAD COUNTER…122
DESCRIPTION…122
VIEWING THE OPERATOR LOAD COUNTER…122
CLEARING THE OPERATOR LOAD COUNTER…122
DIMMING THE LIGHTS ON THE DISPLAY…122
INTITIAL SETUP OF PAYLOAD METER…123
SWITCH SETTINGS…123
CHECKING THE OPERATOR CHECK MODE…123
CHECKING THE SERVICE CHECK MODE…124
SETTING "UP:00"…124
SETTING "PL:00"…124
CHECKING THE Gt SETTING…124
CHECKING THE INCLINOMETER SETTINGS…124
CALIBRATING A TRUCK…125
DISPLAYS AT START-UP…126
SETUP AND MAINTENANCE…127
SETTING THE SPEED LIMIT…127
SETTING THE OPTION CODE…127
SETTING THE MACHINE I.D…127
SETTING THE OPERATOR I.D…128
SETTING THE TIME AND DATE…128
DOWNLOAD OF PAYLOAD AND FAULT CODES…128
DISPLAY OF FAULT CODES…129
CHARTS OF ERROR CODES AND OTHER INFORMATION…130
SERVICE CHECK MODE…132
MONITORING INPUT SIGNALS …132
UP FACTOR – PAYLOAD CALCULATION GAIN…133
PL MODE – LOAD CALCULATION…133
FINAL GEAR RATIO SELECTION…134
BATTERY REPLACEMENT PROCEDURE…135
REPLACING THE BATTERY…135
AFTER REPLACING THE BATTERY…136
SUSPENSION PRESSURE SENSOR…136
REMOVAL…136
INSTALLATION…137
INCLINOMETER…137
REMOVAL…137
INSTALLATION…137
SCOREBOARD…138
DESCRIPTION…138
MAKING CONNECTIONS…138
WIRING DIAGRAM…139
NORMAL OPERATION OF THE SCOREBOARD…140
PAYLOAD METER BACK PANEL…140
CONNECTIONS (AMP PIN IDENTIFICATION)…141
PAYLOAD CIRCUIT NUMBERS…142
PAYLOAD METER II RE-INTIALIZATION PROCEDURE…143
CAB RADIO (AM/FM STERO CASSETTE)…145
CEAM010400 – Dump Truck 830E Operation & Maintenance Manual…148
COVER…148
INTRODUCTION…152
FOREWORD…152
ALERTS PAGE…153
TABLE OF CONTENTS…154
TRUCK MODEL ILLUSTRATION…157
ABOUT THIS MANUAL…158
STANDARD CHARTS AND TABLES…160
SAFETY…166
GENERAL SAFETY…166
PRECAUTIONS DURING OPERATION…170
OPERATING THE MACHINE…171
TOWING…174
BATTERY…175
PRECAUTIONS FOR MAINTENANCE…176
BEFORE CARRYING OUT MAINTENANCE…176
DURING MAINTENANCE…177
TIRES…180
ADDITIONAL JOB SITE RULES…181
WHEN REPAIRS ARE NECESSARY…182
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…184
OPERATION…190
OPERATING INSTRUCTIONS…190
PREPARING FOR OPERATION…190
SAFETY IS THINKING AHEAD…190
AT THE TRUCK – GROUND LEVEL WALK-AROUND INSPECTION…190
WALK-AROUND INSPECTION – ILLUSTRATION…191
ENGINE START-UP SAFETY PRACTICES…193
AFTER ENGINE HAS STARTED…194
MACHINE OPERATION SAFETY PRECAUTIONS…194
LOADING…195
HAULING…195
PASSING…195
DUMPING…196
TOWING…197
SUDDEN LOSS OF ENGINE POWER…198
SAFE PARKING PROCEDURES…198
ENGINE SHUTDOWN PROCEDURE…198
DELAYED ENGINE SHUTDOWN PROCEDURE…199
OPERATOR CAB AND CONTROLS…200
STEERING WHEEL AND CONTROLS…201
SERVICE BRAKE PEDAL…202
DYNAMIC RETARDER PEDAL…202
THROTTLE PEDAL…202
HEATER / AIR CONDITIONER VENTS…202
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…203
CENTER CONSOLE…205
INSTRUMENT PANEL AND INDICATOR LIGHTS…209
CONTROL SYMBOLS…209
INSTRUMENT PANEL…210
PANEL GAUGES, INDICATORS, AND CONTROLS…211
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…216
INDICATOR LIGHT SYMBOLS…217
HAZARD WARNING LIGHTS…221
LAMP TEST SWITCH…221
OPERATOR SEAT…222
MAINTENANCE…224
LUBRICATION AND SERVICE…224
LUBRICATION CHART…225
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…226
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…228
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…229
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…230
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…232
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…233
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…234
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…235
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…235
LINCOLN AUTOMATIC LUBRICATION SYSTEM…236
GENERAL DESCRIPTION…236
SYSTEM COMPONENTS…238
SYSTEM OPERATION…239
INJECTOR OPERATION…241
GENERAL INSTRUCTIONS…242
LUBRICATION REQUIRED…242
SYSTEM PRIMING…242
FILTER ASSEMBLY…242
LUBRICANT PUMP…243
SYSTEM CHECKOUT…245
24 VDC SOLID STATE TIMER CHECK…245
SYSTEM TROUBLESHOOTING CHART…246
PREVENTATIVE MAINTENANCE PROCEDURES…249
SPECIFICATIONS…250
MAJOR COMPONENT DESCRIPTION…250
SPECIFICATIONS…252
PAYLOAD METER III…254
INDEX…254
OPERATION SECTION…256
INTRODUCTION…256
DATA SUMMARY…256
DATA GATHERING…256
COMPONENT DESCRIPTION…257
SYSTEM DIAGRAM…257
SUSPENSION PRESSURE SENSORS…257
INCLINOMETER…257
OPERATOR DISPLAY…257
OPERATOR SWITCH…258
SPEED INPUT…258
BODY-UP SWITCH…258
BRAKE LOCK SWITCH…258
PAYLOAD METER…258
COMMUNICATION PORTS…258
KEYSWITCH INPUT…259
PAYLOAD METER POWER…259
LOAD LIGHTS…259
WIRING AND TERMINATION…260
TCI OUTPUTS…260
OPERATOR DISPLAY AND SWITCH…261
READING THE SPEEDOMETER…261
READING THE LOAD DISPLAY…261
USING THE OPERATOR ID…261
USING THE LOAD AND TON COUNTER…261
TOTAL TON COUNTER…261
TOTAL LOAD COUNTER…262
CLEARING THE COUNTERS…262
VIEWING LIVE SENSOR DATA…262
OTHER DISPLAY MESSAGES…262
PAYLOAD OPERATION & CALCULATION…263
DESCRIPTION OF HAUL CYCLE STATES…263
STATES OR STAGES OF A TYPICAL HAUL CYCLE…263
HAULCYCLE DESCRIPTION…263
LOAD CALCULATION…264
CARRY BACK…264
MEASUREMENT ACCURACY…264
SOURCES FOR PAYLOAD ERROR…264
PAYLOAD ERROR…264
LOADING CONDITIONS…265
PRESSURE SENSORS…265
SWING LOADS…265
SPEED AND DISTANCE…265
HAUL CYCLE DATA…265
HAUL CYCLE DATA…266
HAUL CYCLE WARNING FLAGS…267
ALARM RECORDS…268
FRAME TORQUE DATA…268
SPRUNG WEIGHT DATA…269
MAXIMUM SPEED DATA…269
PC SOFTWARE OVERVIEW…269
PC OVERVIEW…269
SYSTEM CONFIGURATION…269
INSTALLING THE PAYLOAD METER III SOFTWARE…269
DOWNLOADING DATA…270
PLM III SYSTEM CONFIGURATION…271
STARTING COMMUNICATIONS…271
DISPLAYED PAYLOAD UNITS…271
TIME UNITS…271
CONNECTION MENU…271
CONNECTING TO THE PAYLOAD METER…272
CONFIGURE THE PAYLOAD METER…272
SETTING THE DATE AND TIME…272
SETTING THE TRUCK TYPE…273
SETTING THE GAUGE DISPLAY UNITS…273
SETTING THE FRAME SERIAL NUMBER…273
SETTING THE TRUCK NUMBER…273
SETTING THE KMS DISTRIBUTOR…273
SETTING THE KMS CUSTOMER…273
CLEAN TRUCK TARE…274
INCLINOMETER CALIBRATION…274
DATA ANALYSIS…275
CREATING A QUERY…275
SORTING ON TRUCK UNIT NUMBER…275
SORTING ON TRUCK TYPE…275
SORTING ON DATE RANGE…276
SORTING ON TIME RANGE…276
PAYLOAD DETAIL SCREEN…277
CREATING REPORTS…277
SUMMARY – ONE PAGE REPORT…278
DETAILED – MULTI PAGE REPORT…278
CREATING GRAPHS…279
EXPORTING DATA…279
CSV EXPORT…279
COMPRESSED…280
IMPORTING DATA…281
DELETING HAUL CYCLE RECORDS…281
VIEWING ALARMS…282
DELETING ALARM RECORDS…282
CAB RADIO …284
CEAM010600 – Dump Truck 830E Operation & Maintenance Manual…292
COVER…292
INTRODUCTION…296
FOREWORD…296
ALERTS PAGE…297
TABLE OF CONTENTS…298
TRUCK MODEL ILLUSTRATION…301
ABOUT THIS MANUAL…302
STANDARD CHARTS AND TABLES…304
SAFETY…310
GENERAL SAFETY…310
PRECAUTIONS DURING OPERATION…314
OPERATING THE MACHINE…315
TOWING…318
BATTERY…319
PRECAUTIONS FOR MAINTENANCE…320
BEFORE CARRYING OUT MAINTENANCE…320
DURING MAINTENANCE…321
TIRES…324
ADDITIONAL JOB SITE RULES…325
WHEN REPAIRS ARE NECESSARY…326
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…328
OPERATION…336
OPERATING INSTRUCTIONS…336
PREPARING FOR OPERATION…336
SAFETY IS THINKING AHEAD…336
AT THE TRUCK – GROUND LEVEL WALK-AROUND INSPECTION…336
WALK-AROUND INSPECTION – ILLUSTRATION…337
ENGINE START-UP SAFETY PRACTICES…339
AFTER ENGINE HAS STARTED…340
MACHINE OPERATION SAFETY PRECAUTIONS…340
LOADING…341
HAULING…341
PASSING…341
DUMPING…342
TOWING…343
SUDDEN LOSS OF ENGINE POWER…344
SAFE PARKING PROCEDURES…344
ENGINE SHUTDOWN PROCEDURE…344
DELAYED ENGINE SHUTDOWN PROCEDURE…345
RESERVE ENGINE OIL SYSTEM…346
OPERATOR CAB AND CONTROLS…348
STEERING WHEEL AND CONTROLS…349
SERVICE BRAKE PEDAL…350
DYNAMIC RETARDER PEDAL…350
THROTTLE PEDAL…350
HEATER / AIR CONDITIONER VENTS…350
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…351
CENTER CONSOLE…353
INSTRUMENT PANEL AND INDICATOR LIGHTS…357
CONTROL SYMBOLS…357
INSTRUMENT PANEL…358
PANEL GAUGES, INDICATORS, AND CONTROLS…359
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…364
INDICATOR LIGHT SYMBOLS…365
HAZARD WARNING LIGHTS…369
LAMP TEST SWITCH…369
OPERATOR SEAT…370
MAINTENANCE…372
LUBRICATION AND SERVICE…372
HYDRAULIC TANK…372
COOLANT LEVEL CHECK…373
RESERVE ENGINE OIL SYSTEM…373
LUBRICATION CHART…374
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…375
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…377
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…378
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…379
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…381
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…382
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…383
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…383
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…383
LINCOLN AUTOMATIC LUBRICATION SYSTEM…384
GENERAL DESCRIPTION…384
SYSTEM COMPONENTS…386
SYSTEM OPERATION…387
INJECTOR OPERATION…389
GENERAL INSTRUCTIONS…390
LUBRICATION REQUIRED…390
SYSTEM PRIMING…390
FILTER ASSEMBLY…390
LUBRICANT PUMP…391
SYSTEM CHECKOUT…393
24 VDC SOLID STATE TIMER CHECK…393
SYSTEM TROUBLESHOOTING CHART…394
PREVENTATIVE MAINTENANCE PROCEDURES…396
SPECIFICATIONS…398
MAJOR COMPONENT DESCRIPTION…398
SPECIFICATIONS…400
PAYLOAD METER III…402
INDEX…402
OPERATION SECTION…404
INTRODUCTION…404
DATA SUMMARY…404
DATA GATHERING…404
COMPONENT DESCRIPTION…405
SYSTEM DIAGRAM…405
SUSPENSION PRESSURE SENSORS…405
INCLINOMETER…405
OPERATOR DISPLAY…405
OPERATOR SWITCH…406
SPEED INPUT…406
BODY-UP SWITCH…406
BRAKE LOCK SWITCH…406
PAYLOAD METER…406
COMMUNICATION PORTS…406
KEYSWITCH INPUT…407
PAYLOAD METER POWER…407
LOAD LIGHTS…407
WIRING AND TERMINATION…408
TCI OUTPUTS…408
OPERATOR DISPLAY AND SWITCH…409
READING THE SPEEDOMETER…409
READING THE LOAD DISPLAY…409
USING THE OPERATOR ID…409
USING THE LOAD AND TON COUNTER…409
TOTAL TON COUNTER…409
TOTAL LOAD COUNTER…410
CLEARING THE COUNTERS…410
VIEWING LIVE SENSOR DATA…410
OTHER DISPLAY MESSAGES…410
PAYLOAD OPERATION & CALCULATION…411
DESCRIPTION OF HAUL CYCLE STATES…411
STATES OR STAGES OF A TYPICAL HAUL CYCLE…411
HAULCYCLE DESCRIPTION…411
LOAD CALCULATION…412
CARRY BACK…412
MEASUREMENT ACCURACY…412
SOURCES FOR PAYLOAD ERROR…412
PAYLOAD ERROR…412
LOADING CONDITIONS…413
PRESSURE SENSORS…413
SWING LOADS…413
SPEED AND DISTANCE…413
HAUL CYCLE DATA…413
HAUL CYCLE DATA…414
HAUL CYCLE WARNING FLAGS…415
ALARM RECORDS…416
FRAME TORQUE DATA…416
SPRUNG WEIGHT DATA…417
MAXIMUM SPEED DATA…417
PC SOFTWARE OVERVIEW…417
PC OVERVIEW…417
SYSTEM CONFIGURATION…417
INSTALLING THE PAYLOAD METER III SOFTWARE…417
DOWNLOADING DATA…418
PLM III SYSTEM CONFIGURATION…419
STARTING COMMUNICATIONS…419
DISPLAYED PAYLOAD UNITS…419
TIME UNITS…419
CONNECTION MENU…419
CONNECTING TO THE PAYLOAD METER…420
CONFIGURE THE PAYLOAD METER…420
SETTING THE DATE AND TIME…420
SETTING THE TRUCK TYPE…421
SETTING THE GAUGE DISPLAY UNITS…421
SETTING THE FRAME SERIAL NUMBER…421
SETTING THE TRUCK NUMBER…421
SETTING THE KMS DISTRIBUTOR…421
SETTING THE KMS CUSTOMER…421
CLEAN TRUCK TARE…422
INCLINOMETER CALIBRATION…422
DATA ANALYSIS…423
CREATING A QUERY…423
SORTING ON TRUCK UNIT NUMBER…423
SORTING ON TRUCK TYPE…423
SORTING ON DATE RANGE…424
SORTING ON TIME RANGE…424
PAYLOAD DETAIL SCREEN…425
CREATING REPORTS…425
SUMMARY – ONE PAGE REPORT…426
DETAILED – MULTI PAGE REPORT…426
CREATING GRAPHS…427
EXPORTING DATA…427
CSV EXPORT…427
COMPRESSED…428
IMPORTING DATA…429
DELETING HAUL CYCLE RECORDS…429
VIEWING ALARMS…430
DELETING ALARM RECORDS…430
CAB RADIO…432
CEAM011500 – Dump Truck 830E Operation & Maintenance Manual…440
COVER…440
INTRODUCTION…444
FOREWORD…444
ALERTS PAGE…445
TABLE OF CONTENTS…446
TRUCK MODEL ILLUSTRATION…449
ABOUT THIS MANUAL…450
STANDARD CHARTS AND TABLES…452
SAFETY…458
GENERAL SAFETY…458
PRECAUTIONS DURING OPERATION…462
OPERATING THE MACHINE…463
TOWING…466
BATTERY…467
PRECAUTIONS FOR MAINTENANCE…468
BEFORE CARRYING OUT MAINTENANCE…468
DURING MAINTENANCE…469
TIRES…472
ADDITIONAL JOB SITE RULES…473
WHEN REPAIRS ARE NECESSARY…474
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…476
OPERATION…484
OPERATING INSTRUCTIONS…484
PREPARING FOR OPERATION…484
SAFETY IS THINKING AHEAD…484
AT THE TRUCK – GROUND LEVEL WALK-AROUND INSPECTION…484
WALK-AROUND INSPECTION – ILLUSTRATION…485
ENGINE START-UP SAFETY PRACTICES…487
AFTER ENGINE HAS STARTED…488
MACHINE OPERATION SAFETY PRECAUTIONS…488
LOADING…489
HAULING…489
PASSING…489
DUMPING…490
TOWING…491
SUDDEN LOSS OF ENGINE POWER…492
SAFE PARKING PROCEDURES…492
ENGINE SHUTDOWN PROCEDURE…492
DELAYED ENGINE SHUTDOWN PROCEDURE…493
RESERVE ENGINE OIL SYSTEM…494
OPERATOR CAB AND CONTROLS…496
STEERING WHEEL AND CONTROLS…497
SERVICE BRAKE PEDAL…498
DYNAMIC RETARDER PEDAL…498
THROTTLE PEDAL…498
HEATER / AIR CONDITIONER VENTS…498
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…499
CENTER CONSOLE…501
INSTRUMENT PANEL AND INDICATOR LIGHTS…505
CONTROL SYMBOLS…505
INSTRUMENT PANEL…506
PANEL GAUGES, INDICATORS, AND CONTROLS…507
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…512
INDICATOR LIGHT SYMBOLS…513
HAZARD WARNING LIGHTS…517
LAMP TEST SWITCH…517
OPERATOR SEAT…518
MAINTENANCE…520
LUBRICATION AND SERVICE…520
HYDRAULIC TANK…520
COOLANT LEVEL CHECK…521
RESERVE ENGINE OIL SYSTEM…521
LUBRICATION CHART…522
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…523
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…525
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…526
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…527
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…529
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…530
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…531
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…531
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…531
LINCOLN AUTOMATIC LUBRICATION SYSTEM…532
GENERAL DESCRIPTION…532
SYSTEM COMPONENTS…534
SYSTEM OPERATION…535
INJECTOR OPERATION…537
GENERAL INSTRUCTIONS…538
LUBRICATION REQUIRED…538
SYSTEM PRIMING…538
FILTER ASSEMBLY…538
LUBRICANT PUMP…539
SYSTEM CHECKOUT…541
24 VDC SOLID STATE TIMER CHECK…541
SYSTEM TROUBLESHOOTING CHART…542
PREVENTATIVE MAINTENANCE PROCEDURES…544
SPECIFICATIONS…546
MAJOR COMPONENT DESCRIPTION…546
SPECIFICATIONS…548
PAYLOAD METER III…550
INDEX…550
OPERATION SECTION…552
INTRODUCTION…552
DATA SUMMARY…552
DATA GATHERING…552
COMPONENT DESCRIPTION…553
SYSTEM DIAGRAM…553
SUSPENSION PRESSURE SENSORS…553
INCLINOMETER…553
OPERATOR DISPLAY…553
OPERATOR SWITCH…554
SPEED INPUT…554
BODY-UP SWITCH…554
BRAKE LOCK SWITCH…554
PAYLOAD METER…554
COMMUNICATION PORTS…554
KEYSWITCH INPUT…555
PAYLOAD METER POWER…555
LOAD LIGHTS…555
WIRING AND TERMINATION…556
TCI OUTPUTS…556
OPERATOR DISPLAY AND SWITCH…557
READING THE SPEEDOMETER…557
READING THE LOAD DISPLAY…557
USING THE OPERATOR ID…557
USING THE LOAD AND TON COUNTER…557
TOTAL TON COUNTER…557
TOTAL LOAD COUNTER…558
CLEARING THE COUNTERS…558
VIEWING LIVE SENSOR DATA…558
OTHER DISPLAY MESSAGES…558
PAYLOAD OPERATION & CALCULATION…559
DESCRIPTION OF HAUL CYCLE STATES…559
STATES OR STAGES OF A TYPICAL HAUL CYCLE…559
HAULCYCLE DESCRIPTION…559
LOAD CALCULATION…560
CARRY BACK…560
MEASUREMENT ACCURACY…560
SOURCES FOR PAYLOAD ERROR…560
PAYLOAD ERROR…560
LOADING CONDITIONS…561
PRESSURE SENSORS…561
SWING LOADS…561
SPEED AND DISTANCE…561
HAUL CYCLE DATA…561
HAUL CYCLE DATA…562
HAUL CYCLE WARNING FLAGS…563
ALARM RECORDS…564
FRAME TORQUE DATA…564
SPRUNG WEIGHT DATA…565
MAXIMUM SPEED DATA…565
PC SOFTWARE OVERVIEW…565
PC OVERVIEW…565
SYSTEM CONFIGURATION…565
INSTALLING THE PAYLOAD METER III SOFTWARE…565
DOWNLOADING DATA…566
PLM III SYSTEM CONFIGURATION…567
STARTING COMMUNICATIONS…567
DISPLAYED PAYLOAD UNITS…567
TIME UNITS…567
CONNECTION MENU…567
CONNECTING TO THE PAYLOAD METER…568
CONFIGURE THE PAYLOAD METER…568
SETTING THE DATE AND TIME…568
SETTING THE TRUCK TYPE…569
SETTING THE GAUGE DISPLAY UNITS…569
SETTING THE FRAME SERIAL NUMBER…569
SETTING THE TRUCK NUMBER…569
SETTING THE KMS DISTRIBUTOR…569
SETTING THE KMS CUSTOMER…569
CLEAN TRUCK TARE…570
INCLINOMETER CALIBRATION…570
DATA ANALYSIS…571
CREATING A QUERY…571
SORTING ON TRUCK UNIT NUMBER…571
SORTING ON TRUCK TYPE…571
SORTING ON DATE RANGE…572
SORTING ON TIME RANGE…572
PAYLOAD DETAIL SCREEN…573
CREATING REPORTS…573
SUMMARY – ONE PAGE REPORT…574
DETAILED – MULTI PAGE REPORT…574
CREATING GRAPHS…575
EXPORTING DATA…575
CSV EXPORT…575
COMPRESSED…576
IMPORTING DATA…577
DELETING HAUL CYCLE RECORDS…577
VIEWING ALARMS…578
DELETING ALARM RECORDS…578
CAB RADIO…580
CEAM013204 – Dump Truck 830E Operation & Maintenance Manual…588
COVER…588
INTRODUCTION…592
FOREWORD…592
ALERTS PAGE…593
TABLE OF CONTENTS…594
TRUCK MODEL ILLUSTRATION…601
ABOUT THIS MANUAL…602
STANDARD CHARTS AND TABLES…604
GENERAL SAFETY…610
GENERAL SAFETY…610
SAFETY RULES…610
SAFETY FEATURES…610
CLOTHING AND PERSONAL ITEMS…610
UNAUTHORIZED MODIFICATION…610
LEAVING THE OPERATORS SEAT…611
MOUNTING AND DISMOUNTING…611
FIRE PREVENTION FOR FUEL AND OIL…611
PRECAUTIONS WITH HIGH TEMPERATURE FLUIDS…612
ASBESTOS DUST HAZARD PREVENTION…612
PREVENTION OF INJURY BY WORK EQUIPMENT…612
FIRE EXTINGUISHER AND FIRST AID KIT…612
PRECAUTIONS WHEN USING ROPS…613
PRECAUTIONS FOR ATTACHMENTS…613
PRECAUTIONS FOR STARTING MACHINE…613
PRECAUTIONS DURING OPERATION…614
Safety Is Thinking Ahead…614
Safety At The Worksite…614
Fire Prevention…614
Preparing For Operation…614
Ventilation In Enclosed Areas…614
In Operators Cab – Before Starting The Engine…615
Mirrors, Windows, And Lights…615
OPERATING THE MACHINE…615
When Starting The Engine…615
Truck Operation – General…615
Check When Traveling In Reverse…616
Traveling…616
Traveling On Slopes…617
Ensure Good Visibility…617
Operate Carefully On Snow…617
Avoid Damage To Dump Body…617
Driving Near High-voltage Cables…617
When Dumping…618
Working On Loose Ground…618
When Loading…618
Parking The Machine…618
TOWING…618
WORKING NEAR BATTERIES…619
Battery Hazard Prevention…619
Starting With Booster Cables…619
PRECAUTIONS FOR MAINTENANCE…620
BEFORE CARRYING OUT MAINTENANCE…620
Warning Tag…620
Proper Tools…620
Stopping The Engine Before Service…620
Securing The Dump Body…620
DURING MAINTENANCE…621
Personnel…621
Attachments…621
Working Under The Machine…621
Keep The Machine Clean…621
Rules To Follow When Adding Fuel Or Oil…621
Radiator Water Level…622
Use Of Lighting…622
Precautions With The Battery…622
Handling High-pressure Hoses…622
Precautions With High Pressure Oil…622
Precautions When Performing Maintenance Near High Temperature Or High Pressure…623
Rotation Fan And Belts…623
Waste Materials…623
TIRES…624
Handling Tires…624
Storing Tires After Removal…624
ADDITIONAL JOB SITE RULES…625
WHEN REPAIRS ARE NECESSARY…626
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…628
OPERATION…636
OPERATING INSTRUCTIONS…636
PREPARING FOR OPERATION…636
SAFETY IS THINKING AHEAD…636
AT THE TRUCK – GROUND LEVEL WALK-AROUND INSPECTION…636
WALK-AROUND INSPECTION – ILLUSTRATION…637
ENGINE START-UP SAFETY PRACTICES…639
AFTER ENGINE HAS STARTED…640
MACHINE OPERATION SAFETY PRECAUTIONS…640
LOADING…641
HAULING…641
PASSING…641
DUMPING…642
To Raise Body…642
To Lower Body…642
TOWING…643
SUDDEN LOSS OF ENGINE POWER…644
SAFE PARKING PROCEDURES…644
ENGINE SHUTDOWN PROCEDURE…644
DELAYED ENGINE SHUTDOWN PROCEDURE…645
RESERVE ENGINE OIL SYSTEM…646
INSTRUMENT PANEL AND INDICATOR LIGHTS…657
CONTROL SYMBOLS…657
INSTRUMENT PANEL…658
PANEL GAUGES, INDICATORS, AND CONTROLS…659
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…664
INDICATOR LIGHT SYMBOLS…665
HAZARD WARNING LIGHTS…669
LAMP TEST SWITCH…669
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…670
Operation…670
Interface Module…671
Basic Operation…671
OPERATOR SEAT…672
OPERATOR CAB AND CONTROLS…648
STEERING WHEEL AND CONTROLS…649
Horn Button…649
Tilt / Telescope Lever…649
Turn Signal / Headlight Dimmer…649
SERVICE BRAKE PEDAL…650
DYNAMIC RETARDER PEDAL…650
OPTIONAL – DUAL FUNCTION / SINGLE PEDAL…650
THROTTLE PEDAL…650
HEATER / AIR CONDITIONER VENTS…650
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…651
Heater / Air Conditioner Compartment & Controls…651
Defroster Vent Control Switch…651
Heat Vent Control Switch…651
Temperature Control Knob…651
Fan Control Knob…651
Heater / Air Conditioner Selector Switch…651
Heater / Air Conditioner Vents…651
INSTRUMENT PANEL…652
GRADE SPEED WARNING CHART…652
RADIO SPEAKERS…652
WARNING ALARM BUZZER…652
CAB RADIO…652
WARNING LIGHTS DIMMER CONTROL…652
STATUS / WARNING INDICATOR LIGHT PANEL…652
PAYLOAD METER…652
WINDSHIELD WIPERS…652
AIR CLEANER VACUUM GAUGES…653
CENTER CONSOLE…653
F-N-R Selector Switch…653
Hoist Control Lever…654
To Raise Body:…654
To Lower Body:…654
Ash Tray…654
Lighter…654
L.H. Window Control Switch…654
R.H. Window Control Switch…654
Engine Shutdown Switch…654
Override Switch…655
Retard Speed Control (RSC) Switch…655
Retard Speed Control (RSC) Adjust Dial…655
Statex III Propulsion System Diagnostic Connector…656
Komatsu Engine Quantum Connector…656
Komatsu Engine Cense Connector…656
Modular Mining Port Conector…656
Data Store Button…656
Pasenger Seat…656
Service Engine Light (Blue)…656
INSTRUMENT PANEL AND INDICATOR LIGHTS…657
CONTROL SYMBOLS…657
INSTRUMENT PANEL…658
PANEL GAUGES, INDICATORS, AND CONTROLS…659
Key Switch…659
Engine Shutdown Switch with Timer Delay…659
Fog Lights…660
Ladder Light Switch…660
Manual Backup Switch…660
Panel Illumination Lights…660
Cab Air Conditioner / Heater Vents…660
Engine Cold Weather Starting Aid…660
Rotation Beacon Light Switch…660
Heated Mirror Switch…660
Wheel Brake Lock Control…661
Parking Brake Control…661
Tachometer…661
Right Turn Signal Indicator…662
High Beam Indicator…662
Left Turn Signal Indicator…662
Speedometer / Payload Meter…662
Voltmeter…662
Engine Oil Pressure Gauge…662
Water Temperature Gauge…662
Fuel Gauge…662
Hour Meter…663
Headlight Switch…663
Windshield Wiper and Washer…663
Panel Light Dimmer…663
Payload Meter Switch…663
OVERHEAD STATUS WARNING INDICATOR LIGHTS…664
INDICATOR LIGHT SYMBOLS…665
Hazard Warning Lights…669
Lamp Test Switch…669
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…670
Operation…670
Interface Module…671
Basic Precautions…671
OPERATOR COMFORT…672
Operators Seat…672
MAINTENANCE…674
LUBRICATION AND SERVICE…674
HYDRAULIC TANK SERVICE…674
Adding Oil…674
830E SERVICE CAPACITIES…674
COOLANT LEVEL CHECK…675
RADIATOR FILLING PROCEDURE…675
RESERVE ENGINE OIL SYSTEM…675
Reserve Oil Tank Filling Procedure (Remote Fill)…675
LUBRICATION CHART…676
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…677
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…679
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…680
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…681
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…683
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…684
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…685
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…685
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…685
LINCOLN AUTOMATIC LUBRICATION SYSTEM…686
GENERAL DESCRIPTION…686
SYSTEM COMPONENTS…688
SYSTEM OPERATION…689
Normal Operation…689
Pressure Failure Detection Circuits…690
INJECTOR OPERATION…691
GENERAL INSTRUCTIONS…692
LUBRICATION REQUIRED…692
SYSTEM PRIMING…692
FILTER ASSEMBLY…692
LUBRICANT PUMP…693
Pump Housing Oil Level…693
Pump Pressure Control…693
Pressure Control Valve Adjustment…693
INJECTORS…694
Injector Specifications…694
Injector Adjustment…694
SYSTEM CHECKOUT…695
24 VDC SOLID STATE TIMER CHECK…695
Lubrication Cycle Timer Adjustment…695
SYSTEM TROUBLESHOOTING CHART…696
PREVENTATIVE MAINTENANCE PROCEDURES…698
Daily Lubrication System Inspection…698
250 Hour Inspection…698
1000 Hour Inspection…698
SPECIFICATIONS…700
MAJOR COMPONENT DESCRIPTION…700
SPECIFICATIONS…702
PAYLOAD METER III…704
INDEX…704
OPERATION SECTION…706
INTRODUCTION…706
DATA SUMMARY…706
DATA GATHERING…706
COMPONENT DESCRIPTION…707
SYSTEM DIAGRAM…707
SUSPENSION PRESSURE SENSORS…707
INCLINOMETER…707
OPERATOR DISPLAY…707
OPERATOR SWITCH…708
SPEED INPUT…708
BODY-UP SWITCH…708
BRAKE LOCK SWITCH…708
PAYLOAD METER…708
COMMUNICATION PORTS…708
KEYSWITCH INPUT…709
PAYLOAD METER POWER…709
LOAD LIGHTS…709
WIRING AND TERMINATION…710
TCI OUTPUTS…710
OPERATOR DISPLAY AND SWITCH…711
READING THE SPEEDOMETER…711
READING THE LOAD DISPLAY…711
USING THE OPERATOR ID…711
USING THE LOAD AND TON COUNTER…711
TOTAL TON COUNTER…711
TOTAL LOAD COUNTER…712
CLEARING THE COUNTERS…712
VIEWING LIVE SENSOR DATA…712
OTHER DISPLAY MESSAGES…712
PAYLOAD OPERATION & CALCULATION…713
DESCRIPTION OF HAUL CYCLE STATES…713
STATES OR STAGES OF A TYPICAL HAUL CYCLE…713
HAULCYCLE DESCRIPTION…713
LOAD CALCULATION…714
CARRY BACK…714
MEASUREMENT ACCURACY…714
SOURCES FOR PAYLOAD ERROR…714
PAYLOAD ERROR…714
LOADING CONDITIONS…715
PRESSURE SENSORS…715
SWING LOADS…715
SPEED AND DISTANCE…715
HAUL CYCLE DATA…715
HAUL CYCLE DATA…716
HAUL CYCLE WARNING FLAGS…717
A: CONTINUOUS LOADING…717
B: LOADING TO DUMPING TRANSITION…717
C: NO FINAL LOAD…717
D: MANEUVERING TO DUMPING TRANSITION…717
E: AVERAGE LOAD OR TARE USED…717
F: FINAL ZONE TO DUMPING TRANSITION…717
H: FALSE BODY UP…717
I: BODY UP SIGNAL FAILED…717
J: SPEED SENSOR FAILED…717
K: NEW TARE NOT CALCULATED…717
L: INCOMPLETE HAUL CYCLE…717
M: HAUL CYCLE TOO LONG…718
N: SENSOR INPUT ERROR…718
ALARM RECORDS…718
FRAME TORQUE DATA…718
SPRUNG WEIGHT DATA…719
MAXIMUM SPEED DATA…719
PC SOFTWARE OVERVIEW…719
PC OVERVIEW…719
SYSTEM CONFIGURATION…719
INSTALLING THE PAYLOAD METER III SOFTWARE…719
DOWNLOADING DATA…720
PLM III SYSTEM CONFIGURATION…721
STARTING COMMUNICATIONS…721
DISPLAYED PAYLOAD UNITS…721
TIME UNITS…721
CONNECTION MENU…721
CONNECTING TO THE PAYLOAD METER…722
CONFIGURE THE PAYLOAD METER…722
SETTING THE DATE AND TIME…722
SETTING THE TRUCK TYPE…723
SETTING THE GAUGE DISPLAY UNITS…723
SETTING THE FRAME SERIAL NUMBER…723
SETTING THE TRUCK NUMBER…723
SETTING THE KMS DISTRIBUTOR…723
SETTING THE KMS CUSTOMER…723
CLEAN TRUCK TARE…724
INCLINOMETER CALIBRATION…724
DATA ANALYSIS…725
CREATING A QUERY…725
SORTING ON TRUCK UNIT NUMBER…725
SORTING ON TRUCK TYPE…725
SORTING ON DATE RANGE…726
SORTING ON TIME RANGE…726
PAYLOAD DETAIL SCREEN…727
CREATING REPORTS…727
SUMMARY – ONE PAGE REPORT…728
DETAILED – MULTI PAGE REPORT…728
CREATING GRAPHS…729
EXPORTING DATA…729
CSV EXPORT…729
COMPRESSED…730
IMPORTING DATA…731
DELETING HAUL CYCLE RECORDS…731
VIEWING ALARMS…732
DELETING ALARM RECORDS…732
CAB RADIO…734
SETTING THE TIME…734
GENERAL RECEIVER FUNCTIONS…734
Turning the Power On and OFF…734
Display…734
Setting The Default Display…735
Adjusting Display Brightness…735
OPERATING THE RADIO…735
Band…735
Tune / Seek…735
Manual Tuning…735
Seek Mode…735
Scan…735
Auto…735
ADJUSTING THE RECEIVER SETTINGS…736
PROGRAMMING PRESET STATIONS…736
OPERATION OF THE WEATHERBAND…736
SATELLITE RADIO…737
Operating Satellite Radio…737
Program Type Search (PTY)…737
CASSETTE PLAYER…738
Playing a Cassette…738
Cassette Functions…738
PROGRAMMABLE EJECT DEFAULT…738
Bad Tape Detect…739
CASSETTE PLAYER CLEANING…739
CEAM013400 – Dump Truck 830E Operation & Maintenance Manual…742
COVER…742
INTRODUCTION…746
FOREWORD…746
ALERTS PAGE…747
TABLE OF CONTENTS…748
TRUCK MODEL ILLUSTRATION…751
ABOUT THIS MANUAL…752
STANDARD CHARTS AND TABLES…754
SAFETY…760
GENERAL SAFETY…760
PRECAUTIONS DURING OPERATION…764
OPERATING THE MACHINE…765
TOWING…768
BATTERY…769
PRECAUTIONS FOR MAINTENANCE…770
BEFORE CARRYING OUT MAINTENANCE…770
DURING MAINTENANCE…771
TIRES…774
ADDITIONAL JOB SITE RULES…775
WHEN REPAIRS ARE NECESSARY…776
WARNING, CAUTION, AND INSTRUCTION PLATES / DECALS…778
OPERATION…786
OPERATING INSTRUCTIONS…786
PREPARING FOR OPERATION…786
SAFETY IS THINKING AHEAD…786
AT THE TRUCK – GROUND LEVEL WALK-AROUND INSPECTION…786
WALK-AROUND INSPECTION – ILLUSTRATION…787
ENGINE START-UP SAFETY PRACTICES…789
AFTER ENGINE HAS STARTED…790
MACHINE OPERATION SAFETY PRECAUTIONS…790
LOADING…791
HAULING…791
PASSING…791
DUMPING…792
TOWING…793
SUDDEN LOSS OF ENGINE POWER…794
SAFE PARKING PROCEDURES…794
ENGINE SHUTDOWN PROCEDURE…794
DELAYED ENGINE SHUTDOWN PROCEDURE…795
RESERVE ENGINE OIL SYSTEM…796
OPERATOR CAB AND CONTROLS…798
STEERING WHEEL AND CONTROLS…799
SERVICE BRAKE PEDAL…800
DYNAMIC RETARDER PEDAL…800
THROTTLE PEDAL…800
HEATER / AIR CONDITIONER VENTS…800
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…801
CENTER CONSOLE…803
INSTRUMENT PANEL AND INDICATOR LIGHTS…807
CONTROL SYMBOLS…807
INSTRUMENT PANEL…808
PANEL GAUGES, INDICATORS, AND CONTROLS…809
OVERHEAD STATUS / WARNING INDICATOR LIGHT PANEL…814
INDICATOR LIGHT SYMBOLS…815
HAZARD WARNING LIGHTS…819
LAMP TEST SWITCH…819
OPERATOR SEAT…820
MAINTENANCE…822
LUBRICATION AND SERVICE…822
HYDRAULIC TANK…822
COOLANT LEVEL CHECK…823
RESERVE ENGINE OIL SYSTEM…823
LUBRICATION CHART…824
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS…825
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…827
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…828
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…829
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…831
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS…832
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS…833
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS…833
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS…833
LINCOLN AUTOMATIC LUBRICATION SYSTEM…834
GENERAL DESCRIPTION…834
SYSTEM COMPONENTS…836
SYSTEM OPERATION…837
INJECTOR OPERATION…839
GENERAL INSTRUCTIONS…840
LUBRICATION REQUIRED…840
SYSTEM PRIMING…840
FILTER ASSEMBLY…840
LUBRICANT PUMP…841
SYSTEM CHECKOUT…843
24 VDC SOLID STATE TIMER CHECK…843
SYSTEM TROUBLESHOOTING CHART…844
PREVENTATIVE MAINTENANCE PROCEDURES…846
SPECIFICATIONS…848
MAJOR COMPONENT DESCRIPTION…848
SPECIFICATIONS…850
PAYLOAD METER III…852
INDEX…852
OPERATION SECTION…854
INTRODUCTION…854
DATA SUMMARY…854
DATA GATHERING…854
COMPONENT DESCRIPTION…855
SYSTEM DIAGRAM…855
SUSPENSION PRESSURE SENSORS…855
INCLINOMETER…855
OPERATOR DISPLAY…855
OPERATOR SWITCH…856
SPEED INPUT…856
BODY-UP SWITCH…856
BRAKE LOCK SWITCH…856
PAYLOAD METER…856
COMMUNICATION PORTS…856
KEYSWITCH INPUT…857
PAYLOAD METER POWER…857
LOAD LIGHTS…857
WIRING AND TERMINATION…858
TCI OUTPUTS…858
OPERATOR DISPLAY AND SWITCH…859
READING THE SPEEDOMETER…859
READING THE LOAD DISPLAY…859
USING THE OPERATOR ID…859
USING THE LOAD AND TON COUNTER…859
TOTAL TON COUNTER…859
TOTAL LOAD COUNTER…860
CLEARING THE COUNTERS…860
VIEWING LIVE SENSOR DATA…860
OTHER DISPLAY MESSAGES…860
PAYLOAD OPERATION & CALCULATION…861
DESCRIPTION OF HAUL CYCLE STATES…861
STATES OR STAGES OF A TYPICAL HAUL CYCLE…861
HAULCYCLE DESCRIPTION…861
LOAD CALCULATION…862
CARRY BACK…862
MEASUREMENT ACCURACY…862
SOURCES FOR PAYLOAD ERROR…862
PAYLOAD ERROR…862
LOADING CONDITIONS…863
PRESSURE SENSORS…863
SWING LOADS…863
SPEED AND DISTANCE…863
HAUL CYCLE DATA…863
HAUL CYCLE DATA…864
HAUL CYCLE WARNING FLAGS…865
ALARM RECORDS…866
FRAME TORQUE DATA…866
SPRUNG WEIGHT DATA…867
MAXIMUM SPEED DATA…867
PC SOFTWARE OVERVIEW…867
PC OVERVIEW…867
SYSTEM CONFIGURATION…867
INSTALLING THE PAYLOAD METER III SOFTWARE…867
DOWNLOADING DATA…868
PLM III SYSTEM CONFIGURATION…869
STARTING COMMUNICATIONS…869
DISPLAYED PAYLOAD UNITS…869
TIME UNITS…869
CONNECTION MENU…869
CONNECTING TO THE PAYLOAD METER…870
CONFIGURE THE PAYLOAD METER…870
SETTING THE DATE AND TIME…870
SETTING THE TRUCK TYPE…871
SETTING THE GAUGE DISPLAY UNITS…871
SETTING THE FRAME SERIAL NUMBER…871
SETTING THE TRUCK NUMBER…871
SETTING THE KMS DISTRIBUTOR…871
SETTING THE KMS CUSTOMER…871
CLEAN TRUCK TARE…872
INCLINOMETER CALIBRATION…872
DATA ANALYSIS…873
CREATING A QUERY…873
SORTING ON TRUCK UNIT NUMBER…873
SORTING ON TRUCK TYPE…873
SORTING ON DATE RANGE…874
SORTING ON TIME RANGE…874
PAYLOAD DETAIL SCREEN…875
CREATING REPORTS…875
SUMMARY – ONE PAGE REPORT…876
DETAILED – MULTI PAGE REPORT…876
CREATING GRAPHS…877
EXPORTING DATA…877
CSV EXPORT…877
COMPRESSED…878
IMPORTING DATA…879
DELETING HAUL CYCLE RECORDS…879
VIEWING ALARMS…880
DELETING ALARM RECORDS…880
CAB RADIO…882
CEAM015001 – Dump Truck 830E Operation & Maintenance Manual…890
COVER…890
INTRODUCTION…896
FOREWORD…896
ALERTS PAGE…897
TRUCK MODEL ILLUSTRATION…905
ABOUT THIS MANUAL…906
WARNINGS…892
STANDARD CHARTS AND TABLES…908
TABLE OF CONTENTS…898
GENERAL SAFETY…914
Safety Rules…914
Safety Features…914
Clothing And Personal Items…914
Unauthorized Modification…914
Leaving The Operator's Seat…915
Mounting And Dismounting…915
Fire Prevention For Fuel And Oil…915
Precautions With High Temperature Fluids…916
Asbestos Dust Hazard Prevention…916
Prevention Of Injury By Work Equipment…916
Fire Extinguisher And First Aid Kit…916
Precautions When Using Rops…917
Precautions For Attachments…917
Precautions For Starting Machine…917
PRECAUTIONS DURING OPERATION…918
Safety Is Thinking Ahead…918
Safety At The Worksite…918
Fire Prevention…918
Preparing For Operation…918
Ventilation In Enclosed Areas…918
In Operator's Cab – Before Starting The Engine…919
Mirrors, Windows, And Lights…919
OPERATING THE MACHINE…919
When Starting The Engine…919
Truck Operation – General…919
Check When Traveling In Reverse…920
Traveling…920
Traveling On Slopes…921
Ensure Good Visibility…921
Operate Carefully On Snow…921
Avoid Damage To Dump Body…921
Driving Near High-voltage Cables…921
When Dumping…922
Working On Loose Ground…922
When Loading…922
Parking The Machine…922
TOWING…922
WORKING NEAR BATTERIES…923
Battery Hazard Prevention…923
Starting With Booster Cables…923
PRECAUTIONS FOR MAINTENANCE…924
BEFORE PERFORMING MAINTENANCE…924
Warning Tag…924
Proper Tools…924
Stopping The Engine Before Service…924
Securing The Dump Body…924
DURING MAINTENANCE…925
Personnel…925
Attachments…925
Work Under The Machine…925
Keep The Machine Clean…925
Rules To Follow When Adding Fuel Or Oil…925
Radiator Water Level…926
Use Of Lighting…926
Precautions With The Battery…926
Handling High-pressure Hoses…926
Precautions With High Pressure Oil…926
Precautions When Performing Maintenance Near High Temperature Or High Pressure…927
Rotating Fan And Belts…927
Waste Materials…927
TIRES…928
Handling Tires…928
Storing Tires After Removal…928
ADDITIONAL JOB SITE RULES…929
WHEN REPAIRS ARE NECESSARY…930
WARNINGS AND CAUTIONS…932
OPERATING INSTRUCTIONS…940
PREPARING FOR OPERATION…940
Safety Is Thinking Ahead…940
At The Truck – Ground Level Walk Around Inspection…940
ENGINE START-UP SAFETY PRACTICES…943
AFTER ENGINE HAS STARTED…944
MACHINE OPERATION SAFETY PRECAUTIONS…944
LOADING…945
HAULING…945
PASSING…945
DUMPING…946
To Raise Body:…946
To Lower Body: When dumping over a berm or into a crusher:…946
To Lower Body: When dumping on flat ground:…947
TOWING…947
SUDDEN LOSS OF ENGINE POWER…948
SAFE PARKING PROCEDURES…948
ENGINE SHUTDOWN PROCEDURE…948
DELAYED ENGINE SHUTDOWN PROCEDURE…949
RESERVE ENGINE OIL SYSTEM (Optional)…950
Operation…950
LED Monitor Light…950
Changing Oil…950
OPERATOR CAB AND CONTROLS…952
STEERING WHEEL AND CONTROLS…953
Horn Button…953
Tilt / Telescope Lever…953
Multi-function Turn Signal Switch…953
Turn Signal Operation…953
High Beam Headlight Operation…953
Windshieldindshield Wiper Operation…953
PEDALS…954
Service Brake Pedal…954
Dynamic Retarder Pedal…954
Optional – Dual Function / Single Pedal…954
Throttle Pedal…954
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…955
Defroster Vent Control Switch…955
Heat Vent Control Switch…955
Temperature Control Knob…955
Fan Control Knob…955
Heater/air Conditioner Selector Switch…955
Heater/air Conditioner Vents…955
OVERHEAD PANEL AND DISPLAY…956
Grade/speed Warning Chart…956
Radio Speakers…956
Warning Alarm Buzzer…956
Cab Radio…956
Warning Lights Dimmer Control…956
Status / Warning Indicator Light Panel…956
Windshield Wipers…956
Air Cleaner Vacuum Gauges…957
CENTER CONSOLE…957
F-n-r Selector Switch…957
Hoist Control Lever…958
To Raise Body:…958
To Lower Body:…958
Ash Tray…958
Lighter…958
L.h. Window Control Switch…958
R.h. Window Control Switch…958
Engine Shutdown Switch…958
Override Switch…959
Retard Speed Control (RSC) Off/on Switch…959
Retard Speed Control (RSC) Adjust Dial…959
Statex III Propulsion System Diagnostic Connector…960
Komatsu Engine Quantum Connector…960
Komatsu Engine Cense Connector…960
Unused Connector…960
Modular Mining Port Conector…960
Data Store Button…960
Passenger Seat…960
Service Engine Light (Blue)…960
Payload Meter…960
INSTRUMENT PANEL AND INDICATOR LIGHTS…961
CONTROL SYMBOLS…961
INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS…962
Key Switch…963
Starting…963
Engine Shutdown Switch With Timer Delay (Optional)…963
Fog Lights (Optional)…964
Ladder Light Switch…964
Manual Backup Switch…964
Panel Illumination Lights…964
Cab Air Conditioner / Heater Vents…964
Engine Cold Weather Starting Aid (Optional)…964
Rotating Beacon Light Switch (Optional)…964
Heated Mirror Switch (Optional)…964
Wheel Brake Lock Control…965
Parking Brake Control…965
Tachometer…965
Right Turn Signal Indicator…966
High Beam Indicator…966
Left Turn Signal Indicator…966
Speedometer / Payload Meter…966
Voltmeter…966
Engine Oil Pressure Gauge…966
Water Temperature Gauge…966
Fuel Gauge…966
Hourmeter…967
Headlight Switch…967
Panel Light Dimmer…967
Payload Meter Switch…967
INDICATOR LIGHT SYMBOLS…969
Hazard Warning Lights…973
Lamp Test Switch…973
OPERATOR COMFORT…974
OPERATOR SEAT…974
Adjustment…974
Seat Removal…974
Seat Installation…975
LUBRICATION AND SERVICE…976
830E SERVICE CAPACITIES…976
HYDRAULIC TANK SERVICE…976
Adding Oil…976
COOLANT LEVEL CHECK…977
RADIATOR FILLING PROCEDURE…977
RESERVE ENGINE OIL SYSTEM (Optional)…977
Reserve Oil Tank Filling Procedure (Remote fill)…977
LUBRICATION CHART…978
10 HOUR (DAILY) INSPECTION…979
10 HOUR LUBRICATION AND MAINTENANCE CHECKS…979
LED Light Signals:…979
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…981
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…982
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…983
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…985
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…986
2500 HOUR MAIN1TENANCE CHECKS…987
5000 HOUR MAINTENANCE CHECKS…987
10,000 HOUR MAINTENANCE CHECKS…987
AUTOMATIC LUBRICATION SYSTEM…988
GENERAL DESCRIPTION…988
SYSTEM COMPONENTS…990
Filter …990
Hydraulic Motor and Pump …990
Grease Reservoir …990
Pressure Reducing Valve…990
Flow Control Valve…990
Solenoid Valve …990
Vent Valve…990
Lubrication Cycle Timer…990
Delay Timer…990
Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]) …990
Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])…990
Pressure Gauge…990
Injectors…990
SYSTEM OPERATION…991
Normal Operation:…991
Pressure Failure Detection Circuits:…992
INJECTOR OPERATION…993
System Priming…994
Filter Assembly…994
LUBRICANT PUMP…995
Pump Housing Oil Level…995
Pump Pressure Control…995
Pressure Control Valve Adjustment…995
INJECTORS (SL-1 Series “H”))…996
Injector Specifications…996
Injector Adjustment…996
SYSTEM CHECKOUT…997
Lubrication Cycle Timer Check…997
Lubrication Cycle Timer Adjustment…997
SYSTEM TROUBLESHOOTING CHART…998
PREVENTATIVE MAINTENANCE PROCEDURES…1000
Daily Lubrication System Inspection…1000
250 Hour Inspection…1000
1000 Hour Inspection…1000
TRUCK COMPONENT DESCRIPTION…1002
SPECIFICATIONS…1004
PAYLOAD METER III…1006
OPERATION SECTION…1008
Introduction…1008
Data Summary…1008
Data Gathering…1008
COMPONENT DESCRIPTION…1009
System Diagram…1009
Suspension Pressure Sensors…1009
Inclinometer…1009
Operator Display…1009
Operator Switch…1010
Speed Input…1010
Body-Up Switch…1010
Brake Lock Switch…1010
Payload Meter…1010
Communications Ports…1010
Keyswitch Input…1011
Payload Meter Power…1011
Load Lights…1011
Wiring and Termination…1012
TCI Outputs…1012
OPERATOR’S DISPLAY AND SWITCH…1013
Reading the Speedometer…1013
Reading the Load Display…1013
Using the Operator ID…1013
Using the Load and Ton Counter…1013
Total Ton Counter…1013
Total Load Counter…1014
Clearing the Counters…1014
Viewing Live Sensor Data…1014
Other Display Messages…1014
PAYLOAD OPERATION & CALCULATION…1015
Description of Haul Cycle States…1015
Haul Cycle Description…1015
Load Calculation…1016
Carry Back…1016
Measurement Accuracy…1016
SOURCES FOR PAYLOAD ERROR…1016
Payload Error…1016
Loading Conditions…1017
Pressure Sensors…1017
Swingloads…1017
Speed and Distance…1017
HAUL CYCLE DATA…1017
Haul Cycle Data…1018
Haul Cycle Warning Flags…1019
A: Continuous Loading…1019
B: Loading to Dumping Transition…1019
C: No Final Load…1019
D: Maneuvering to Dumping Transition…1019
E: Average Load or Tare Used…1019
F: Final Zone to Dumping Transition…1019
H: False Body Up…1019
I: Body Up Signal Failed…1019
J: Speed Sensor Failed…1019
K: New Tare Not Calculated…1019
L: Incomplete Haul Cycle…1019
M: Haul Cycle Too Long…1020
N: Sensor Input Error…1020
Alarm Records…1020
Frame Torque Data…1020
Sprung Weight Data…1021
Maximum Speed Data…1021
PC SOFTWARE OVERVIEW…1021
PC Overview…1021
System Configuration…1021
Installing the PLMIII Software…1021
DOWNLOADING DATA…1022
PLMIII SYSTEM CONFIGURATION…1023
Starting Communications…1023
Displayed Payload Units…1023
Time Units…1023
Connection Menu…1023
Connecting to the Payload Meter…1024
Configure the Payload Meter…1024
Setting the Date and Time…1024
Setting the Truck Type…1025
Setting the Gauge Display Units…1025
Setting the Frame Serial Number…1025
Setting the Truck Number…1025
Setting the Komatsu Distributor…1025
Setting the Komatsu Customer…1025
Clean Truck Tare…1026
Inclinometer Calibration…1026
DATA ANALYSIS…1027
Sorting on Truck Unit Number…1027
Creating a Query…1027
Sorting on Truck Type…1027
Sorting on Date Range…1028
Sorting on Time Range…1028
Payload Detail Screen…1029
Creating Reports…1029
Summary – one page report…1030
Detailed – multi-page report…1030
Creating Graphs…1031
Exporting Data…1031
CSV Export…1031
Compressed…1032
To export data in ZIP format:…1033
Importing Data…1033
Deleting Haul Cycle Records…1033
Viewing Alarms…1034
Deleting Alarm Records…1034
RADIO, AM / FM STEREO CASSETTE…1036
SETTING THE TIME…1036
GENERAL RECEIVER FUNCTIONS…1036
Turning The Power On And Off…1036
Display…1036
Setting The Default Display…1037
Adjusting Display Brightness…1037
OPERATING THE RADIO…1037
BAND…1037
TUNE/SEEK…1037
Manual Tuning…1037
SEEK Mode…1037
SCAN…1037
AUTO…1037
ADJUSTING THE RECEIVER SETTINGS…1038
PROGRAMMING PRESET STATIONS…1038
OPERATION OF THE WEATHERBAND (U.S.)…1038
SATELLITE RADIO…1039
Operating Satellite Radio…1039
Program Type Search (PTY)…1039
CASSETTE PLAYER…1040
Playing A Cassette…1040
Cassette Functions…1040
PROGRAMMABLE EJECT DEFAULT…1040
Bad Tape Detect…1041
CASSETTE PLAYER CLEANING…1041
CEAM015201 – Dump Truck 830E Operation & Maintenance Manual…1044
COVER…1044
WARNINGS…1046
INTRODUCTION…1050
FOREWORD…1050
ALERTS PAGE…1051
TRUCK MODEL ILLUSTRATION…1059
ABOUT THIS MANUAL…1060
TABLE OF CONTENTS…1052
STANDARD CHARTS AND TABLES…1062
GENERAL SAFETY…1068
Safety Rules…1068
Safety Features…1068
Clothing And Personal Items…1068
Unauthorized Modification…1068
Leaving The Operator's Seat…1069
Mounting And Dismounting…1069
Fire Prevention For Fuel And Oil…1069
Precautions With High Temperature Fluids…1070
Asbestos Dust Hazard Prevention…1070
Prevention Of Injury By Work Equipment…1070
Fire Extinguisher And First Aid Kit…1070
Precautions When Using Rops…1071
Precautions For Attachments…1071
Precautions For Starting Machine…1071
PRECAUTIONS DURING OPERATION…1072
Safety Is Thinking Ahead…1072
Safety At The Worksite…1072
Fire Prevention…1072
Preparing For Operation…1072
Ventilation In Enclosed Areas…1072
In Operator's Cab – Before Starting The Engine…1073
Mirrors, Windows, And Lights…1073
OPERATING THE MACHINE…1073
When Starting The Engine…1073
Truck Operation – General…1073
Check When Traveling In Reverse…1074
Traveling…1074
Traveling On Slopes…1075
Ensure Good Visibility…1075
Operate Carefully On Snow…1075
Avoid Damage To Dump Body…1075
Driving Near High-voltage Cables…1075
When Dumping…1076
Working On Loose Ground…1076
When Loading…1076
Parking The Machine…1076
TOWING…1076
WORKING NEAR BATTERIES…1077
Battery Hazard Prevention…1077
Starting With Booster Cables…1077
PRECAUTIONS FOR MAINTENANCE…1078
BEFORE PERFORMING MAINTENANCE…1078
Warning Tag…1078
Proper Tools…1078
Stopping The Engine Before Service…1078
Securing The Dump Body…1078
DURING MAINTENANCE…1079
Personnel…1079
Attachments…1079
Work Under The Machine…1079
Keep The Machine Clean…1079
Rules To Follow When Adding Fuel Or Oil…1079
Radiator Water Level…1080
Use Of Lighting…1080
Precautions With The Battery…1080
Handling High-pressure Hoses…1080
Precautions With High Pressure Oil…1080
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1081
Rotating Fan And Belts…1081
Waste Materials…1081
TIRES…1082
Handling Tires…1082
Storing Tires After Removal…1082
ADDITIONAL JOB SITE RULES…1083
WHEN REPAIRS ARE NECESSARY…1084
WARNINGS AND CAUTIONS…1086
OPERATING INSTRUCTIONS…1094
PREPARING FOR OPERATION…1094
Safety Is Thinking Ahead…1094
At The Truck – Ground Level Walk Around Inspection…1094
ENGINE START-UP SAFETY PRACTICES…1097
AFTER ENGINE HAS STARTED…1098
MACHINE OPERATION SAFETY PRECAUTIONS…1098
LOADING…1099
HAULING…1099
PASSING…1099
DUMPING…1100
To Raise Body:…1100
To Lower Body: When dumping over a berm or into a crusher:…1100
To Lower Body: When dumping on flat ground:…1101
TOWING…1101
SUDDEN LOSS OF ENGINE POWER…1102
SAFE PARKING PROCEDURES…1102
ENGINE SHUTDOWN PROCEDURE…1102
DELAYED ENGINE SHUTDOWN PROCEDURE…1103
RESERVE ENGINE OIL SYSTEM (Optional)…1104
Operation…1104
LED Monitor Light…1104
Changing Oil…1104
OPERATOR CAB AND CONTROLS…1106
STEERING WHEEL AND CONTROLS…1107
Horn Button…1107
Tilt / Telescope Lever…1107
Multi-function Turn Signal Switch…1107
Turn Signal Operation…1107
High Beam Headlight Operation…1107
Windshieldindshield Wiper Operation…1107
PEDALS…1108
Service Brake Pedal…1108
Dynamic Retarder Pedal…1108
Optional – Dual Function / Single Pedal…1108
Throttle Pedal…1108
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1109
Defroster Vent Control Switch…1109
Heat Vent Control Switch…1109
Temperature Control Knob…1109
Fan Control Knob…1109
Heater/air Conditioner Selector Switch…1109
Heater/air Conditioner Vents…1109
OVERHEAD PANEL AND DISPLAY…1110
Grade/speed Warning Chart…1110
Radio Speakers…1110
Warning Alarm Buzzer…1110
Cab Radio…1110
Warning Lights Dimmer Control…1110
Status / Warning Indicator Light Panel…1110
Windshield Wipers…1110
Air Cleaner Vacuum Gauges…1111
CENTER CONSOLE…1111
F-n-r Selector Switch…1111
Hoist Control Lever…1112
To Raise Body:…1112
To Lower Body:…1112
Ash Tray…1112
Lighter…1112
L.h. Window Control Switch…1112
R.h. Window Control Switch…1112
Engine Shutdown Switch…1112
Override Switch…1113
Retard Speed Control (RSC) Off/on Switch…1113
Retard Speed Control (RSC) Adjust Dial…1113
Statex III Propulsion System Diagnostic Connector…1114
Komatsu Engine Quantum Connector…1114
Komatsu Engine Cense Connector…1114
Unused Connector…1114
Modular Mining Port Conector…1114
Data Store Button…1114
Passenger Seat…1114
Service Engine Light (Blue)…1114
Payload Meter…1114
INSTRUMENT PANEL AND INDICATOR LIGHTS…1115
CONTROL SYMBOLS…1115
INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS…1116
Key Switch…1117
Starting…1117
Engine Shutdown Switch With Timer Delay (Optional)…1117
Fog Lights (Optional)…1118
Ladder Light Switch…1118
Manual Backup Switch…1118
Panel Illumination Lights…1118
Cab Air Conditioner / Heater Vents…1118
Engine Cold Weather Starting Aid (Optional)…1118
Rotating Beacon Light Switch (Optional)…1118
Heated Mirror Switch (Optional)…1118
Wheel Brake Lock Control…1119
Parking Brake Control…1119
Tachometer…1119
Right Turn Signal Indicator…1120
High Beam Indicator…1120
Left Turn Signal Indicator…1120
Speedometer / Payload Meter…1120
Voltmeter…1120
Engine Oil Pressure Gauge…1120
Water Temperature Gauge…1120
Fuel Gauge…1120
Hourmeter…1121
Headlight Switch…1121
Panel Light Dimmer…1121
Payload Meter Switch…1121
INDICATOR LIGHT SYMBOLS…1123
Hazard Warning Lights…1127
Lamp Test Switch…1127
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1128
Operation…1128
Interface Module…1129
Basic Precautions…1129
OPERATOR COMFORT…1130
OPERATOR SEAT…1130
Adjustment…1130
Seat Removal…1130
Seat Installation…1131
LUBRICATION AND SERVICE…1132
830E SERVICE CAPACITIES…1132
HYDRAULIC TANK SERVICE…1132
Adding Oil…1132
COOLANT LEVEL CHECK…1133
RADIATOR FILLING PROCEDURE…1133
RESERVE ENGINE OIL SYSTEM (Optional)…1133
Reserve Oil Tank Filling Procedure (Remote fill)…1133
LUBRICATION CHART…1134
10 HOUR (DAILY) INSPECTION…1135
10 HOUR LUBRICATION AND MAINTENANCE CHECKS…1135
LED Light Signals:…1135
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1137
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1138
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1139
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1141
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1142
2500 HOUR MAIN1TENANCE CHECKS…1143
5000 HOUR MAINTENANCE CHECKS…1143
10,000 HOUR MAINTENANCE CHECKS…1143
AUTOMATIC LUBRICATION SYSTEM…1144
GENERAL DESCRIPTION…1144
SYSTEM COMPONENTS…1146
Filter …1146
Hydraulic Motor and Pump …1146
Grease Reservoir …1146
Pressure Reducing Valve…1146
Flow Control Valve…1146
Solenoid Valve …1146
Vent Valve…1146
Lubrication Cycle Timer…1146
Delay Timer…1146
Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa]) …1146
Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])…1146
Pressure Gauge…1146
Injectors…1146
SYSTEM OPERATION…1147
Normal Operation:…1147
Pressure Failure Detection Circuits:…1148
INJECTOR OPERATION…1149
System Priming…1150
Filter Assembly…1150
LUBRICANT PUMP…1151
Pump Housing Oil Level…1151
Pump Pressure Control…1151
Pressure Control Valve Adjustment…1151
INJECTORS (SL-1 Series “H”))…1152
Injector Specifications…1152
Injector Adjustment…1152
SYSTEM CHECKOUT…1153
Lubrication Cycle Timer Check…1153
Lubrication Cycle Timer Adjustment…1153
SYSTEM TROUBLESHOOTING CHART…1154
PREVENTATIVE MAINTENANCE PROCEDURES…1156
Daily Lubrication System Inspection…1156
250 Hour Inspection…1156
1000 Hour Inspection…1156
TRUCK COMPONENT DESCRIPTION…1158
SPECIFICATIONS…1160
PAYLOAD METER III…1162
OPERATION SECTION…1164
Introduction…1164
Data Summary…1164
Data Gathering…1164
COMPONENT DESCRIPTION…1165
System Diagram…1165
Suspension Pressure Sensors…1165
Inclinometer…1165
Operator Display…1165
Operator Switch…1166
Speed Input…1166
Body-Up Switch…1166
Brake Lock Switch…1166
Payload Meter…1166
Communications Ports…1166
Keyswitch Input…1167
Payload Meter Power…1167
Load Lights…1167
Wiring and Termination…1168
TCI Outputs…1168
OPERATOR’S DISPLAY AND SWITCH…1169
Reading the Speedometer…1169
Reading the Load Display…1169
Using the Operator ID…1169
Using the Load and Ton Counter…1169
Total Ton Counter…1169
Total Load Counter…1170
Clearing the Counters…1170
Viewing Live Sensor Data…1170
Other Display Messages…1170
PAYLOAD OPERATION & CALCULATION…1171
Description of Haul Cycle States…1171
Haul Cycle Description…1171
Load Calculation…1172
Carry Back…1172
Measurement Accuracy…1172
SOURCES FOR PAYLOAD ERROR…1172
Payload Error…1172
Loading Conditions…1173
Pressure Sensors…1173
Swingloads…1173
Speed and Distance…1173
HAUL CYCLE DATA…1173
Haul Cycle Data…1174
Haul Cycle Warning Flags…1175
A: Continuous Loading…1175
B: Loading to Dumping Transition…1175
C: No Final Load…1175
D: Maneuvering to Dumping Transition…1175
E: Average Load or Tare Used…1175
F: Final Zone to Dumping Transition…1175
H: False Body Up…1175
I: Body Up Signal Failed…1175
J: Speed Sensor Failed…1175
K: New Tare Not Calculated…1175
L: Incomplete Haul Cycle…1175
M: Haul Cycle Too Long…1176
N: Sensor Input Error…1176
Alarm Records…1176
Frame Torque Data…1176
Sprung Weight Data…1177
Maximum Speed Data…1177
PC SOFTWARE OVERVIEW…1177
PC Overview…1177
System Configuration…1177
Installing the PLMIII Software…1177
DOWNLOADING DATA…1178
PLMIII SYSTEM CONFIGURATION…1179
Starting Communications…1179
Displayed Payload Units…1179
Time Units…1179
Connection Menu…1179
Connecting to the Payload Meter…1180
Configure the Payload Meter…1180
Setting the Date and Time…1180
Setting the Truck Type…1181
Setting the Gauge Display Units…1181
Setting the Frame Serial Number…1181
Setting the Truck Number…1181
Setting the Komatsu Distributor…1181
Setting the Komatsu Customer…1181
Clean Truck Tare…1182
Inclinometer Calibration…1182
DATA ANALYSIS…1183
Sorting on Truck Unit Number…1183
Creating a Query…1183
Sorting on Truck Type…1183
Sorting on Date Range…1184
Sorting on Time Range…1184
Payload Detail Screen…1185
Creating Reports…1185
Summary – one page report…1186
Detailed – multi-page report…1186
Creating Graphs…1187
Exporting Data…1187
CSV Export…1187
Compressed…1188
To export data in ZIP format:…1189
Importing Data…1189
Deleting Haul Cycle Records…1189
Viewing Alarms…1190
Deleting Alarm Records…1190
RADIO, AM / FM STEREO CASSETTE…1192
SETTING THE TIME…1192
GENERAL RECEIVER FUNCTIONS…1192
Turning The Power On And Off…1192
Display…1192
Setting The Default Display…1193
Adjusting Display Brightness…1193
OPERATING THE RADIO…1193
BAND…1193
TUNE/SEEK…1193
Manual Tuning…1193
SEEK Mode…1193
SCAN…1193
AUTO…1193
ADJUSTING THE RECEIVER SETTINGS…1194
PROGRAMMING PRESET STATIONS…1194
OPERATION OF THE WEATHERBAND (U.S.)…1194
SATELLITE RADIO…1195
Operating Satellite Radio…1195
Program Type Search (PTY)…1195
CASSETTE PLAYER…1196
Playing A Cassette…1196
Cassette Functions…1196
PROGRAMMABLE EJECT DEFAULT…1196
Bad Tape Detect…1197
CASSETTE PLAYER CLEANING…1197
CEAM016303 – Dump Truck 830E-AC Operation & Maintenance Manual…1200
COVER…1200
WARNING…1202
NON-OEM PARTS…1203
FOREWORD…1204
ALERTS PAGE…1205
TABLE OF CONTENTS…1206
TRUCK MODEL ILLUSTRATION…1213
KOMATSU MODEL 830E-AC DUMP TRUCK…1213
ABOUT THIS MANUAL…1214
STANDARD CHARTS AND TABLES…1216
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1216
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…1217
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1217
GENERAL SAFETY…1222
Safety Rules…1222
Truck Safety Features…1222
Clothing And Personal Items…1222
Unauthorized Modification…1222
Leaving The Operator’s Seat…1222
Mounting And Dismounting…1223
Fire Extinguishers And First Aid Kits…1223
Precautions For High Temperature Fluids…1223
Asbestos Dust Hazard Prevention…1223
Fire Prevention For Fuel And Oil…1224
ROPS Precautions…1224
Preventing Injury From Work Equipment…1224
Precautions For Optional Attachments…1224
Precautions When Starting The Machine…1224
PRECAUTIONS FOR TRUCK OPERATION…1225
Safety Is Thinking Ahead…1225
Safety At The Worksite…1225
Fire Prevention…1225
Preparing For Operation…1225
Ventilation For Enclosed Areas…1225
Mirrors, Windows, And Lights…1226
In The Operator’s Cab – Before Starting The Engine…1226
Seat Belts…1226
OPERATING THE MACHINE…1226
Starting The Engine…1226
Truck Operation – General…1226
Traveling In The Truck…1227
Precautions When Traveling In Reverse…1227
Traveling On Slopes…1227
Ensuring Good Visibility…1228
Operating On Snow…1228
Avoid Damage To The Dump Body…1228
Driving Near High Voltage Cables…1228
When Loading The Truck…1228
When Dumping…1228
Working On Loose Ground…1229
Parking The Machine…1229
TOWING…1229
WORKING NEAR BATTERIES…1230
Jump Starting With Booster Cables…1231
Jump Starting With Receptacles…1231
PRECAUTIONS FOR MAINTENANCE…1232
BEFORE PERFORMING MAINTENANCE…1232
Warning Tag…1232
Proper Tools…1232
Securing The Dump Body…1232
DURING MAINTENANCE…1233
Personnel…1233
Attachments…1233
Working Under The Machine…1233
Keeping The Machine Clean…1233
Rules To Follow When Adding Fuel Or Oil…1233
Radiator Coolant Level…1233
Use Of Lighting…1233
Precautions With The Battery…1234
Handling High Pressure Hoses…1234
Precautions With High Pressure Oil…1234
Maintenance Near High Temperatures And High Pressures…1234
Rotating Fan And Belts…1234
Waste Materials…1234
TIRES…1235
Handling Tires…1235
Tire Maintenance…1236
Storing Tires After Removal…1236
ADDITIONAL JOB SITE RULES…1237
WHEN REPAIRS ARE NECESSARY…1238
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…1239
Preliminary Procedures before Welding or Performing Maintenance…1239
Engine Shutdown Procedure before Welding or Performing Maintenance…1239
WARNINGS AND CAUTIONS…1242
TRUCK OPERATION…1254
PREPARING FOR OPERATION…1254
Safety Is Thinking Ahead…1254
WALK AROUND INSPECTION…1254
ENGINE START-UP SAFETY PRACTICES…1258
AFTER ENGINE HAS STARTED…1259
EMERGENCY STEERING SYSTEM…1260
Operation…1260
Pre-Operation Testing…1260
Additional Guidelines…1261
MACHINE OPERATION SAFETY PRECAUTIONS…1261
MACHINE OPERATION ON THE HAUL ROAD…1262
STARTING ON A GRADE WITH A LOADED TRUCK…1263
PASSING…1263
LOADING…1263
DUMPING…1263
Raising The Dump Body…1263
Lowering The Dump Body…1264
SUDDEN LOSS OF ENGINE POWER…1265
FUEL DEPLETION…1266
SAFE PARKING PROCEDURES…1266
NORMAL ENGINE SHUTDOWN PROCEDURE…1267
DELAYED ENGINE SHUTDOWN PROCEDURE…1268
DISABLED TRUCK DUMPING PROCEDURE…1269
GENERAL…1269
STEERING AND BRAKE SYSTEM…1269
Hookup…1269
HOIST SYSTEM…1270
Hookup…1270
Dumping Procedure…1270
TOWING…1271
RESERVE ENGINE OIL SYSTEM (Optional)…1272
OPERATOR CAB AND CONTROLS…1274
STEERING WHEEL AND CONTROLS…1275
Horn Button…1275
Tilt / Telescope Lever…1275
Multi-Function Turn Signal Switch…1275
PEDALS…1276
Service Brake Pedal…1276
Dynamic Retarding…1276
Dynamic Retard Pedal…1276
Throttle/Accelerator Pedal…1277
GRADE/SPEED RETARD CHART…1277
OVERHEAD PANEL AND DISPLAYS…1279
CENTER CONSOLE…1280
Directional Control Lever…1280
Override/Fault Reset Switch…1281
Engine Stop Switch…1281
L.H. Window Control Switch…1281
R.H. Window Control Switch…1281
Hoist Control Lever…1281
Raising The Dump Body…1281
Lowering The Dump Body…1281
Retard Speed Control (RSC) Adjust Dial…1282
Retard Speed Control (RSC) Switch…1282
Data Store Button…1283
VHMS Snapshot In Progress Light…1283
Link Energized Light…1283
Service Engine Light…1283
DIAGNOSTIC PORTS…1283
VHMS Diagnostic Port…1283
Interface Module (IM) Diagnostic Port…1283
Payload Meter Diagnostic Port…1283
Truck Control Interface (TCI) Diagnostic Port…1283
Propulsion System Controller (PSC) Diagnostic Port…1283
Engine Diagnostic Port (CENSE)…1283
Engine Diagnostic Port (QUANTUM)…1283
OPERATOR’S SEAT…1284
Seat Belts…1284
Adjustment…1284
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1285
Fan Control Knob…1285
Temperature Control Knob…1285
Directional Control Knob…1285
Heater Vents…1285
INSTRUMENT PANEL…1286
Key Switch…1288
Starting…1288
Engine Stop Switch with Five Minute Idle Timer Delay…1288
Rotating Beacon Light Switch (Optional)…1289
Heated Mirror Switch (Optional)…1289
Rest Switch…1289
Wheel Brake Lock Control…1289
Hazard Warning Lights…1289
Cab/Air Conditioner Vents…1289
Engine Oil Pressure Gauge…1290
Right Turn Signal Indicator…1290
Tachometer…1290
High Beam Indicator…1290
Speedometer/Payload Meter Display…1290
Left Turn Signal Indicator…1290
Water Temperature Gauge…1290
Lamp Test Switch…1290
Light Switch…1290
Ladder Light Switch…1291
Manual Backup Switch…1291
Fog Lights (Optional)…1291
Payload Meter Switch…1291
Panel Light Dimmer…1291
Hydraulic Oil Temperature Gauge…1292
Hourmeter…1292
Fuel Level Gauge…1292
OVERHEAD STATUS / WARNING INDICATORS…1293
Status / Warning Indicator Light Symbols…1294
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1299
Operation…1299
Interface Module…1300
Basic Precautions…1300
CIRCUIT BREAKERS…1303
LUBRICATION AND SERVICE…1304
830E SERVICE CAPACITIES…1304
HYDRAULIC TANK SERVICE…1304
Adding Oil…1304
WHEEL MOTOR SERVICE…1304
COOLANT LEVEL CHECK…1305
RADIATOR FILLING PROCEDURE…1305
RESERVE ENGINE OIL SYSTEM (Optional)…1305
Reserve Oil Tank Filling Procedure (Remote fill)…1305
LUBRICATION CHART…1306
10 HOUR (DAILY) INSPECTION…1307
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1310
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1311
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1312
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1315
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1316
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1317
2500 HOUR MAINTENANCE CHECKS…1318
5000 HOUR MAINTENANCE CHECKS…1318
10,000 HOUR MAINTENANCE CHECKS…1319
AUTOMATIC LUBRICATION SYSTEM…1320
GENERAL DESCRIPTION…1320
SYSTEM COMPONENTS…1322
Filter…1322
Hydraulic Motor and Pump…1322
Grease Reservoir…1322
Pressure Reducing Valve…1322
Pressure Gauge…1322
Flow Control Valve…1322
Solenoid Valve…1322
Vent Valve…1322
Lubrication Cycle Timer…1322
Over Pressure Cutoff Switch…1322
Grease Pressure Failure Switch…1322
Injectors…1322
Relief Valve (unloader valve)…1322
SYSTEM OPERATION…1323
GENERAL INSTRUCTIONS…1324
Required Lubricant…1324
System Priming…1324
Filter Assembly…1324
LUBRICANT PUMP…1325
Pump Housing Oil Level…1325
Pump Pressure Control…1325
INJECTORS (SL-1 Series “H”)…1326
Injector Specifications…1326
Injector Adjustment…1326
INJECTOR OPERATION…1327
PREVENTIVE MAINTENANCE PROCEDURES…1328
Daily Lubrication System Inspection…1328
250 Hour Inspection…1328
1000 Hour Inspection…1328
SYSTEM CHECKOUT…1329
Lubrication Controller Check…1329
Lubrication Controller Operation…1329
Lubrication Controller Components…1329
Lubrication Controller Adjustment…1329
SYSTEM TROUBLESHOOTING CHART…1331
MAJOR COMPONENT DESCRIPTION…1334
PAYLOAD METER III™…1338
INDEX…1338
Introduction…1340
Data Summary…1340
Data Gathering…1340
COMPONENT DESCRIPTION…1341
System Diagram…1341
Suspension Pressure Sensors…1341
Inclinometer…1341
Operator Display…1341
Operator Switch…1342
Speed Input…1342
Body-Up Switch…1342
Brake Lock Switch…1342
Payload Meter…1342
Communications Ports…1342
Key Switch Input…1343
Payload Meter Power…1343
Load Lights…1343
Wiring and Termination…1344
TCI Outputs…1344
OPERATOR’S DISPLAY AND SWITCH…1345
Reading the Speedometer…1345
Reading the Load Display…1345
Using the Operator ID…1345
Using the Load and Ton Counter…1345
Total Ton Counter…1345
Total Load Counter…1346
Clearing the Counters…1346
Viewing Live Sensor Data…1346
Other Display Messages…1346
PAYLOAD OPERATION & CALCULATION…1347
Haul Cycle States…1347
Haul Cycle Description…1347
Load Calculation…1348
Carry Back…1348
Measurement Accuracy…1348
SOURCES FOR PAYLOAD ERROR…1348
Payload Error…1348
Loading Conditions…1349
Pressure Sensors…1349
Swingloads…1349
Speed and Distance…1349
HAUL CYCLE DATA…1349
Haul Cycle Data…1350
Haul Cycle Warning Flags…1351
Frame Torque Data…1352
Sprung Weight Data…1352
Maximum Speed Data…1352
Alarm Records…1352
Fault Code Data…1353
PC SOFTWARE OVERVIEW…1354
PC Overview…1354
System Configuration…1354
Installing the PLMIII Software…1354
DOWNLOADING DATA…1355
PLM III SYSTEM CONFIGURATION…1356
Starting Communications…1356
Displayed Payload Units…1356
Time Units…1356
Connection Menu…1356
Connecting to the Payload Meter…1357
Configure the Payload Meter…1357
Setting the Date and Time…1357
Setting the Truck Type…1358
Setting the Gauge Display Units…1358
Setting the Frame Serial Number…1358
Setting the Truck Number…1358
Setting the Komatsu Distributor…1358
Setting the Komatsu Customer…1358
Clean Truck Tare…1359
Inclinometer Calibration…1359
DATA ANALYSIS…1360
Creating a Query…1360
Sorting on Truck Unit Number…1360
Sorting on Truck Type…1360
Sorting on Date Range…1361
Sorting on Time Range…1361
Payload Detail Screen…1362
Creating Reports…1362
Summary – one page report…1363
Detailed – multi-page report…1363
Creating Graphs…1364
Exporting Data…1364
CSV Export…1364
Compressed…1365
Importing Data…1366
Deleting Haul Cycle Records…1366
Viewing Alarms…1367
Deleting Alarm Records…1367
RADIO / CASSETTE PLAYER…1370
GENERAL RECEIVER FUNCTIONS…1370
Turning The Power On And Off…1370
Display…1370
Setting The Default Display…1370
Adjusting Display Brightness…1370
SETTING THE TIME…1371
OPERATING THE RADIO…1371
BAND…1371
TUNE/SEEK…1371
Manual Tuning…1371
SEEK Mode…1371
SCAN…1371
AUTO…1371
ADJUSTING THE RECEIVER SETTINGS…1372
PROGRAMMING PRESET STATIONS…1372
OPERATION OF THE WEATHERBAND (U.S.)…1372
SATELLITE RADIO…1373
Operating Satellite Radio…1373
Program Type Search (PTY)…1373
CASSETTE PLAYER…1374
Playing A Cassette…1374
Cassette Functions…1374
Programmable Eject Default…1374
Bad Tape Detect…1375
Cleaning The Cassette Player…1375
CEAM016800 – Dump Truck 830E Operation & Maintenance Manual…1378
COVER…1378
WARNINGS…1380
INTRODUCTION…1384
FOREWORD…1384
ALERTS PAGE…1385
TRUCK MODEL ILLUSTRATION…1393
ABOUT THIS MANUAL…1394
TABLE OF CONTENTS…1386
STANDARD CHARTS AND TABLES…1396
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1396
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…1397
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1397
GENERAL SAFETY…1402
Safety Rules…1402
Safety Features…1402
Clothing And Personal Items…1402
Unauthorized Modification…1402
Leaving The Operator's Seat…1403
Mounting And Dismounting…1403
Fire Prevention For Fuel And Oil…1403
Precautions With High Temperature Fluids…1404
Asbestos Dust Hazard Prevention…1404
Prevention Of Injury By Work Equipment…1404
Fire Extinguisher And First Aid Kit…1404
Precautions When Using Rops…1405
Precautions For Attachments…1405
Precautions For Starting Machine…1405
PRECAUTIONS DURING OPERATION…1406
Safety Is Thinking Ahead…1406
Safety At The Worksite…1406
Fire Prevention…1406
Preparing For Operation…1406
Ventilation In Enclosed Areas…1406
In Operator's Cab – Before Starting The Engine…1407
Mirrors, Windows, And Lights…1407
OPERATING THE MACHINE…1407
When Starting The Engine…1407
Truck Operation – General…1407
Check When Traveling In Reverse…1408
Traveling…1408
Traveling On Slopes…1409
Ensure Good Visibility…1409
Operate Carefully On Snow…1409
Avoid Damage To Dump Body…1409
Driving Near High-voltage Cables…1409
When Dumping…1410
Working On Loose Ground…1410
When Loading…1410
Parking The Machine…1410
TOWING…1410
WORKING NEAR BATTERIES…1411
Battery Hazard Prevention…1411
Starting With Booster Cables…1411
PRECAUTIONS FOR MAINTENANCE…1412
BEFORE PERFORMING MAINTENANCE…1412
Warning Tag…1412
Proper Tools…1412
Stopping The Engine Before Service…1412
Securing The Dump Body…1412
DURING MAINTENANCE…1413
Personnel…1413
Attachments…1413
Work Under The Machine…1413
Keep The Machine Clean…1413
Rules To Follow When Adding Fuel Or Oil…1413
Radiator Water Level…1414
Use Of Lighting…1414
Precautions With The Battery…1414
Handling High-pressure Hoses…1414
Precautions With High Pressure Oil…1414
Precautions When Performing Maintenance Near High Temperature Or High Pressure…1415
Rotating Fan And Belts…1415
Waste Materials…1415
TIRES…1416
Handling Tires…1416
Storing Tires After Removal…1416
ADDITIONAL JOB SITE RULES…1417
WHEN REPAIRS ARE NECESSARY…1418
WARNINGS AND CAUTIONS…1420
TRUCK OPERATION…1428
PREPARING FOR OPERATION…1428
Safety Is Thinking Ahead…1428
WALK AROUND INSPECTION…1428
ENGINE START-UP SAFETY PRACTICES…1431
AFTER ENGINE HAS STARTED…1432
MACHINE OPERATION SAFETY PRECAUTIONS…1432
HAULING…1433
STARTING ON A GRADE WITH A LOADED TRUCK…1433
PASSING…1434
LOADING…1434
DUMPING…1434
To Raise Body:…1434
To Lower Body: When dumping over a berm or into a crusher:…1435
To Lower Body: When dumping on flat ground:…1435
SUDDEN LOSS OF ENGINE POWER…1436
SAFE PARKING PROCEDURES…1436
ENGINE SHUTDOWN PROCEDURE…1436
DELAYED ENGINE SHUTDOWN PROCEDURE…1437
EMERGENCY STEERING SYSTEM…1438
Operation…1438
Testing…1438
DISABLED TRUCK DUMPING PROCEDURE…1439
Hookup…1439
Raising the Body…1439
Lowering the Body…1439
TOWING…1440
RESERVE ENGINE OIL SYSTEM (Optional)…1441
Operation…1441
LED Monitor Light…1441
Changing Oil…1441
OPERATOR CAB AND CONTROLS…1442
STEERING WHEEL AND CONTROLS…1443
Horn Button…1443
Tilt / Telescope Lever…1443
Multi-function Turn Signal Switch…1443
Turn Signal Operation…1443
High Beam Headlight Operation…1443
Windshield Wiper Operation…1443
PEDALS…1444
Service Brake Pedal…1444
Dynamic Retarder Pedal…1444
Optional – Dual Function / Single Pedal…1444
Throttle Pedal…1444
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1445
Defroster Vent Control Switch…1445
Heat Vent Control Switch…1445
Temperature Control Knob…1445
Fan Control Knob…1445
Heater/air Conditioner Selector Switch…1445
Heater/air Conditioner Vents…1445
OVERHEAD PANEL AND DISPLAY…1446
Grade/speed Warning Chart…1446
Radio Speakers…1446
Warning Alarm Buzzer…1446
Cab Radio…1446
Warning Lights Dimmer Control…1446
Status / Warning Indicator Light Panel…1446
Windshield Wipers…1446
Air Cleaner Vacuum Gauges…1447
CENTER CONSOLE…1447
F-N-R Selector Switch…1447
Hoist Control Lever…1448
To Raise Body:…1448
To Lower Body:…1448
Ash Tray…1448
Lighter…1448
L.h. Window Control Switch…1448
R.h. Window Control Switch…1448
Engine Shutdown Switch…1448
Override Switch…1449
Retard Speed Control (RSC) Off/on Switch…1449
Retard Speed Control (RSC) Adjust Dial…1449
Statex III Propulsion System Diagnostic Connector…1450
Komatsu Engine Quantum Connector…1450
Komatsu Engine Cense Connector…1450
Unused Connector…1450
Modular Mining Port Conector…1450
Data Store Button…1450
Passenger Seat…1450
Service Engine Light (Blue)…1450
Payload Meter…1450
INSTRUMENT PANEL AND INDICATOR LIGHTS…1451
CONTROL SYMBOLS…1451
INSTRUMENT PANEL GAUGES, INDICATORS, & CONTROLS…1452
Key Switch…1453
Starting…1453
Engine Shutdown Switch With Timer Delay (Optional)…1453
Fog Lights (Optional)…1454
Ladder Light Switch…1454
Manual Backup Switch…1454
Panel Illumination Lights…1454
Cab Air Conditioner / Heater Vents…1454
Engine Cold Weather Starting Aid (Optional)…1454
Rotating Beacon Light Switch (Optional)…1454
Heated Mirror Switch (Optional)…1454
Wheel Brake Lock Control…1455
Parking Brake Control…1455
Tachometer…1455
Right Turn Signal Indicator…1456
High Beam Indicator…1456
Left Turn Signal Indicator…1456
Speedometer / Payload Meter…1456
Voltmeter…1456
Engine Oil Pressure Gauge…1456
Water Temperature Gauge…1456
Fuel Gauge…1456
Hourmeter…1457
Headlight Switch…1457
Panel Light Dimmer…1457
Payload Meter Switch…1457
INDICATOR LIGHT SYMBOLS…1459
Hazard Warning Lights…1463
Lamp Test Switch…1463
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1464
Operation…1464
Interface Module…1465
Basic Precautions…1465
OPERATOR COMFORT…1466
OPERATOR SEAT…1466
Adjustment…1466
Seat Removal…1466
Seat Installation…1467
LUBRICATION AND SERVICE…1468
830E SERVICE CAPACITIES…1468
HYDRAULIC TANK SERVICE…1468
Adding Oil…1468
WHEEL MOTOR SERVICE…1468
COOLANT LEVEL CHECK…1469
RADIATOR FILLING PROCEDURE…1469
RESERVE ENGINE OIL SYSTEM (Optional)…1469
Reserve Oil Tank Filling Procedure (Remote fill)…1469
LUBRICATION CHART…1470
10 HOUR (DAILY) INSPECTION…1471
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1474
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1475
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1476
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1479
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1481
2500 HOUR MAINTENANCE CHECKS…1482
5000 HOUR MAINTENANCE CHECKS…1482
10,000 HOUR MAINTENANCE CHECKS…1483
AUTOMATIC LUBRICATION SYSTEM…1484
GENERAL DESCRIPTION…1484
SYSTEM COMPONENTS…1486
Filter…1486
Hydraulic Motor and Pump…1486
Grease Reservoir…1486
Pressure Reducing Valve…1486
Flow Control Valve…1486
Solenoid Valve…1486
Vent Valve…1486
Lubrication Cycle Timer…1486
Delay Timer…1486
Pump Cutoff Pressure Switch (N.O. 2500 psi [17 237 kPa])…1486
Grease Pressure Failure Switch (N.O. 2000 psi [13 789 kPa])…1486
Pressure Gauge…1486
Injectors…1486
SYSTEM OPERATION…1487
Normal Operation:…1487
Pressure Failure Detection Circuits:…1488
INJECTOR OPERATION…1489
System Priming…1490
Filter Assembly…1490
LUBRICANT PUMP…1491
Pump Housing Oil Level…1491
Pump Pressure Control…1491
Pressure Control Valve Adjustment…1491
INJECTORS (SL-1 Series “H”))…1492
Injector Specifications…1492
Injector Adjustment…1492
SYSTEM CHECKOUT…1493
Lubrication Cycle Timer Check…1493
Lubrication Cycle Timer Adjustment…1493
SYSTEM TROUBLESHOOTING CHART…1494
PREVENTATIVE MAINTENANCE PROCEDURES…1496
Daily Lubrication System Inspection…1496
250 Hour Inspection…1496
1000 Hour Inspection…1496
TRUCK COMPONENT DESCRIPTION…1498
SPECIFICATIONS…1500
PAYLOAD METER III™…1502
INDEX…1502
Introduction…1504
Data Summary…1504
Data Gathering…1504
COMPONENT DESCRIPTION…1505
System Diagram…1505
Suspension Pressure Sensors…1505
Inclinometer…1505
Operator Display…1505
Operator Switch…1506
Speed Input…1506
Body-Up Switch…1506
Brake Lock Switch…1506
Payload Meter…1506
Communications Ports…1506
Keyswitch Input…1507
Payload Meter Power…1507
Load Lights…1507
Wiring and Termination…1508
TCI Outputs…1508
OPERATOR’S DISPLAY AND SWITCH…1509
Reading the Speedometer…1509
Reading the Load Display…1509
Using the Operator ID…1509
Using the Load and Ton Counter…1509
Total Ton Counter…1509
Total Load Counter…1510
Clearing the Counters…1510
Viewing Live Sensor Data…1510
Other Display Messages…1510
PAYLOAD OPERATION & CALCULATION…1511
Description of Haul Cycle States…1511
Haul Cycle Description…1511
Load Calculation…1512
Carry Back…1512
Measurement Accuracy…1512
SOURCES FOR PAYLOAD ERROR…1512
Payload Error…1512
Loading Conditions…1513
Pressure Sensors…1513
Swingloads…1513
Speed and Distance…1513
HAUL CYCLE DATA…1513
Haul Cycle Data…1514
Haul Cycle Warning Flags…1515
M: Haul Cycle Too Long…1516
N: Sensor Input Error…1516
Frame Torque Data…1516
Sprung Weight Data…1516
Maximum Speed Data…1516
Alarm Records…1516
Fault Code Data…1517
PC SOFTWARE OVERVIEW…1518
PC Overview…1518
System Configuration…1518
Installing the PLMIII Software…1518
DOWNLOADING DATA…1519
PLM III SYSTEM CONFIGURATION…1520
Starting Communications…1520
Displayed Payload Units…1520
Time Units…1520
Connection Menu…1520
Connecting to the Payload Meter…1521
Configure the Payload Meter…1521
Setting the Date and Time…1521
Setting the Truck Type…1522
Setting the Gauge Display Units…1522
Setting the Frame Serial Number…1522
Setting the Truck Number…1522
Setting the Komatsu Distributor…1522
Setting the Komatsu Customer…1522
Clean Truck Tare…1523
Inclinometer Calibration…1523
DATA ANALYSIS…1524
Creating a Query…1524
Sorting on Truck Unit Number…1524
Sorting on Truck Type…1524
Sorting on Date Range…1525
Sorting on Time Range…1525
Payload Detail Screen…1526
Creating Reports…1526
Summary – one page report…1527
Detailed – multi-page report…1527
Creating Graphs…1528
Exporting Data…1528
CSV Export…1528
Compressed…1529
Importing Data…1530
Deleting Haul Cycle Records…1530
Viewing Alarms…1531
Deleting Alarm Records…1531
RADIO / CASSETTE PLAYER…1534
GENERAL RECEIVER FUNCTIONS…1534
Turning The Power On And Off…1534
Display…1534
Setting The Default Display…1534
Adjusting Display Brightness…1534
SETTING THE TIME…1535
OPERATING THE RADIO…1535
BAND…1535
TUNE/SEEK…1535
Manual Tuning…1535
SEEK Mode…1535
SCAN…1535
AUTO…1535
ADJUSTING THE RECEIVER SETTINGS…1536
PROGRAMMING PRESET STATIONS…1536
OPERATION OF THE WEATHERBAND (U.S.)…1536
SATELLITE RADIO…1537
Operating Satellite Radio…1537
Program Type Search (PTY)…1537
CASSETTE PLAYER…1538
Playing A Cassette…1538
Cassette Functions…1538
Progrommable Eject Default…1538
Bad Tape Detect…1539
Cleaning The Cassette Player…1539
CEAM018802 – Dump Truck 830E-AC Operation & Maintenance Manual…1542
COVER…1542
WARNING…1544
NON-OEM PARTS…1545
FOREWORD…1546
ALERTS PAGE…1547
TABLE OF CONTENTS…1548
TRUCK MODEL ILLUSTRATION…1555
KOMATSU MODEL 830E-AC DUMP TRUCK…1555
ABOUT THIS MANUAL…1556
STANDARD CHARTS AND TABLES…1558
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1558
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…1559
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1559
GENERAL SAFETY…1564
Safety Rules…1564
Truck Safety Features…1564
Clothing And Personal Items…1564
Unauthorized Modification…1564
Leaving The Operator’s Seat…1564
Mounting And Dismounting…1565
Fire Extinguishers And First Aid Kits…1565
Precautions For High Temperature Fluids…1565
Asbestos Dust Hazard Prevention…1565
Fire Prevention For Fuel And Oil…1566
ROPS Precautions…1566
Preventing Injury From Work Equipment…1566
Precautions For Optional Attachments…1566
Precautions When Starting The Machine…1566
PRECAUTIONS FOR TRUCK OPERATION…1567
Safety Is Thinking Ahead…1567
Safety At The Worksite…1567
Fire Prevention…1567
Preparing For Operation…1567
Ventilation For Enclosed Areas…1567
Mirrors, Windows, And Lights…1568
In The Operator’s Cab – Before Starting The Engine…1568
Seat Belts…1568
OPERATING THE MACHINE…1568
Starting The Engine…1568
Truck Operation – General…1568
Traveling In The Truck…1569
Precautions When Traveling In Reverse…1569
Traveling On Slopes…1569
Ensuring Good Visibility…1570
Operating On Snow…1570
Avoid Damage To The Dump Body…1570
Driving Near High Voltage Cables…1570
When Loading The Truck…1570
When Dumping…1570
Working On Loose Ground…1571
Parking The Machine…1571
TOWING…1571
WORKING NEAR BATTERIES…1572
Jump Starting With Booster Cables…1573
Jump Starting With Receptacles…1573
PRECAUTIONS FOR MAINTENANCE…1574
BEFORE PERFORMING MAINTENANCE…1574
Warning Tag…1574
Proper Tools…1574
Securing The Dump Body…1574
DURING MAINTENANCE…1575
Personnel…1575
Attachments…1575
Working Under The Machine…1575
Keeping The Machine Clean…1575
Rules To Follow When Adding Fuel Or Oil…1575
Radiator Coolant Level…1575
Use Of Lighting…1575
Precautions With The Battery…1576
Handling High Pressure Hoses…1576
Precautions With High Pressure Oil…1576
Maintenance Near High Temperatures And High Pressures…1576
Rotating Fan And Belts…1576
Waste Materials…1576
TIRES…1577
Handling Tires…1577
Tire Maintenance…1578
Storing Tires After Removal…1578
ADDITIONAL JOB SITE RULES…1579
WHEN REPAIRS ARE NECESSARY…1580
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…1581
Preliminary Procedures before Welding or Performing Maintenance…1581
Engine Shutdown Procedure before Welding or Performing Maintenance…1581
WARNINGS AND CAUTIONS…1584
TRUCK OPERATION…1596
PREPARING FOR OPERATION…1596
Safety Is Thinking Ahead…1596
WALK AROUND INSPECTION…1596
ENGINE START-UP SAFETY PRACTICES…1600
AFTER ENGINE HAS STARTED…1601
EMERGENCY STEERING SYSTEM…1602
Operation…1602
Pre-Operation Testing…1602
Additional Guidelines…1603
MACHINE OPERATION SAFETY PRECAUTIONS…1603
MACHINE OPERATION ON THE HAUL ROAD…1604
STARTING ON A GRADE WITH A LOADED TRUCK…1605
PASSING…1605
LOADING…1605
DUMPING…1605
Raising The Dump Body…1605
Lowering The Dump Body…1606
SUDDEN LOSS OF ENGINE POWER…1607
FUEL DEPLETION…1608
SAFE PARKING PROCEDURES…1608
NORMAL ENGINE SHUTDOWN PROCEDURE…1609
DELAYED ENGINE SHUTDOWN PROCEDURE…1610
DISABLED TRUCK DUMPING PROCEDURE…1611
GENERAL…1611
STEERING AND BRAKE SYSTEM…1611
Hookup…1611
HOIST SYSTEM…1612
Hookup…1612
Dumping Procedure…1612
TOWING…1613
RESERVE ENGINE OIL SYSTEM (Optional)…1614
OPERATOR CAB AND CONTROLS…1616
STEERING WHEEL AND CONTROLS…1617
Horn Button…1617
Tilt / Telescope Lever…1617
Multi-Function Turn Signal Switch…1617
PEDALS…1618
Service Brake Pedal…1618
Dynamic Retarding…1618
Dynamic Retard Pedal…1618
Throttle/Accelerator Pedal…1619
GRADE/SPEED RETARD CHART…1619
OVERHEAD PANEL AND DISPLAYS…1621
CENTER CONSOLE…1622
Directional Control Lever…1622
Override/Fault Reset Switch…1623
Engine Stop Switch…1623
L.H. Window Control Switch…1623
R.H. Window Control Switch…1623
Hoist Control Lever…1623
Raising The Dump Body…1623
Lowering The Dump Body…1623
Retard Speed Control (RSC) Adjust Dial…1624
Retard Speed Control (RSC) Switch…1624
Data Store Button…1625
VHMS Snapshot In Progress Light…1625
Link Energized Light…1625
Service Engine Light…1625
DIAGNOSTIC PORTS…1625
VHMS Diagnostic Port…1625
Interface Module (IM) Diagnostic Port…1625
Payload Meter Diagnostic Port…1625
Truck Control Interface (TCI) Diagnostic Port…1625
Propulsion System Controller (PSC) Diagnostic Port…1625
Engine Diagnostic Port (CENSE)…1625
Engine Diagnostic Port (QUANTUM)…1625
OPERATOR’S SEAT…1626
Seat Belts…1626
Adjustment…1626
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1627
Fan Control Knob…1627
Temperature Control Knob…1627
Directional Control Knob…1627
Heater Vents…1627
INSTRUMENT PANEL…1628
Key Switch…1630
Starting…1630
Engine Stop Switch with Five Minute Idle Timer Delay…1630
Rotating Beacon Light Switch (Optional)…1631
Heated Mirror Switch (Optional)…1631
Rest Switch…1631
Wheel Brake Lock Control…1631
Hazard Warning Lights…1631
Cab/Air Conditioner Vents…1631
Engine Oil Pressure Gauge…1632
Right Turn Signal Indicator…1632
Tachometer…1632
High Beam Indicator…1632
Speedometer/Payload Meter Display…1632
Left Turn Signal Indicator…1632
Water Temperature Gauge…1632
Lamp Test Switch…1632
Light Switch…1632
Ladder Light Switch…1633
Manual Backup Switch…1633
Fog Lights (Optional)…1633
Payload Meter Switch…1633
Panel Light Dimmer…1633
Hydraulic Oil Temperature Gauge…1634
Hourmeter…1634
Fuel Level Gauge…1634
OVERHEAD STATUS / WARNING INDICATORS…1635
Status / Warning Indicator Light Symbols…1636
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1641
Operation…1641
Interface Module…1642
Basic Precautions…1642
CIRCUIT BREAKERS…1645
LUBRICATION AND SERVICE…1646
830E SERVICE CAPACITIES…1646
HYDRAULIC TANK SERVICE…1646
Adding Oil…1646
WHEEL MOTOR SERVICE…1646
COOLANT LEVEL CHECK…1647
RADIATOR FILLING PROCEDURE…1647
RESERVE ENGINE OIL SYSTEM (Optional)…1647
Reserve Oil Tank Filling Procedure (Remote fill)…1647
LUBRICATION CHART…1648
10 HOUR (DAILY) INSPECTION…1649
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1652
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1653
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1654
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1657
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1658
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1659
2500 HOUR MAINTENANCE CHECKS…1660
5000 HOUR MAINTENANCE CHECKS…1660
10,000 HOUR MAINTENANCE CHECKS…1661
AUTOMATIC LUBRICATION SYSTEM…1662
GENERAL DESCRIPTION…1662
SYSTEM COMPONENTS…1664
Filter…1664
Hydraulic Motor and Pump…1664
Grease Reservoir…1664
Pressure Reducing Valve…1664
Pressure Gauge…1664
Flow Control Valve…1664
Solenoid Valve…1664
Vent Valve…1664
Lubrication Cycle Timer…1664
Over Pressure Cutoff Switch…1664
Grease Pressure Failure Switch…1664
Injectors…1664
Relief Valve (unloader valve)…1664
SYSTEM OPERATION…1665
GENERAL INSTRUCTIONS…1666
Required Lubricant…1666
System Priming…1666
Filter Assembly…1666
LUBRICANT PUMP…1667
Pump Housing Oil Level…1667
Pump Pressure Control…1667
INJECTORS (SL-1 Series “H”)…1668
Injector Specifications…1668
Injector Adjustment…1668
INJECTOR OPERATION…1669
PREVENTIVE MAINTENANCE PROCEDURES…1670
Daily Lubrication System Inspection…1670
250 Hour Inspection…1670
1000 Hour Inspection…1670
SYSTEM CHECKOUT…1671
Lubrication Controller Check…1671
Lubrication Controller Operation…1671
Lubrication Controller Components…1671
Lubrication Controller Adjustment…1671
SYSTEM TROUBLESHOOTING CHART…1673
MAJOR COMPONENT DESCRIPTION…1676
PAYLOAD METER III™…1680
INDEX…1680
Introduction…1682
Data Summary…1682
Data Gathering…1682
COMPONENT DESCRIPTION…1683
System Diagram…1683
Suspension Pressure Sensors…1683
Inclinometer…1683
Operator Display…1683
Operator Switch…1684
Speed Input…1684
Body-Up Switch…1684
Brake Lock Switch…1684
Payload Meter…1684
Communications Ports…1684
Key Switch Input…1685
Payload Meter Power…1685
Load Lights…1685
Wiring and Termination…1686
TCI Outputs…1686
OPERATOR’S DISPLAY AND SWITCH…1687
Reading the Speedometer…1687
Reading the Load Display…1687
Using the Operator ID…1687
Using the Load and Ton Counter…1687
Total Ton Counter…1687
Total Load Counter…1688
Clearing the Counters…1688
Viewing Live Sensor Data…1688
Other Display Messages…1688
PAYLOAD OPERATION & CALCULATION…1689
Haul Cycle States…1689
Haul Cycle Description…1689
Load Calculation…1690
Carry Back…1690
Measurement Accuracy…1690
SOURCES FOR PAYLOAD ERROR…1690
Payload Error…1690
Loading Conditions…1691
Pressure Sensors…1691
Swingloads…1691
Speed and Distance…1691
HAUL CYCLE DATA…1691
Haul Cycle Data…1692
Haul Cycle Warning Flags…1693
Frame Torque Data…1694
Sprung Weight Data…1694
Maximum Speed Data…1694
Alarm Records…1694
Fault Code Data…1695
PC SOFTWARE OVERVIEW…1696
PC Overview…1696
System Configuration…1696
Installing the PLMIII Software…1696
DOWNLOADING DATA…1697
PLM III SYSTEM CONFIGURATION…1698
Starting Communications…1698
Displayed Payload Units…1698
Time Units…1698
Connection Menu…1698
Connecting to the Payload Meter…1699
Configure the Payload Meter…1699
Setting the Date and Time…1699
Setting the Truck Type…1700
Setting the Gauge Display Units…1700
Setting the Frame Serial Number…1700
Setting the Truck Number…1700
Setting the Komatsu Distributor…1700
Setting the Komatsu Customer…1700
Clean Truck Tare…1701
Inclinometer Calibration…1701
DATA ANALYSIS…1702
Creating a Query…1702
Sorting on Truck Unit Number…1702
Sorting on Truck Type…1702
Sorting on Date Range…1703
Sorting on Time Range…1703
Payload Detail Screen…1704
Creating Reports…1704
Summary – one page report…1705
Detailed – multi-page report…1705
Creating Graphs…1706
Exporting Data…1706
CSV Export…1706
Compressed…1707
Importing Data…1708
Deleting Haul Cycle Records…1708
Viewing Alarms…1709
Deleting Alarm Records…1709
RADIO / CASSETTE PLAYER…1712
GENERAL RECEIVER FUNCTIONS…1712
Turning The Power On And Off…1712
Display…1712
Setting The Default Display…1712
Adjusting Display Brightness…1712
SETTING THE TIME…1713
OPERATING THE RADIO…1713
BAND…1713
TUNE/SEEK…1713
Manual Tuning…1713
SEEK Mode…1713
SCAN…1713
AUTO…1713
ADJUSTING THE RECEIVER SETTINGS…1714
PROGRAMMING PRESET STATIONS…1714
OPERATION OF THE WEATHERBAND (U.S.)…1714
SATELLITE RADIO…1715
Operating Satellite Radio…1715
Program Type Search (PTY)…1715
CASSETTE PLAYER…1716
Playing A Cassette…1716
Cassette Functions…1716
Programmable Eject Default…1716
Bad Tape Detect…1717
Cleaning The Cassette Player…1717
CEAM018903 – Dump Truck 830E-1AC Operation & Maintenance Manual…1720
COVER…1720
WARNING…1722
NON OEM PARTS…1723
FOREWORD…1724
ALERTS PAGE…1725
TABLE OF CONTENTS…1726
TRUCK MODEL ILLUSTRATION…1733
ABOUT THIS MANUAL…1734
STANDARD CHARTS AND TABLES…1736
GENERAL SAFETY…1742
GENERAL SAFETY…1742
Safety Rules…1742
Truck Safety Features…1742
Clothing And Personal Items…1742
Unauthorized Modification…1742
Leaving The Operator’s Seat…1742
Mounting And Dismounting…1743
Fire Extinguishers And First Aid Kits…1743
Precautions For High Temperature Fluids…1743
Asbestos Dust Hazard Prevention…1743
Fire Prevention For Fuel And Oil…1744
ROPS Precautions…1744
Preventing Injury From Work Equipment…1744
Precautions For Optional Attachments…1744
Precautions When Starting The Machine…1744
PRECAUTIONS FOR TRUCK OPERATION…1745
Safety Is Thinking Ahead…1745
Safety At The Worksite…1745
Fire Prevention…1745
Preparing For Operation…1745
Ventilation For Enclosed Areas…1745
Mirrors, Windows, And Lights…1746
In The Operator’s Cab – Before Starting The Engine…1746
Seat Belts…1746
OPERATING THE MACHINE…1746
Starting The Engine…1746
Truck Operation – General…1746
Traveling In The Truck…1747
Precautions When Traveling In Reverse…1747
Traveling On Slopes…1747
Ensuring Good Visibility…1748
Operating On Snow…1748
Avoid Damage To The Dump Body…1748
Driving Near High Voltage Cables…1748
When Loading The Truck…1748
When Dumping…1748
Working On Loose Ground…1749
Parking The Machine…1749
TOWING…1749
WORKING NEAR BATTERIES…1750
Battery Hazard Prevention…1750
Jump Starting With Booster Cables…1751
Jump Starting With Receptacles…1751
BEFORE PERFORMING MAINTENANCE…1752
Stopping The Engine Before Service…1752
Warning Tag…1752
Proper Tools…1752
Securing The Dump Body…1752
DURING MAINTENANCE…1753
Personnel…1753
Attachments…1753
Working Under The Machine…1753
Keeping The Machine Clean…1753
Rules To Follow When Adding Fuel Or Oil…1753
Radiator Coolant Level…1753
Use Of Lighting…1753
Precautions With The Battery…1754
Handling High Pressure Hoses…1754
Precautions With High Pressure Oil…1754
Maintenance Near High Temperatures And High Pressures…1754
Rotating Fan And Belts…1754
Waste Materials…1754
TIRES…1755
Handling Tires…1755
Tire Maintenance…1756
Storing Tires After Removal…1756
Preliminary Procedures before Welding or Performing Maintenance…1759
Engine Shutdown Procedure before Welding or Performing Maintenance…1759
ADDITIONAL JOB SITE RULES…1757
WHEN REPAIRS ARE NECESSARY…1758
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…1759
WARNINGS AND CAUTIONS…1762
TRUCK OPERATION…1774
PREPARING FOR OPERATION…1774
Safety Is Thinking Ahead…1774
WALK AROUND INSPECTION…1774
FIGURE 30-1. WALK AROUND INSPECTION…1775
ENGINE START-UP SAFETY PRACTICES…1778
AFTER ENGINE HAS STARTED…1779
EMERGENCY STEERING SYSTEM…1780
Operation…1780
Pre-Operation Testing…1780
Additional Guidelines…1781
MACHINE OPERATION SAFETY PRECAUTIONS…1781
MACHINE OPERATION ON THE HAUL ROAD…1782
STARTING ON A GRADE WITH A LOADED TRUCK…1783
PASSING…1783
LOADING…1783
DUMPING…1783
Raising The Dump Body…1783
Lowering The Dump Body…1784
Lowering The Dump Body…1785
SUDDEN LOSS OF ENGINE POWER…1785
FUEL DEPLETION…1786
SAFE PARKING PROCEDURES…1786
NORMAL ENGINE SHUTDOWN PROCEDURE…1787
DELAYED ENGINE SHUTDOWN PROCEDURE…1788
DISABLED TRUCK DUMPING PROCEDURE…1789
GENERAL…1789
STEERING AND BRAKE SYSTEM…1789
Hookup…1789
HOIST SYSTEM…1790
FIGURE 30-3. HOIST CONNECTIONS…1790
Hookup…1790
Dumping Procedure…1790
TOWING…1791
RESERVE ENGINE OIL SYSTEM (Optional)…1792
Operation…1792
LED Monitor Light…1792
Changing Oil…1792
OPERATOR CAB AND CONTROLS…1794
STEERING WHEEL AND CONTROLS…1795
Horn Button…1795
Tilt / Telescope Lever…1795
Multi-Function Turn Signal Switch…1795
Turn Signal Operation…1795
High Beam Headlight Operation…1795
Windshield Wiper Operation…1795
PEDALS…1796
Service Brake Pedal…1796
Dynamic Retarding…1796
Dynamic Retard Pedal…1796
Throttle/Accelerator Pedal…1797
GRADE/SPEED RETARD CHART…1797
OVERHEAD PANEL AND DISPLAYS…1799
Radio Speakers…1799
Warning Alarm Buzzer…1799
Cab Radio…1799
Warning Light Dimmer Control…1799
Status/Warning Indicator Light Panel…1799
Air Cleaner Vacuum Gauges…1799
Windshield Wipers…1799
CENTER CONSOLE…1800
FIGURE 32-3. CENTER CONSOLE…1800
Directional Control Lever…1800
Override/Fault Reset Switch…1801
Engine Stop Switch…1801
L.H. Window Control Switch…1801
R.H. Window Control Switch…1801
Hoist Control Lever…1801
Raising The Dump Body…1801
Lowering The Dump Body…1801
Retard Speed Control (RSC) Adjust Dial…1802
Retard Speed Control (RSC) Switch…1802
Data Store Button…1803
VHMS Snapshot In Progress Light…1803
Link Energized Light…1803
Service Engine Light…1803
DIAGNOSTIC PORTS…1803
VHMS Diagnostic Port…1803
Interface Module (IM) Diagnostic Port…1803
Payload Meter Diagnostic Port…1803
Truck Control Interface (TCI) Diagnostic Port…1803
Propulsion System Controller (PSC) Diagnostic Port…1803
Engine Diagnostic Port (CENSE)…1803
Engine Diagnostic Port (QUANTUM)…1803
OPERATOR’S SEAT…1804
Seat Belts…1804
Adjustment…1804
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1805
Fan Control Knob…1805
Temperature Control Knob…1805
Directional Control Knob…1805
Heater Vents…1805
INSTRUMENT PANEL…1806
Key Switch…1808
Starting…1808
Engine Stop Switch with Five Minute Idle Timer Delay…1808
Operation…1808
Rotating Beacon Light Switch (Optional)…1809
Heated Mirror Switch (Optional)…1809
Rest Switch…1809
Wheel Brake Lock Control…1809
Hazard Warning Lights…1809
Cab/Air Conditioner Vents…1809
Engine Oil Pressure Gauge…1810
Right Turn Signal Indicator…1810
Tachometer…1810
High Beam Indicator…1810
Speedometer/Payload Meter Display…1810
Left Turn Signal Indicator…1810
Water Temperature Gauge…1810
Lamp Test Switch…1810
Light Switch…1810
Ladder Light Switch…1811
Manual Backup Switch…1811
Fog Lights (Optional)…1811
Payload Meter Switch…1811
Panel Light Dimmer…1811
Hydraulic Oil Temperature Gauge…1812
Hourmeter…1812
Fuel Level Gauge…1812
OVERHEAD STATUS / WARNING INDICATORS…1813
FIGURE 32-8. OVERHEAD STATUS / WARNING INDICATOR…1813
Status / Warning Indicator Light Symbols…1814
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…1819
Operation…1819
Interface Module…1820
Basic Precautions…1820
FUSE BLOCKS…1821
CIRCUIT BREAKERS…1823
LUBRICATION AND SERVICE…1824
830E SERVICE CAPACITIES…1824
HYDRAULIC TANK SERVICE…1824
Adding Oil…1824
WHEEL MOTOR SERVICE…1824
COOLANT LEVEL CHECK…1825
RADIATOR FILLING PROCEDURE…1825
RESERVE ENGINE OIL SYSTEM (Optional)…1825
Reserve Oil Tank Filling Procedure (Remote fill)…1825
LUBRICATION CHART…1826
10 HOUR (DAILY) INSPECTION…1827
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…1830
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…1831
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…1832
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…1835
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…1836
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…1837
2500 HOUR MAINTENANCE CHECKS…1838
5000 HOUR MAINTENANCE CHECKS…1838
10,000 HOUR MAINTENANCE CHECKS…1839
AUTOMATIC LUBRICATION SYSTEM…1840
GENERAL DESCRIPTION…1840
FIGURE 42-1. PUMP & RESERVOIR COMPONENTS…1840
FIGURE 42-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION…1841
SYSTEM COMPONENTS…1842
Filter…1842
Hydraulic Motor and Pump…1842
Grease Reservoir…1842
Pressure Reducing Valve…1842
Pressure Gauge…1842
Flow Control Valve…1842
Solenoid Valve…1842
Vent Valve…1842
Lubrication Cycle Timer…1842
Over Pressure Cutoff Switch…1842
Grease Pressure Failure Switch…1842
Injectors…1842
Relief Valve (unloader valve)…1842
SYSTEM OPERATION…1843
GENERAL INSTRUCTIONS…1844
Required Lubricant…1844
System Priming…1844
Filter Assembly…1844
LUBRICANT PUMP…1845
Pump Housing Oil Level…1845
Pump Pressure Control…1845
INJECTORS (SL-1 Series “H”)…1846
Injector Specifications…1846
Injector Adjustment…1846
INJECTOR OPERATION…1847
PREVENTIVE MAINTENANCE PROCEDURES…1848
Daily Lubrication System Inspection…1848
250 Hour Inspection…1848
1000 Hour Inspection…1848
SYSTEM CHECKOUT…1849
SYSTEM TROUBLESHOOTING CHART…1851
MAJOR COMPONENT DESCRIPTION…1854
PAYLOAD METER III…1858
Introduction…1860
Data Summary…1860
Data Gathering…1860
COMPONENT DESCRIPTION…1861
System Diagram…1861
Suspension Pressure Sensors…1861
Inclinometer…1861
Operator Display…1861
Operator Switch…1862
Speed Input…1862
Body-Up Switch…1862
Brake Lock Switch…1862
Payload Meter…1862
Communications Ports…1862
Key Switch Input…1863
Payload Meter Power…1863
Load Lights…1863
Wiring and Termination…1864
TCI Outputs…1864
OPERATOR’S DISPLAY AND SWITCH…1865
Reading the Speedometer…1865
Reading the Load Display…1865
Using the Operator ID…1865
Using the Load and Ton Counter…1865
Total Ton Counter…1865
Total Load Counter…1866
Clearing the Counters…1866
Viewing Live Sensor Data…1866
Other Display Messages…1866
PAYLOAD OPERATION & CALCULATION…1867
Haul Cycle States…1867
Haul Cycle Description…1867
Load Calculation…1868
Carry Back…1868
Measurement Accuracy…1868
SOURCES FOR PAYLOAD ERROR…1868
Payload Error…1868
Loading Conditions…1869
Pressure Sensors…1869
Swingloads…1869
Speed and Distance…1869
HAUL CYCLE DATA…1869
Haul Cycle Data…1870
Fault Code Data…1873
PC SOFTWARE OVERVIEW…1874
PC Overview…1874
System Configuration…1874
Installing the PLMIII Software…1874
DOWNLOADING DATA…1875
PLM III SYSTEM CONFIGURATION…1876
Starting Communications…1876
Displayed Payload Units…1876
Time Units…1876
Connection Menu…1876
Connecting to the Payload Meter…1877
Configure the Payload Meter…1877
Setting the Date and Time…1877
Setting the Truck Type…1878
Setting the Gauge Display Units…1878
Setting the Frame Serial Number…1878
Setting the Truck Number…1878
Setting the Komatsu Distributor…1878
Setting the Komatsu Customer…1878
Clean Truck Tare…1879
Inclinometer Calibration…1879
DATA ANALYSIS…1880
Creating a Query…1880
Sorting on Truck Unit Number…1880
Sorting on Truck Type…1880
Sorting on Date Range…1881
Sorting on Time Range…1881
Payload Detail Screen…1882
Creating Reports…1882
Summary – one page report…1883
Detailed – multi-page report…1883
Creating Graphs…1884
Exporting Data…1884
CSV Export…1884
Compressed…1885
Importing Data…1886
Deleting Haul Cycle Records…1886
Viewing Alarms…1887
Deleting Alarm Records…1887
OPERATING INSTRUCTIONS…1890
AM/FM RADIO…1890
GENERAL RADIO RECEIVER FUNCTIONS…1890
Turning On the Power…1890
One-Hour Timer…1890
Display…1891
Setting a Default Display…1891
Adjusting the Brightness of the Display…1891
Auxiliary Mode…1891
Adjusting the Receiver Settings…1891
USING THE CLOCK…1892
Setting the Clock…1892
USING THE ALARM…1892
Setting the Alarm…1892
Turning the Alarm Off…1892
Activating Snooze…1892
Setting Alarm Volume…1892
USING THE RADIO…1893
Finding a Station…1893
Setting the Presets…1894
SATELLITE RADIO SERVICE (Optional)…1894
Activating Satellite Radio (Optional)…1894
USING THE WEATHERBAND…1895
USING THE COMPACT DISC PLAYER…1895
Playing a Compact Disc…1895
Button Functions…1895
PLAYING AN MP3 DISC…1896
MP3 Format Compatibility…1896
Root Directory…1896
Empty Directory or Folder…1896
No Folder…1896
File Name Display…1896
Pre-Programmed Playlists…1897
Playing MP3 Files…1897
Button Functions…1897
TROUBLESHOOTING…1898
CEAM019102 – Dump Truck 830E-1AC Operation & Maintenance Manual…1902
COVER…1902
WARNING…1904
WARNING NON-OEM PARTS…1905
FOREWORD…1906
ALERTS PAGE…1907
TABLE OF CONTENTS…1908
TRUCK MODEL ILLUSTRATION…1915
ABOUT THIS MANUAL…1915
STANDARD CHARTS AND TABLES…1918
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…1918
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…1919
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…1919
GENERAL SAFETY…1924
Safety Rules…1924
Truck Safety Features…1924
Clothing And Personal Items…1924
Unauthorized Modification…1924
Leaving The Operator’s Seat…1924
Mounting And Dismounting…1925
Fire Extinguishers And First Aid Kits…1925
Precautions For High Temperature Fluids…1925
Asbestos Dust Hazard Prevention…1925
Fire Prevention For Fuel And Oil…1926
ROPS Precautions…1926
Preventing Injury From Work Equipment…1926
Precautions For Optional Attachments…1926
Precautions When Starting The Machine…1926
PRECAUTIONS FOR TRUCK OPERATION…1927
Safety Is Thinking Ahead…1927
Safety At The Worksite…1927
Fire Prevention…1927
Preparing For Operation…1927
Ventilation For Enclosed Areas…1927
Mirrors, Windows, And Lights…1928
In The Operator’s Cab – Before Starting The Engine…1928
Seat Belts…1928
OPERATING THE MACHINE…1928
Starting The Engine…1928
Truck Operation – General…1928
Traveling In The Truck…1929
Precautions When Traveling In Reverse…1929
Traveling On Slopes…1929
Ensuring Good Visibility…1930
Operating On Snow…1930
Avoid Damage To The Dump Body…1930
Driving Near High Voltage Cables…1930
When Loading The Truck…1930
When Dumping…1930
Working On Loose Ground…1931
Parking The Machine…1931
TOWING…1931
WORKING NEAR BATTERIES…1932
Jump Starting With Booster Cables…1933
Jump Starting With Receptacles…1933
PRECAUTIONS FOR MAINTENANCE…1934
BEFORE PERFORMING MAINTENANCE…1934
Stopping The Engine Before Service…1934
Warning Tag…1934
Proper Tools…1934
Securing The Dump Body…1934
DURING MAINTENANCE…1935
Personnel…1935
Attachments…1935
Working Under The Machine…1935
Keeping The Machine Clean…1935
Rules To Follow When Adding Fuel Or Oil…1935
Radiator Coolant Level…1935
Use Of Lighting…1935
Precautions With The Battery…1936
Handling High Pressure Hoses…1936
Precautions With High Pressure Oil…1936
Maintenance Near High Temperatures And High Pressures…1936
Rotating Fan And Belts…1936
Waste Materials…1936
TIRES…1937
Handling Tires…1937
Tire Maintenance…1938
Storing Tires After Removal…1938
ADDITIONAL JOB SITE RULES…1939
WHEN REPAIRS ARE NECESSARY…1940
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…1941
Preliminary Procedures before Welding or Performing Maintenance…1941
Engine Shutdown Procedure before Welding or Performing Maintenance…1941
WARNINGS AND CAUTIONS…1944
TRUCK OPERATION…1956
PREPARIN G FOR OPERATION…1956
Safety Is Thinking Ahead…1956
WALK AROUND INSPECTION…1956
ENGINE START-UP SAFETY PRACTICES…1960
AFTER ENGINE HAS STARTED…1961
EMERGENCY STEERING SYSTEM…1962
Operation…1962
Pre-Operation Testing…1962
Additional Guidelines…1963
MACHINE OPERATION SAFETY PRECAUTIONS…1963
MACHINE OPERATION ON THE HAUL ROAD…1964
STARTING ON A GRADE WITH A LOADED TRUCK…1965
PASSING…1965
LOADING…1965
DUMPING…1965
Raising The Dump Body…1965
Lowering The Dump Body…1966
SUDDEN LOSS OF ENGINE POWER…1967
FUEL DEPLETION…1968
SAFE PARKING PROCEDURES…1968
NORMAL ENGINE SHUTDOWN PROCEDURE…1969
DISABLED TRUCK CONNECTIONS…1970
GENERAL…1970
STEERING AND BRAKE SYSTEM…1970
Hookup…1970
HOIST SYSTEM…1971
Hookup…1971
Dumping Procedure…1971
TOWING…1972
Special Wiring Harness…1972
Towing Procedure…1973
RESERVE ENGINE OIL SYSTEM (Optional)…1975
Operation…1975
OPERATOR CAB AND CONTROLS…1976
STEERING WHEEL AND CONTROLS…1977
Horn Button…1977
Tilt / Telescope Lever…1977
Multi-Function Turn Signal Switch…1977
PEDALS…1978
Service Brake Pedal…1978
Dynamic Retarding…1978
Dynamic Retard Pedal…1978
Throttle/Accelerator Pedal…1979
GRADE/SPEED RETARD CHART…1979
OVERHEAD PANEL AND DISPLAYS…1981
CENTER CONSOLE…1982
Directional Control Lever…1982
Override/Fault Reset Switch…1983
Engine Stop Switch…1983
L.H. Window Control Switch…1983
R.H. Window Control Switch…1983
Hoist Control Lever…1983
Raising The Dump Body…1983
Lowering The Dump Body…1983
Retard Speed Control (RSC) Adjust Dial…1984
Retard Speed Control (RSC) Switch…1984
Data Store Button…1985
VHMS Snapshot In Progress Light…1985
Link Energized Light…1985
Service Engine Light…1985
DIAGNOSTIC PORTS…1985
VHMS Diagnostic Port…1985
Interface Module (IM) Diagnostic Port…1985
Payload Meter Diagnostic Port…1985
Truck Control Interface (TCI) Diagnostic Port…1985
Propulsion System Controller (PSC) Diagnostic Port…1985
Engine Diagnostic Port (CENSE)…1985
Engine Diagnostic Port (QUANTUM)…1985
OPERATOR’S SEAT…1986
Seat Belts…1986
Adjustment…1986
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…1987
Fan Control Knob…1987
Temperature Control Knob…1987
Directional Control Knob…1987
Heater Vents…1987
INSTRUMENT PANEL…1988
Key Switch…1990
Starting…1990
Rotating Beacon Light Switch (Optional)…1990
Heated Mirror Switch (Optional)…1990
Rest Switch…1990
Wheel Brake Lock Control…1991
Hazard Warning Lights…1991
Cab/Air Conditioner Vents…1991
Engine Oil Pressure Gauge…1991
Right Turn Signal Indicator…1991
Tachometer…1991
High Beam Indicator…1992
Speedometer/Payload Meter Display…1992
Left Turn Signal Indicator…1992
Water Temperature Gauge…1992
Lamp Test Switch…1992
Light Switch…1992
Ladder Light Switch…1992
Manual Backup Switch…1993
Fog Lights (Optional)…1993
Payload Meter Switch…1993
Panel Light Dimmer…1993
Hydraulic Oil Temperature Gauge…1993
Hourmeter…1994
Fuel Level Gauge…1994
OVERHEAD STATUS / WARNING INDICATORS…1995
Status / Warning Indicator Light Symbols…1996
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2001
Operation…2001
Interface Module…2002
Basic Precautions…2003
FUSE BLOCKS…2004
CIRCUIT BREAKERS…2006
LUBRICATION AND SERVICE…2008
830E SERVICE CAPACITIES…2008
HYDRAULIC TANK SERVICE…2008
Adding Oil…2008
WHEEL MOTOR SERVICE…2008
COOLANT LEVEL CHECK…2009
RADIATOR FILLING PROCEDURE…2009
RESERVE ENGINE OIL SYSTEM (Optional)…2009
Reserve Oil Tank Filling Procedure (Remote fill)…2009
LUBRICATION CHART…2010
10 HOUR (DAILY) INSPECTION…2011
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2014
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2015
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2016
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2019
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2020
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2021
2500 HOUR MAINTENANCE CHECKS…2022
5000 HOUR MAINTENANCE CHECKS…2022
10,000 HOUR MAINTENANCE CHECKS…2023
AUTOMATIC LUBRICATION SYSTEM…2024
GENERAL DESCRIPTION…2024
SYSTEM COMPONENTS…2026
Filter…2026
Hydraulic Motor and Pump…2026
Grease Reservoir…2026
Pressure Reducing Valve…2026
Pressure Gauge…2026
Flow Control Valve…2026
Solenoid Valve…2026
Vent Valve…2026
Lubrication Cycle Timer…2026
Over Pressure Cutoff Switch…2026
Grease Pressure Failure Switch…2026
Injectors…2026
Relief Valve (unloader valve)…2026
SYSTEM OPERATION…2027
GENERAL INSTRUCTIONS…2028
Required Lubricant…2028
System Priming…2028
Filter Assembly…2028
LUBRICANT PUMP…2029
Pump Housing Oil Level…2029
Pump Pressure Control…2029
INJECTORS (SL-1 Series “H”)…2030
Injector Specifications…2030
Injector Adjustment…2030
INJECTOR OPERATION…2031
PREVENTIVE MAINTENANCE PROCEDURES…2032
Daily Lubrication System Inspection…2032
250 Hour Inspection…2032
1000 Hour Inspection…2032
SYSTEM CHECKOUT…2033
Lubrication Controller Check…2033
Lubrication Controller Operation…2033
Lubrication Controller Components…2033
Lubrication Controller Adjustment…2033
SYSTEM TROUBLESHOOTING CHART…2035
MAJOR COMPONENT DESCRIPTION…2038
PAYLOAD METER III™…2042
INDEX…2042
Introduction…2044
Data Summary…2044
Data Gathering…2044
COMPONENT DESCRIPTION…2045
System Diagram…2045
Suspension Pressure Sensors…2045
Inclinometer…2045
Operator Display…2045
Operator Switch…2046
Speed Input…2046
Body-Up Switch…2046
Brake Lock Switch…2046
Payload Meter…2046
Communications Ports…2046
Key Switch Input…2047
Payload Meter Power…2047
Load Lights…2047
Wiring and Termination…2048
TCI Outputs…2048
OPERATOR’S DISPLAY AND SWITCH…2049
Reading the Speedometer…2049
Reading the Load Display…2049
Using the Operator ID…2049
Using the Load and Ton Counter…2049
Total Ton Counter…2049
Total Load Counter…2050
Clearing the Counters…2050
Viewing Live Sensor Data…2050
Other Display Messages…2050
PAYLOAD OPERATION & CALCULATION…2051
Haul Cycle States…2051
Haul Cycle Description…2051
Load Calculation…2052
Carry Back…2052
Measurement Accuracy…2052
SOURCES FOR PAYLOAD ERROR…2052
Payload Error…2052
Loading Conditions…2053
Pressure Sensors…2053
Swingloads…2053
Speed and Distance…2053
HAUL CYCLE DATA…2053
Haul Cycle Data…2054
Haul Cycle Warning Flags…2055
Frame Torque Data…2056
Sprung Weight Data…2056
Maximum Speed Data…2056
Alarm Records…2056
Fault Code Data…2057
PC SOFTWARE OVERVIEW…2058
PC Overview…2058
System Configuration…2058
Installing the PLMIII Software…2058
DOWNLOADING DATA…2059
PLM III SYSTEM CONFIGURATION…2060
Starting Communications…2060
Displayed Payload Units…2060
Time Units…2060
Connection Menu…2060
Connecting to the Payload Meter…2061
Configure the Payload Meter…2061
Setting the Date and Time…2061
Setting the Truck Type…2062
Setting the Gauge Display Units…2062
Setting the Frame Serial Number…2062
Setting the Truck Number…2062
Setting the Komatsu Distributor…2062
Setting the Komatsu Customer…2062
Clean Truck Tare…2063
Inclinometer Calibration…2063
DATA ANALYSIS…2064
Creating a Query…2064
Sorting on Truck Unit Number…2064
Sorting on Truck Type…2064
Sorting on Date Range…2065
Sorting on Time Range…2065
Payload Detail Screen…2066
Creating Reports…2066
Summary – one page report…2067
Detailed – multi-page report…2067
Creating Graphs…2068
Exporting Data…2068
CSV Export…2068
Compressed…2069
Importing Data…2070
Deleting Haul Cycle Records…2070
Viewing Alarms…2071
Deleting Alarm Records…2071
AM/FM RADIO / CD PLAYER…2074
OPERATING INSTRUCTIONS…2074
GENERAL RADIO RECEIVER FUNCTIONS…2074
Turning On the Power…2074
One-Hour Timer…2074
Display…2075
Setting a Default Display…2075
Adjusting the Brightness of the Display…2075
Auxiliary Mode…2075
Adjusting the Receiver Settings…2075
USING THE CLOCK…2076
Setting the Clock…2076
USING THE ALARM…2076
Setting the Alarm…2076
Turning the Alarm Off…2076
Activating Snooze…2076
Setting Alarm Volume…2076
USING THE RADIO…2077
Finding a Station…2077
Setting the Presets…2078
SATELLITE RADIO SERVICE (Optional)…2078
Activating Satellite Radio (Optional)…2078
USING THE WEATHERBAND…2079
USING THE COMPACT DISC PLAYER…2079
Playing a Compact Disc…2079
Button Functions…2079
PLAYING AN MP3 DISC…2080
MP3 Format Compatibility…2080
Root Directory…2080
Empty Directory or Folder…2080
No Folder…2080
File Name Display…2080
Pre-Programmed Playlists…2081
Playing MP3 Files…2081
Button Functions…2081
TROUBLESHOOTING…2082
CEAM019302 – Dump Truck 830E-1AC Operation & Maintenance Manual…2086
COVER…2086
WARNING…2088
WARNING NON-OEM PARTS…2089
FOREWORD…2090
ALERTS PAGE…2091
TABLE OF CONTENTS…2092
TRUCK MODEL ILLUSTRATION…2099
ABOUT THIS MANUAL…2099
STANDARD CHARTS AND TABLES…2102
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2102
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2103
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2103
GENERAL SAFETY…2108
Safety Rules…2108
Truck Safety Features…2108
Clothing And Personal Items…2108
Unauthorized Modification…2108
Leaving The Operator’s Seat…2108
Mounting And Dismounting…2109
Fire Extinguishers And First Aid Kits…2109
Precautions For High Temperature Fluids…2109
Asbestos Dust Hazard Prevention…2109
Fire Prevention For Fuel And Oil…2110
ROPS Precautions…2110
Preventing Injury From Work Equipment…2110
Precautions For Optional Attachments…2110
Precautions When Starting The Machine…2110
PRECAUTIONS FOR TRUCK OPERATION…2111
Safety Is Thinking Ahead…2111
Safety At The Worksite…2111
Fire Prevention…2111
Preparing For Operation…2111
Ventilation For Enclosed Areas…2111
Mirrors, Windows, And Lights…2112
In The Operator’s Cab – Before Starting The Engine…2112
Seat Belts…2112
OPERATING THE MACHINE…2112
Starting The Engine…2112
Truck Operation – General…2112
Traveling In The Truck…2113
Precautions When Traveling In Reverse…2113
Traveling On Slopes…2113
Ensuring Good Visibility…2114
Operating On Snow…2114
Avoid Damage To The Dump Body…2114
Driving Near High Voltage Cables…2114
When Loading The Truck…2114
When Dumping…2114
Working On Loose Ground…2115
Parking The Machine…2115
TOWING…2115
WORKING NEAR BATTERIES…2116
Jump Starting With Booster Cables…2117
Jump Starting With Receptacles…2117
PRECAUTIONS FOR MAINTENANCE…2118
BEFORE PERFORMING MAINTENANCE…2118
Stopping The Engine Before Service…2118
Warning Tag…2118
Proper Tools…2118
Securing The Dump Body…2118
DURING MAINTENANCE…2119
Personnel…2119
Attachments…2119
Working Under The Machine…2119
Keeping The Machine Clean…2119
Rules To Follow When Adding Fuel Or Oil…2119
Radiator Coolant Level…2119
Use Of Lighting…2119
Precautions With The Battery…2120
Handling High Pressure Hoses…2120
Precautions With High Pressure Oil…2120
Maintenance Near High Temperatures And High Pressures…2120
Rotating Fan And Belts…2120
Waste Materials…2120
TIRES…2121
Handling Tires…2121
Tire Maintenance…2122
Storing Tires After Removal…2122
ADDITIONAL JOB SITE RULES…2123
WHEN REPAIRS ARE NECESSARY…2124
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…2125
Preliminary Procedures before Welding or Performing Maintenance…2125
Engine Shutdown Procedure before Welding or Performing Maintenance…2125
WARNINGS AND CAUTIONS…2128
TRUCK OPERATION…2140
PREPARIN G FOR OPERATION…2140
Safety Is Thinking Ahead…2140
WALK AROUND INSPECTION…2140
ENGINE START-UP SAFETY PRACTICES…2144
AFTER ENGINE HAS STARTED…2145
EMERGENCY STEERING SYSTEM…2146
Operation…2146
Pre-Operation Testing…2146
Additional Guidelines…2147
MACHINE OPERATION SAFETY PRECAUTIONS…2147
MACHINE OPERATION ON THE HAUL ROAD…2148
STARTING ON A GRADE WITH A LOADED TRUCK…2149
PASSING…2149
LOADING…2149
DUMPING…2149
Raising The Dump Body…2149
Lowering The Dump Body…2150
SUDDEN LOSS OF ENGINE POWER…2151
FUEL DEPLETION…2152
SAFE PARKING PROCEDURES…2152
NORMAL ENGINE SHUTDOWN PROCEDURE…2153
DISABLED TRUCK CONNECTIONS…2154
GENERAL…2154
STEERING AND BRAKE SYSTEM…2154
Hookup…2154
HOIST SYSTEM…2155
Hookup…2155
Dumping Procedure…2155
TOWING…2156
Special Wiring Harness…2156
Towing Procedure…2157
RESERVE ENGINE OIL SYSTEM (Optional)…2159
Operation…2159
OPERATOR CAB AND CONTROLS…2160
STEERING WHEEL AND CONTROLS…2161
Horn Button…2161
Tilt / Telescope Lever…2161
Multi-Function Turn Signal Switch…2161
PEDALS…2162
Service Brake Pedal…2162
Dynamic Retarding…2162
Dynamic Retard Pedal…2162
Throttle/Accelerator Pedal…2163
GRADE/SPEED RETARD CHART…2163
OVERHEAD PANEL AND DISPLAYS…2165
CENTER CONSOLE…2166
Directional Control Lever…2166
Override/Fault Reset Switch…2167
Engine Stop Switch…2167
L.H. Window Control Switch…2167
R.H. Window Control Switch…2167
Hoist Control Lever…2167
Raising The Dump Body…2167
Lowering The Dump Body…2167
Retard Speed Control (RSC) Adjust Dial…2168
Retard Speed Control (RSC) Switch…2168
Data Store Button…2169
VHMS Snapshot In Progress Light…2169
Link Energized Light…2169
Service Engine Light…2169
DIAGNOSTIC PORTS…2169
VHMS Diagnostic Port…2169
Interface Module (IM) Diagnostic Port…2169
Payload Meter Diagnostic Port…2169
Truck Control Interface (TCI) Diagnostic Port…2169
Propulsion System Controller (PSC) Diagnostic Port…2169
Engine Diagnostic Port (CENSE)…2169
Engine Diagnostic Port (QUANTUM)…2169
OPERATOR’S SEAT…2170
Seat Belts…2170
Adjustment…2170
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2171
Fan Control Knob…2171
Temperature Control Knob…2171
Directional Control Knob…2171
Heater Vents…2171
INSTRUMENT PANEL…2172
Key Switch…2174
Starting…2174
Rotating Beacon Light Switch (Optional)…2174
Heated Mirror Switch (Optional)…2174
Rest Switch…2174
Wheel Brake Lock Control…2175
Hazard Warning Lights…2175
Cab/Air Conditioner Vents…2175
Engine Oil Pressure Gauge…2175
Right Turn Signal Indicator…2175
Tachometer…2175
High Beam Indicator…2176
Speedometer/Payload Meter Display…2176
Left Turn Signal Indicator…2176
Water Temperature Gauge…2176
Lamp Test Switch…2176
Light Switch…2176
Ladder Light Switch…2176
Manual Backup Switch…2177
Fog Lights (Optional)…2177
Payload Meter Switch…2177
Panel Light Dimmer…2177
Hydraulic Oil Temperature Gauge…2177
Hourmeter…2178
Fuel Level Gauge…2178
OVERHEAD STATUS / WARNING INDICATORS…2179
Status / Warning Indicator Light Symbols…2180
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2185
Operation…2185
Interface Module…2186
Basic Precautions…2187
FUSE BLOCKS…2188
CIRCUIT BREAKERS…2190
LUBRICATION AND SERVICE…2192
830E SERVICE CAPACITIES…2192
HYDRAULIC TANK SERVICE…2192
Adding Oil…2192
WHEEL MOTOR SERVICE…2192
COOLANT LEVEL CHECK…2193
RADIATOR FILLING PROCEDURE…2193
RESERVE ENGINE OIL SYSTEM (Optional)…2193
Reserve Oil Tank Filling Procedure (Remote fill)…2193
LUBRICATION CHART…2194
10 HOUR (DAILY) INSPECTION…2195
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2198
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2199
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2200
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2203
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2204
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2205
2500 HOUR MAINTENANCE CHECKS…2206
5000 HOUR MAINTENANCE CHECKS…2206
10,000 HOUR MAINTENANCE CHECKS…2207
AUTOMATIC LUBRICATION SYSTEM…2208
GENERAL DESCRIPTION…2208
SYSTEM COMPONENTS…2210
Filter…2210
Hydraulic Motor and Pump…2210
Grease Reservoir…2210
Pressure Reducing Valve…2210
Pressure Gauge…2210
Flow Control Valve…2210
Solenoid Valve…2210
Vent Valve…2210
Lubrication Cycle Timer…2210
Over Pressure Cutoff Switch…2210
Grease Pressure Failure Switch…2210
Injectors…2210
Relief Valve (unloader valve)…2210
SYSTEM OPERATION…2211
GENERAL INSTRUCTIONS…2212
Required Lubricant…2212
System Priming…2212
Filter Assembly…2212
LUBRICANT PUMP…2213
Pump Housing Oil Level…2213
Pump Pressure Control…2213
INJECTORS (SL-1 Series “H”)…2214
Injector Specifications…2214
Injector Adjustment…2214
INJECTOR OPERATION…2215
PREVENTIVE MAINTENANCE PROCEDURES…2216
Daily Lubrication System Inspection…2216
250 Hour Inspection…2216
1000 Hour Inspection…2216
SYSTEM CHECKOUT…2217
Lubrication Controller Check…2217
Lubrication Controller Operation…2217
Lubrication Controller Components…2217
Lubrication Controller Adjustment…2217
SYSTEM TROUBLESHOOTING CHART…2219
MAJOR COMPONENT DESCRIPTION…2222
PAYLOAD METER III™…2226
INDEX…2226
Introduction…2228
Data Summary…2228
Data Gathering…2228
COMPONENT DESCRIPTION…2229
System Diagram…2229
Suspension Pressure Sensors…2229
Inclinometer…2229
Operator Display…2229
Operator Switch…2230
Speed Input…2230
Body-Up Switch…2230
Brake Lock Switch…2230
Payload Meter…2230
Communications Ports…2230
Key Switch Input…2231
Payload Meter Power…2231
Load Lights…2231
Wiring and Termination…2232
TCI Outputs…2232
OPERATOR’S DISPLAY AND SWITCH…2233
Reading the Speedometer…2233
Reading the Load Display…2233
Using the Operator ID…2233
Using the Load and Ton Counter…2233
Total Ton Counter…2233
Total Load Counter…2234
Clearing the Counters…2234
Viewing Live Sensor Data…2234
Other Display Messages…2234
PAYLOAD OPERATION & CALCULATION…2235
Haul Cycle States…2235
Haul Cycle Description…2235
Load Calculation…2236
Carry Back…2236
Measurement Accuracy…2236
SOURCES FOR PAYLOAD ERROR…2236
Payload Error…2236
Loading Conditions…2237
Pressure Sensors…2237
Swingloads…2237
Speed and Distance…2237
HAUL CYCLE DATA…2237
Haul Cycle Data…2238
Haul Cycle Warning Flags…2239
Frame Torque Data…2240
Sprung Weight Data…2240
Maximum Speed Data…2240
Alarm Records…2240
Fault Code Data…2241
PC SOFTWARE OVERVIEW…2242
PC Overview…2242
System Configuration…2242
Installing the PLMIII Software…2242
DOWNLOADING DATA…2243
PLM III SYSTEM CONFIGURATION…2244
Starting Communications…2244
Displayed Payload Units…2244
Time Units…2244
Connection Menu…2244
Connecting to the Payload Meter…2245
Configure the Payload Meter…2245
Setting the Date and Time…2245
Setting the Truck Type…2246
Setting the Gauge Display Units…2246
Setting the Frame Serial Number…2246
Setting the Truck Number…2246
Setting the Komatsu Distributor…2246
Setting the Komatsu Customer…2246
Clean Truck Tare…2247
Inclinometer Calibration…2247
DATA ANALYSIS…2248
Creating a Query…2248
Sorting on Truck Unit Number…2248
Sorting on Truck Type…2248
Sorting on Date Range…2249
Sorting on Time Range…2249
Payload Detail Screen…2250
Creating Reports…2250
Summary – one page report…2251
Detailed – multi-page report…2251
Creating Graphs…2252
Exporting Data…2252
CSV Export…2252
Compressed…2253
Importing Data…2254
Deleting Haul Cycle Records…2254
Viewing Alarms…2255
Deleting Alarm Records…2255
AM/FM RADIO / CD PLAYER…2258
OPERATING INSTRUCTIONS…2258
GENERAL RADIO RECEIVER FUNCTIONS…2258
Turning On the Power…2258
One-Hour Timer…2258
Display…2259
Setting a Default Display…2259
Adjusting the Brightness of the Display…2259
Auxiliary Mode…2259
Adjusting the Receiver Settings…2259
USING THE CLOCK…2260
Setting the Clock…2260
USING THE ALARM…2260
Setting the Alarm…2260
Turning the Alarm Off…2260
Activating Snooze…2260
Setting Alarm Volume…2260
USING THE RADIO…2261
Finding a Station…2261
Setting the Presets…2262
SATELLITE RADIO SERVICE (Optional)…2262
Activating Satellite Radio (Optional)…2262
USING THE WEATHERBAND…2263
USING THE COMPACT DISC PLAYER…2263
Playing a Compact Disc…2263
Button Functions…2263
PLAYING AN MP3 DISC…2264
MP3 Format Compatibility…2264
Root Directory…2264
Empty Directory or Folder…2264
No Folder…2264
File Name Display…2264
Pre-Programmed Playlists…2265
Playing MP3 Files…2265
Button Functions…2265
TROUBLESHOOTING…2266
CEAM019903 – Dump Truck 830E-1AC Operation & Maintenance Manual…2270
COVER…2270
WARNING…2272
WARNING NON-OEM PARTS…2273
FOREWORD…2274
ALERTS PAGE…2275
TABLE OF CONTENTS…2276
TRUCK MODEL ILLUSTRATION…2283
ABOUT THIS MANUAL…2283
STANDARD CHARTS AND TABLES…2286
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2286
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2287
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2287
GENERAL SAFETY…2292
Safety Rules…2292
Truck Safety Features…2292
Clothing And Personal Items…2292
Unauthorized Modification…2292
Leaving The Operator’s Seat…2292
Mounting And Dismounting…2293
Fire Extinguishers And First Aid Kits…2293
Precautions For High Temperature Fluids…2293
Asbestos Dust Hazard Prevention…2293
Fire Prevention For Fuel And Oil…2294
ROPS Precautions…2294
Preventing Injury From Work Equipment…2294
Precautions For Optional Attachments…2294
Precautions When Starting The Machine…2294
PRECAUTIONS FOR TRUCK OPERATION…2295
Safety Is Thinking Ahead…2295
Safety At The Worksite…2295
Fire Prevention…2295
Preparing For Operation…2295
Ventilation For Enclosed Areas…2295
Mirrors, Windows, And Lights…2296
In The Operator’s Cab – Before Starting The Engine…2296
Seat Belts…2296
OPERATING THE MACHINE…2296
Starting The Engine…2296
Truck Operation – General…2296
Traveling In The Truck…2297
Precautions When Traveling In Reverse…2297
Traveling On Slopes…2297
Ensuring Good Visibility…2298
Operating On Snow…2298
Avoid Damage To The Dump Body…2298
Driving Near High Voltage Cables…2298
When Loading The Truck…2298
When Dumping…2298
Working On Loose Ground…2299
Parking The Machine…2299
TOWING…2299
WORKING NEAR BATTERIES…2300
Jump Starting With Booster Cables…2301
Jump Starting With Receptacles…2301
PRECAUTIONS FOR MAINTENANCE…2302
BEFORE PERFORMING MAINTENANCE…2302
Stopping The Engine Before Service…2302
Warning Tag…2302
Proper Tools…2302
Securing The Dump Body…2302
DURING MAINTENANCE…2303
Personnel…2303
Attachments…2303
Working Under The Machine…2303
Keeping The Machine Clean…2303
Rules To Follow When Adding Fuel Or Oil…2303
Radiator Coolant Level…2303
Use Of Lighting…2303
Precautions With The Battery…2304
Handling High Pressure Hoses…2304
Precautions With High Pressure Oil…2304
Maintenance Near High Temperatures And High Pressures…2304
Rotating Fan And Belts…2304
Waste Materials…2304
TIRES…2305
Handling Tires…2305
Tire Maintenance…2306
Storing Tires After Removal…2306
ADDITIONAL JOB SITE RULES…2307
WHEN REPAIRS ARE NECESSARY…2308
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…2309
Preliminary Procedures before Welding or Performing Maintenance…2309
Engine Shutdown Procedure before Welding or Performing Maintenance…2309
WARNINGS AND CAUTIONS…2312
TRUCK OPERATION…2324
PREPARIN G FOR OPERATION…2324
Safety Is Thinking Ahead…2324
WALK AROUND INSPECTION…2324
ENGINE START-UP SAFETY PRACTICES…2328
AFTER ENGINE HAS STARTED…2329
EMERGENCY STEERING SYSTEM…2330
Operation…2330
Pre-Operation Testing…2330
Additional Guidelines…2331
MACHINE OPERATION SAFETY PRECAUTIONS…2331
MACHINE OPERATION ON THE HAUL ROAD…2332
STARTING ON A GRADE WITH A LOADED TRUCK…2333
PASSING…2333
LOADING…2333
DUMPING…2333
Raising The Dump Body…2333
Lowering The Dump Body…2334
SUDDEN LOSS OF ENGINE POWER…2335
FUEL DEPLETION…2336
SAFE PARKING PROCEDURES…2336
NORMAL ENGINE SHUTDOWN PROCEDURE…2337
DISABLED TRUCK CONNECTIONS…2338
GENERAL…2338
STEERING AND BRAKE SYSTEM…2338
Hookup…2338
HOIST SYSTEM…2339
Hookup…2339
Dumping Procedure…2339
TOWING…2340
Special Wiring Harness…2340
Towing Procedure…2341
RESERVE ENGINE OIL SYSTEM (Optional)…2343
Operation…2343
OPERATOR CAB AND CONTROLS…2344
STEERING WHEEL AND CONTROLS…2345
Horn Button…2345
Tilt / Telescope Lever…2345
Multi-Function Turn Signal Switch…2345
PEDALS…2346
Service Brake Pedal…2346
Dynamic Retarding…2346
Dynamic Retard Pedal…2346
Throttle/Accelerator Pedal…2347
GRADE/SPEED RETARD CHART…2347
OVERHEAD PANEL AND DISPLAYS…2349
CENTER CONSOLE…2350
Directional Control Lever…2350
Override/Fault Reset Switch…2351
Engine Stop Switch…2351
L.H. Window Control Switch…2351
R.H. Window Control Switch…2351
Hoist Control Lever…2351
Raising The Dump Body…2351
Lowering The Dump Body…2351
Retard Speed Control (RSC) Adjust Dial…2352
Retard Speed Control (RSC) Switch…2352
Data Store Button…2353
VHMS Snapshot In Progress Light…2353
Link Energized Light…2353
Service Engine Light…2353
DIAGNOSTIC PORTS…2353
VHMS Diagnostic Port…2353
Interface Module (IM) Diagnostic Port…2353
Payload Meter Diagnostic Port…2353
Truck Control Interface (TCI) Diagnostic Port…2353
Propulsion System Controller (PSC) Diagnostic Port…2353
Engine Diagnostic Port (CENSE)…2353
Engine Diagnostic Port (QUANTUM)…2353
OPERATOR’S SEAT…2354
Seat Belts…2354
Adjustment…2354
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2355
Fan Control Knob…2355
Temperature Control Knob…2355
Directional Control Knob…2355
Heater Vents…2355
INSTRUMENT PANEL…2356
Key Switch…2358
Starting…2358
Rotating Beacon Light Switch (Optional)…2358
Heated Mirror Switch (Optional)…2358
Rest Switch…2358
Wheel Brake Lock Control…2359
Hazard Warning Lights…2359
Cab/Air Conditioner Vents…2359
Engine Oil Pressure Gauge…2359
Right Turn Signal Indicator…2359
Tachometer…2359
High Beam Indicator…2360
Speedometer/Payload Meter Display…2360
Left Turn Signal Indicator…2360
Water Temperature Gauge…2360
Lamp Test Switch…2360
Light Switch…2360
Ladder Light Switch…2360
Manual Backup Switch…2361
Fog Lights (Optional)…2361
Payload Meter Switch…2361
Panel Light Dimmer…2361
Hydraulic Oil Temperature Gauge…2361
Hourmeter…2362
Fuel Level Gauge…2362
OVERHEAD STATUS / WARNING INDICATORS…2363
Status / Warning Indicator Light Symbols…2364
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2369
Operation…2369
Interface Module…2370
Basic Precautions…2371
FUSE BLOCKS…2372
CIRCUIT BREAKERS…2374
LUBRICATION AND SERVICE…2376
830E SERVICE CAPACITIES…2376
HYDRAULIC TANK SERVICE…2376
Adding Oil…2376
WHEEL MOTOR SERVICE…2376
COOLANT LEVEL CHECK…2377
RADIATOR FILLING PROCEDURE…2377
RESERVE ENGINE OIL SYSTEM (Optional)…2377
Reserve Oil Tank Filling Procedure (Remote fill)…2377
LUBRICATION CHART…2378
10 HOUR (DAILY) INSPECTION…2379
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2382
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2383
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2384
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2387
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2388
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2389
2500 HOUR MAINTENANCE CHECKS…2390
5000 HOUR MAINTENANCE CHECKS…2390
10,000 HOUR MAINTENANCE CHECKS…2391
AUTOMATIC LUBRICATION SYSTEM…2392
GENERAL DESCRIPTION…2392
SYSTEM COMPONENTS…2394
Filter…2394
Hydraulic Motor and Pump…2394
Grease Reservoir…2394
Pressure Reducing Valve…2394
Pressure Gauge…2394
Flow Control Valve…2394
Solenoid Valve…2394
Vent Valve…2394
Lubrication Cycle Timer…2394
Over Pressure Cutoff Switch…2394
Grease Pressure Failure Switch…2394
Injectors…2394
Relief Valve (unloader valve)…2394
SYSTEM OPERATION…2395
GENERAL INSTRUCTIONS…2396
Required Lubricant…2396
System Priming…2396
Filter Assembly…2396
LUBRICANT PUMP…2397
Pump Housing Oil Level…2397
Pump Pressure Control…2397
INJECTORS (SL-1 Series “H”)…2398
Injector Specifications…2398
Injector Adjustment…2398
INJECTOR OPERATION…2399
PREVENTIVE MAINTENANCE PROCEDURES…2400
Daily Lubrication System Inspection…2400
250 Hour Inspection…2400
1000 Hour Inspection…2400
SYSTEM CHECKOUT…2401
Lubrication Controller Check…2401
Lubrication Controller Operation…2401
Lubrication Controller Components…2401
Lubrication Controller Adjustment…2401
SYSTEM TROUBLESHOOTING CHART…2403
MAJOR COMPONENT DESCRIPTION…2406
PAYLOAD METER III™…2410
INDEX…2410
Introduction…2412
Data Summary…2412
Data Gathering…2412
COMPONENT DESCRIPTION…2413
System Diagram…2413
Suspension Pressure Sensors…2413
Inclinometer…2413
Operator Display…2413
Operator Switch…2414
Speed Input…2414
Body-Up Switch…2414
Brake Lock Switch…2414
Payload Meter…2414
Communications Ports…2414
Key Switch Input…2415
Payload Meter Power…2415
Load Lights…2415
Wiring and Termination…2416
TCI Outputs…2416
OPERATOR’S DISPLAY AND SWITCH…2417
Reading the Speedometer…2417
Reading the Load Display…2417
Using the Operator ID…2417
Using the Load and Ton Counter…2417
Total Ton Counter…2417
Total Load Counter…2418
Clearing the Counters…2418
Viewing Live Sensor Data…2418
Other Display Messages…2418
PAYLOAD OPERATION & CALCULATION…2419
Haul Cycle States…2419
Haul Cycle Description…2419
Load Calculation…2420
Carry Back…2420
Measurement Accuracy…2420
SOURCES FOR PAYLOAD ERROR…2420
Payload Error…2420
Loading Conditions…2421
Pressure Sensors…2421
Swingloads…2421
Speed and Distance…2421
HAUL CYCLE DATA…2421
Haul Cycle Data…2422
Haul Cycle Warning Flags…2423
Frame Torque Data…2424
Sprung Weight Data…2424
Maximum Speed Data…2424
Alarm Records…2424
Fault Code Data…2425
PC SOFTWARE OVERVIEW…2426
PC Overview…2426
System Configuration…2426
Installing the PLMIII Software…2426
DOWNLOADING DATA…2427
PLM III SYSTEM CONFIGURATION…2428
Starting Communications…2428
Displayed Payload Units…2428
Time Units…2428
Connection Menu…2428
Connecting to the Payload Meter…2429
Configure the Payload Meter…2429
Setting the Date and Time…2429
Setting the Truck Type…2430
Setting the Gauge Display Units…2430
Setting the Frame Serial Number…2430
Setting the Truck Number…2430
Setting the Komatsu Distributor…2430
Setting the Komatsu Customer…2430
Clean Truck Tare…2431
Inclinometer Calibration…2431
DATA ANALYSIS…2432
Creating a Query…2432
Sorting on Truck Unit Number…2432
Sorting on Truck Type…2432
Sorting on Date Range…2433
Sorting on Time Range…2433
Payload Detail Screen…2434
Creating Reports…2434
Summary – one page report…2435
Detailed – multi-page report…2435
Creating Graphs…2436
Exporting Data…2436
CSV Export…2436
Compressed…2437
Importing Data…2438
Deleting Haul Cycle Records…2438
Viewing Alarms…2439
Deleting Alarm Records…2439
AM/FM RADIO / CD PLAYER…2442
OPERATING INSTRUCTIONS…2442
GENERAL RADIO RECEIVER FUNCTIONS…2442
Turning On the Power…2442
One-Hour Timer…2442
Display…2443
Setting a Default Display…2443
Adjusting the Brightness of the Display…2443
Auxiliary Mode…2443
Adjusting the Receiver Settings…2443
USING THE CLOCK…2444
Setting the Clock…2444
USING THE ALARM…2444
Setting the Alarm…2444
Turning the Alarm Off…2444
Activating Snooze…2444
Setting Alarm Volume…2444
USING THE RADIO…2445
Finding a Station…2445
Setting the Presets…2446
SATELLITE RADIO SERVICE (Optional)…2446
Activating Satellite Radio (Optional)…2446
USING THE WEATHERBAND…2447
USING THE COMPACT DISC PLAYER…2447
Playing a Compact Disc…2447
Button Functions…2447
PLAYING AN MP3 DISC…2448
MP3 Format Compatibility…2448
Root Directory…2448
Empty Directory or Folder…2448
No Folder…2448
File Name Display…2448
Pre-Programmed Playlists…2449
Playing MP3 Files…2449
Button Functions…2449
TROUBLESHOOTING…2450
CEAM020101 – Dump Truck 830E-1AC Operation & Maintenance Manual…2454
COVER…2454
WARNING…2456
WARNING NON-OEM PARTS…2457
FOREWORD…2458
ALERTS PAGE…2459
TABLE OF CONTENTS…2460
TRUCK MODEL ILLUSTRATION…2467
ABOUT THIS MANUAL…2467
STANDARD CHARTS AND TABLES…2470
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2470
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2471
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2471
GENERAL SAFETY…2476
Safety Rules…2476
Truck Safety Features…2476
Clothing And Personal Items…2476
Unauthorized Modification…2476
Leaving The Operator’s Seat…2476
Mounting And Dismounting…2477
Fire Extinguishers And First Aid Kits…2477
Precautions For High Temperature Fluids…2477
Asbestos Dust Hazard Prevention…2477
Fire Prevention For Fuel And Oil…2478
ROPS Precautions…2478
Preventing Injury From Work Equipment…2478
Precautions For Optional Attachments…2478
Precautions When Starting The Machine…2478
PRECAUTIONS FOR TRUCK OPERATION…2479
Safety Is Thinking Ahead…2479
Safety At The Worksite…2479
Fire Prevention…2479
Preparing For Operation…2479
Ventilation For Enclosed Areas…2479
Mirrors, Windows, And Lights…2480
In The Operator’s Cab – Before Starting The Engine…2480
Seat Belts…2480
OPERATING THE MACHINE…2480
Starting The Engine…2480
Truck Operation – General…2480
Traveling In The Truck…2481
Precautions When Traveling In Reverse…2481
Traveling On Slopes…2481
Ensuring Good Visibility…2482
Operating On Snow…2482
Avoid Damage To The Dump Body…2482
Driving Near High Voltage Cables…2482
When Loading The Truck…2482
When Dumping…2482
Working On Loose Ground…2483
Parking The Machine…2483
TOWING…2483
WORKING NEAR BATTERIES…2484
Jump Starting With Booster Cables…2485
Jump Starting With Receptacles…2485
PRECAUTIONS FOR MAINTENANCE…2486
BEFORE PERFORMING MAINTENANCE…2486
Stopping The Engine Before Service…2486
Warning Tag…2486
Proper Tools…2486
Securing The Dump Body…2486
DURING MAINTENANCE…2487
Personnel…2487
Attachments…2487
Working Under The Machine…2487
Keeping The Machine Clean…2487
Rules To Follow When Adding Fuel Or Oil…2487
Radiator Coolant Level…2487
Use Of Lighting…2487
Precautions With The Battery…2488
Handling High Pressure Hoses…2488
Precautions With High Pressure Oil…2488
Maintenance Near High Temperatures And High Pressures…2488
Rotating Fan And Belts…2488
Waste Materials…2488
TIRES…2489
Handling Tires…2489
Tire Maintenance…2490
Storing Tires After Removal…2490
ADDITIONAL JOB SITE RULES…2491
WHEN REPAIRS ARE NECESSARY…2492
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK…2493
Preliminary Procedures before Welding or Performing Maintenance…2493
Engine Shutdown Procedure before Welding or Performing Maintenance…2493
WARNINGS AND CAUTIONS…2496
TRUCK OPERATION…2508
PREPARIN G FOR OPERATION…2508
Safety Is Thinking Ahead…2508
WALK AROUND INSPECTION…2508
ENGINE START-UP SAFETY PRACTICES…2512
AFTER ENGINE HAS STARTED…2513
EMERGENCY STEERING SYSTEM…2514
Operation…2514
Pre-Operation Testing…2514
Additional Guidelines…2515
MACHINE OPERATION SAFETY PRECAUTIONS…2515
MACHINE OPERATION ON THE HAUL ROAD…2516
STARTING ON A GRADE WITH A LOADED TRUCK…2517
PASSING…2517
LOADING…2517
DUMPING…2517
Raising The Dump Body…2517
Lowering The Dump Body…2518
SUDDEN LOSS OF ENGINE POWER…2519
FUEL DEPLETION…2520
SAFE PARKING PROCEDURES…2520
NORMAL ENGINE SHUTDOWN PROCEDURE…2521
DISABLED TRUCK CONNECTIONS…2522
GENERAL…2522
STEERING AND BRAKE SYSTEM…2522
Hookup…2522
HOIST SYSTEM…2523
Hookup…2523
Dumping Procedure…2523
TOWING…2524
Special Wiring Harness…2524
Towing Procedure…2525
RESERVE ENGINE OIL SYSTEM (Optional)…2527
Operation…2527
OPERATOR CAB AND CONTROLS…2528
STEERING WHEEL AND CONTROLS…2529
Horn Button…2529
Tilt / Telescope Lever…2529
Multi-Function Turn Signal Switch…2529
PEDALS…2530
Service Brake Pedal…2530
Dynamic Retarding…2530
Dynamic Retard Pedal…2530
Throttle/Accelerator Pedal…2531
GRADE/SPEED RETARD CHART…2531
OVERHEAD PANEL AND DISPLAYS…2533
CENTER CONSOLE…2534
Directional Control Lever…2534
Override/Fault Reset Switch…2535
Engine Stop Switch…2535
L.H. Window Control Switch…2535
R.H. Window Control Switch…2535
Hoist Control Lever…2535
Raising The Dump Body…2535
Lowering The Dump Body…2535
Retard Speed Control (RSC) Adjust Dial…2536
Retard Speed Control (RSC) Switch…2536
Data Store Button…2537
VHMS Snapshot In Progress Light…2537
Link Energized Light…2537
Service Engine Light…2537
DIAGNOSTIC PORTS…2537
VHMS Diagnostic Port…2537
Interface Module (IM) Diagnostic Port…2537
Payload Meter Diagnostic Port…2537
Truck Control Interface (TCI) Diagnostic Port…2537
Propulsion System Controller (PSC) Diagnostic Port…2537
Engine Diagnostic Port (CENSE)…2537
Engine Diagnostic Port (QUANTUM)…2537
OPERATOR’S SEAT…2538
Seat Belts…2538
Adjustment…2538
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…2539
Fan Control Knob…2539
Temperature Control Knob…2539
Directional Control Knob…2539
Heater Vents…2539
INSTRUMENT PANEL…2540
Key Switch…2542
Starting…2542
Rotating Beacon Light Switch (Optional)…2542
Heated Mirror Switch (Optional)…2542
Rest Switch…2542
Wheel Brake Lock Control…2543
Hazard Warning Lights…2543
Cab/Air Conditioner Vents…2543
Engine Oil Pressure Gauge…2543
Right Turn Signal Indicator…2543
Tachometer…2543
High Beam Indicator…2544
Speedometer/Payload Meter Display…2544
Left Turn Signal Indicator…2544
Water Temperature Gauge…2544
Lamp Test Switch…2544
Light Switch…2544
Ladder Light Switch…2544
Manual Backup Switch…2545
Fog Lights (Optional)…2545
Payload Meter Switch…2545
Panel Light Dimmer…2545
Hydraulic Oil Temperature Gauge…2545
Hourmeter…2546
Fuel Level Gauge…2546
OVERHEAD STATUS / WARNING INDICATORS…2547
Status / Warning Indicator Light Symbols…2548
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2553
Operation…2553
Interface Module…2554
Basic Precautions…2555
FUSE BLOCKS…2556
CIRCUIT BREAKERS…2558
LUBRICATION AND SERVICE…2560
830E SERVICE CAPACITIES…2560
HYDRAULIC TANK SERVICE…2560
Adding Oil…2560
WHEEL MOTOR SERVICE…2560
COOLANT LEVEL CHECK…2561
RADIATOR FILLING PROCEDURE…2561
RESERVE ENGINE OIL SYSTEM (Optional)…2561
Reserve Oil Tank Filling Procedure (Remote fill)…2561
LUBRICATION CHART…2562
10 HOUR (DAILY) INSPECTION…2563
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2566
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2567
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2568
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2571
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2572
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2573
2500 HOUR MAINTENANCE CHECKS…2574
5000 HOUR MAINTENANCE CHECKS…2574
10,000 HOUR MAINTENANCE CHECKS…2575
AUTOMATIC LUBRICATION SYSTEM…2576
GENERAL DESCRIPTION…2576
SYSTEM COMPONENTS…2578
Filter…2578
Hydraulic Motor and Pump…2578
Grease Reservoir…2578
Pressure Reducing Valve…2578
Pressure Gauge…2578
Flow Control Valve…2578
Solenoid Valve…2578
Vent Valve…2578
Lubrication Cycle Timer…2578
Over Pressure Cutoff Switch…2578
Grease Pressure Failure Switch…2578
Injectors…2578
Relief Valve (unloader valve)…2578
SYSTEM OPERATION…2579
GENERAL INSTRUCTIONS…2580
Required Lubricant…2580
System Priming…2580
Filter Assembly…2580
LUBRICANT PUMP…2581
Pump Housing Oil Level…2581
Pump Pressure Control…2581
INJECTORS (SL-1 Series “H”)…2582
Injector Specifications…2582
Injector Adjustment…2582
INJECTOR OPERATION…2583
PREVENTIVE MAINTENANCE PROCEDURES…2584
Daily Lubrication System Inspection…2584
250 Hour Inspection…2584
1000 Hour Inspection…2584
SYSTEM CHECKOUT…2585
Lubrication Controller Check…2585
Lubrication Controller Operation…2585
Lubrication Controller Components…2585
Lubrication Controller Adjustment…2585
SYSTEM TROUBLESHOOTING CHART…2587
MAJOR COMPONENT DESCRIPTION…2590
PAYLOAD METER III™…2594
INDEX…2594
Introduction…2596
Data Summary…2596
Data Gathering…2596
COMPONENT DESCRIPTION…2597
System Diagram…2597
Suspension Pressure Sensors…2597
Inclinometer…2597
Operator Display…2597
Operator Switch…2598
Speed Input…2598
Body-Up Switch…2598
Brake Lock Switch…2598
Payload Meter…2598
Communications Ports…2598
Key Switch Input…2599
Payload Meter Power…2599
Load Lights…2599
Wiring and Termination…2600
TCI Outputs…2600
OPERATOR’S DISPLAY AND SWITCH…2601
Reading the Speedometer…2601
Reading the Load Display…2601
Using the Operator ID…2601
Using the Load and Ton Counter…2601
Total Ton Counter…2601
Total Load Counter…2602
Clearing the Counters…2602
Viewing Live Sensor Data…2602
Other Display Messages…2602
PAYLOAD OPERATION & CALCULATION…2603
Haul Cycle States…2603
Haul Cycle Description…2603
Load Calculation…2604
Carry Back…2604
Measurement Accuracy…2604
SOURCES FOR PAYLOAD ERROR…2604
Payload Error…2604
Loading Conditions…2605
Pressure Sensors…2605
Swingloads…2605
Speed and Distance…2605
HAUL CYCLE DATA…2605
Haul Cycle Data…2606
Haul Cycle Warning Flags…2607
Frame Torque Data…2608
Sprung Weight Data…2608
Maximum Speed Data…2608
Alarm Records…2608
Fault Code Data…2609
PC SOFTWARE OVERVIEW…2610
PC Overview…2610
System Configuration…2610
Installing the PLMIII Software…2610
DOWNLOADING DATA…2611
PLM III SYSTEM CONFIGURATION…2612
Starting Communications…2612
Displayed Payload Units…2612
Time Units…2612
Connection Menu…2612
Connecting to the Payload Meter…2613
Configure the Payload Meter…2613
Setting the Date and Time…2613
Setting the Truck Type…2614
Setting the Gauge Display Units…2614
Setting the Frame Serial Number…2614
Setting the Truck Number…2614
Setting the Komatsu Distributor…2614
Setting the Komatsu Customer…2614
Clean Truck Tare…2615
Inclinometer Calibration…2615
DATA ANALYSIS…2616
Creating a Query…2616
Sorting on Truck Unit Number…2616
Sorting on Truck Type…2616
Sorting on Date Range…2617
Sorting on Time Range…2617
Payload Detail Screen…2618
Creating Reports…2618
Summary – one page report…2619
Detailed – multi-page report…2619
Creating Graphs…2620
Exporting Data…2620
CSV Export…2620
Compressed…2621
Importing Data…2622
Deleting Haul Cycle Records…2622
Viewing Alarms…2623
Deleting Alarm Records…2623
AM/FM RADIO / CD PLAYER…2626
OPERATING INSTRUCTIONS…2626
GENERAL RADIO RECEIVER FUNCTIONS…2626
Turning On the Power…2626
One-Hour Timer…2626
Display…2627
Setting a Default Display…2627
Adjusting the Brightness of the Display…2627
Auxiliary Mode…2627
Adjusting the Receiver Settings…2627
USING THE CLOCK…2628
Setting the Clock…2628
USING THE ALARM…2628
Setting the Alarm…2628
Turning the Alarm Off…2628
Activating Snooze…2628
Setting Alarm Volume…2628
USING THE RADIO…2629
Finding a Station…2629
Setting the Presets…2630
SATELLITE RADIO SERVICE (Optional)…2630
Activating Satellite Radio (Optional)…2630
USING THE WEATHERBAND…2631
USING THE COMPACT DISC PLAYER…2631
Playing a Compact Disc…2631
Button Functions…2631
PLAYING AN MP3 DISC…2632
MP3 Format Compatibility…2632
Root Directory…2632
Empty Directory or Folder…2632
No Folder…2632
File Name Display…2632
Pre-Programmed Playlists…2633
Playing MP3 Files…2633
Button Functions…2633
TROUBLESHOOTING…2634
CEAM020801 – Dump Truck 830E-1AC Operation & Maintenance Manual…2638
COVER…2638
FOREWORD…2642
ALERTS PAGE…2643
TABLE OF CONTENTS…2644
ABOUT THIS MANUAL…2653
STANDARD CHARTS AND TABLES…2654
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2654
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2655
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2655
GENERAL SAFETY…2660
Safety Rules…2660
Truck Safety Features…2660
Clothing And Personal Items…2660
Unauthorized Modification…2660
Leaving The Operator’s Seat…2660
Mounting And Dismounting…2661
Fire Extinguishers And First Aid Kits…2661
Precautions For High Temperature Fluids…2661
Asbestos Dust Hazard Prevention…2661
Fire Prevention For Fuel And Oil…2662
ROPS Precautions…2662
Preventing Injury From Work Equipment…2662
Precautions For Optional Attachments…2662
Precautions When Starting The Machine…2662
PRECAUTIONS FOR TRUCK OPERATION…2663
Safety Is Thinking Ahead…2663
Safety At The Worksite…2663
Fire Prevention…2663
Preparing For Operation…2663
Ventilation For Enclosed Areas…2663
Mirrors, Windows, And Lights…2664
In The Operator’s Cab – Before Starting The Engine…2664
OPERATING THE MACHINE…2664
Starting The Engine…2664
Truck Operation – General…2664
Traveling In The Truck…2665
Precautions When Traveling In Reverse…2665
Traveling On Slopes…2665
Ensuring Good Visibility…2666
Operating On Snow…2666
Avoid Damage To The Dump Body…2666
Driving Near High Voltage Cables…2666
When Loading The Truck…2666
When Dumping…2666
Working On Loose Ground…2667
Parking The Machine…2667
TOWING…2667
WORKING NEAR BATTERIES…2668
Jump Starting With Booster Cables…2669
Jump Starting With Receptacles…2669
PRECAUTIONS FOR MAINTENANCE…2670
BEFORE PERFORMING MAINTENANCE…2670
Stopping The Engine Before Service…2670
Electrical Systems Isolation…2670
Warning Tag…2672
Proper Tools…2672
Securing The Dump Body…2672
DURING MAINTENANCE…2673
Personnel…2673
Attachments…2673
Working Under The Machine…2673
Keeping The Machine Clean…2673
Rules To Follow When Adding Fuel Or Oil…2673
Radiator Coolant Level…2673
Use Of Lighting…2673
Precautions With The Battery…2674
Handling High Pressure Hoses…2674
Precautions With High Pressure Oil…2674
Maintenance Near High Temperatures And High Pressures…2674
Rotating Fan And Belts…2674
Waste Materials…2674
TIRES…2675
Handling Tires…2675
Tire Maintenance…2676
Storing Tires After Removal…2676
ADDITIONAL JOB SITE RULES…2677
WHEN REPAIRS ARE NECESSARY…2678
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK…2679
Preliminary Procedures before Welding or Performing Maintenance…2679
Engine Shutdown Procedure before Welding or Performing Maintenance…2679
WARNINGS AND CAUTIONS…2682
TRUCK OPERATION…2696
PREPARING FOR OPERATION…2696
Safety Is Thinking Ahead…2696
WALK AROUND INSPECTION…2696
ENGINE START-UP SAFETY PRACTICES…2700
AFTER ENGINE HAS STARTED…2701
EMERGENCY STEERING SYSTEM…2702
Operation…2702
Pre-Operation Testing…2702
Additional Guidelines…2703
MACHINE OPERATION SAFETY PRECAUTIONS…2703
MACHINE OPERATION ON THE HAUL ROAD…2704
STARTING ON A GRADE WITH A LOADED TRUCK…2705
PASSING…2705
LOADING…2705
DUMPING…2705
Raising The Dump Body…2705
Lowering The Dump Body…2706
SUDDEN LOSS OF ENGINE POWER…2707
FUEL DEPLETION…2708
SAFE PARKING PROCEDURES…2708
NORMAL ENGINE SHUTDOWN PROCEDURE…2709
DISABLED TRUCK CONNECTORS…2710
GENERAL…2710
STEERING AND BRAKE SYSTEM…2710
Hookup…2710
HOIST SYSTEM…2711
Hookup…2711
Dumping Procedure…2711
TOWING…2712
RESERVE ENGINE OIL SYSTEM (Optional)…2713
Operation…2713
LED Monitor Light…2713
Changing Oil…2713
OPERATOR CAB AND CONTROLS…2714
STEERING WHEEL AND CONTROLS…2715
Horn Button…2715
Tilt / Telescope Lever…2715
Multi-Function Turn Signal Switch…2715
PEDALS…2716
Service Brake Pedal…2716
Dynamic Retarding…2716
Dynamic Retard Pedal…2716
Throttle/Accelerator Pedal…2717
GRADE/SPEED RETARD CHART…2717
OVERHEAD PANEL AND DISPLAYS…2719
Radio Speakers…2719
Warning Alarm Buzzer…2719
Cab Radio…2719
Warning Light Dimmer Control…2719
Status/Warning Indicator Light Panel…2719
Air Cleaner Vacuum Gauges…2719
Windshield Wipers…2719
CENTER CONSOLE…2720
Directional Control Lever…2720
Override/Fault Reset Switch…2721
Engine Stop Switch…2721
L.H. Window Control Switch…2721
R.H. Window Control Switch…2721
Hoist Control Lever…2721
Raising The Dump Body…2721
Lowering The Dump Body…2721
Retard Speed Control (RSC) Adjust Dial…2722
Retard Speed Control (RSC) Switch…2722
Data Store Button…2723
VHMS Snapshot In Progress Light…2723
Link Energized Light…2723
Service Engine Light…2723
DIAGNOSTIC PORTS…2723
VHMS Diagnostic Port…2723
Interface Module (IM) Diagnostic Port…2723
Payload Meter Diagnostic Port…2723
Truck Control Interface (TCI) Diagnostic Port…2723
Propulsion System Controller (PSC) Diagnostic Port…2723
Engine Diagnostic Port (CENSE)…2723
Engine Diagnostic Port (QUANTUM)…2723
OPERATOR’S SEAT…2724
Adjustment…2724
HEATER / AIR CONDITIONER CONTROLS…2725
Fan Speed Control Knob…2725
Temperature Control Knob…2725
Air Flow Directional Knob…2725
Heater/Air Conditioner Vents…2725
INSTRUMENT PANEL…2726
Key Switch…2728
Starting…2728
Rotating Beacon Light Switch (Optional)…2728
Heated Mirror Switch (Optional)…2728
Rest Switch…2728
Wheel Brake Lock Control…2729
Hazard Warning Lights…2729
Cab/Air Conditioner Vents…2729
Engine Oil Pressure Gauge…2729
Right Turn Signal Indicator…2729
Tachometer…2729
High Beam Indicator…2730
Speedometer/Payload Meter Display…2730
Left Turn Signal Indicator…2730
Water Temperature Gauge…2730
Lamp Test Switch…2730
Light Switch…2730
Ladder Light Switch…2730
Manual Backup Switch…2731
Fog Lights (Optional)…2731
Payload Meter Switch…2731
Panel Light Dimmer…2731
Hydraulic Oil Temperature Gauge…2731
Hourmeter…2732
Fuel Level Gauge…2732
OVERHEAD STATUS / WARNING INDICATORS…2733
Status / Warning Indicator Light Symbols…2734
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2739
Operation…2739
Interface Module…2740
Basic Precautions…2741
CIRCUIT BREAKERS…2744
LUBRICATION AND SERVICE…2746
830E SERVICE CAPACITIES…2746
HYDRAULIC TANK SERVICE…2746
Adding Oil…2746
WHEEL MOTOR SERVICE…2746
COOLANT LEVEL CHECK…2747
RADIATOR FILLING PROCEDURE…2747
RESERVE ENGINE OIL SYSTEM (Optional)…2747
Reserve Oil Tank Filling Procedure (Remote fill)…2747
LUBRICATION CHART…2748
10 HOUR (DAILY) INSPECTION…2749
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2752
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2753
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2754
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2757
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…2758
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2759
2500 HOUR MAINTENANCE CHECKS…2760
5000 HOUR MAINTENANCE CHECKS…2760
10,000 HOUR MAINTENANCE CHECKS…2761
AUTOMATIC LUBRICATION SYSTEM…2762
GENERAL DESCRIPTION…2762
SYSTEM COMPONENTS…2764
Filter…2764
Hydraulic Motor and Pump…2764
Grease Reservoir…2764
Pressure Reducing Valve…2764
Flow Control Valve…2764
Solenoid Valve…2764
Vent Valve…2764
Lubrication Cycle Timer…2764
Pump Cutoff Pressure Switch…2764
Grease Pressure Failure Switch…2764
Pressure Gauge…2764
Injectors…2764
SYSTEM OPERATION…2765
Normal Operation…2765
GENERAL INSTRUCTIONS…2766
Lubricant Required For System…2766
System Priming…2766
Filter Assembly…2766
LUBRICANT PUMP…2767
Pump Housing Oil Level…2767
Pump Pressure Control…2767
Pressure Control Valve Adjustment…2767
Flow Control Valve Adjustment…2767
INJECTORS (SL-1 Series “H”))…2768
Injector Specifications…2768
Injector Adjustment…2768
PREVENTIVE MAINTENANCE PROCEDURES…2770
Daily Lubrication System Inspection…2770
250 Hour Inspection…2770
1000 Hour Inspection…2770
SYSTEM CHECKOUT…2771
Lubrication Controller Check…2771
Lubrication Controller Operation…2771
Lubrication Controller Components…2771
Lubrication Controller Adjustment…2771
SYSTEM TROUBLESHOOTING CHART…2773
INJECTOR OPERATION…2769
MAJOR COMPONENT DESCRIPTION…2776
PAYLOAD METER III™…2780
INDEX…2780
Introduction…2782
Data Summary…2782
Data Gathering…2782
COMPONENT DESCRIPTION…2783
System Diagram…2783
Suspension Pressure Sensors…2783
Inclinometer…2783
Operator Display…2783
Operator Switch…2784
Speed Input…2784
Body-Up Switch…2784
Brake Lock Switch…2784
Payload Meter…2784
Communications Ports…2784
Key Switch Input…2785
Payload Meter Power…2785
Load Lights…2785
Wiring and Termination…2786
TCI Outputs…2786
OPERATOR’S DISPLAY AND SWITCH…2787
Reading the Speedometer…2787
Reading the Load Display…2787
Using the Operator ID…2787
Using the Load and Ton Counter…2787
Total Ton Counter…2787
Total Load Counter…2788
Clearing the Counters…2788
Viewing Live Sensor Data…2788
Other Display Messages…2788
PAYLOAD OPERATION & CALCULATION…2789
Haul Cycle States…2789
Haul Cycle Description…2789
Load Calculation…2790
Carry Back…2790
Measurement Accuracy…2790
SOURCES FOR PAYLOAD ERROR…2790
Payload Error…2790
Loading Conditions…2791
Pressure Sensors…2791
Swingloads…2791
Speed and Distance…2791
HAUL CYCLE DATA…2791
Haul Cycle Data…2792
Haul Cycle Warning Flags…2793
Frame Torque Data…2794
Sprung Weight Data…2794
Maximum Speed Data…2794
Alarm Records…2794
Fault Code Data…2795
PC SOFTWARE OVERVIEW…2796
PC Overview…2796
System Configuration…2796
Installing the PLMIII Software…2796
DOWNLOADING DATA…2797
PLM III SYSTEM CONFIGURATION…2798
Starting Communications…2798
Displayed Payload Units…2798
Time Units…2798
Connection Menu…2798
Connecting to the Payload Meter…2799
Configure the Payload Meter…2799
Setting the Date and Time…2799
Setting the Truck Type…2800
Setting the Gauge Display Units…2800
Setting the Frame Serial Number…2800
Setting the Truck Number…2800
Setting the Komatsu Distributor…2800
Setting the Komatsu Customer…2800
Clean Truck Tare…2801
Inclinometer Calibration…2801
DATA ANALYSIS…2802
Creating a Query…2802
Sorting on Truck Unit Number…2802
Sorting on Truck Type…2802
Sorting on Date Range…2803
Sorting on Time Range…2803
Payload Detail Screen…2804
Creating Reports…2804
Summary – one page report…2805
Detailed – multi-page report…2805
Creating Graphs…2806
Exporting Data…2806
CSV Export…2806
Compressed…2807
Importing Data…2808
Deleting Haul Cycle Records…2808
Viewing Alarms…2809
Deleting Alarm Records…2809
AM/FM RADIO / CD PLAYER…2812
OPERATING INSTRUCTIONS…2812
GENERAL RADIO RECEIVER FUNCTIONS…2812
Turning On the Power…2812
One-Hour Timer…2812
Display…2813
Setting a Default Display…2813
Adjusting the Brightness of the Display…2813
Auxiliary Mode…2813
Adjusting the Receiver Settings…2813
USING THE CLOCK…2814
Setting the Clock…2814
USING THE ALARM…2814
Setting the Alarm…2814
Turning the Alarm Off…2814
Activating Snooze…2814
Setting Alarm Volume…2814
USING THE RADIO…2815
Finding a Station…2815
Setting the Presets…2816
SATELLITE RADIO SERVICE (Optional)…2816
Activating Satellite Radio (Optional)…2816
USING THE WEATHERBAND…2817
USING THE COMPACT DISC PLAYER…2817
Playing a Compact Disc…2817
Button Functions…2817
PLAYING AN MP3 DISC…2818
MP3 Format Compatibility…2818
Root Directory…2818
Empty Directory or Folder…2818
No Folder…2818
File Name Display…2818
Pre-Programmed Playlists…2819
Playing MP3 Files…2819
Button Functions…2819
TROUBLESHOOTING…2820
CEAM021501 – Dump Truck 830E-1AC Operation & Maintenance Manual…2822
COVER…2822
FOREWORD…2826
ALERTS PAGE…2827
TABLE OF CONTENTS…2828
TRUCK MODEL ILLUSTRATION…2836
ABOUT THIS MANUAL…2837
STANDARD CHARTS AND TABLES…2838
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…2838
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…2839
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…2839
GENERAL SAFETY…2844
Safety Rules…2844
Truck Safety Features…2844
Clothing And Personal Items…2844
Unauthorized Modification…2844
Leaving The Operator’s Seat…2844
Mounting And Dismounting…2845
Fire Extinguishers And First Aid Kits…2845
Precautions For High Temperature Fluids…2845
Asbestos Dust Hazard Prevention…2845
Fire Prevention For Fuel And Oil…2846
ROPS Precautions…2846
Preventing Injury From Work Equipment…2846
Precautions For Optional Attachments…2846
Precautions When Starting The Machine…2846
PRECAUTIONS FOR TRUCK OPERATION…2847
Safety Is Thinking Ahead…2847
Safety At The Worksite…2847
Fire Prevention…2847
Preparing For Operation…2847
Ventilation For Enclosed Areas…2847
Mirrors, Windows, And Lights…2848
In The Operator’s Cab – Before Starting The Engine…2848
OPERATING THE MACHINE…2848
Starting The Engine…2848
Truck Operation – General…2848
Traveling In The Truck…2849
Precautions When Traveling In Reverse…2849
Traveling On Slopes…2849
Ensuring Good Visibility…2850
Operating On Snow…2850
Avoid Damage To The Dump Body…2850
Driving Near High Voltage Cables…2850
When Loading The Truck…2850
When Dumping…2850
Working On Loose Ground…2851
Parking The Machine…2851
TOWING…2851
WORKING NEAR BATTERIES…2852
Jump Starting With Booster Cables…2853
Jump Starting With Receptacles…2853
PRECAUTIONS FOR MAINTENANCE…2854
BEFORE PERFORMING MAINTENANCE…2854
Stopping The Engine Before Service…2854
Electrical Systems Isolation…2854
Warning Tag…2856
Proper Tools…2856
Securing The Dump Body…2856
DURING MAINTENANCE…2857
Personnel…2857
Attachments…2857
Working Under The Machine…2857
Keeping The Machine Clean…2857
Rules To Follow When Adding Fuel Or Oil…2857
Radiator Coolant Level…2857
Use Of Lighting…2858
Precautions With The Battery…2858
Handling High Pressure Hoses…2858
Precautions With High Pressure Oil…2858
Maintenance Near High Temperatures And High Pressures…2858
Rotating Fan And Belts…2858
Waste Materials…2858
TIRES…2859
Handling Tires…2859
Tire Maintenance…2860
Storing Tires After Removal…2860
ADDITIONAL JOB SITE RULES…2861
WHEN REPAIRS ARE NECESSARY…2862
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK…2863
Preliminary Procedures before Welding or Performing Maintenance…2863
Engine Shutdown Procedure before Welding or Performing Maintenance…2863
WARNINGS AND CAUTIONS…2866
TRUCK OPERATION…2880
PREPARING FOR OPERATION…2880
Safety Is Thinking Ahead…2880
WALK AROUND INSPECTION…2880
RETRACTABLE LADDER SYSTEM (If equipped)…2884
LADDER SYSTEM DESCRIPTION…2884
LADDER SYSTEM OPERATION…2885
Normal Operation…2885
GENERAL SAFETY…2885
IN-CAB CONTROL PANEL…2885
IN-CAB CONTROL PANEL FEATURES…2886
Digital Display Screen…2886
Command Buttons…2886
USING THE IN-CAB CONTROL PANEL…2887
Raising the Ladder…2887
Lowering the Ladder…2888
USING THE GROUND LEVEL CONTROL BOX…2889
Raising the Ladder…2889
Lowering the Ladder…2889
Emergency Operation…2890
ENGINE START-UP SAFETY PRACTICES…2891
AFTER ENGINE HAS STARTED…2892
PRE-SHIFT BRAKE CHECK (if equipped)…2893
Events…2893
OPERATION…2893
Description…2893
Brake Test Exit Criteria…2894
PERFORMING THE BRAKE TESTS…2894
Setup…2894
Service Brake Test…2895
Parking Brake Test…2896
Retard System Test:…2896
EMERGENCY STEERING SYSTEM…2897
Operation…2897
Pre-Operation Testing…2897
Additional Guidelines…2898
MACHINE OPERATION SAFETY PRECAUTIONS…2898
MACHINE OPERATION ON THE HAUL ROAD…2899
STARTING ON A GRADE WITH A LOADED TRUCK…2900
PASSING…2900
LOADING…2900
DUMPING…2900
Raising The Dump Body…2900
Lowering The Dump Body…2901
SUDDEN LOSS OF ENGINE POWER…2902
FUEL DEPLETION…2903
SAFE PARKING PROCEDURES…2903
NORMAL ENGINE SHUTDOWN PROCEDURE…2904
DISABLED TRUCK CONNECTORS…2905
GENERAL…2905
STEERING AND BRAKE SYSTEM…2905
Hookup…2905
HOIST SYSTEM…2906
Hookup…2906
Dumping Procedure…2906
TOWING…2908
Special Wiring Harness…2908
Towing Procedure…2908
RESERVE ENGINE OIL SYSTEM (Optional)…2911
Operation…2911
LED Monitor Light…2911
Changing Oil…2911
OPERATOR CAB AND CONTROLS…2912
STEERING WHEEL AND CONTROLS…2913
Horn Button…2913
Tilt / Telescope Lever…2913
Multi-Function Turn Signal Switch…2913
PEDALS…2914
Service Brake Pedal…2914
Dynamic Retarding…2914
Dynamic Retard Pedal…2914
Throttle/Accelerator Pedal…2915
GRADE/SPEED RETARD CHART…2915
OVERHEAD PANEL AND DISPLAYS…2917
Radio Speakers…2917
Warning Alarm Buzzer…2917
Cab Radio…2917
Warning Light Dimmer Control…2917
Status/Warning Indicator Light Panel…2917
Air Cleaner Vacuum Gauges…2917
Windshield Wipers…2917
CENTER CONSOLE…2918
Directional Control Lever…2918
Override/Fault Reset Switch…2919
Engine Stop Switch…2919
L.H. Window Control Switch…2919
R.H. Window Control Switch…2919
Hoist Control Lever…2919
Raising The Dump Body…2919
Lowering The Dump Body…2919
Retard Speed Control (RSC) Adjust Dial…2920
Retard Speed Control (RSC) Switch…2920
Data Store Button…2921
VHMS Snapshot In Progress Light…2921
Link Energized Light…2921
Service Engine Light…2921
DIAGNOSTIC PORTS…2921
VHMS Diagnostic Port…2921
Interface Module (IM) Diagnostic Port…2921
Payload Meter Diagnostic Port…2921
Truck Control Interface (TCI) Diagnostic Port…2921
Propulsion System Controller (PSC) Diagnostic Port…2921
Engine Diagnostic Port (CENSE)…2921
Engine Diagnostic Port (QUANTUM)…2921
OPERATOR’S SEAT…2922
Adjustment…2922
HEATER / AIR CONDITIONER CONTROLS…2923
Fan Speed Control Knob…2923
Temperature Control Knob…2923
Air Flow Directional Knob…2923
Heater/Air Conditioner Vents…2923
INSTRUMENT PANEL…2924
Key Switch…2926
Starting…2926
Rotating Beacon Light Switch (Optional)…2926
Heated Mirror Switch (Optional)…2926
Rest Switch…2926
Wheel Brake Lock Control…2927
Hazard Warning Lights…2927
Cab/Air Conditioner Vents…2927
Engine Oil Pressure Gauge…2927
Right Turn Signal Indicator…2927
Tachometer…2927
High Beam Indicator…2928
Speedometer/Payload Meter Display…2928
Left Turn Signal Indicator…2928
Water Temperature Gauge…2928
Lamp Test Switch…2928
Light Switch…2928
Ladder Light Switch…2928
Manual Backup Switch…2929
Fog Lights (Optional)…2929
Payload Meter Switch…2929
Panel Light Dimmer…2929
Hydraulic Oil Temperature Gauge…2929
Hourmeter…2930
Fuel Level Gauge…2930
OVERHEAD STATUS / WARNING INDICATORS…2931
Status / Warning Indicator Light Symbols…2932
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…2938
Operation…2938
Interface Module…2939
Basic Precautions…2939
CIRCUIT BREAKERS…2942
LUBRICATION AND SERVICE…2944
830E SERVICE CAPACITIES…2944
HYDRAULIC TANK SERVICE…2944
Adding Oil…2944
WHEEL MOTOR SERVICE…2945
COOLANT LEVEL CHECK…2945
RADIATOR FILLING PROCEDURE…2945
RESERVE ENGINE OIL SYSTEM (Optional)…2945
Reserve Oil Tank Filling Procedure (Remote fill)…2946
LUBRICATION CHART…2947
10 HOUR (DAILY) INSPECTION…2948
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…2951
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…2952
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…2953
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…2957
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…2959
2500 HOUR MAINTENANCE CHECKS…2960
5000 HOUR MAINTENANCE CHECKS…2960
10,000 HOUR MAINTENANCE CHECKS…2961
AUTOMATIC LUBRICATION SYSTEM…2962
GENERAL DESCRIPTION…2962
SYSTEM COMPONENTS…2964
Filter…2964
Hydraulic Motor and Pump…2964
Grease Reservoir…2964
Pressure Reducing Valve…2964
Flow Control Valve…2964
Solenoid Valve…2964
Vent Valve…2964
Lubrication Cycle Timer…2964
Over Pressure Cut Off Switch…2964
Grease Pressure Failure Switch…2964
Injectors…2964
Relief Valve (unloader valve)…2964
SYSTEM OPERATION…2965
Normal Operation…2965
GENERAL INSTRUCTIONS…2966
Lubricant Required For System…2966
System Priming…2966
Filter Assembly…2966
LUBRICANT PUMP…2967
Pump Housing Oil Level…2967
Pump Pressure Control…2967
INJECTORS (SL-1 Series “H”))…2968
Injector Specifications…2968
Injector Adjustment…2968
INJECTOR OPERATION…2969
PREVENTIVE MAINTENANCE PROCEDURES…2970
Daily Lubrication System Inspection…2970
250 Hour Inspection…2970
1000 Hour Inspection…2970
SYSTEM CHECKOUT…2971
Lubrication Controller Check…2971
Lubrication Controller Components…2971
Lubrication Controller Adjustment…2971
SYSTEM TROUBLESHOOTING CHART…2973
MAJOR COMPONENT DESCRIPTION…2976
PAYLOAD METER III™…2980
INDEX…2980
Introduction…2982
Data Summary…2982
Data Gathering…2982
COMPONENT DESCRIPTION…2983
System Diagram…2983
Suspension Pressure Sensors…2983
Inclinometer…2983
Operator Display…2983
Operator Switch…2984
Speed Input…2984
Body-Up Switch…2984
Brake Lock Switch…2984
Payload Meter…2984
Communications Ports…2984
Key Switch Input…2985
Payload Meter Power…2985
Load Lights…2985
Wiring and Termination…2986
TCI Outputs…2986
OPERATOR’S DISPLAY AND SWITCH…2987
Reading the Speedometer…2987
Reading the Load Display…2987
Using the Operator ID…2987
Using the Load and Ton Counter…2987
Total Ton Counter…2987
Total Load Counter…2988
Clearing the Counters…2988
Viewing Live Sensor Data…2988
Other Display Messages…2988
PAYLOAD OPERATION & CALCULATION…2989
Haul Cycle States…2989
Haul Cycle Description…2989
Load Calculation…2990
Carry Back…2990
Measurement Accuracy…2990
SOURCES FOR PAYLOAD ERROR…2990
Payload Error…2990
Loading Conditions…2991
Pressure Sensors…2991
Swingloads…2991
Speed and Distance…2991
HAUL CYCLE DATA…2991
Haul Cycle Data…2992
Haul Cycle Warning Flags…2993
Frame Torque Data…2994
Sprung Weight Data…2994
Maximum Speed Data…2994
Alarm Records…2994
Fault Code Data…2995
PC SOFTWARE OVERVIEW…2996
PC Overview…2996
System Configuration…2996
Installing the PLMIII Software…2996
DOWNLOADING DATA…2997
PLM III SYSTEM CONFIGURATION…2998
Starting Communications…2998
Displayed Payload Units…2998
Time Units…2998
Connection Menu…2998
Connecting to the Payload Meter…2999
Configure the Payload Meter…2999
Setting the Date and Time…2999
Setting the Truck Type…3000
Setting the Gauge Display Units…3000
Setting the Frame Serial Number…3000
Setting the Truck Number…3000
Setting the Komatsu Distributor…3000
Setting the Komatsu Customer…3000
Clean Truck Tare…3001
Inclinometer Calibration…3001
DATA ANALYSIS…3002
Creating a Query…3002
Sorting on Truck Unit Number…3002
Sorting on Truck Type…3002
Sorting on Date Range…3003
Sorting on Time Range…3003
Payload Detail Screen…3004
Creating Reports…3004
Summary – one page report…3005
Detailed – multi-page report…3005
Creating Graphs…3006
Exporting Data…3006
CSV Export…3006
Compressed…3007
Importing Data…3008
Deleting Haul Cycle Records…3008
Viewing Alarms…3009
Deleting Alarm Records…3009
AM/FM RADIO / CD PLAYER…3012
OPERATING INSTRUCTIONS…3012
GENERAL RADIO RECEIVER FUNCTIONS…3012
Turning On the Power…3012
One-Hour Timer…3012
Display…3013
Setting a Default Display…3013
Adjusting the Brightness of the Display…3013
Auxiliary Mode…3013
Adjusting the Receiver Settings…3013
USING THE CLOCK…3014
Setting the Clock…3014
USING THE ALARM…3014
Setting the Alarm…3014
Turning the Alarm Off…3014
Activating Snooze…3014
Setting Alarm Volume…3014
USING THE RADIO…3015
Finding a Station…3015
Setting the Presets…3016
SATELLITE RADIO SERVICE (Optional)…3016
Activating Satellite Radio (Optional)…3016
USING THE WEATHERBAND…3017
USING THE COMPACT DISC PLAYER…3017
Playing a Compact Disc…3017
Button Functions…3017
PLAYING AN MP3 DISC…3018
MP3 Format Compatibility…3018
Root Directory…3018
Empty Directory or Folder…3018
No Folder…3018
File Name Display…3018
Pre-Programmed Playlists…3019
Playing MP3 Files…3019
Button Functions…3019
TROUBLESHOOTING…3020
CEAM022303 – Dump Truck 830E-1AC Operation & Maintenance Manual…3024
1 INTRODUCTION…3039
FOREWORD…3039
ABOUT THIS MANUAL…3040
ALERTS…3041
TRUCK MODEL ILLUSTRATION…3042
NON-OEM PARTS IN CRITICAL SYSTEMS…3043
2 STANDARD CHARTS AND TABLES…3045
GENERAL INFORMATION…3045
EFFECT OF SPECIAL LUBRICANTS…3045
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…3045
STANDARD TIGHTENING TORQUES…3046
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…3046
SAE GRADE 5 AND GRADE 8 CAP SCREWS…3047
SAE GRADE 9 CAP SCREWS…3048
T-BOLT CLAMPS…3048
SPLIT FLANGE CLAMPS…3049
FLARED TUBE AND HOSE FITTINGS…3049
JIC 37° SWIVEL NUTS…3050
PIPE THREAD FITTINGS…3051
O-RING BOSS FITTINGS…3052
O-RING FACE SEAL FITTINGS…3053
CONVERSION MULTIPLIERS…3054
METRIC TO ENGLISH…3054
ENGLISH TO METRIC…3055
TEMPERATURE CONVERSIONS…3056
3 GENERAL SAFETY…3059
GENERAL SAFETY…3059
Safety Rules…3059
Truck Safety Features…3059
Clothing And Personal Items…3059
Unauthorized Modification…3059
Leaving The Operator’S Seat…3059
Mounting And Dismounting…3060
Fire Extinguishers And First Aid Kits…3060
Precautions For High Temperature Fluids…3060
Asbestos Dust Hazard Prevention…3060
Fire Prevention…3060
Rops Precautions…3061
Preventing Injury From Work Equipment…3061
Precautions For Optional Attachments…3061
Precautions When Starting The Machine…3061
PRECAUTIONS FOR TRUCK OPERATION…3062
Safety Is Thinking Ahead…3062
Safety At The Worksite…3062
Preparing For Operation…3062
Ventilation For Enclosed Areas…3062
Mirrors, Windows, And Lights…3062
Before Starting The Engine…3062
Seat Belts…3063
Emergency Egress Ladders…3063
OPERATING THE MACHINE…3064
General Information…3064
Starting The Engine…3064
Traveling In The Machine…3064
Traveling In Reverse…3065
Traveling On Slopes…3065
Traveling On Snow…3065
Traveling Near High Voltage Cables…3065
Traveling On Loose Ground…3065
Ensuring Good Visibility…3066
Avoid Damage To The Dump Body…3066
Parking The Machine…3066
Loading The Machine…3066
Dumping The Machine…3066
Towing The Machine…3066
EXTERIOR LIGHTING…3067
Fog Lights…3067
Headlights…3067
Brake Light…3067
Retard Light…3067
Clearance/Turn Signal Lights…3068
Backup Lights…3068
Retard Lights…3068
Brake Lights…3068
Backup Alarm…3068
PRECAUTIONS FOR MAINTENANCE…3069
BEFORE PERFORMING MAINTENANCE…3069
Electrical System Isolation…3069
Securing The Dump Body…3070
DURING MAINTENANCE…3071
Warning Tag…3071
Proper Tools…3071
Attachments…3071
Working Under The Machine…3071
Keeping The Machine Clean…3072
Adding Fuel Or Oil To The Machine…3072
Radiator Coolant Level…3072
Use Of Lighting…3072
Handling High Pressure Hoses…3073
Precautions With High Pressure Oil…3073
Maintenance Near High Temperatures and High Pressures…3073
Rotating Fan And Belts…3073
Waste Materials…3073
Use of Tie-Off Anchor During Maintenance…3073
Battery Hazard Prevention…3074
Jump Starting With Booster Cables…3074
Jump Starting With Receptacles…3075
Handling Tires…3076
Tire Maintenance…3076
Storing Tires After Removal…3076
WHEN REPAIRS ARE NECESSARY…3078
Observe The Following Precautions…3078
SPECIAL PRECAUTIONS…3079
Preliminary Procedures Before Welding or Performing Maintenance…3079
Engine Shutdown Procedure Before Welding or Performing Maintenan…3079
Discharging Control Cabinet Capacitors…3080
4 WARNING AND CAUTIONS…3083
GENERAL INFORMATION…3083
PIN PLATE…3083
GRADE SPEED CHART…3084
MACHINE SAFETY…3084
KEY SWITCH…3086
OIL FILL AND CHECK…3087
HIGH PRESSURES…3088
BATTERY AND ISOLATION BOX…3090
HIGH VOLTAGE…3093
WELDING…3095
LIFTING POINTS…3096
EMERGENCY DUMPING…3097
AUTOMATIC LUBRICATION FILL…3098
POISON DANGER…3098
ROPS/FOPS…3099
TOWING…3099
LUBRICATION CHART…3099
5 OPERATING INSTRUCTIONS…3101
PREPARING FOR OPERATION…3101
Safety Is Thinking Ahead…3101
Walk Around Inspection…3101
RETRACTABLE LADDER SYSTEM (If Equipped)…3106
GENERAL INFORMATION…3106
LADDER SYSTEM DESCRIPTION…3106
LADDER SYSTEM OPERATION…3106
In-Cab Control Panel…3107
Ground Level Control Box…3109
Emergency Down Valve…3110
PRE-SHIFT BRAKE TEST…3112
OPERATION…3112
Service Brake Test…3113
Parking Brake Test…3114
Retard System Test…3114
Brake Test Exit Criteria…3115
TRUCK OPERATION…3116
ENGINE START-UP SAFETY…3116
After Engine Has Started…3116
MACHINE OPERATION SAFETY PRECAUTIONS…3117
Machine Operation On The Haul Road…3118
Starting On A Grade With A Loaded Truck…3118
Retarding On A Grade…3119
Passing…3120
Loading…3120
Dumping…3120
Lowering The Dump Body (When Dumping On Flat Ground)…3121
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…3121
SUDDEN LOSS OF ENGINE POWER…3122
EMERGENCY STEERING SYSTEM…3122
Operation…3122
Pre-Operation Testing…3123
Additional Guidelines…3123
FUEL DEPLETION…3124
SAFE PARKING PROCEDURES…3124
NORMAL ENGINE SHUTDOWN PROCEDURE…3124
DISABLED TRUCK CONNECTORS…3126
GENERAL INFORMATION…3126
STEERING AND BRAKE SYSTEM…3126
Hookup…3126
HOIST SYSTEM…3127
Hookup…3127
Dumping Procedure…3127
TOWING…3129
Towing Procedure…3129
SPECIAL WIRING HARNESS…3130
PAYLOAD METER III SYSTEM…3133
GENERAL INFORMATION…3133
Data Summary…3133
Data Gathering…3133
COMPONENT DESCRIPTION…3133
Operator Display…3133
Operator Switch…3133
Brake Lock Switch…3134
Payload Meter Module…3134
Communications Ports…3134
Load Lights…3134
OPERATORS DISPLAY AND SWITCH…3134
Reading the Load Display…3134
Setting the Operator ID…3135
Load and Ton Counter…3135
Viewing Live Sensor Data…3135
Other Display Messages…3136
HAUL CYCLE WARNING FLAGS…3136
Haul Cycle Data…3136
Haul Cycle Warning Flags…3138
PC SOFTWARE OVERVIEW…3139
SYSTEM CONFIGURATION…3140
Connecting to the Payload Meter…3140
Displayed Payload Units…3140
Connection Menu…3140
Configure the Payload Meter…3141
Setting the Date and Time…3141
Setting the Truck Type and Serial Number…3142
Setting the Gauge Display Units…3142
Setting the Carryback Alarm Threshold…3142
Setting the Truck Number…3143
Setting the Komatsu Distributor…3143
Setting the Komatsu Customer…3143
Clean Truck Tare Calibration…3143
Inclinometer Calibration…3144
DOWNLOADING PAYLOAD DATA…3144
UPLOADING DATA…3145
DATA ANALYSIS…3146
Creating a Query…3146
Payload Detail Screen…3147
Creating Reports…3147
Creating Graphs…3147
Exporting Data…3148
Importing Data…3149
Deleting Haul Cycle Records…3149
Viewing Alarms…3149
Deleting Alarm Records…3149
Patent Acknowledment…3149
AUTOMATIC LUBRICATION SYSTEM…3150
GENERAL INFORMATION…3150
COMPONENT DESCRIPTION…3150
Filter…3151
Hydraulic Motor and Pump…3151
Grease Reservoir…3151
Pressure Reducing Valve…3151
Flow Control Valve…3152
Solenoid Valve…3152
Vent Valve…3152
Lubrication Cycle Timer…3152
Pressure Cut Off Switch…3152
Injectors…3153
Grease Pressure Failure Switch…3153
Relief Valve (unloader valve)…3154
SYSTEM OPERATION…3154
Filling The Reservoir…3154
Priming The Automatic Lubrication System…3155
PREVENTIVE MAINTENANCE PROCEDURES…3155
Daily Lubrication System Inspection…3155
250 Hour Inspection…3156
1000 Hour Inspection…3156
SYSTEM CHECKOUT…3157
General Checks…3157
Lubrication Controller Components…3157
RESERVE ENGINE OIL SYSTEM (Optional)…3159
Operation…3159
Changing Oil…3159
6 OPERATOR CAB AND CONTROLS…3163
CAB INTERIOR…3163
STEERING WHEEL AND CONTROLS…3164
Horn Button…3164
Tilt / Telescope Lever…3164
Multi-Function Turn Signal Switch…3164
Turn Signal Operation…3164
High Beam Headlight Operation…3164
Windshield Wiper Operation…3165
PEDALS…3166
SERVICE BRAKE PEDAL…3166
DYNAMIC RETARD PEDAL…3166
Dynamic Retarding…3166
ACCELERATOR PEDAL…3166
OVERHEAD PANEL AND DISPLAYS…3168
RADIO SPEAKERS…3168
WARNING ALARM BUZZER…3168
CAB RADIO…3168
WARNING LIGHT DIMMER CONTROL…3168
STATUS/WARNING INDICATOR LIGHT PANEL…3168
AIR CLEANER VACUUM GAUGES…3168
WINDSHIELD WIPERS…3168
CENTER CONSOLE…3169
DIRECTIONAL CONTROL LEVER…3169
OVERRIDE/FAULT RESET SWITCH…3169
ENGINE STOP SWITCH…3170
WINDOW CONTROL SWITCHES…3170
HOIST CONTROL LEVER…3170
Raising The Dump Body…3170
Lowering The Dump Body…3170
RETARD SPEED CONTROL (RSC) ADJUST DIAL…3170
RETARD SPEED CONTROL (RSC) SWITCH…3171
DATA STORE BUTTON…3171
KOMTRAX Plus SNAPSHOT IN PROGRESS LIGHT…3171
LINK ENERGIZED LIGHT…3171
SERVICE ENGINE LIGHT…3171
DIAGNOSTIC PORTS…3172
KOMTRAX Plus …3172
INTERFACE MODULE (IM)…3172
PAYLOAD METER…3172
TRUCK CONTROL INTERFACE (TCI)…3172
PROPULSION SYSTEM CONTROLLER (PSC)…3172
ENGINE (CENSE)…3172
ENGINE (QUANTUM)…3172
OPERATOR’S SEAT (Standard)…3173
SEAT BELTS…3173
ADJUSTMENT…3173
PASSENGER SEAT (Standard)…3175
SEAT BELTS…3175
ADJUSTMENT…3175
HEATER / AIR CONDITIONER CONTROLS…3176
Fan Speed Control Knob…3176
Temperature Control Knob…3176
Air Flow Directional Knob…3176
Heater/Air Conditioner Vents…3176
INSTRUMENT PANEL …3177
CONTROL SYMBOLS…3177
Key Switch…3178
Rotating Beacon Light Switch (Optional)…3179
Heated Mirror Switch (Optional)…3179
Rest Switch…3179
Wheel Brake Lock Control Switch…3179
Hazard Warning Light Switch…3180
Cab/Air Conditioner Vents…3180
Engine Oil Pressure Gauge…3180
Right Turn Signal Indicator…3180
Tachometer…3180
High Beam Indicator…3180
Speedometer/Payload Meter Display…3180
Left Turn Signal Indicator…3180
Water Temperature Gauge…3181
Lamp Test Switch…3181
Light Switch…3181
Ladder Light Switch…3181
Manual Backup Switch…3181
Fog Light Swich(Optional)…3181
Payload Meter Switch…3182
Panel Light Dimmer…3182
Hydraulic Oil Temperature Gauge…3182
Hourmeter…3182
Fuel Level Gauge…3182
OVERHEAD STATUS/WARNING INDICATOR…3183
STATUS / WARNING INDICATOR LIGHT SYMBOLS…3184
High Hydraulic Oil Temperature…3184
Low Steering Pressure…3185
Low Accumulator Precharge Pressure…3185
Low Brake Pressure…3186
Low Hydraulic Tank Level…3186
Automatic Lubrication System Pressure…3186
Circuit Breaker Tripped…3186
Hydraulic Oil Filter Monitor…3186
Low Fuel…3186
Parking Brake…3186
Service Brake…3187
Body Up…3187
Dynamic Retarding…3187
Stop Engine…3187
Cranking Motor Failure…3188
Manual Backup Lights…3188
Engine Shutdown Timer…3188
Retard Speed Control (RSC) Indicator…3188
Check Engine…3188
No Power…3188
Propulsion System Warning…3189
Propulsion System Temperature…3189
System/Component Failure…3189
Battery Charging System Failure…3189
No Propel…3189
Propel System At Rest…3189
Propel System Not Ready…3190
Reduced Propulsion…3190
Retard At Continuous Level…3190
Brake Test Light (If Equipped)…3190
Maintenance Monitor…3190
Brake Test Switch (If Equipped)…3190
KOMTRAX Plus…3191
KOMTRAX Plus OPERATION…3191
Basic Precautions…3191
Interface Module…3192
DOWNLOADING KOMTRAX Plus DATA…3193
GENERAL INFORMATION…3193
KOMTRAX Plus DOWNLOADING PROCEDURE…3193
Location of Downloaded Files…3194
UPLOADING KOMTRAX Plus DATA…3194
ORBCOMM…3196
KOMATSU WIRELESS BRIDGE (Optional)…3196
General Information…3196
Communication Setup…3197
Switching to the KWB_SETUP Network…3197
Setting the Computer Subnet Mask and IP Address…3197
Setting Up the KWB…3198
Adding Encryption…3199
Final Computer Settings…3199
Downloading Data…3199
Resetting the KWB…3200
FUSES AND CIRCUIT BREAKERS…3201
FUSE BLOCK #1…3201
FUSE BLOCK #2…3202
FUSE BLOCK #3…3202
FUSE BLOCK #4…3203
FUSE HOLDERS…3203
CIRCUIT BREAKERS…3203
7 LUBRICATION AND SERVICE…3205
GENERAL INFORMATION…3205
HYDRAULIC SYSTEM SERVICE…3205
Hydraulic Tank…3205
Hydraulic Filters…3206
Hydraulic Pump Drive Shaft…3206
WHEEL MOTOR SERVICE…3206
COOLANT LEVEL SERVICE…3206
Radiator Filling Procedure…3207
Coolant Specifications…3207
Unacceptable Practices…3207
RESERVE ENGINE OIL SERVICE…3207
Reserve Oil Tank Filling Procedure (Remote Fill)…3208
CAB AIR FILTER SERVICE…3208
FUEL SYSTEM SERVICE…3209
Fuel Tank Cleaning…3209
Fuel Filter Service…3209
INTAKE AIR CLEANER SERVICE…3209
FRONT WHEEL SERVICE…3211
Oil Sampling…3211
FRONT ENGINE MOUNT TRUNION SERVICE…3211
QUICK FILL SERVICE CENTER…3211
LUBRICATION CHART…3213
EVERY 10 HOUR (DAILY) MAINTENANCE…3214
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3216
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3217
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3218
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3220
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3222
EVERY 2500 HOUR MAINTENANCE…3223
EVERY 5000 HOUR MAINTENANCE…3224
EVERY 10,000 HOUR MAINTENANCE…3225
8 SPECIFICATIONS…3227
MAJOR COMPONENT DESCRIPTION…3227
Truck And Engine…3227
Alternator (GTA-41)…3227
AC Induction Traction Motorized Wheels…3227
Suspension…3227
Operator's Cab…3227
Power Steering…3227
Dynamic Retarding Gird…3227
Brake System…3227
SPECIFICATIONS…3229
Engine…3229
AC Electric Drive System…3229
Dynamic Retarding…3229
Battery Electric System…3229
Service Capacities…3229
Hydraulic Systems…3229
Service Brakes…3229
Parking Brake…3229
Steering…3230
Standard Dump Body Capacities And Dimensions…3230
Tires…3230
Weight Distribution…3230
Overall Truck Dimensions…3230
9 RADIO…3233
RADIO OPERATION…3233
GENERAL RADIO RECEIVER FUNCTIONS…3233
Turning On the Power…3233
One-Hour Timer…3234
Finding a Station…3234
Setting the Presets…3234
Adjusting the Receiver Audio Settings…3235
Display…3235
Adjusting the Receiver Menu Settings…3235
Front Auxiliary Mode…3236
Rear Auxiliary Mode…3236
CLOCK…3237
Clock/Alarm Button…3237
Setting the Clock…3237
Setting the Alarm…3237
Turning the Alarm Off…3238
Activating Snooze…3238
CD PLAYER…3239
Playing A Compact Disc…3239
Playing an MP3 DISC…3239
CD Mode Displays…3239
Button Functions…3239
MP3 PLAYER…3241
Playing MP3 Files…3241
MP3 Mode Displays…3241
Button Functions…3242
iPod®…3243
Playing an iPod®…3243
iPod® Mode Displays…3243
Button Functions…3243
WEATHERBAND (USA Only)…3245
TROUBLESHOOTING…3246
Tips About The Audio System…3246
Understanding Radio Reception…3246
Care of The Compact Discs…3246
CEAM024100 – Dump Truck 830E-1AC Operation & Maintenance Manual…3247
COVER…3247
WARNING…3249
NON-OEM PARTS…3250
FOREWORD…3251
ALERTS PAGE…3252
TABLE OF CONTENTS…3253
TRUCK MODEL ILLUSTRATION…3261
ABOUT THIS MANUAL…3262
STANDARD CHARTS AND TABLES…3263
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3263
STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)…3264
STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3264
GENERAL SAFETY…3273
Safety Rules…3273
Truck Safety Features…3273
Clothing And Personal Items…3273
Unauthorized Modification…3273
Leaving The Operator’s Seat…3273
Mounting And Dismounting…3274
Fire Extinguishers And First Aid Kits…3274
Precautions For High Temperature Fluids…3274
Asbestos Dust Hazard Prevention…3274
Fire Prevention For Fuel And Oil…3275
ROPS Precautions…3275
Preventing Injury From Work Equipment…3275
Precautions For Optional Attachments…3275
Precautions When Starting The Machine…3275
PRECAUTIONS FOR TRUCK OPERATION…3276
Safety Is Thinking Ahead…3276
Safety At The Worksite…3276
Fire Prevention…3276
Preparing For Operation…3276
Ventilation For Enclosed Areas…3276
Mirrors, Windows, And Lights…3277
In The Operator’s Cab – Before Starting The Engine…3277
Seat Belts…3277
OPERATING THE MACHINE…3277
Starting The Engine…3277
Truck Operation – General…3277
Traveling In The Truck…3278
Precautions When Traveling In Reverse…3278
Traveling On Slopes…3278
Ensuring Good Visibility…3279
Operating On Snow…3279
Avoid Damage To The Dump Body…3279
Driving Near High Voltage Cables…3279
When Loading The Truck…3279
When Dumping…3279
Working On Loose Ground…3280
Parking The Machine…3280
TOWING…3280
WORKING NEAR BATTERIES…3281
Jump Starting With Booster Cables…3282
Jump Starting With Receptacles…3282
PRECAUTIONS FOR MAINTENANCE…3283
BEFORE PERFORMING MAINTENANCE…3283
Stopping The Engine Before Service…3283
Electrical Systems Isolation…3283
Warning Tag…3285
Proper Tools…3285
Securing The Dump Body…3285
DURING MAINTENANCE…3286
Personnel…3286
Attachments…3286
Working Under The Machine…3286
Keeping The Machine Clean…3286
Rules To Follow When Adding Fuel Or Oil…3286
Radiator Coolant Level…3286
Use Of Lighting…3287
Precautions With The Battery…3287
Handling High Pressure Hoses…3287
Precautions With High Pressure Oil…3287
Maintenance Near High Temperatures And High Pressures…3287
Rotating Fan And Belts…3287
Waste Materials…3287
TIRES…3288
Handling Tires…3288
Tire Maintenance…3289
Storing Tires After Removal…3289
ADDITIONAL JOB SITE RULES…3290
WHEN REPAIRS ARE NECESSARY…3291
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK…3292
Preliminary Procedures before Welding or Performing Maintenance…3292
Engine Shutdown Procedure before Welding or Performing Maintenance…3292
WARNINGS AND CAUTIONS…3295
TRUCK OPERATION…3309
PREPARING FOR OPERATION…3309
Safety Is Thinking Ahead…3309
WALK AROUND INSPECTION…3309
RETRACTABLE LADDER SYSTEM (If equipped)…3313
LADDER SYSTEM DESCRIPTION…3313
LADDER SYSTEM OPERATION…3314
Normal Operation…3314
GENERAL SAFETY…3314
IN-CAB CONTROL PANEL…3314
IN-CAB CONTROL PANEL FEATURES…3315
Digital Display Screen…3315
Command Buttons…3315
USING THE IN-CAB CONTROL PANEL…3316
Raising the Ladder…3316
Lowering the Ladder…3317
USING THE GROUND LEVEL CONTROL BOX…3318
Raising the Ladder…3318
Lowering the Ladder…3318
Emergency Operation…3319
ENGINE START-UP SAFETY PRACTICES…3320
AFTER ENGINE HAS STARTED…3321
PRE-SHIFT BRAKE CHECK (if equipped)…3322
Events…3322
OPERATION…3322
Description…3322
Brake Test Exit Criteria…3323
PERFORMING THE BRAKE TESTS…3323
Setup…3323
Service Brake Test…3324
Parking Brake Test…3325
Retard System Test:…3325
EMERGENCY STEERING SYSTEM…3326
Operation…3326
Pre-Operation Testing…3326
Additional Guidelines…3327
MACHINE OPERATION SAFETY PRECAUTIONS…3327
MACHINE OPERATION ON THE HAUL ROAD…3328
STARTING ON A GRADE WITH A LOADED TRUCK…3329
PASSING…3329
LOADING…3329
DUMPING…3329
Raising The Dump Body…3329
Lowering The Dump Body…3330
SUDDEN LOSS OF ENGINE POWER…3331
FUEL DEPLETION…3332
SAFE PARKING PROCEDURES…3332
NORMAL ENGINE SHUTDOWN PROCEDURE…3333
DISABLED TRUCK CONNECTORS…3334
GENERAL…3334
STEERING AND BRAKE SYSTEM…3334
Hookup…3334
HOIST SYSTEM…3335
Hookup…3335
Dumping Procedure…3335
TOWING…3337
Special Wiring Harness…3337
Towing Procedure…3337
RESERVE ENGINE OIL SYSTEM (Optional)…3340
Operation…3340
LED Monitor Light…3340
Changing Oil…3340
OPERATOR CAB AND CONTROLS…3341
STEERING WHEEL AND CONTROLS…3342
Horn Button…3342
Tilt / Telescope Lever…3342
Multi-Function Turn Signal Switch…3342
PEDALS…3343
Service Brake Pedal…3343
Dynamic Retarding…3343
Dynamic Retard Pedal…3343
Throttle/Accelerator Pedal…3344
GRADE/SPEED RETARD CHART…3344
OVERHEAD PANEL AND DISPLAYS…3346
Radio Speakers…3346
Warning Alarm Buzzer…3346
Cab Radio…3346
Warning Light Dimmer Control…3346
Status/Warning Indicator Light Panel…3346
Air Cleaner Vacuum Gauges…3346
Windshield Wipers…3346
CENTER CONSOLE…3347
Directional Control Lever…3347
Override/Fault Reset Switch…3348
Engine Stop Switch…3348
L.H. Window Control Switch…3348
R.H. Window Control Switch…3348
Hoist Control Lever…3348
Raising The Dump Body…3348
Lowering The Dump Body…3348
Retard Speed Control (RSC) Adjust Dial…3349
Retard Speed Control (RSC) Switch…3349
Data Store Button…3350
VHMS Snapshot In Progress Light…3350
Link Energized Light…3350
Service Engine Light…3350
DIAGNOSTIC PORTS…3350
VHMS Diagnostic Port…3350
Interface Module (IM) Diagnostic Port…3350
Payload Meter Diagnostic Port…3350
Truck Control Interface (TCI) Diagnostic Port…3350
Propulsion System Controller (PSC) Diagnostic Port…3350
Engine Diagnostic Port (CENSE)…3350
Engine Diagnostic Port (QUANTUM)…3350
OPERATOR’S SEAT…3351
Seat Belts…3351
Adjustment…3351
HEATER / AIR CONDITIONER CONTROLS…3352
Fan Speed Control Knob…3352
Temperature Control Knob…3352
Air Flow Directional Knob…3352
Heater/Air Conditioner Vents…3352
INSTRUMENT PANEL…3353
Key Switch…3355
Starting…3355
Rotating Beacon Light Switch (Optional)…3355
Heated Mirror Switch (Optional)…3355
Rest Switch…3355
Wheel Brake Lock Control…3356
Hazard Warning Lights…3356
Cab/Air Conditioner Vents…3356
Engine Oil Pressure Gauge…3356
Right Turn Signal Indicator…3356
Tachometer…3356
High Beam Indicator…3357
Speedometer/Payload Meter Display…3357
Left Turn Signal Indicator…3357
Water Temperature Gauge…3357
Lamp Test Switch…3357
Light Switch…3357
Ladder Light Switch…3357
Manual Backup Switch…3358
Fog Lights (Optional)…3358
Payload Meter Switch…3358
Panel Light Dimmer…3358
Hydraulic Oil Temperature Gauge…3358
Hourmeter…3359
Fuel Level Gauge…3359
OVERHEAD STATUS / WARNING INDICATORS…3360
Status / Warning Indicator Light Symbols…3361
VEHICLE HEALTH MONITORING SYSTEM (VHMS)…3367
Operation…3367
Interface Module…3368
Basic Precautions…3368
CIRCUIT BREAKERS…3371
LUBRICATION AND SERVICE…3373
830E SERVICE CAPACITIES…3373
HYDRAULIC TANK SERVICE…3373
Adding Oil…3373
WHEEL MOTOR SERVICE…3374
COOLANT LEVEL CHECK…3374
RADIATOR FILLING PROCEDURE…3374
RESERVE ENGINE OIL SYSTEM (Optional)…3374
Reserve Oil Tank Filling Procedure (Remote fill)…3375
LUBRICATION CHART…3376
10 HOUR (DAILY) INSPECTION…3377
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…3380
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…3381
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…3382
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…3386
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)…3387
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…3388
2500 HOUR MAINTENANCE CHECKS…3389
5000 HOUR MAINTENANCE CHECKS…3389
5000 HOUR MAINTENANCE CHECKS (Continued)…3390
10,000 HOUR MAINTENANCE CHECKS…3390
AUTOMATIC LUBRICATION SYSTEM…3391
GENERAL DESCRIPTION…3391
SYSTEM COMPONENTS…3393
Filter…3393
Hydraulic Motor and Pump…3393
Grease Reservoir…3393
Pressure Reducing Valve…3393
Flow Control Valve…3393
Solenoid Valve…3393
Vent Valve…3393
Lubrication Cycle Timer…3393
Over Pressure Cut Off Switch…3393
Grease Pressure Failure Switch…3393
Injectors…3393
Relief Valve (unloader valve)…3393
SYSTEM OPERATION…3394
Normal Operation…3394
GENERAL INSTRUCTIONS…3395
Lubricant Required For System…3395
System Priming…3395
Filter Assembly…3395
LUBRICANT PUMP…3396
Pump Housing Oil Level…3396
Pump Pressure Control…3396
INJECTORS (SL-1 Series “H”))…3397
Injector Specifications…3397
Injector Adjustment…3397
PREVENTIVE MAINTENANCE PROCEDURES…3399
Daily Lubrication System Inspection…3399
250 Hour Inspection…3399
1000 Hour Inspection…3399
SYSTEM CHECKOUT…3400
Lubrication Controller Check…3400
Lubrication Controller Components…3400
Lubrication Controller Adjustment…3400
SYSTEM TROUBLESHOOTING CHART…3402
INJECTOR OPERATION…3398
MAJOR COMPONENT DESCRIPTION…3405
PAYLOAD METER III™…3409
INDEX…3409
Introduction…3411
Data Summary…3411
Data Gathering…3411
COMPONENT DESCRIPTION…3412
System Diagram…3412
Suspension Pressure Sensors…3412
Inclinometer…3412
Operator Display…3412
Operator Switch…3413
Speed Input…3413
Body-Up Switch…3413
Brake Lock Switch…3413
Payload Meter…3413
Communications Ports…3413
Key Switch Input…3414
Payload Meter Power…3414
Load Lights…3414
Wiring and Termination…3415
TCI Outputs…3415
OPERATOR’S DISPLAY AND SWITCH…3416
Reading the Speedometer…3416
Reading the Load Display…3416
Using the Operator ID…3416
Using the Load and Ton Counter…3416
Total Ton Counter…3416
Total Load Counter…3417
Clearing the Counters…3417
Viewing Live Sensor Data…3417
Other Display Messages…3417
PAYLOAD OPERATION & CALCULATION…3418
Haul Cycle States…3418
Haul Cycle Description…3418
Load Calculation…3419
Carry Back…3419
Measurement Accuracy…3419
SOURCES FOR PAYLOAD ERROR…3419
Payload Error…3419
Loading Conditions…3420
Pressure Sensors…3420
Swingloads…3420
Speed and Distance…3420
HAUL CYCLE DATA…3420
Haul Cycle Data…3421
Haul Cycle Warning Flags…3422
Frame Torque Data…3423
Sprung Weight Data…3423
Maximum Speed Data…3423
Alarm Records…3423
Fault Code Data…3424
PC SOFTWARE OVERVIEW…3425
PC Overview…3425
System Configuration…3425
Installing the PLMIII Software…3425
DOWNLOADING DATA…3426
PLM III SYSTEM CONFIGURATION…3427
Starting Communications…3427
Displayed Payload Units…3427
Time Units…3427
Connection Menu…3427
Connecting to the Payload Meter…3428
Configure the Payload Meter…3428
Setting the Date and Time…3428
Setting the Truck Type…3429
Setting the Gauge Display Units…3429
Setting the Frame Serial Number…3429
Setting the Truck Number…3429
Setting the Komatsu Distributor…3429
Setting the Komatsu Customer…3429
Clean Truck Tare…3430
Inclinometer Calibration…3430
DATA ANALYSIS…3431
Creating a Query…3431
Sorting on Truck Unit Number…3431
Sorting on Truck Type…3431
Sorting on Date Range…3432
Sorting on Time Range…3432
Payload Detail Screen…3433
Creating Reports…3433
Summary – one page report…3434
Detailed – multi-page report…3434
Creating Graphs…3435
Exporting Data…3435
CSV Export…3435
Compressed…3436
Importing Data…3437
Deleting Haul Cycle Records…3437
Viewing Alarms…3438
Deleting Alarm Records…3438
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER…3441
OPERATING INSTRUCTIONS…3441
GENERAL RADIO RECEIVER FUNCTIONS…3441
Turning On the Power…3441
One-Hour Timer…3441
Adjusting the Volume…3442
Display…3442
Radio Mode Displays…3442
CD Mode Displays…3442
MP3/USB/iPod Mode Displays…3442
AUX Input Displays…3443
CLOCK/ALARM Button…3443
Front Auxiliary Mode…3443
Rear Auxiliary Mode…3443
Adjusting the Receiver Audio Settings…3443
Adjusting the Receiver Menu Settings…3444
USING THE RADIO…3445
Finding a Station…3445
Setting the Presets…3445
USING THE CLOCK…3446
Setting the Clock…3446
USING THE ALARM…3446
Setting the Alarm…3446
Turning the Alarm Off…3447
Activating Snooze…3447
USING THE WEATHERBAND (USA Only)…3447
USING THE COMPACT DISC PLAYER/USB…3448
Playing A Compact Disc…3448
Button Functions…3448
PLAYING AN MP3 DISC/USB…3449
Root Directory…3449
Empty Directory or Folder…3449
No Folder…3449
File Name Display…3449
PLAYING MP3 FILES…3449
Button Functions…3449
USING AN iPOD®…3450
Playing an iPod…3450
Button Functions…3450
OPERATING TIPS…3451
Tips About The Audio System…3451
Understanding Radio Reception…3451
Care of The Compact Discs…3451
TROUBLESHOOTING…3452
CEAM024403 – Dump Truck 830E-1AC Operation & Maintenance Manual…3455
COVER…3455
TABLE OF CONTENTS…3457
1 INTRODUCTION…3468
FOREWORD…3468
ABOUT THIS MANUAL…3469
WARNINGS…3470
CALIFORNIA PROPOSITION 65 WARNINGS…3470
ALERTS…3471
TRUCK MODEL ILLUSTRATION…3472
NON-OEM PARTS IN CRITICAL SYSTEMS…3473
2 STANDARD CHARTS AND TABLES…3476
GENERAL INFORMATION…3476
EFFECT OF SPECIAL LUBRICANTS…3476
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…3476
STANDARD TIGHTENING TORQUES…3477
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…3477
SAE GRADE 5 AND GRADE 8 CAP SCREWS…3478
SAE GRADE 9 CAP SCREWS…3479
T-BOLT CLAMPS…3479
SPLIT FLANGE CLAMPS…3479
FLARED TUBE AND HOSE FITTINGS…3480
JIC 37° SWIVEL NUTS…3480
PIPE THREAD FITTINGS…3481
O-RING BOSS FITTINGS…3482
O-RING FACE SEAL FITTINGS…3483
CONVERSION MULTIPLIERS…3485
METRIC TO ENGLISH…3485
ENGLISH TO METRIC…3485
TEMPERATURE CONVERSIONS…3486
3 GENERAL SAFETY…3490
GENERAL SAFETY…3490
Safety Rules…3490
Truck Safety Features…3490
Clothing And Personal Items…3490
Unauthorized Modification…3490
Leaving The Operator’s Seat…3490
Mounting And Dismounting…3490
Fire Extinguishers And First Aid Kits…3491
Precautions For High Temperature Fluids…3491
Asbestos Dust Hazard Prevention…3491
Fire Prevention…3491
Rops Precautions…3492
Preventing Injury From Work Equipment…3492
Precautions For Optional Attachments…3492
Precautions When Starting The Machine…3492
PRECAUTIONS FOR TRUCK OPERATION…3493
Safety Is Thinking Ahead…3493
Safety At The Worksite…3493
Preparing For Operation…3493
Ventilation For Enclosed Areas…3493
Mirrors, Windows, And Lights…3493
Before Starting The Engine…3493
Seat Belts…3493
Emergency Egress Ladders…3494
OPERATING THE MACHINE…3495
General Information…3495
Starting The Engine…3495
Traveling In The Machine…3495
Traveling In Reverse…3495
Traveling On Slopes…3496
Traveling On Snow…3496
Traveling Near High Voltage Cables…3496
Traveling On Loose Ground…3496
Ensuring Good Visibility…3496
Avoid Damage To The Dump Body…3496
Safe Parking Of The Machine…3496
Loading The Machine…3497
Dumping The Machine…3497
Towing The Machine…3497
EXTERIOR LIGHTING…3497
Fog Lights…3498
Headlights…3498
Brake Light…3498
Retard Light…3498
Clearance/Turn Signal Lights…3499
Backup Lights…3499
Retard Lights…3499
Brake Lights…3500
Backup Alarm…3500
HID Backup Light…3500
PRECAUTIONS FOR MAINTENANCE…3501
BEFORE PERFORMING MAINTENANCE…3501
Electrical System Isolation…3501
Securing The Dump Body…3502
DURING MAINTENANCE…3503
Warning Tag…3503
Proper Tools…3503
Attachments…3503
Working Under The Machine…3503
Keeping The Machine Clean…3504
Adding Fuel Or Oil To The Machine…3504
Radiator Coolant Level…3504
Use Of Lighting…3504
Handling High Pressure Hoses…3504
Precautions With High Pressure Oil…3504
Maintenance Near High Temperatures and High Pressures…3505
Rotating Fan And Belts…3505
Waste Materials…3505
Use of Tie-Off Anchor During Maintenance…3505
Handling Tires…3505
Tire Maintenance…3506
Storing Tires After Removal…3506
Battery Hazard Prevention…3506
Jump Starting With Booster Cables…3507
Jump Starting With Receptacles…3508
WHEN REPAIRS ARE NECESSARY…3509
Observe The Following Precautions…3509
SPECIAL PRECAUTIONS…3510
Preliminary Procedures Before Welding or Performing Maintenance…3510
Engine Shutdown Procedure Before Welding or Performing Maintenan…3510
Discharging Control Cabinet Capacitors…3511
4 WARNING AND CAUTIONS…3514
GENERAL INFORMATION…3514
PIN PLATE…3514
GRADE SPEED CHART…3515
MACHINE SAFETY…3515
KEY SWITCH…3517
OIL FILL AND CHECK…3518
HIGH PRESSURES…3519
BATTERY AND ISOLATION BOX…3521
HIGH VOLTAGE…3524
WELDING…3527
LIFTING POINTS…3527
EMERGENCY DUMPING…3528
AUTOMATIC LUBRICATION FILL…3529
ROPS/FOPS…3529
TOWING…3529
LUBRICATION CHART…3530
5 OPERATING INSTRUCTIONS…3532
PREPARING FOR OPERATION…3532
Safety Is Thinking Ahead…3532
Walk Around Inspection…3532
RETRACTABLE LADDER SYSTEM (If Equipped)…3537
GENERAL INFORMATION…3537
LADDER SYSTEM DESCRIPTION…3537
LADDER SYSTEM OPERATION…3537
In-Cab Control Panel…3538
Ground Level Control Box…3540
Emergency Down Valve…3541
PRE-SHIFT BRAKE TEST…3542
OPERATION…3542
Service Brake Test…3543
Parking Brake Test…3543
Retard System Test…3544
Brake Test Exit Criteria…3544
TRUCK OPERATION…3545
ENGINE START-UP SAFETY…3545
After Engine Has Started…3545
MACHINE OPERATION SAFETY PRECAUTIONS…3546
Machine Operation On The Haul Road…3547
Starting On A Grade With A Loaded Truck…3547
Retarding On A Grade…3547
Passing…3548
Loading…3548
Dumping…3549
Lowering The Dump Body (When Dumping On Flat Ground)…3549
Lowering The Dump Body (When Dumping Over A Berm Or Into A Crush…3550
SUDDEN LOSS OF ENGINE POWER…3550
EMERGENCY STEERING SYSTEM…3551
Operation…3551
Pre-Operation Testing…3551
Additional Guidelines…3552
CAMERA SYSTEM (Optional)…3552
General…3553
Operation…3553
Camera Monitor…3554
Camera Selection…3554
Auto Backlight Control/Day/Night Settings…3554
Contrast Adjustment…3554
Brightness Adjustment…3555
Saturation Adjustment…3555
Single Scan / Return…3555
Minus…3555
Plus…3555
Enter…3555
FUEL DEPLETION…3555
SAFE PARKING PROCEDURES…3556
NORMAL ENGINE SHUTDOWN PROCEDURE…3556
DISABLED TRUCK CONNECTORS…3558
GENERAL INFORMATION…3558
STEERING AND BRAKE SYSTEM…3558
Hookup…3558
HOIST SYSTEM…3559
Hookup…3559
Dumping Procedure…3560
TOWING…3561
Towing Procedure…3561
SPECIAL WIRING HARNESS…3561
PAYLOAD METER III SYSTEM…3564
GENERAL INFORMATION…3564
Data Summary…3564
Data Gathering…3564
COMPONENT DESCRIPTION…3564
Operator Display…3564
Operator Switch…3564
Brake Lock Switch…3564
Payload Meter Module…3565
Communications Ports…3565
Load Lights…3565
OPERATORS DISPLAY AND SWITCH…3565
Reading the Load Display…3565
Setting the Operator ID…3566
Load and Ton Counter…3566
Viewing Live Sensor Data…3566
Other Display Messages…3566
HAUL CYCLE WARNING FLAGS…3567
Haul Cycle Data…3567
Haul Cycle Warning Flags…3568
PC SOFTWARE OVERVIEW…3570
SYSTEM CONFIGURATION…3570
Connecting to the Payload Meter…3570
Displayed Payload Units…3571
Connection Menu…3571
Configure the Payload Meter…3571
Setting the Date and Time…3571
Setting the Truck Type and Serial Number…3572
Setting the Gauge Display Units…3572
Setting the Carryback Alarm Threshold…3572
Setting the Truck Number…3573
Setting the Komatsu Distributor…3573
Setting the Komatsu Customer…3573
Clean Truck Tare Calibration…3573
Inclinometer Calibration…3574
DOWNLOADING PAYLOAD DATA…3574
UPLOADING DATA…3575
DATA ANALYSIS…3576
Creating a Query…3576
Payload Detail Screen…3577
Creating Reports…3577
Creating Graphs…3577
Exporting Data…3578
Importing Data…3578
Deleting Haul Cycle Records…3578
Viewing Alarms…3579
Deleting Alarm Records…3579
Patent Acknowledment…3579
AUTOMATIC LUBRICATION SYSTEM…3580
GENERAL INFORMATION…3580
COMPONENT DESCRIPTION…3580
Filter…3581
Hydraulic Motor and Pump…3581
Grease Reservoir…3581
Pressure Reducing Valve…3581
Flow Control Valve…3581
Solenoid Valve…3582
Vent Valve…3582
Lubrication Cycle Timer…3582
Pressure Cut Off Switch…3582
Injectors…3582
Grease Pressure Failure Switch…3583
Relief Valve (unloader valve)…3583
SYSTEM OPERATION…3583
Filling The Reservoir…3583
Priming The Automatic Lubrication System…3584
PREVENTIVE MAINTENANCE PROCEDURES…3584
Daily Lubrication System Inspection…3584
250 Hour Inspection…3585
1000 Hour Inspection…3585
SYSTEM CHECKOUT…3585
General Checks…3585
Lubrication Controller Components…3586
RESERVE ENGINE OIL SYSTEM (Optional)…3587
Operation…3587
Changing Oil…3587
6 OPERATOR CAB AND CONTROLS…3590
CAB INTERIOR…3590
STEERING WHEEL AND CONTROLS…3591
Horn Button…3591
Tilt / Telescope Lever…3591
Multi-Function Turn Signal Switch…3591
Turn Signal Operation…3591
High Beam Headlight Operation…3591
Windshield Wiper Operation…3591
PEDALS…3592
SERVICE BRAKE PEDAL…3592
DYNAMIC RETARD PEDAL…3592
Dynamic Retarding…3592
ACCELERATOR PEDAL…3592
OVERHEAD PANEL AND DISPLAYS…3593
RADIO SPEAKERS…3593
WARNING ALARM BUZZER…3593
CAB RADIO…3593
WARNING LIGHT DIMMER CONTROL…3593
STATUS/WARNING INDICATOR LIGHT PANEL…3593
AIR CLEANER VACUUM GAUGES…3593
WINDSHIELD WIPERS…3593
CAMERA MONITOR (OPTIONAL)…3593
CENTER CONSOLE…3594
DIRECTIONAL CONTROL LEVER…3594
OVERRIDE/FAULT RESET SWITCH…3594
ENGINE STOP SWITCH…3595
WINDOW CONTROL SWITCHES…3595
HOIST CONTROL LEVER…3595
Raising The Dump Body…3595
Lowering The Dump Body…3595
RETARD SPEED CONTROL (RSC) ADJUST DIAL…3595
RETARD SPEED CONTROL (RSC) SWITCH…3596
DATA STORE BUTTON…3596
KOMTRAX Plus SNAPSHOT IN PROGRESS LIGHT…3596
LINK ENERGIZED LIGHT…3596
SERVICE ENGINE LIGHT…3596
DIAGNOSTIC PORTS…3597
KOMTRAX Plus …3597
INTERFACE MODULE (IM)…3597
PAYLOAD METER…3597
TRUCK CONTROL INTERFACE (TCI)…3597
PROPULSION SYSTEM CONTROLLER (PSC)…3597
ENGINE (CENSE)…3597
ENGINE (QUANTUM)…3597
OPERATOR’S SEAT (Standard)…3598
SEAT BELTS…3598
ADJUSTMENT…3598
PASSENGER SEAT (Standard)…3600
SEAT BELTS…3600
ADJUSTMENT…3600
OPERATOR’S SEAT (Optional)…3601
SEAT BELTS…3601
ADJUSTMENT…3601
PASSENGER SEAT (Optional)…3602
SEAT BELTS…3602
ADJUSTMENT…3602
HEATER / AIR CONDITIONER CONTROLS…3604
Fan Speed Control Knob…3604
Temperature Control Knob…3604
Air Flow Directional Knob…3604
Heater/Air Conditioner Vents…3604
INSTRUMENT PANEL …3605
CONTROL SYMBOLS…3605
Key Switch…3606
Grid Dryer (Optional)…3606
Camera System (Optional)…3607
Rotating Beacon Light Switch (Optional)…3607
Heated Mirror Switch (Optional)…3607
Rest Switch…3607
Wheel Brake Lock Control Switch…3608
Hazard Warning Light Switch…3608
Cab/Air Conditioner Vents…3608
Engine Oil Pressure Gauge…3608
Right Turn Signal Indicator…3609
Tachometer…3609
High Beam Indicator…3609
Speedometer/Payload Meter Display…3609
Left Turn Signal Indicator…3609
Water Temperature Gauge…3609
Lamp Test Switch…3609
Light Switch…3609
Ladder Light Switch…3610
Manual Backup Switch…3610
Fog Light Switch (Optional)…3610
Payload Meter Switch…3610
Panel Light Dimmer…3610
Hydraulic Oil Temperature Gauge…3610
Hourmeter…3611
Fuel Level Gauge…3611
OVERHEAD STATUS/WARNING INDICATOR…3612
STATUS / WARNING INDICATOR LIGHT SYMBOLS…3613
High Hydraulic Oil Temperature…3613
Low Steering Pressure…3613
Low Accumulator Precharge Pressure…3614
Low Brake Pressure…3614
Low Hydraulic Tank Level…3614
Automatic Lubrication System Pressure…3614
Circuit Breaker Tripped…3614
Hydraulic Oil Filter Monitor…3614
Low Fuel…3615
Parking Brake…3615
Service Brake…3615
Body Up…3615
Dynamic Retarding…3615
Stop Engine…3615
Cranking Motor Failure…3616
Manual Backup Lights…3616
Engine Shutdown Timer…3616
Retard Speed Control (RSC) Indicator…3616
Check Engine…3616
No Power…3616
Propulsion System Warning…3617
Propulsion System Temperature…3617
System/Component Failure…3617
Battery Charging System Failure…3617
No Propel…3617
Propel System At Rest…3617
Propel System Not Ready…3617
Reduced Propulsion…3618
Retard At Continuous Level…3618
Brake Test Light (If Equipped)…3618
Maintenance Monitor…3618
Brake Test Switch (If Equipped)…3618
KOMTRAX Plus…3619
KOMTRAX Plus OPERATION…3619
Basic Precautions…3619
Interface Module…3620
DOWNLOADING KOMTRAX Plus DATA…3621
GENERAL INFORMATION…3621
KOMTRAX Plus DOWNLOADING PROCEDURE…3621
Location of Downloaded Files…3621
UPLOADING KOMTRAX Plus DATA…3622
ORBCOMM…3623
KOMATSU WIRELESS BRIDGE (Optional)…3624
General Information…3624
Communication Setup…3624
Switching to the KWB_SETUP Network…3624
Setting the Computer Subnet Mask and IP Address…3625
Setting Up the KWB…3625
Adding Encryption…3626
Final Computer Settings…3626
Downloading Data…3626
Resetting the KWB…3627
FUSES AND CIRCUIT BREAKERS…3628
FUSE BLOCK #1…3628
FUSE BLOCK #2…3629
FUSE BLOCK #3…3629
FUSE BLOCK #4…3630
FUSE HOLDERS…3630
CIRCUIT BREAKERS…3630
7 LUBRICATION AND SERVICE…3632
GENERAL INFORMATION…3632
HYDRAULIC SYSTEM SERVICE…3632
Hydraulic Tank…3632
Hydraulic Filters…3633
Hydraulic Pump Drive Shaft…3633
WHEEL MOTOR SERVICE…3633
COOLANT LEVEL SERVICE…3633
Radiator Filling Procedure…3634
Coolant Specifications…3634
Unacceptable Practices…3634
RESERVE ENGINE OIL SERVICE (If Equipped)…3634
Reserve Oil Tank Filling Procedure (Remote Fill)…3635
Inline Screen…3635
CAB AIR FILTER SERVICE…3635
FUEL SYSTEM SERVICE…3636
Fuel Tank Cleaning…3636
Fuel Filter Service…3636
INTAKE AIR CLEANER SERVICE…3637
FRONT WHEEL SERVICE…3638
Oil Sampling…3638
FRONT ENGINE MOUNT TRUNION SERVICE…3639
QUICK FILL SERVICE CENTER…3639
LUBRICATION CHART…3640
EVERY 10 HOUR (DAILY) MAINTENANCE…3641
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3643
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3644
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…3645
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…3647
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…3649
EVERY 2500 HOUR MAINTENANCE…3650
EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION…3651
EVERY 5000 HOUR MAINTENANCE…3652
8 SPECIFICATIONS…3654
MAJOR COMPONENT DESCRIPTION…3654
Truck And Engine…3654
Alternator (GTA-41)…3654
AC Induction Traction Motorized Wheels…3654
Suspension…3654
Operator's Cab…3654
Power Steering…3654
Dynamic Retarding Grid…3654
Brake System…3654
SPECIFICATIONS…3655
Engine…3655
AC Electric Drive System…3655
Dynamic Retarding…3655
Battery Electric System…3655
Service Capacities…3655
Hydraulic Systems…3655
Service Brakes…3655
Parking Brake…3655
Steering…3655
Standard Dump Body Capacities And Dimensions…3655
Tires…3656
Weight Distribution…3656
Overall Truck Dimensions…3656
9 RADIO…3660
RADIO OPERATION…3660
GENERAL RADIO RECEIVER FUNCTIONS…3660
Turning On the Power…3660
One-Hour Timer…3661
Finding a Station…3661
Setting the Presets…3661
Adjusting the Receiver Audio Settings…3661
Display…3662
Adjusting the Receiver Menu Settings…3662
Front Auxiliary Mode…3663
Rear Auxiliary Mode…3663
CLOCK…3664
Clock/Alarm Button…3664
Setting the Clock…3664
Setting the Alarm…3664
Turning the Alarm Off…3665
Activating Snooze…3665
CD PLAYER…3666
Playing A Compact Disc…3666
Playing an MP3 DISC…3666
CD Mode Displays…3666
Button Functions…3666
MP3 PLAYER…3668
Playing MP3 Files…3668
MP3 Mode Displays…3668
Button Functions…3669
iPod®…3670
Playing an iPod®…3670
iPod® Mode Displays…3670
Button Functions…3670
WEATHERBAND (USA Only)…3672
TROUBLESHOOTING…3673
Tips About The Audio System…3673
Understanding Radio Reception…3673
Care of The Compact Discs…3673
CEAM025001 – Dump Truck 830E-1AC Operation & Maintenance Manual…3675
CEAM026901 – Dump Truck 830E-1AC Operation & Maintenance Manual…3911
COVER…3911
FOREWORD…3913
ALERTS PAGE…3914
TABLE OF CONTENTS…3915
TRUCK MODEL ILLUSTRATION…3919
ABOUT THIS MANUAL…3920
TORQUE TABLES AND CONVERSION CHARTS…3921
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values…3922
STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts…3922
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws…3923
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws…3924
GENERAL SAFETY…3931
Safety Rules…3931
Truck Safety Features…3931
Clothing And Personal Items…3931
Unauthorized Modification…3931
Leaving The Operator’s Seat…3931
Mounting And Dismounting…3932
Fire Extinguishers And First Aid Kits…3932
Precautions For High Temperature Fluids…3932
Asbestos Dust Hazard Prevention…3932
Fire Prevention For Fuel And Oil…3933
ROPS Precautions…3933
Preventing Injury From Work Equipment…3933
Precautions For Optional Attachments…3933
Precautions When Starting The Machine…3933
WORKING NEAR BATTERIES…3934
PRECAUTIONS FOR MAINTENANCE…3935
BEFORE PERFORMING MAINTENANCE…3935
Stopping The Engine Before Service…3935
Electrical Systems Isolation…3935
Warning Tag…3937
Proper Tools…3937
Use of Tie-Off Anchor During Maintenance…3937
Securing The Dump Body…3937
DURING MAINTENANCE…3938
Personnel…3938
Attachments…3938
Working Under The Machine…3938
Keeping The Machine Clean…3938
Use Of Lighting…3938
Precautions With The Battery…3938
Handling High Pressure Hoses…3939
Precautions With High Pressure Oil…3939
Maintenance Near High Temperatures And High Pressures…3939
Rotating Fan And Belts…3939
Waste Materials…3939
WHEN REPAIRS ARE NECESSARY…3940
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-AC TRUCK…3941
Preliminary Procedures before Welding or Performing Maintenance…3941
Engine Shutdown Procedure before Welding or Performing Maintenance…3941
CAPACITOR DISCHARGE SYSTEM…3943
Necessary Tools…3943
Warnings And Cautions…3944
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE…3945
Preparation…3945
CAPACITOR CHARGE LIGHTS…3947
FAILURE OF DISCHARGE SYSTEM…3948
Measuring Dc Voltage On Capacitors…3948
MANUAL DISCHARGE OF CAPACITORS…3949
SHORT ISOLATED CAPACITOR TERMINALS…3952
CHASSIS SOUND ATTENUATION SYSTEM…3955
OVERVIEW…3955
Preparing For Operation…3955
Safety Is Thinking Ahead…3955
Components…3955
General…3955
Maintenance…3955
Exhaust System…3956
General…3956
Maintenance…3956
Approximate weights…3956
Attenuators…3957
General…3957
Engine Side Panels…3958
General…3958
Maintenance…3958
Engine Belly Pan Assembly…3960
General…3960
Maintenance…3961
Approximate weights…3961
Radiator Silencer…3962
General…3962
Maintenance…3962
Approximate weights…3962
Rear Engine Compartment Enclosure…3963
General…3963
Maintenance…3963
Approximate weights…3963
Center Deck Lining…3964
General…3964
Front Panel Assembly Below Radiator…3965
General…3965
Hood Seals…3966
Upper Horse Collar Panels…3967
Maintenance…3967
Blower Duct Cover & Hoses…3968
General…3968
Maintenance…3968
DRIVE SYSTEM SOUND ATTENUATION SYSTEM…3969
RETARDING GRID ATTENUATION PACKAGE…3969
General…3969
Maintenance…3970
Alternator Air Intake Silencer…3971
Maintenance…3971
SOUND ATTENUATION SYSTEM SERVICE INTERVALS…3973
10 HOUR (DAILY) INSPECTION CHECKS…3973
500 HOUR INSPECTION CHECKS…3974
6000 HOURS MAINTENANCE CHECKS…3976
10,000 HOURS LUBRICATION AND MAINTENANCE CHECKS…3976
MAJOR COMPONENT DESCRIPTION…3977
SPECIFICATIONS…3977
WEIGHT DISTRIBUTION…3977
OVERALL TRUCK DIMENSIONS (Empty with Standard Body)…3977
CEAM027001 – Dump Truck 830E-1AC Operation & Maintenance Manual…3981
1 INTRODUCTION…3994
FOREWORD…3994
ABOUT THIS MANUAL…3995
WARNINGS…3996
CALIFORNIA PROPOSITION 65 WARNINGS…3996
ALERTS…3997
TRUCK MODEL ILLUSTRATION…3998
NON-OEM PARTS IN CRITICAL SYSTEMS…3999
2 STANDARD CHARTS AND TABLES…4002
GENERAL INFORMATION…4002
EFFECT OF SPECIAL LUBRICANTS…4002
SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE…4002
STANDARD TIGHTENING TORQUES…4003
CLASS 10.9 CAP SCREWS & CLASS 10 NUTS…4003
SAE GRADE 5 AND GRADE 8 CAP SCREWS…4004
SAE GRADE 9 CAP SCREWS…4005
T-BOLT CLAMPS…4005
SPLIT FLANGE CLAMPS…4006
FLARED TUBE AND HOSE FITTINGS…4006
JIC 37° SWIVEL NUTS…4007
PIPE THREAD FITTINGS…4008
O-RING BOSS FITTINGS…4009
O-RING FACE SEAL FITTINGS…4010
CONVERSION MULTIPLIERS…4011
METRIC TO ENGLISH…4011
ENGLISH TO METRIC…4012
TEMPERATURE CONVERSIONS…4013
3 GENERAL SAFETY…4016
GENERAL SAFETY…4016
Safety Rules…4016
Truck Safety Features…4016
Clothing And Personal Items…4016
Unauthorized Modification…4016
Leaving The Operator’s Seat…4016
Mounting And Dismounting…4016
Fire Extinguishers And First Aid Kits…4017
Precautions For High Temperature Fluids…4017
Asbestos Dust Hazard Prevention…4017
Fire Prevention…4017
ROPS Precautions…4017
Preventing Injury From Work Equipment…4018
Precautions For Optional Attachments…4018
Precautions When Starting The Machine…4018
PRECAUTIONS FOR TRUCK OPERATION…4019
Safety Is Thinking Ahead…4019
Safety At The Worksite…4019
Preparing For Operation…4019
Ventilation For Enclosed Areas…4019
Mirrors, Windows, And Lights…4019
Before Starting The Engine…4019
Seat Belts…4019
Emergency Egress Ladders…4020
OPERATING THE MACHINE…4021
General Information…4021
Starting The Engine…4021
Traveling In The Machine…4021
Traveling In Reverse…4021
Traveling On Slopes…4022
Traveling On Snow…4022
Traveling Near High Voltage Cables…4022
Traveling On Loose Ground…4022
Ensuring Good Visibility…4022
Avoid Damage To The Dump Body…4022
Safe Parking Of The Machine…4023
Loading The Machine…4023
Dumping The Machine…4023
Towing The Machine…4023
EXTERIOR LIGHTING…4024
Fog Lights…4024
Headlights…4024
Brake Light…4024
Retard Light…4024
Clearance/Turn Signal Lights…4024
Backup Lights…4025
Retard Lights…4025
Brake Lights…4025
Backup Alarm…4025
HID Backup Light…4025
PRECAUTIONS FOR MAINTENANCE…4026
BEFORE PERFORMING MAINTENANCE…4026
Electrical System Isolation…4026
Securing The Dump Body…4027
DURING MAINTENANCE…4028
Warning Tag…4028
Proper Tools…4028
Attachments…4028
Working Under The Machine…4028
Keeping The Machine Clean…4029
Adding Fuel Or Oil To The Machine…4029
Radiator Coolant Level…4029
Use of Lighting…4029
Handling High Pressure Hoses…4029
Precautions With High Pressure Oil…4029
Maintenance Near High Temperatures and High Pressures…4030
Rotating Fan and Belts…4030
Waste Materials…4030
Use of Tie-Off Anchor During Maintenance…4030
Handling Tires…4030
Tire Maintenance…4031
Storing Tires After Removal…4031
BATTERY HAZARD PREVENTION…4031
Jump Starting With Booster Cables…4032
Jump Starting With Receptacles…4033
WHEN REPAIRS ARE NECESSARY…4034
Observe The Following Precautions…4034
SPECIAL PRECAUTIONS…4035
Preliminary Procedures Before Welding or Performing Maintenance…4035
Engine Shutdown Procedure Before Welding or Performing Maintenan…4035
Before welding on the machine, obey the following guidelines:…4035
Discharging Control Cabinet Capacitors…4036
4 WARNING AND CAUTIONS…4038
GENERAL INFORMATION…4038
PIN PLATE…4038
GRADE SPEED CHART…4039
MACHINE SAFETY…4039
KEY SWITCH…4041
OIL FILL AND CHECK…4041
HIGH PRESSURES…4042
BATTERY AND ISOLATION BOX…4045
HIGH VOLTAGE…4048
WELDING…4051
LIFTING POINTS…4052
EMERGENCY DUMPING…4053
AUTOMATIC LUBRICATION FILL…4053
ROPS/FOPS…4053
TOWING…4054
LUBRICATION CHART…4054
5 OPERATING INSTRUCTIONS…4056
PREPARING FOR OPERATION…4056
Safety Is Thinking Ahead…4056
Walk Around Inspection…4056
RETRACTABLE LADDER SYSTEM (If Equipped)…4061
GENERAL INFORMATION…4061
LADDER SYSTEM DESCRIPTION…4061
LADDER SYSTEM OPERATION…4061
In-Cab Control Panel…4062
Ground Level Control Box…4064
Emergency Down Valve…4064
PRE-SHIFT BRAKE TEST…4065
OPERATION…4065
Service Brake Test…4066
Parking Brake Test…4066
Retard System Test…4067
Brake Test Exit Criteria…4067
TRUCK OPERATION…4068
ENGINE START-UP SAFETY…4068
After Engine Has Started…4068
MACHINE OPERATION SAFETY PRECAUTIONS…4069
Machine Operation on the Haul Road…4069
Starting on a Grade With a Loaded Truck…4070
Retarding on a Grade…4070
Passing…4071
Loading…4071
Overload Speed Limit Function…4072
Dumping…4072
Lowering the Dump Body (When Dumping on Flat Ground)…4073
Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush…4073
SUDDEN LOSS OF ENGINE POWER…4074
EMERGENCY STEERING SYSTEM…4074
Operation…4074
Pre-Operation Testing…4075
Additional Guidelines…4075
CAMERA SYSTEM (Optional)…4076
General…4076
Operation…4076
Camera Monitor…4077
Camera Selection…4077
Auto Backlight Control/Day/Night Settings…4077
Contrast Adjustment…4077
Brightness Adjustment…4077
Saturation Adjustment…4077
Single Scan / Return…4077
Minus…4077
Plus…4077
Enter…4077
FUEL DEPLETION…4078
SAFE PARKING PROCEDURES…4078
NORMAL ENGINE SHUTDOWN PROCEDURE…4078
DISABLED TRUCK CONNECTORS…4080
GENERAL INFORMATION…4080
STEERING AND BRAKE SYSTEM…4080
Hookup…4080
HOIST SYSTEM…4081
Hookup…4081
Dumping Procedure…4082
TOWING…4083
SPECIAL WIRING HARNESS…4083
TOWING PROCEDURE…4083
PAYLOAD METER III SYSTEM…4085
GENERAL INFORMATION…4085
Data Summary…4085
Data Gathering…4085
COMPONENT DESCRIPTION…4085
Operator Display…4085
Operator Switches…4085
Brake Lock Switch…4086
Payload Meter Module…4086
Communications Ports…4086
Load Lights…4086
OPERATOR’S DISPLAY AND SWITCH…4086
Reading the Load Display…4086
Setting the Operator ID…4087
Load and Ton Counter…4087
Viewing Live Sensor Data…4087
Other Display Messages…4088
HAUL CYCLE WARNING FLAGS…4088
Haul Cycle Data…4088
Haul Cycle Warning Flags…4090
PC SOFTWARE OVERVIEW…4091
SYSTEM CONFIGURATION…4091
Connecting to the Payload Meter…4091
Displayed Payload Units…4092
Connection Menu…4092
Configure the Payload Meter…4092
Setting the Date and Time…4092
Setting the Truck Type and Serial Number…4093
Setting the Gauge Display Units…4093
Setting the Carryback Alarm Threshold…4093
Setting the Truck Number…4094
Setting the Komatsu Distributor…4094
Setting the Komatsu Customer…4094
Clean Truck Tare Calibration…4094
Inclinometer Calibration…4095
DOWNLOADING PAYLOAD DATA…4095
UPLOADING DATA…4096
DATA ANALYSIS…4097
Creating a Query…4097
Payload Detail Screen…4098
Creating Reports…4098
Creating Graphs…4098
Exporting Data…4099
Importing Data…4099
Deleting Haul Cycle Records…4099
Viewing Alarms…4100
Deleting Alarm Records…4100
Patent Acknowledgment…4100
AUTOMATIC LUBRICATION SYSTEM…4101
GENERAL INFORMATION…4101
COMPONENT DESCRIPTION…4101
Filter…4102
Hydraulic Motor and Pump…4102
Grease Reservoir…4102
Pressure Reducing Valve…4102
Flow Control Valve…4102
Solenoid Valve…4103
Vent Valve…4103
Interface Module…4103
Pressure Cut Off Switch…4103
Injectors…4104
Grease Pressure Failure Switch…4105
Relief Valve (unloader valve)…4105
SYSTEM OPERATION…4105
Filling The Reservoir…4105
Priming The Automatic Lubrication System…4106
PREVENTIVE MAINTENANCE PROCEDURES…4106
Daily Lubrication System Inspection…4106
250 Hour Inspection…4107
1000 Hour Inspection…4107
SYSTEM CHECKOUT…4107
General Checks…4107
Lubrication Cycle Operation…4108
RESERVE ENGINE OIL SYSTEM…4109
Operation…4109
Changing Oil…4109
6 OPERATOR CAB AND CONTROLS…4112
CAB INTERIOR…4112
STEERING WHEEL AND CONTROLS…4113
Horn Button…4113
Tilt / Telescope Lever…4113
Multi-Function Turn Signal Switch…4113
Turn Signal Operation…4113
High Beam Headlight Operation…4113
Windshield Wiper Operation…4113
PEDALS…4114
SERVICE BRAKE PEDAL…4114
DYNAMIC RETARD PEDAL…4114
Dynamic Retarding…4114
ACCELERATOR PEDAL…4114
OVERHEAD PANEL AND DISPLAYS…4115
RADIO SPEAKERS…4115
WARNING ALARM BUZZER…4115
CAB RADIO…4115
AIR CLEANER VACUUM GAUGES…4115
CAMERA MONITOR (OPTIONAL)…4115
CENTER CONSOLE…4116
DIRECTIONAL CONTROL LEVER…4116
OVERRIDE/FAULT RESET SWITCH…4116
ENGINE STOP SWITCH…4116
WINDOW CONTROL SWITCHES…4117
HOIST CONTROL LEVER…4117
Raising The Dump Body…4117
Lowering The Dump Body…4117
RETARD SPEED CONTROL (RSC) ADJUST DIAL…4117
RETARD SPEED CONTROL (RSC) SWITCH…4118
DATA STORE BUTTON…4118
12V AUXILIARY POWER OUTLETS…4118
FIRE SUPPRESSION CONTROL OUTLET…4118
COMMUNICATION RADIO OUTLET…4118
DIAGNOSTIC PORTS…4119
KOMTRAX Plus …4119
INTERFACE MODULE (IM)…4119
PAYLOAD METER…4119
DRIVE SYSTEM OR MODULAR MINING…4119
DRIVE SYSTEM CONTROLLER (DSC)…4119
ENGINE (CENSE)…4119
ENGINE (QUANTUM)…4119
OPERATOR SEAT (Standard)…4120
SEAT BELTS…4120
ADJUSTMENT…4120
PASSENGER SEAT (Standard)…4122
SEAT BELTS…4122
ADJUSTMENT…4122
OPERATOR SEAT (Optional)…4123
SEAT BELTS…4123
ADJUSTMENT…4123
PASSENGER SEAT (Optional)…4124
SEAT BELTS…4124
ADJUSTMENT…4124
HEATER / AIR CONDITIONER CONTROLS…4125
Fan Speed Control Knob…4125
Temperature Control Knob…4125
Air Flow Directional Knob…4125
Heater/Air Conditioner Vents…4125
INSTRUMENT PANEL …4126
CONTROL SYMBOLS…4126
Cab/Air Conditioner Vents…4127
Status Indicator Light Panel…4127
Hydraulic Oil Temperature Gauge…4127
Coolant Temperature Gauge…4127
Speedometer/Digital Display…4127
Fuel Level Gauge…4127
Drive System Temperature Gauge…4128
Hazard Warning Light Switch…4128
Pre-Shift Brake Test Switch…4128
Wheel Brake Lock Control Switch…4128
Rest Switch…4128
Engine Warm Up…4129
Heated Mirror Switch (Optional)…4129
Rotating Beacon Light Switch (Optional)…4129
Camera System (Optional)…4129
Key Switch…4129
Warning Light…4130
Digital Display Contrast Buttons…4130
Turn Signal Indicators…4130
Panel Light Dimmer…4130
Mode Switches…4130
Fog Light Swich…4130
Backup Light Switch…4130
Ladder Light Switch…4130
Headlight/Panel Illumination Light Switch…4130
STATUS INDICATOR LIGHT PANEL…4132
STATUS INDICATOR LIGHT SYMBOLS…4132
Body Up…4132
Parking Brake…4132
Propel System Not Ready…4132
No Propel…4133
Engine Warm Up…4133
Engine Shutdown Delay…4133
Not used…4133
Wheel Brake Lock…4133
Traction Control…4133
Repair Monitor…4133
Retractable Ladder Down…4133
Snapshot In Progress…4133
Pantograph Energized…4133
Pantograph Up…4134
Service Brake…4134
Dynamic Retarding…4134
No DC Link Voltage…4134
DIGITAL DISPLAY OPERATION…4135
Toggling Through Main Level Screens…4135
Toggling Through Warning Screens…4136
Entering Payload Meter Data…4137
KOMTRAX Plus…4138
KOMTRAX Plus OPERATION…4138
Basic Precautions…4138
Interface Module…4139
DOWNLOADING KOMTRAX Plus DATA…4140
GENERAL INFORMATION…4140
KOMTRAX Plus DOWNLOADING PROCEDURE…4140
Location of Downloaded Files…4141
UPLOADING KOMTRAX Plus DATA…4141
ORBCOMM…4143
KOMATSU WIRELESS BRIDGE (Optional)…4143
General Information…4143
Communication Setup…4144
Switching to the KWB_SETUP Network…4144
Setting the Computer Subnet Mask and IP Address…4144
Setting Up the KWB…4145
Adding Encryption…4145
Final Computer Settings…4146
Downloading Data…4146
Resetting the KWB…4146
FUSES AND CIRCUIT BREAKERS…4148
VEHICLE ELECTRICAL CENTER 89…4148
VEHICLE ELECTRICAL CENTER 90…4150
VEHICLE ELECTRICAL CENTER 91…4152
CIRCUIT BREAKERS…4154
7 LUBRICATION AND SERVICE…4156
GENERAL INFORMATION…4156
HYDRAULIC SYSTEM SERVICE…4156
Hydraulic Tank…4156
Hydraulic Filters…4157
Hydraulic Pump Drive Shaft…4157
WHEEL MOTOR SERVICE…4157
COOLANT LEVEL SERVICE…4157
Radiator Filling Procedure…4158
Coolant Specifications…4158
Unacceptable Practices…4158
RESERVE ENGINE OIL SERVICE…4158
Reserve Oil Tank Filling Procedure (Remote Fill)…4159
Inline Screen…4159
CAB AIR FILTER SERVICE…4159
FUEL SYSTEM SERVICE…4160
Fuel Tank Cleaning…4160
Fuel Filter Service…4160
INTAKE AIR CLEANER SERVICE…4161
FRONT WHEEL SERVICE…4162
Oil Sampling…4162
FRONT ENGINE MOUNT TRUNION SERVICE…4162
QUICK FILL SERVICE CENTER…4162
TIE ROD INSPECTION AND TORQUE PROCEDURE…4163
LUBRICATION CHART…4165
EVERY 10 HOUR (DAILY) MAINTENANCE…4166
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION…4168
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION…4169
EVERY 250 HOUR LUBRICATION AND MAINTENANCE…4170
EVERY 500 HOUR LUBRICATION AND MAINTENANCE…4172
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE…4174
EVERY 2500 HOUR MAINTENANCE…4175
EVERY 5000 HOUR MAINTENANCE…4176
8 SPECIFICATIONS…4178
MAJOR COMPONENT DESCRIPTION…4178
Truck And Engine…4178
Traction Alternator…4178
Main Control Cabinet…4178
AC Induction Traction Motorized Wheels…4178
Suspension…4178
Operator's Cab…4178
Power Steering…4178
Dynamic Retarding Grid…4178
Brake System…4178
SPECIFICATIONS…4179
Engine…4179
AC Electric Drive System…4179
Dynamic Retarding…4179
Battery Electric System…4179
Service Capacities…4179
Hydraulic Systems…4179
Service Brakes…4180
Parking Brake…4180
Steering…4180
Standard Dump Body Capacities And Dimensions…4180
Tires…4180
Weight Distribution…4180
Overall Truck Dimensions…4181
9 RADIO…4184
RADIO OPERATION…4184
GENERAL RADIO RECEIVER FUNCTIONS…4184
Turning On the Power…4184
One-Hour Timer…4184
Finding a Station…4184
Setting the Presets…4185
Adjusting the Receiver Audio Settings…4185
Display…4186
Adjusting the Receiver Menu Settings…4186
Front Auxiliary Mode…4186
Rear Auxiliary Mode…4186
CLOCK…4187
Clock/Alarm Button…4187
Setting the Clock…4187
Setting the Alarm…4187
Turning the Alarm Off…4188
Activating Snooze…4188
CD PLAYER…4189
Playing a Compact Disc…4189
Playing an MP3 DISC…4189
CD Mode Displays…4189
Button Functions…4189
MP3 PLAYER…4191
Playing MP3 Files…4191
MP3 Mode Displays…4191
Button Functions…4191
iPod®…4193
Playing an iPod®…4193
iPod® Mode Displays…4193
Button Functions…4193
WEATHERBAND (USA Only)…4195
TROUBLESHOOTING…4196
Tips About the Audio System…4196
Understanding Radio Reception…4196
Care of the Compact Discs…4196
CEBM010501 – Dump Truck 830E Operation & Maintenance Manual…4197
COVER…4197
FOREWORD…4201
TABLE OF CONTENTS…4203
SECTION A…4205
SECTION A2 – MAJOR COMPONENTS & SPECIFICATIONS…4207
SECTION A3 – GENERAL SAFETY AND OPERATING INSTRUCTIONS – INDEX…4211
GENERAL SAFETY…4213
Safety Rules…4213
Truck Safety Features…4213
Clothing And Personal Items…4213
Unauthorized Modification…4213
Leaving The Operator’s Seat…4213
Mounting And Dismounting…4213
Fire Extinguishers And First Aid Kits…4214
Precautions For High Temperature Fluids…4214
Asbestos Dust Hazard Prevention…4214
Fire Prevention For Fuel And Oil…4214
ROPS Precautions…4215
Preventing Injury From Work Equipment…4215
Precautions For Optional Attachments…4215
Precautions When Starting The Machine…4215
PRECAUTIONS FOR TRUCK OPERATION…4216
Safety Is Thinking Ahead…4216
Safety At The Worksite…4216
Fire Prevention…4216
Preparing For Operation…4216
Ventilation For Enclosed Areas…4216
Mirrors, Windows, And Lights…4216
In The Operator’s Cab – Before Starting The Engine…4217
OPERATING THE MACHINE…4217
Starting The Engine…4217
Truck Operation – General…4217
Traveling In The Truck…4218
Precautions When Traveling In Reverse…4218
Traveling On Slopes…4218
Ensuring Good Visibility…4219
Operating On Snow…4219
Avoid Damage To The Dump Body…4219
Driving Near High Voltage Cables…4219
When Loading The Truck…4219
When Dumping…4219
Working On Loose Ground…4219
Parking The Machine…4220
TOWING…4220
WORKING NEAR BATTERIES…4220
Jump Starting With Booster Cables…4220
PRECAUTIONS FOR MAINTENANCE…4221
BEFORE PERFORMING MAINTENANCE…4221
Stopping The Engine Before Service…4221
Warning Tag…4221
Proper Tools…4221
Securing The Dump Body…4221
DURING MAINTENANCE…4222
Personnel…4222
Attachments…4222
Working Under The Machine…4222
Keeping The Machine Clean…4222
Rules To Follow When Adding Fuel Or Oil…4222
Radiator Coolant Level…4222
Use Of Lighting…4222
Precautions With The Battery…4223
Handling High Pressure Hoses…4223
Precautions With High Pressure Oil…4223
Maintenance Near High Temperatures And High Pressures…4223
Rotating Fan And Belts…4223
Waste Materials…4223
TIRES…4224
Handling Tires…4224
Storing Tires After Removal…4224
ADDITIONAL JOB SITE RULES…4225
WHEN REPAIRS ARE NECESSARY…4226
SPECIAL PRECAUTIONS FOR WORKING ON A 930E TRUCK…4227
Preliminary Procedures before Welding or Performing Maintenance…4227
Normal Engine Shutdown Procedure…4227
Engine Shutdown Procedure before Welding or Performing Maintenance…4227
TRUCK OPERATION…4230
PREPARING FOR OPERATION…4230
Safety Is Thinking Ahead…4230
WALK AROUND INSPECTION…4230
ENGINE START-UP SAFETY PRACTICES…4234
AFTER STARTING THE ENGINE…4235
Additional Guidelines…4235
MACHINE OPERATION SAFETY PRECAUTIONS…4235
MACHINE OPERATION ON THE HAUL ROAD…4236
DYNAMIC RETARDING OPERATION…4237
Dynamic Retarder Control Lever…4237
Dynamic Retarder/Service Brake Pedal…4237
STARTING ON A GRADE WITH A LOADED TRUCK…4238
PASSING…4238
LOADING…4238
DUMPING…4238
Raising The Dump Body…4238
Lowering The Dump Body…4239
TOWING…4240
SAFE PARKING PROCEDURES…4241
NORMAL ENGINE SHUTDOWN PROCEDURE…4241
DELAYED ENGINE SHUTDOWN PROCEDURE…4241
SUDDEN LOSS OF ENGINE POWER…4242
SECTION A4 – WARNINGS AND CAUTIONS…4243
SECTION A5 – STANDARD CHARTS AND TABLES…4251
SECTION A7 – STORAGE AND IDLE MACHINE PREPARATION – INDEX…4257
STORAGE AND IDLE MACHINE PREPARATION…4259
Short Term Idle Periods…4259
PREPARATION FOR STORAGE…4260
REMOVAL FROM STORAGE…4261
RECONDITIONING AN IDLE VEHICLE…4263
ENGINE OPERATION…4266
After The Engine Has Started…4267
ENGINE STORAGE…4268
Preparing Engine For Storage…4268
Temporary Storage (30 Days Or Less)…4268
Extended Storage (more Than 30 Days)…4268
RESTORING AN ENGINE AFTER EXTENDED STORAGE…4270
ELECTRIC DRIVE TRUCKS…4271
Storage Instructions and Procedures…4271
Placing Equipment Into Storage…4271
Storing A Truck That Is Operational…4271
Storing A Truck That Is Not Operational…4272
Storing A Major Component…4272
Periodic Inspections…4273
Placing Equipment Into Service After Storage…4273
When A Truck Is Operational…4273
When A Truck Is Not Operational…4273
For The First Hour…4274
SECTION B – STRUCTURES – INDEX…4275
SECTION B2 – STRUCTURAL COMPONENTS – INDEX…4277
STRUCTURAL COMPONENTS…4279
Preparation…4279
GRILLE, HOOD AND LADDER…4280
Removal…4280
Installation…4280
DECKS…4281
RIGHT DECK AND COMPONENTS…4281
Removal…4281
Installation…4282
LEFT DECK…4282
Removal…4282
Installation…4282
CENTER DECK…4282
SECTION B3 – DUMP BODY – INDEX…4283
DUMP BODY…4285
Removal…4285
Installation…4286
BODY PADS…4287
Adjustment…4287
BODY GUIDE…4288
HOIST LIMIT SWITCH…4288
BODY UP SWITCH…4288
BODY-UP RETENTION CABLE…4288
ROCK EJECTORS…4289
Rock Ejectors (Type I)…4289
Inspection…4289
Rock Ejectors (Type II)…4290
Inspection…4290
SECTION B4 – FUEL TANK – INDEX…4291
FUEL TANK…4293
Removal…4294
Installation…4294
Repair…4294
Cleaning…4294
FUEL GAUGE SENDER…4295
Removal…4295
Installation…4295
LOW FUEL SWITCH…4295
WIGGINS QUICK FILL FUEL SYSTEM…4296
FUEL RECEIVER…4296
TANK BREATHER VALVE…4296
Removal…4296
Installation…4296
Disassembly…4296
Assembly…4296
LEFT SIDE FILL…4297
FUEL – WATER SEPARATOR…4298
Installation…4298
Filter Service…4299
Backflushing Procedure…4299
Filter Element Replacement…4299
SECTION C – ENGINE – INDEX…4301
SECTION C2 – POWER MODULE – INDEX…4303
Preparation…4305
Preparation for Removal…4306
Power Module Removal…4309
Power Module Installation…4311
Power Module Hookup…4311
Series 4000 Fuel System Priming Procedure (For new engine or after engine overhaul)…4313
SECTION C3 – COOLING SYSTEM – INDEX…4315
COOLING SYSTEM…4317
COOLING SYSTEM DESCRIPTION…4317
Coolant Flow…4317
RADIATOR…4318
Removal…4318
RADIATOR REPAIR…4320
Internal Inspection…4320
External Cleaning…4320
Disassembly…4321
Cleaning and Inspection…4322
Assembly…4322
Pressure Testing…4323
Additional Service Information…4323
Installation…4324
RADIATOR FILL PROCEDURE…4324
Radiator Pressure Regulator Valve…4325
COOLING SYSTEM TROUBLESHOOTING…4325
SECTION C4 – POWERTRAIN – INDEX…4327
POWER TRAIN…4329
ALTERNATOR REMOVAL PROCEDURE…4329
Removal (MTU/DDC 4000 Engine)…4329
ENGINE/ALTERNATOR MATING…4331
General Instructions…4331
MEASURING PROCEDURE…4331
Joining Alternator and MTU/DDC Engine…4333
ENGINE…4334
Removal…4334
Service…4334
Installation…4334
SECTION C5 – AIR CLEANERS – INDEX…4335
AIR CLEANERS…4337
AIR CLEANERS…4337
Operation…4337
General Service Information…4337
FILTER ELEMENT REPLACEMENT…4338
Main Filter Element Cleaning…4339
Precleaner Section…4340
Cleaning Precleaner Tubes…4340
AIR INTAKE TROUBLESHOOTING…4341
SECTION C7 – FAN CLUTCH – INDEX…4343
FAN CLUTCH…4345
REMOVAL & INSTALLATION TOOLING…4345
FAN CLUTCH – DISASSEMBLY…4348
CLEANING AND INSPECTION…4358
ASSEMBLY – FAN CLUTCH…4362
TEST PROCEDURE…4376
SECTION D – ELECTRICAL SYSTEM (24VDC NON-PROPULSION) – INDEX…4377
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX …4379
24VDC ELECTRIC SUPPLY SYSTEM…4381
ELECTRICAL SYSTEM DESCRIPTION…4381
BATTERIES…4381
Maintenance and Service…4381
Troubleshooting…4381
BATTERY SUPPLY SYSTEM…4383
24VDC Battery Charging Alternator…4383
Battery Box…4383
Battery Control Box…4383
System Battery Starter Disconnect Relay…4383
Battery Disconnect Switches…4384
24VDC Auxiliary Battery Connectors…4384
Battery Equalizer…4385
Troubleshooting…4385
SECTION D3 – 24VDC ELECTRICAL SYSTEM COMPONENTS – INDEX…4387
24 VDC ELECTRICAL SYSTEM COMPONENTS…4389
PASSENGER SEAT BASE COMPARTMENT…4389
TRUCK SHUTDOWN PROCEDURE…4389
COMPONENTS…4389
Tail Light Resistor Diode Assemblies…4389
5 Minute Idle Timer Components…4389
Inclinometer…4391
Brake Warning Buzzer (BWB)…4391
Alarm Indicating Device (AID) System…4391
ELECTRICAL INTERFACE CABINET…4394
Lubrication System Timer…4394
Barometric Pressure Transducer…4394
Special Interface Module…4394
Power Distribution Terminals…4394
Truck Control Interface Panel…4394
Control Power Relay…4394
Circuit Breaker Panel…4394
Diode Board – DB1…4396
Diode Testing…4396
RELAY BOARDS…4397
Relay Boards – RB1, RB2, RB3, RB4, RB5…4397
Service…4397
Relay Board Identification…4398
Relay Board Functions…4399
Relay Board 6 (RB6)…4400
BODY-UP SWITCH…4401
Operation…4401
Adjustment…4401
Service…4401
HOIST LIMIT SWITCH…4402
Operation…4402
Adjustment…4402
Service…4402
SECTION D5 – DDEC ELECTRONIC ENGINE CONTROL – INDEX…4405
DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE…4407
COMPONENT DESCRIPTION…4408
Electronic Control Module…4408
Electronic Unit Nozzles…4410
System Sensors and Operator Inputs…4410
ENGINE PROTECTION SYSTEM…4411
DIAGNOSTICS…4412
SECTION D10 – BATTERY CHARGING ALTERNATOR – INDEX…4413
BATTERY CHARGING ALTERNATOR…4415
ELECTRICAL SYSTEM DESCRIPTION…4415
BATTERY…4415
Maintenance and Service…4415
Troubleshooting…4415
BATTERY CHARGING SYSTEM (Niehoff)…4417
General Description…4417
TROUBLESHOOTING PROCEDURES (On-Truck)…4417
Equipment Required:…4417
Preliminary Checks…4418
Test Setup…4418
Test Procedure…4418
Regulator Bypass Test…4419
ON VEHICLE TROUBLESHOOTING GUIDE…4421
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage…4421
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:…4421
CHARGE VOLT AND AMP VALUES…4422
DEFINITIONS…4422
ADVANCED SYSTEM TROUBLESHOOTING…4423
Static Test – Engine OFF, Key ON, Battery Switch ON…4423
Go To Alternator…4423
Go To Regulator (If Required)…4424
Go To Regulator Connector On The Alternator…4424
ALTERNATOR OVERHAUL…4425
ALTERNATOR DIMENSIONS…4425
ALTERNATOR SPECIFICATIONS…4426
SERVICE PARTS…4427
ON-VEHICLE TEST…4429
Equipment:…4429
Preliminary Checks:…4429
Test Set-up…4429
Test Procedure…4429
ON-VEHICLE TEST…4430
Bypass Test:…4430
BENCH TEST…4431
STATIC TESTS…4432
Regulator Tests…4432
Control Box Tests…4433
ALTERNATOR DISASSEMBLY…4435
ASSEMBLY- ALTERNATOR…4440
BF4822 STATOR SERVICE TOOL INSTRUCTIONS…4449
Stator Removal And Replacement…4449
Stator Installation…4450
SECTION E – ELECTRICAL PROPULSION SYSTEM – INDEX…4453
SECTION E2 – ELECTRICAL PROPULSION SYSTEM COMPONENTS – INDEX…4455
ELECTRICAL PROPULSION SYSTEM COMPONENTS…4457
GENERAL SYSTEM DESCRIPTION…4457
SYSTEM COMPONENTS…4459
Auxiliary Blower System…4459
Propulsion System Controller (PSC)…4459
TRUCK CONTROL INTERFACE PANEL (TCI)…4460
Diagnostic Information Display…4461
DID PANEL EVENT CODES…4461
PSC SOFTWARE FUNCTIONS…4486
Input Processing…4486
STATE MANAGEMENT…4486
State Machine…4486
Transitions Between States…4487
DC Link State…4489
Powering the Link…4489
De-Powering the Link…4489
Control Functions…4489
Engine Control…4489
ALTERNATOR FIELD CONTROL…4490
Desired Three-Phase Voltage…4490
Desired DC Link Voltage…4490
Self-load…4490
Propel Torque Control…4491
Retard Torque Control…4491
Wheel Slide Control…4491
Resistor Grid Control…4492
Chopper Voltage Control…4492
AUXILIARY BLOWER CONTROL…4492
EVENT PROCESSING…4492
Event Detection…4492
Power On Tests…4492
Initiated Tests…4493
Periodic Tests…4493
EVENT RESTRICTIONS…4493
EVENT LOGGING AND STORAGE…4493
Event History Buffer…4494
Data Packs…4494
To Record and Save a Data Pack to a Floppy Disk…4494
Event Reset…4495
SERIAL DATA COMMUNICATIONS…4496
PSC – TCI Communications processing…4496
PSC – PTU Communications Processing…4496
Inverter Communications Processing…4496
OUTPUT PROCESSING…4497
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS…4497
Fast Start…4497
Engine Shutdown/Engine Not Running…4497
Limp Home Mode…4497
Entering/Exiting Limp Home Mode…4497
PROPULSION SYSTEM COMPONENT ABBREVIATIONS…4498
ELECTRONIC ACCELERATOR AND RETARD PEDALS…4508
Removal…4508
Installation…4508
Disassembly…4508
Assembly…4508
SECTION E3 – AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE – INDEX…4509
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE…4511
AC DRIVE SYSTEM MAINTENANCE…4511
TRUCK SHUTDOWN PROCEDURES…4511
NORMAL TRUCK SHUTDOWN PROCEDURE…4512
SHUTDOWN AFTER SYSTEM FAILURE…4513
SYSTEM CHECKOUT…4514
Battery and Control Checks of System WITH Battery Power OFF…4514
Battery and Control Circuit Checks of System With Battery Power ON…4517
Checks with Key Switch OFF…4518
CPU Battery Checks…4520
MEMORY BACKUP BATTERY REPLACEMENT…4520
TCI PROGRAMMING…4521
PSC PROGRAMMING…4521
INVERTER PROGRAMMING…4522
TCI CHECKOUT…4522
Modular Mining Communication Port…4523
TCI Input Checks…4524
TCI Digital Output Tests…4526
TCI Digital Input Tests…4528
PSC Checkout Procedure…4530
PSC Digital Input Checks…4534
Miscellaneous Checks…4535
A3PV Panel…4535
LINKV Panel…4535
Thermistor Checks…4535
17FM384 Panel Check…4535
Pedal Percentages and Meter Calibration…4536
Meter Calibration Procedure…4536
Reprogram With Serial Numbers and Pedal Percentages…4538
LOAD TESTING…4540
Preload Checks…4540
ADDITIONAL TRUCK CHECKS…4542
On-Board Load Testing…4544
Preparation…4544
Initiate Loadbox Test…4547
Manual Offset HP Output Adjustment…4549
TROUBLESHOOTING…4551
PVM Optimum Load Curve Handshaking Troubleshooting…4551
MISCELLANEOUS COMPONENT REPAIR…4552
Troubleshooting Phase Modules and Chopper Modules…4552
Phase Module Removal and Snubber Resistor Replacement…4552
Snubber Resistor Installation…4553
Phase Module Installation…4553
AUXILLIARY BLOWER CONTROL SYSTEM TROUBLESHOOTING…4554
AUXILLIARY INVERTER (CONTROLLER) TROUBLESHOOTING…4557
AUXILLIARY SNUBBER PANEL TROUBLESHOOTING…4558
IGBT TROUBLESHOOTING…4559
SECTION G – REAR AXLE, SPINDLE, AND WHEELS – INDEX…4561
SECTION G2 – TIRES AND RIMS – INDEX…4563
TIRES AND RIMS…4565
WHEEL STUD MAINTENANCE…4566
FRONT TIRES AND RIMS…4567
Removal…4567
Installation…4568
REAR TIRES AND RIMS…4569
Removal…4569
Installation…4570
RIM…4571
Tire Removal…4571
Tire Installation…4572
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX…4575
FRONT WHEEL HUB AND SPINDLE…4577
WHEEL HUB AND SPINDLE ASSEMBLY…4577
Preparation…4577
Removal…4577
Installation – Wheel Hub and Spindle Assembly…4580
Disassembly – Wheel Hub and Spindle Assembly…4581
Cleaning and Inspection – Wheel Hub and Spindle Assembly…4581
Assembly – Wheel Hub and Spindle Assembly…4583
Wheel Bearing Adjustment:…4583
Brake Installation…4584
Seal Assembly Gap Check…4585
STEERING CYLINDERS AND TIE ROD…4586
Spherical Bearing Wear Limits…4586
Removal – Steering Cylinder and Tie Rod…4587
Installation – Steering Cylinder and Tie Rod…4588
Bearing Replacement…4588
TOE-IN ADJUSTMENT…4589
SECTION G4 – REAR AXLE HOUSING ATTACHMENT – INDEX…4591
REAR AXLE HOUSING ATTACHMENT…4593
PIVOT PIN…4593
Removal…4593
Installation…4593
PIVOT EYE BEARING…4594
Disassembly…4594
Assembly…4594
PIVOT EYE REPAIR…4595
Removal…4595
Disassembly…4595
Assembly…4595
Installation…4595
ANTI-SWAY BAR…4596
Removal…4596
Installation…4596
Disassembly…4596
Cleaning and Inspection…4596
Assembly…4596
SECTION G5 – REAR AXLE HOUSING – INDEX…4597
REAR AXLE HOUSING…4599
REAR AXLE HOUSING…4599
Preparation…4599
Removal…4599
Cleaning and Inspection – Rear Axle Housing…4601
Installation – Rear Axle Housing…4601
WHEEL MOTOR…4602
Preparation…4602
Removal…4602
Cleaning and Inspection – Wheel Motor…4603
Installation – Wheel Motor…4604
WHEEL MOTOR GEAR OIL…4607
Filtering Requirements…4607
Particle Size Analysis…4607
Flushing…4607
Oil Sample Analysis…4608
ELEMENT SPECIFICATION CHARTS…4609
SECTION H – HYDRAIR II SUSPENSIONS – INDEX…4613
SECTION H2 – FRONT SUSPENSIONS – INDEX…4615
FRONT SUSPENSION…4617
Removal…4617
Installation – Front Suspension…4618
"Turn-Of-The-Nut" Tightening Procedure…4621
MINOR REPAIRS (LOWER BEARING & SEALS)…4622
Removal – Bearing Retainer…4622
Installation – Bearing Retainer…4622
MAJOR SUSPENSION REBUILD…4624
Disassembly…4624
Assembly…4624
SECTION H3 – REAR SUSPENSIONS – INDEX…4627
REAR SUSPENSIONS…4629
Removal…4629
Installation – Rear Suspension…4631
Disassembly – Rear Suspension…4632
Cleaning and Inspection – Rear Suspension…4632
Assembly – Rear Suspension…4632
SECTION H4 – SUSPENSION OILING AND CHARGING PROCEDURE – INDEX…4635
SUSPENSION OILING AND CHARGING PROCEDURE…4637
GENERAL…4637
EQUIPMENT LIST…4637
Hydrair® Charging Kit…4637
Installation of Charging Kit…4637
Removal of Charging Kit…4638
Support Blocks For Oiling And Charging Dimensions…4638
FRONT SUSPENSION…4639
Front Suspension Oiling…4639
Front Suspension Nitrogen Charging…4640
REAR SUSPENSION…4641
Rear Suspension Oiling…4641
Rear Suspension Nitrogen Charging…4642
OIL AND NITROGEN SPECIFICATIONS CHART…4644
SECTION J – BRAKE CIRCUIT – INDEX…4645
SECTION J2 – BRAKE CIRCUIT – INDEX…4647
BRAKE CIRCUIT…4649
SERVICE BRAKE CIRCUIT…4649
SECONDARY BRAKING AND AUTOMATIC APPLY…4651
PARKING BRAKE CIRCUIT…4651
BRAKE LOCK CIRCUIT…4652
WARNING CIRCUIT…4652
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX…4655
BRAKE CIRCUIT COMPONENT SERVICE…4657
BRAKE VALVE…4657
Rebuild Criteria…4657
Removal – Brake Valve…4658
Installation – Brake Valve…4658
Disassembly – Brake Valve…4659
Cleaning and Inspection – Brake Valve…4662
Assembly – Actuator Base Threaded Inserts…4662
Assembly – Boot and Cap…4662
Installation – Valve Body Seal…4662
Installation – Regulator Sleeve O-Ring…4663
Installation – Actuator Plunger O-ring…4663
Assembly – Brake Valve…4663
DIFFERENTIAL PRESSURE SWITCH…4665
Disassembly…4665
Cleaning and Inspection…4665
Assembly…4665
VALVE BENCH TEST AND ADJUSTMENT…4666
Test Set Up Procedure…4667
Adjustment – Brake Valve Output Pressure…4667
Adjustment – Differential Pressure Switch…4667
Final Test and Adjustment…4668
Installation – Brake Pedal Actuator Assembly to Brake Valve…4669
Installation – Retard Pedal To Brake Pedal…4669
DUAL RELAY VALVE…4671
Removal…4671
Installation…4671
Disassembly – Dual Relay Valve…4673
Cleaning and Inspection – Dual Relay Valve…4673
Assembly – Dual Relay Valve…4673
DIFFERENTIAL PRESSURE SWITCH…4674
Disassembly…4674
Cleaning and Inspection…4674
Assembly…4674
VALVE TEST AND ADJUSTMENT…4675
Test Set Up Procedure…4676
Adjustment – Brake Valve Output Pressure…4676
Adjustment – Differential Pressure Switch…4677
BRAKE MANIFOLD…4678
Removal…4678
Installation…4679
Disassembly…4679
Cleaning and Inspection…4679
Assembly…4679
HYDRAULIC BRAKE ACCUMULATORS…4680
Brake Accumulator Bleed Down Procedure…4680
ACCUMULATORS – HYDRAULIC COMPONENT CABINET…4680
Removal…4680
Installation…4680
Disassembly…4680
Cleaning and Inspection…4682
Assembly…4682
BLADDER ACCUMULATOR CHARGING PROCEDURE…4684
Temperature During Precharge…4685
Precharge Maintenance…4685
Accumulator Storage Procedures…4686
Bladder Storage Procedures…4687
ACCUMULATORS – FRAME MOUNTED…4687
Removal…4687
Installation…4687
Disassembly…4689
Cleaning and Inspection…4689
Assembly – Accumulator…4690
Accumulator Testing…4690
ACCUMULATOR CHARGING PROCEDURE…4691
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)…4692
Removal – Retarder Control Lever…4692
Installation – Retarder Control Lever…4692
Disassembly and Adjustment – Retarder Control Lever…4693
Potentiometer Check – Retarder Control Lever…4693
Assembly – Retarder Control Lever…4693
SECTION J4 – BRAKE CIRCUIT CHECKOUT PROCEDURE – INDEX…4695
BRAKE CIRCUIT CHECK-OUT PROCEDURE…4697
EQUIPMENT REQUIRED…4699
INITIAL SYSTEM SET-UP…4700
BRAKE SYSTEM CHECKOUT…4701
Failure Modes Check-Out…4702
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING…4705
CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET…4709
SECTION J5 – WET DISC BRAKE ASSEMBLY – INDEX…4711
WET DISC BRAKE ASSEMBLY…4713
OPERATION…4713
MAINTENANCE…4714
Brake Disc Wear Indicator…4714
Removal/Installation – Wet Disc Brake Assembly…4714
BRAKE REBUILD…4716
Disassembly…4716
Cleaning and Inspection…4719
Assembly…4720
Floating Ring Seal Assembly/Installation…4723
WET DISC BRAKE BLEEDING PROCEDURE…4726
SECTION J7 – PARKING BRAKE – INDEX…4727
PARKING BRAKE…4729
OPERATION…4729
MAINTENANCE…4730
Inspection – Parking Brake…4730
Removal – Parking Brake…4730
Installation – Parking Brake…4731
Disassembly – Parking Brake…4732
Cleaning and Inspection – Parking Brake…4732
Assembly – Parking Brake…4732
PARKING BRAKE BLEEDING PROCEDURE…4734
SECTION L – HYDRAULIC SYSTEM – INDEX…4735
SECTION L2 – HYDRAULIC SYSTEM – INDEX…4737
HYDRAULIC SYSTEM…4739
Hoist Circuit Operation…4740
Steering Circuit Operation…4742
Disc Brake Cooling System…4744
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX…4747
HYDRAULIC SYSTEM COMPONENT REPAIR…4749
HOIST PUMP…4749
Removal…4749
Installation…4751
Disassembly…4752
Inspection Of Parts…4756
Assembly…4756
TROUBLESHOOTING GUIDE…4761
HYDRAULIC TANK…4762
Filling Instructions…4762
Removal…4762
Installation…4763
HYDRAULIC TANK STRAINERS…4763
Removal…4763
Inspect and Clean…4763
Installation…4763
Hydraulic Tank Breathers…4764
SECTION L4 – STEERING CIRCUIT – INDEX…4765
STEERING CIRCUIT…4767
STEERING CIRCUIT OPERATION…4767
COMPONENT DESCRIPTION…4768
Steering Control Valve…4768
Bleeddown Manifold Valve…4769
Bleeddown Solenoids…4769
Accumulators…4770
Low Precharge Warning Switch…4770
High Pressure Filter…4770
Flow Amplifier…4770
FLOW AMPLIFIER SYSTEM OPERATION…4772
No Steer…4772
Steering Left…4774
Steering Right…4776
No Steer, External Shock Load…4778
STEERING PUMP…4780
Operation…4780
High Altitude Operation…4780
PRINCIPLE OF OPERATION…4782
Steering Pump…4783
SECTION L5 – STEERING CONTROL UNIT – INDEX…4785
STEERING CONTROL UNIT…4787
Removal…4787
Installation…4787
STEERING CONTROL UNIT REBUILD…4788
Disassembly…4788
Cleaning and Inspection – Steering Control Unit…4789
Assembly – Steering Control Unit…4791
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX…4795
STEERING CIRCUIT COMPONENT REPAIR…4797
BLEEDDOWN MANIFOLD VALVE…4797
Removal…4797
Installation…4797
ACCUMULATORS…4798
Removal…4798
Installation…4798
Disassembly…4799
Cleaning and Inspection…4799
Assembly…4800
TESTING…4800
STEERING ACCUMULATOR CHARGING PROCEDURE…4801
FLOW AMPLIFIER…4802
Removal…4802
Installation…4802
FLOW AMPLIFIER REBUILD…4802
Disassembly…4804
Assembly…4805
STEERING CYLINDERS…4806
Disassembly…4807
Piston Seal & Bearing Installation…4807
Cylinder Assembly…4807
Test…4807
STEERING AND BRAKE PUMP…4808
Removal…4808
Installation…4808
Disassembly…4810
Control Piston Group…4810
Valve Plate Group…4810
Rotating Group…4813
Swashblock Group…4813
Driveshaft Group…4813
Inspection…4813
Control Piston Group…4813
Valve Plate Group…4813
Rotating Group…4813
Swashblock Group…4815
Driveshaft Group…4816
Compensator Block and Unloader Module…4816
Stroke Adjuster Assembly…4816
Assembly…4816
Swashblock Group…4816
Driveshaft Group…4817
Rotating Group…4817
Control Piston Group…4817
Valve Plate Group…4818
TROUBLESHOOTING CHART…4819
SECTION L7 – HOIST CIRCUIT – INDEX…4825
HOIST CIRCUIT…4827
HOIST CIRCUIT OPERATION…4827
COMPONENT DESCRIPTION…4828
Hydraulic Tank…4828
Hydraulic Pump…4828
High Pressure Filters…4828
Hoist Valve…4828
Inlet Sections…4828
Spool Sections…4829
Work Ports (Rear) Spool Section…4829
Tank Ports (Front) Spool Section…4829
Hoist Pilot Valve…4829
Hoist Up Limit Solenoid…4830
Pilot Operated Check Valve…4830
Snubber Valve…4830
Counterbalance Valve…4830
HOIST CIRCUIT OPERATION…4830
POWER UP OPERATION (Figure 7-5)…4832
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX…4841
HOIST CIRCUIT COMPONENT REPAIR…4843
HOIST VALVE…4843
Removal…4843
Installation…4844
O-Ring Replacement…4844
INLET SECTION…4845
Disassembly…4845
Cleaning and Inspection…4846
Assembly…4846
REAR SPOOL SECTION (Work Ports)…4846
Disassembly…4846
Cleaning and Inspection…4848
Assembly…4848
FRONT SPOOL SECTION (Tank Ports)…4849
Disassembly…4849
Cleaning and Inspection…4849
Assembly…4849
HOIST PILOT VALVE…4851
Removal…4851
Installation…4851
Disassembly…4852
Cleaning and Inspection…4853
Assembly…4853
HOIST – UP LIMIT SOLENOID VALVE…4854
HOIST CYLINDERS…4854
Removal…4854
Installation…4855
Disassembly…4857
Cleaning and Inspection…4858
ASSEMBLY OF QUILL AND CYLINDER…4859
Quill Installation…4859
Installation Of Check Balls And Plugs In Quill…4860
Assembly of Cylinder…4861
DISABLED TRUCK DUMPING PROCEDURE…4862
HOOKUP…4862
DUMPING PROCEDURE…4862
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX…4863
HYDRAULIC SYSTEM FILTERS…4865
HOIST CIRCUIT FILTER…4865
Filter Element Replacement…4865
Removal – Hoist Circuit Filter…4866
Installation – Hoist Circuit Filter…4866
Indicator Switch – Hoist Circuit Filter…4866
STEERING CIRCUIT FILTER…4867
Filter Element Replacement…4867
Removal – Steering Circuit Filter…4868
Installation – Steering Circuit Filter…4868
Indicator Switch – Steering Circuit Filter…4868
INDICATOR SWITCH…4868
Test Procedure…4868
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX…4871
HYDRAULIC CHECK-OUT PROCEDURE…4873
GENERAL INFORMATION…4873
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE…4873
Equipment Requirements…4874
Pump Pressure Control Adjustments…4874
Steering Control Valve and Flow Amplifier Leakage Test…4875
Bleeddown Manifold Leakage Test…4875
Steering / Brake Pump Stroke Adjustment…4876
Shock And Suction Valves…4877
Equipment Requirements…4877
HOIST SYSTEM RELIEF VALVE AND BRAKE COOLING CIRCUIT PRESSURES…4878
Equipment Requirements…4878
Pressure Checks…4878
Brake Cooling Circuit Test…4878
Power Up Relief Pressure Test…4879
Adjustment…4879
Power Down Relief Pressure Test…4880
Adjustment…4880
Hoist Counterbalance Valve Adjustment…4881
HYDRAULIC SYSTEM FLUSHING PROCEDURE…4882
Preparation…4882
Flushing Procedure…4882
Filter Element Replacement…4883
930E CHECK-OUT PROCEDURE STEERING SYSTEM DATA SHEET…4885
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX…4887
SECTION M2 – FIRE CONTROL SYSTEMS – INDEX…4889
FIRE CONTROL SYSTEM (MANUAL)…4891
Operation…4891
Inspection and Maintenance…4891
Recharging Procedures…4892
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1…4893
Control Module…4893
Actuator…4894
Linear Detection Wire…4894
Power Wire…4894
Test Kit…4894
Squib…4894
Securing the Detection Wire…4895
Preliminary Test Before Final Hook-Up…4895
Installation Procedure for Squib…4897
Placing the Electric Detection & Actuation System Into Service…4897
INSPECTION AND MAINTENANCE SCHEDULES…4898
Daily…4898
Normal Maintenance Based On Actual Operating Hours…4898
IN CASE OF FIRE…4899
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM…4901
POSSIBLE CAUSES…4901
SUGGESTED CORRECTIVE ACTION…4901
TROUBLE: Test Module Light Will Not Illuminate…4901
POSSIBLE CAUSES…4901
SUGGESTED CORRECTIVE ACTION…4901
TROUBLE: Test Module Light Will Not Go Out…4901
POSSIBLE CAUSES…4901
SUGGESTED CORRECTIVE ACTION…4901
TROUBLE: Detonated Squib…4901
POSSIBLE CAUSES…4901
SUGGESTED CORRECTIVE ACTION…4901
SECTION M8 – SPECIAL TOOLS…4903
SECTION M20 – PAYLOAD METER II (ON BOARD WEIGHING SYSTEM) – INDEX…4909
LIGHTS, SWITCHES AND COMPONENTS…4912
TIPS FOR OPERATION…4913
EXTERNAL DISPLAY LIGHTS…4913
THEORY OF OPERATION…4914
Basic Description…4914
Inclinometer…4914
Linkage Factor…4914
Gain Factor…4915
Brake Lock…4915
Sources of Error…4915
Typical Data From Service Check Mode…4915
Example Calculation of Payload…4916
Viewing Payload Calculation Inputs…4916
Checking the Gain…4917
Adjusting the Gain…4917
TYPES OF DATA STORED…4918
Cycle Data…4918
Engine ON/OFF Data…4919
Fault Codes and Warning Data…4919
Engine Operation…4920
Total Payload and Total Number of Cycles…4920
Other Data…4920
OPERATOR FUNCTIONS…4921
Using the Operator Load Counter…4921
Viewing the Operator Load Counter…4921
Clearing the Operator Load Counter…4921
Dimming the Lights on the Display…4921
INITIAL SETUP OF PAYLOAD METER…4922
Switch Settings…4922
Checking the Operator Check Mode…4923
Checking the Service Check Mode…4923
Checking the Gt setting:…4924
Checking the Inclinometer Settings…4924
Calibrating a Truck…4924
DISPLAYS AT START-UP…4925
Normal Operation…4925
SETUP AND MAINTENANCE…4926
Setting The Speed Limit…4926
Setting the Option Code…4926
Setting The Machine I.D. Code…4927
Setting The Operator I.D. Code…4927
Setting The Time and Date…4927
DOWNLOAD OF INFORMATION…4928
DISPLAY OF FAULT CODES…4928
Monitoring Input Signals…4932
Service Check Mode…4932
UP FACTOR – PAYLOAD CALCULATION GAIN…4933
PL MODE -LOAD CALCULATION TIMING…4933
FINAL GEAR RATIO SELECTION…4934
BATTERY REPLACEMENT PROCEDURE…4935
Replacing the Battery…4935
After Replacing the Battery…4936
SUSPENSION PRESSURE SENSOR…4936
Removal…4936
Installation…4937
INCLINOMETER…4937
Removal…4937
Installation…4937
Adjustment…4937
PAYLOAD METER BACK PANEL…4938
CONNECTIONS…4939
GENERAL INFORMATION…4911
Haul Cycles…4911
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE…4940
PAYLOAD CIRCUIT NUMBERS…4941
TROUBLESHOOTING…4942
COMMON PROBLEMS…4942
Suspension Charging…4942
Symptom Table…4943
Missing Body-Up Signal…4943
Missing Speed Signal…4944
F-18: Alternator R-Terminal, Oil Pressure Signals…4944
Shorted 18v Sensor Power Supply (930E)…4944
FAULT TREE DIAGNOSIS…4945
Payload Lights Won't Illuminate…4945
Red, Amber or Green Payload Light Does Not Illuminate…4946
Cannot Download – PC Communications…4947
PC Communications Configuration…4948
F.CAL: Payload Meter Won't Calibrate…4949
F-20: Sensor Power Fault…4950
F-21, F-25: Left Front Pressure Sensor…4952
F-22, F-26: Right Front Pressure Sensor…4952
F-23, F-27: Left Rear Pressure Sensor…4952
F-24, F-28: Right Rear Pressure Sensor…4952
F-31, F-32: Inclinometer…4954
Body Up Input…4956
Brake Lock Input…4957
Speed Signal…4958
Adjusting the Speed Sensor…4958
CONNECTORS AND PRESSURE SENSORS…4960
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM…4963
Menu Functions…4966
Using Scope…4966
Log File Information…4966
Connections to Payload Meter II™…4967
USING SCOPE…4968
Monitoring Inputs Using Scope…4968
Monitoring Suspension Charging Using Scope…4968
Pressure Sensor Dummy Loads…4971
GAIN ADJUSTMENT WORKSHEET…4972
SECTION N – CAB COMPONENTS – INDEX…4973
SECTION N2 – TRUCK CAB – INDEX…4975
TRUCK CAB…4977
Description…4977
Preparation…4978
Removal – Cab…4978
Installation – Cab…4980
CAB DOOR…4980
Removal…4980
Installation…4980
Door Adjustment…4981
Door Jamb Bolt Adjustment…4981
Door Handle Plunger Adjustment…4982
Door Glass Replacement…4983
Door Window Regulator Replacement…4987
Door Handle or Latch Assembly Replacement…4987
Door and Door Hinge Seal Replacement…4988
Door Opening Seal Removal…4988
Installation…4988
GLASS REPLACEMENT…4989
Adhesive Bonded Windows…4989
Replacement Procedure…4989
Windshield And Rear Glass…4990
Removal…4990
Installation…4991
SECTION N3 – CAB COMPONENTS – INDEX…4993
CAB COMPONENTS…4995
WINDSHIELD WIPERS…4995
Wiper Motor Replacement…4995
Removal…4995
Installation…4995
Wiper Arm Replacement…4995
Removal…4995
Installation…4996
Wiper Linkage Replacement…4996
Removal…4996
Installation…4996
WINDSHIELD WASHER…4997
Operation…4997
Service…4997
OPERATOR SEAT…4998
Adjustment…4998
Removal…4998
Installation…4998
SECTION N4 – OPERATOR COMFORT – INDEX…4999
OPERATOR COMFORT…5001
HEATER/AIR CONDITIONER…5001
Operation…5001
HEATER COMPONENTS…5002
Circuit Breakers…5002
Heater Control Components…5002
Heater Coil…5002
Fan Motor And Speed Control…5003
Actuators…5003
Filter Service…5003
AIR CONDITIONING SYSTEM…5005
Environmental Impact…5005
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES…5006
PRINCIPLES OF REFRIGERATION…5006
Air Conditioning…5006
Refrigeration – The Act Of Cooling…5007
The Refrigeration Cycle…5007
AIR CONDITIONER SYSTEM COMPONENTS…5008
Compressor (Refrigerant Pump)…5008
Service Valves…5008
Condenser…5008
Receiver-Drier…5008
Expansion Block Valve…5009
Accumulator…5009
Evaporator…5009
ELECTRICAL CIRCUIT…5010
Thermostat…5010
Compressor Clutch…5010
Trinary™ Switch…5011
SYSTEM SERVICING…5012
SERVICE TOOLS AND EQUIPMENT…5013
Recovery/Recycle Station…5013
Leak Detector…5013
Service Valves…5014
Vacuum Pump…5014
Manifold Gauge Set…5015
Installing Manifold Gauge Set…5016
Purging Air From Service Hoses…5016
SYSTEM PERFORMANCE TEST…5017
SYSTEM OIL…5018
Handling and Reusing PAG Oil…5018
Oil Quantity…5018
Checking System Oil…5018
REFRIGERANT…5019
Recycled Refrigerant…5019
Reclaimed Refrigerant…5019
Refrigerant Quantity…5019
R-134a Refrigerant Containers…5019
SYSTEM LEAK TESTING…5020
Electronic Leak Detector…5020
Tracer Dyes…5020
Soap and Water…5020
RECOVERING AND RECYCLING THE REFRIGERANT…5021
Performing the Recovery Cycle…5021
Performing the Recycling Procedure…5021
Evacuating and Charging the A/C System…5021
SYSTEM REPAIR…5022
System Flushing…5022
COMPONENT REPLACEMENT…5022
Hoses and Fittings…5022
Lines…5022
Expansion Valve…5023
Receiver-Drier…5023
Thermostat…5023
Compressor…5023
Accumulator…5023
Clutch…5024
Servicing the Compressor Clutch…5024
Pulley Removal…5026
Clutch Coil Check…5027
Pulley Installation…5027
Clutch Assembly Installation…5027
EVACUATING THE SYSTEM…5029
CHARGING THE A/C SYSTEM…5031
TROUBLESHOOTING…5032
Preliminary Checks…5032
Diagnosis Of Gauge Readings And System Performance…5032
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS…5033
PREVENTATIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM…5039
SECTION N5 – OPERATOR CAB CONTROLS – INDEX…5041
OPERATOR CAB CONTROLS…5043
STEERING COLUMN…5043
Removal…5043
Installation…5043
STEERING WHEEL AND CONTROLS…5045
HORN BUTTON…5045
TELESCOPE LOCK RING…5045
TILT WHEEL LEVER…5045
TURN SIGNAL / HEADLIGHT DIMMER…5045
DYNAMIC RETARDING…5045
RETARDER CONTROL LEVER…5046
DYNAMIC RETARDER/SERVICE BRAKE PEDAL…5046
ACCELERATOR (THROTTLE) PEDAL…5046
Starting on a Grade With a Loaded Truck…5046
GRADE/SPEED RETARD CHART…5047
HEATER / AIR CONDITIONER VENTS…5048
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS…5048
DEFROSTER VENT CONTROL SWITCH…5048
HEAT VENT CONTROL SWITCH…5048
FAN CONTROL KNOB…5048
AIR CONDITIONER CONTROL KNOB…5048
OUTSIDE/INSIDE AIR CONTROL SWITCH…5048
SELECTION CONTROL SWITCH…5048
HEATER/AIR CONDITIONER VENTS…5048
INSTRUMENT PANEL…5049
OVERHEAD PANEL AND DISPLAYS…5049
CENTER CONSOLE…5050
F-N-R SELECTOR SWITCH…5050
HOIST CONTROL LEVER…5051
To Raise dump body:…5051
To lower body:…5051
ASH TRAY…5051
LIGHTER…5051
L.H. WINDOW CONTROL SWITCH…5051
R.H. WINDOW CONTROL SWITCH…5051
ENGINE SHUTDOWN SWITCH…5051
OVERRIDE /FAULT RESET SWITCH…5052
10, FIGURE 5-5 – BLANK…5052
RETARD SPEED CONTROL (RSC) "OFF/ON" SWITCH…5052
RETARD SPEED CONTROL (RSC) ADJUST DIAL…5052
INSTRUMENT PANEL AND INDICATOR LIGHTS…5055
CONTROL SYMBOLS…5055
INSTRUMENT PANEL (Figure 5-6)…5055
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 5-6)…5057
Starting…5057
Cold Weather Starting…5057
Normal Engine Shutdown…5057
Operation…5058
STATUS / WARNING INDICATOR LIGHT SYMBOLS…5064
SECTION P – LUBRICATION AND SERVICE – INDEX…5071
SECTION P2 – LUBRICATION AND SERVICE – INDEX…5073
LUBRICATION AND SERVICE…5075
930E SERVICE CAPACITIES…5075
HYDRAULIC TANK SERVICE…5075
Adding Oil…5075
WHEEL MOTOR SERVICE…5075
COOLANT LEVEL CHECK…5076
RADIATOR FILLING PROCEDURE…5076
LUBRICATION CHART…5077
10 HOUR (DAILY) INSPECTION…5078
50 HOUR LUBRICATION AND MAINTENANCE CHECKS…5081
100 HOUR LUBRICATION AND MAINTENANCE CHECKS…5082
250 HOUR LUBRICATION AND MAINTENANCE CHECKS…5083
500 HOUR LUBRICATION AND MAINTENANCE CHECKS…5086
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS…5087
5000 HOUR MAINTENANCE CHECKS…5088
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX…5089
LINCOLN AUTOMATIC LUBRICATION SYSTEM…5091
System Components…5091
System Operation…5093
GENERAL INSTRUCTIONS…5094
Lubricant Required for System…5094
System Priming…5094
SYSTEM CHECKOUT…5094
24 VDC SOLID STATE TIMER CHECK…5095
24 VDC Solid State Timer Adjustment…5095
INJECTORS (SL-1 Series "H")…5096
Injector Specifications…5096
Injector Adjustment…5096
INJECTOR OPERATION…5097
PUMP CYCLE TIMER (FLASHER TIMER)…5098
Pump Cycle Timer (Flasher Timer) Installation…5098
Pump Cycle Timer (Flasher Timer) Adjustment:…5098
Pressure Switch, 2,000 psi (13 790 kPa) Normally Closed (N.C.)…5098
PRESSURE REDUCER ADJUSTMENT…5100
TROUBLESHOOTING CHART…5101
Preventative Maintenance Procedures…5104
Daily Lubrication System Inspection…5104
250 Hour Inspection…5104
SECTION Q ALPHABETICAL INDEX…5105
SECTION R…5109
HYDRAULIC BRAKE SYSTEM SCHEMATIC – HH348…5111
HYDRAULIC SUPPLY AND BRAKE COOLING SCHEMATIC – HH337…5112
ELECTRICAL SCHEMATIC – EG7500…5113
24 VOLT ELECTRICAL SCHEMATIC – HE464…5126
ENGINE RUN AND START ELECTRICAL SCHEMATIC – HE460…5141
DG621 – Dump Truck 830E Operator Handbook…5144
DG723 – Dump Truck 830E Operation & Maintenance Manual…5224
OM6004.pdf…0
PAYLOAD METER…5297
GENERAL INFORMATION…5297
FRONT PANEL CONTROLS…5297
OPERATION AND FUNCTIONS…5298
DISPLAY LOGIC…5298
METRIC / SHORT TON SELECTION…5298
DECK MOUNTED LIGHTS…5299
DATA STORAGE LOGIC…5299
DATA PRINT OUT…5300
REPLACING PRINTER PAPER…5301
To replace paper:…5301
CLEAR MEMORY…5301
CALIBRATION…5301
To perform calibration:…5302
SENSOR CHECK…5302
To perform a sensor check:…5302
Dimming Display…5302
SETTING THE TIME OF DAY…5303
ERROR CODES…5303
Komatsu Dump Trucks 830E Operation & Maintenance Manuals