Komatsu Dump Trucks 830E Operation & Maintenance Manuals
Komatsu Dump Trucks 830E Operation & Maintenance Manuals
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
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CEAM011500 - Dump Truck 830E Operation & Maintenance Manual.pdf
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CEAM015001 - Dump Truck 830E Operation & Maintenance Manual.pdf
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CEAM024100 - Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
CEAM024403 - Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
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CEAM026901 - Dump Truck 830E-1AC Operation & Maintenance Manual.pdf
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CEBM010501 - Dump Truck 830E Operation & Maintenance Manual.pdf
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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
