Komatsu 830E-1AC Operation & Maintenance Manual
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Komatsu 830E-1AC Operation & Maintenance Manual

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CEAM026901
Operation & Maintenance
Manual
SOUND ATTENUATION PACKAGE
A30500 & UP
SERIAL NUMBERS
®

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  • Page 1 CEAM026901 Operation & Maintenance Manual SOUND ATTENUATION PACKAGE A30500 & UP SERIAL NUMBERS ®...

  • Page 3: Foreword

    (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system;...
  • Page 4 Introduction - Section 10 OM1099 Page 10-2 ALERTS PAGE...

  • Page 5: Table Of Contents

    OM1099 Introduction - Section 10 Page 10-3 TABLE OF CONTENTS FOREWORD ..............10-1 “Alerts”...

  • Page 6: Table Of Contents

    Introduction - Section 10 OM1099 Page 10-4 TABLE OF CONTENTS (cont.) Use of Tie-Off Anchor During Maintenance ........20-7 Securing The Dump Body .
  • Page 7 OM1099 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS (cont.) CHASSIS SOUND ATTENUATION SYSTEM ..........30-1 OVERVIEW .
  • Page 8 Introduction - Section 10 OM1099 Page 10-6 TABLE OF CONTENTS (cont.) Center Deck Lining ............30-10 General .

  • Page 9: Truck Model Illustration

    OM1099 Introduction - Section 10 Page 10-7 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 830E-AC DUMP TRUCK...

  • Page 10: About This Manual

    The front cover of this manual includes a form number. This form number should be referenced when ordering additional copies of this manual, or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu America Corp. Datakom, Peoria Technical Publications P.O. Box 240...
  • Page 11 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 12 N•m ft lb kg•m NOTE: This list represents the current engineering M6 x1 1.22 approved sources for use in Komatsu manufacture. It M8 x 1.25 3.06 is not exclusive. Other products may meet the same M10 x 1.5 5.61 specifications of this list.
  • Page 13 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 14 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 15 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 16 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) –...
  • Page 17 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size (OD) Threads UNF-2B (ft lb) (N·m) Code – 2 0.125 0.312 – 24 4 ±...
  • Page 18 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km)
  • Page 19 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From inch (in.) millimeter (mm) 25.40 inch (in.) centimeter (cm) 2.54 foot (ft) meter (m) 0.3048 yard (yd) meter (m) 0.914 mile (mi)
  • Page 20 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C°...

  • Page 21: General Safety

    Before making any modification, consult your • Ensure all guards and covers are in their proper authorized regional Komatsu America Corp. position. Repair any damaged guards and distributor. Komatsu will not be responsible for covers. (See Walk-Around Inspection, later in injury damage caused this section.)

  • Page 22: Mounting And Dismounting

    Safety - Section 20 2/13 OM2049 Page 20-2 Precautions For High Temperature Fluids Mounting And Dismounting • Never jump on or off the machine. Never climb on • Immediately after machine operation, engine coolant, or off a machine while it is moving. engine oil, and hydraulic oil are •...

  • Page 23: Fire Prevention For Fuel And Oil

    Optimum machine’s path. strength of the structure can only be achieved if it is repaired or modified as specified by Komatsu.

  • Page 24: Working Near Batteries

    Safety - Section 20 2/13 OM2049 Page 20-4 WORKING NEAR BATTERIES • When removing or installing a battery, positively identify the positive (+) terminal and negative (-) terminal and use precautions not to short circuit Battery Hazard Prevention between the terminals. Battery electrolyte contains sulfuric acid and can •...

  • Page 25: Precautions For Maintenance

    OM2049 2/13 Safety - Section 20 Page 20-5 PRECAUTIONS FOR MAINTENANCE BEFORE PERFORMING MAINTENANCE Electrical Systems Isolation • Isolation box (6, Figure 20-2) contains master Stopping The Engine Before Service disconnect switch (3), starter disconnect switch (4) and propel lockout lever (5). The isolation box •...
  • Page 26 Safety - Section 20 2/13 OM2049 Page 20-6 FIGURE 20-2. ISOLATION BOX ASSEMBLY (COVERS REMOVED) 1. Engine Shutdown Switch 3. Master Disconnect Switch 6. Isolation Box 2. Access Ladder Light 4. Starter Disconnect Switch 7. LED Lights (on) Switch 5. Propel Lockout Lever 8.

  • Page 27: Warning Tag

    Komatsu anchor (58B-98-75190) is available for use with fall protection harnesses. Carefully read and understand the harness maker's instructions before using any fall protection harness.

  • Page 28: During Maintenance

    Safety - Section 20 2/13 OM2049 Page 20-8 DURING MAINTENANCE • Use extreme care when washing the electrical control cabinet. DO NOT allow water to enter the control cabinet around the doors or vents. DO Personnel NOT allow any water to enter the cooling air inlet •...

  • Page 29: Handling High Pressure Hoses

    OM2049 2/13 Safety - Section 20 Page 20-9 • Small, high pressure pin-hole leaks are extremely Handling High Pressure Hoses dangerous. The jet stream of high-pressure oil • DO NOT bend high-pressure hoses or hit them can pierce the skin and eyes. Always wear safety with hard objects.

  • Page 30: When Repairs Are Necessary

    (Also refer to sec- tion 30 - Towing.) 2. Many components on the Komatsu truck are large and heavy. Ensure that lifting equipment - 10. Drain, clean and ventilate fuel tanks and/or hoists, slings, chains, lifting eyes - are of ade- hydraulic tanks before making any welding quate capacity to handle the lift.

  • Page 31: Special Precautions For Working On An 830E-Ac Truck

    However, in a Komatsu service representative. Only qualified per- the event of a system failure, performing the follow- sonnel, specifically trained for servicing the AC drive ing procedure prior to any maintenance activities will system, must perform this service.
  • Page 32 DO NOT repair cable cleats by encircling the power cables with metal clamps or hardware. Always inspect power Notify your Komatsu service representative, cable insulation prior to servicing the cables and immediately. Only qualified personnel, specifi- prior to returning the truck to service. Discard cally trained for servicing the A-C drive system, cables with broken insulation.

  • Page 33: Capacitor Discharge System

    • Grounding stick pair (Figure 20-5) (Komatsu Kit p/n 58B-06-00800) Because a danger can still exist with the capacitor (HVR Advanced Power Components MAS- charge lights off, it is necessary to adhere to the fol-...

  • Page 34: Warnings And Cautions

    Safety - Section 20 2/13 OM2049 Page 20-14 Warnings And Cautions All applicable local mine, government, and industry rules for working with high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes, high voltage gloves, Hazardous voltages are present in this equip- and safety glasses must be worn.

  • Page 35: Manual Dc Link Capacitor Discharge Procedure

    OM2049 2/13 Safety - Section 20 Page 20-15 MANUAL DC LINK CAPACITOR • The generator field is cut out via GF cutout switch (2, Figure 20-6) in the low voltage area of the DISCHARGE PROCEDURE control cabinet. Preparation 1. Apply control power for a minimum of 30 sec- onds.
  • Page 36 Safety - Section 20 2/13 OM2049 Page 20-16 In most control cabinets, RP2 is the normal dis- charge path. In groups containing an RP3 contactor, RP2 and RP3 are alternated as the normal discharge path. Refer to Figure 20-7. FIGURE 20-7. DISCHARGE PATHS...

  • Page 37: Capacitor Charge Lights

    OM2049 2/13 Safety - Section 20 Page 20-17 CAPACITOR CHARGE LIGHTS Observe both capacitor charge lights (CCL1, CCL2). CCL1 is on the outside of the contactor box. CCL2 is on the switch panel inside the low voltage area. The lights will stay illuminated as long as the voltage on Verify functionality of the measurement equip- the DC link is greater than 50 VDC.

  • Page 38: Failure Of Discharge System

    Safety - Section 20 2/13 OM2049 Page 20-18 FAILURE OF DISCHARGE SYSTEM If the capacitor charge lights remain illuminated, a failure of the normal (fast) capacitor discharge system (RP dis- charge path) has likely occurred. The slow discharge resistors that are hard wired across the DC link should then discharge the capacitors.

  • Page 39: Manual Discharge Of Capacitors

    OM2049 2/13 Safety - Section 20 Page 20-19 FIGURE 20-10. CAPACITOR TERMINAL POLARITY MANUAL DISCHARGE OF CAPACITORS 3. Discharge the relevant capacitors. Open the door(s) and place one grounding stick on one of If the voltage is greater than 1V on any of the capaci- the positive (+) capacitor terminals and the other tors, the capacitor must be manually discharged.
  • Page 40 Safety - Section 20 2/13 OM2049 Page 20-20 FIGURE 20-11. GROUNDING STICK LEAD CONNECTION AND CHECK...
  • Page 41 OM2049 2/13 Safety - Section 20 Page 20-21 4. Measure voltage on all capacitors as described in “Measuring Dc Voltage On Capacitors” on page 18. Discharge any capacitors that show voltage. 5. If all capacitors read discharged, verify that the Voltages in excess of 1500 VDC may be present.

  • Page 42: Short Isolated Capacitor Terminals

    Safety - Section 20 2/13 OM2049 Page 20-22 SHORT ISOLATED CAPACITOR Any capacitor that is isolated from the DC link and confirmed discharged must have its terminals electri- TERMINALS cally shorted together to prevent static charge build up. Use bare wire to jumper all four terminals on the capacitor.
  • Page 43 OM2049 2/13 Safety - Section 20 Page 20-23...
  • Page 44 Safety - Section 20 2/13 OM2049 Page 20-24 NOTES:...

  • Page 45: Chassis Sound Attenuation System

    This document gives instructions about the mainte- attenuation parts for damage or incorrect installation, nance of a sound suppression kit for an 830E-1AC fixing where necessary. If this does not lower the rear dump truck.

  • Page 46: Exhaust System

    Operating Instructions - Section 30 2/13 OM3072 Page 30-2 Exhaust System General The exhaust system on a sound suppressed truck exits from the back of the machine. There are two exhaust pipes wrapped with heat blankets (1, Figure 30-1) that carry the exhaust to muffler (2), located in between the chassis rails.

  • Page 47: Attenuators

    OM3072 2/13 Operating Instructions - Section 30 Page 30-3 Attenuators General Attenuators are fitted in various places around the engine compartment to muffle the noise. A typical attenuator is made of up numerous perforated split- ters (2, Figure 30-2). Each splitter is filled with a spe- cial insulation pillow (3, Figure 30-3).

  • Page 48: Engine Side Panels

    Operating Instructions - Section 30 2/13 OM3072 Page 30-4 Engine Side Panels NOTE: If a significant amount of damage or soiling of any of the parts has been observed, replacement General insulation pillows must be installed to ensure correct performance of the parts. Both sides of the engine bay have been enclosed with attenuator panels (8, Figure 30-4), and access doors (7) for maintenance personnel.
  • Page 49 OM3072 2/13 Operating Instructions - Section 30 Page 30-5 FIGURE 30-4. ENGINE SIDE PANEL ASSEMBLY 1. Seals 6. Panel (Perforated Sheet) 2. Upper Panel (Perforated Sheet) 7. Access Door Assembly 3. Insulation 8. Attenuator Assembly 4. Bulkhead Panel Assembly 9. Panel Assembly 5.

  • Page 50: Engine Belly Pan Assembly

    Operating Instructions - Section 30 2/13 OM3072 Page 30-6 Engine Belly Pan Assembly The acoustic insulation in the doors and panels have a protective sheathing to reduce oil and grease pene- General tration into the insulation. An attenuator (8) is also installed in the belly pan to allow hot air to exit the The engine belly pan (Figure 30-5) is fitted below the engine compartment.

  • Page 51: Maintenance

    OM3072 2/13 Operating Instructions - Section 30 Page 30-7 Maintenance Approximate weights Refer to the Sound Attenuation System Service sec- tion for inspection requirements. Always use a lifting device that can handle the load safely. Lifting lugs are fitted to the top of the attenuator housings (8).

  • Page 52: Radiator Silencer

    Operating Instructions - Section 30 2/13 OM3072 Page 30-8 Radiator Silencer Periodically, the attenuators need to be disassem- bled for maintenance. Refer to Sound Attenuation General System Service for maintenance intervals. Follow the steps below to service the attenuators. Sound attenuators have been added to the front of the radiator.

  • Page 53: Rear Engine Compartment Enclosure

    OM3072 2/13 Operating Instructions - Section 30 Page 30-9 Rear Engine Compartment Enclosure protective cloth between the insulation and the perforated cover. The insulation should be General clean, soft, and free from debris. The insulation should be of consistent density, and fill the cav- There are acoustic panels located on the lower struc- ity completely, not slumping to the bottom.

  • Page 54: Center Deck Lining

    Operating Instructions - Section 30 2/13 OM3072 Page 30-10 Center Deck Lining General The underside of the cabin deck has been lined with acoustic insulation. Do not pressure wash the sound attenuation sur- faces. Malfunction and damage may occur, reducing the effectiveness of the attenuators. Maintenance Refer to the Sound Attenuation System Service sec- tion for inspection requirements.

  • Page 55: Front Panel Assembly Below Radiator Attenuator

    OM3072 2/13 Operating Instructions - Section 30 Page 30-11 Front Panel Assembly Below Radiator Do not pressure wash the sound attenuation sur- faces. Malfunction and damage may occur, General reducing the effectiveness of the attenuators. Acoustic panelling has been installed below the radi- ator attenuator.

  • Page 56: Hood Seals

    Operating Instructions - Section 30 2/13 OM3072 Page 30-12 Hood Seals Maintenance Refer to the Sound Attenuation System Service sec- Acoustic panels, sheet metal, and seals (2, 3 & 4, tion for inspection requirements. Figure 30-11) have been fitted to the grille structure, firewall and grille hood.

  • Page 57: Upper Horse Collar Panels

    OM3072 2/13 Operating Instructions - Section 30 Page 30-13 Upper Horse Collar Panels Acoustic panels (3, Figure 30-12) sheet metal (1) and seals (2) and (4) have been fitted under the control cabinet and around the top of the horse collar. Do not pressure wash the sound attenuation sur- faces.

  • Page 58: Blower Duct Cover & Hoses

    Operating Instructions - Section 30 2/13 OM3072 Page 30-14 Blower Duct Cover & Hoses Maintenance Refer to the Sound Attenuation System Service sec- General tion for inspection requirements. Insulated blower hoses (1 & 2, Figure 30-13) have been installed between the axle box & fan housing and in between the transition duct and control cabi- net.

  • Page 59: Drive System Sound Attenuation System

    OM3262 2/13 Operator Cab And Controls - Section 32 Page 32-1 DRIVE SYSTEM SOUND ATTENUATION SYSTEM RETARDING GRID ATTENUATION Approximate weights PACKAGE General The retarding grids have been modified with sound Always use a lifting device that can handle the attenuation devices attached to the inlet &...

  • Page 60: Maintenance

    Operator Cab And Controls - Section 32 2/13 OM3262 Page 32-2 Maintenance Refer to the Sound Attenuation System Service sec- tion for inspection requirements. The exhaust attenu- ators can not be serviced. If damaged, replace the entire exhaust attenuator. Do not pressure wash inside the inlets or exhausts areas.

  • Page 61: Maintenance

    OM3262 2/13 Operator Cab And Controls - Section 32 Page 32-3 Alternator Air Intake Silencer Approximate weights There is an alternator air intake silencer (2, Figure 32-3) fitted to the intake of the alternator blower fan ducting. Maintenance Always use a lifting device that can handle the load safely.
  • Page 62 Operator Cab And Controls - Section 32 2/13 OM3262 Page 32-4 NOTES:...

  • Page 63: Sound Attenuation System Service

    OM4066 Lubrication & Service - Section 40 Page 40-1 SOUND ATTENUATION SYSTEM SERVICE INTERVALS Recommended preventive maintenance will contrib- The service intervals presented here are in hours of ute to the long life and dependability of the truck and operation. However, if the truck is being operated its components.
  • Page 64 Lubrication & Service - Section 40 OM4066 Page 40-2 500 HOUR INSPECTION CHECKS EVERY 500 HOUR INSPECTION Item Task Inspect panels for damage and repair or replace where necessary. Inspect door seals for damage or misalignment and repair or replace where necessary.
  • Page 65 OM4066 Lubrication & Service - Section 40 Page 40-3 EVERY 500 HOUR INSPECTION (Continued) Item Task Inspect panels for damage and repair or replace where necessary. Inspect seals for damage or misalignment and repair or replace where necessary. Upper Horse Collar Panels Inspect the acoustic insulation and perforated steel covers for damage or soil build- up and repair or replace where necessary.

  • Page 66: 500 Hour Lubrication And Maintenance Checks

    Lubrication & Service - Section 40 OM4066 Page 40-4 EVERY 500 HOUR INSPECTION (Continued) Item Task Inspect visible air flow paths for any debris or mud. Replace silencer element if any defects are found. Do not remove any baffles or screens to perform inspection. Inspect the mounting hardware between each element, supporting duct work, and mounting posts.

  • Page 67: Major Component Description

    Total (100% Fuel) ..170 782 . . . (376,509) poses. Please contact your Komatsu distributor for Standard Komatsu Body ..27 669 ..(61,000) specific application requirements.
  • Page 68 Specification - Section 50 OM5059 Page 50-2 Component Descriptions NOTES:...
  • Page 70 ® www.komatsuamerica.com Copyright 2013 Komatsu Komatsu America Corp. Printed in U.S.A. 2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072...

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