Komatsu 830E-1AC Operation & Maintenance Manual Download | Manualshive

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CEAM029701

Operation & Maintenance
Manual

830E

-1AC

DUMP TRUCK

SERIAL NUMBERS

830E-1AC A40939-A40961

ENGINE

16V160

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2017 Komatsu
Printed in U.S.A

January 2017

Komatsu America Corp.

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Summary of Contents for 830E-1AC

Page 1: ...licy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously Due to this continuous program of research and development revisions may be made to this publication It is recommended that customers contact their distributor for informatio...

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Page 3: ...ic 2 12 Temperature Conversions 2 13 GENERAL SAFETY GENERAL SAFETY 3 2 Safety Rules 3 2 Truck Safety Features 3 2 Clothing And Personal Items 3 2 Unauthorized Modification 3 2 Leaving The Operator s Seat 3 2 Mounting And Dismounting 3 2 Fire Extinguishers And First Aid Kits 3 3 Precautions For High Temperature Fluids 3 3 Asbestos Dust Hazard Prevention 3 3 Fire Prevention 3 3 ROPS Precautions 3 3 ...

Page 4: ...MAINTENANCE 3 15 Warning Tag 3 15 Proper Tools 3 15 Attachments 3 15 Working Under The Machine 3 15 Keeping The Machine Clean 3 16 Adding Fuel Or Oil To The Machine 3 16 Radiator Coolant Level 3 16 Use Of Lighting 3 16 Handling High Pressure Hoses 3 16 Precautions With High Pressure Oil 3 16 Maintenance Near High Temperatures And High Pressures 3 17 Rotating Fan And Belts 3 17 Waste Materials 3 17...

Page 5: ...n 5 7 In Cab Control Panel 5 8 Ground Level Control Box 5 10 Emergency Down Valve 5 11 PRE SHIFT BRAKE TEST 5 12 Operation 5 12 Service Brake Test 5 13 Parking Brake Test 5 13 Retard System Test 5 14 Brake Test Exit Criteria 5 14 TRUCK OPERATION 5 15 ENGINE START UP SAFETY 5 15 After Engine Has Started 5 15 MACHINE OPERATION SAFETY PRECAUTIONS 5 16 Machine Operation On The Haul Road 5 17 Starting ...

Page 6: ...AYLOAD METER III SYSTEM 5 33 GENERAL INFORMATION 5 33 Data Summary 5 33 Data Gathering 5 33 COMPONENT DESCRIPTION 5 33 Operator Display 5 33 Operator Switches 5 33 Brake Lock Switch 5 33 Payload Meter Module 5 33 Communications Ports 5 34 Load Lights 5 34 SCOREBOARD 5 34 OPERATOR S DISPLAY AND SWITCH 5 35 Reading the Load Display 5 35 Setting the Operator ID 5 35 Load and Ton Counter 5 35 Viewing ...

Page 7: ...Acknowledgment 5 49 AUTOMATIC LUBRICATION SYSTEM 5 50 GENERAL INFORMATION 5 50 COMPONENT DESCRIPTION 5 50 Filter 5 51 Hydraulic Motor and Pump 5 51 Grease Reservoir 5 51 Pressure Reducing Valve 5 51 Flow Control Valve 5 51 Solenoid Valve 5 52 Vent Valve 5 52 Interface Module 5 52 Injectors 5 53 Grease Pressure Failure Switch 5 54 Relief Valve unloader valve 5 54 SYSTEM OPERATION 5 54 Filling The R...

Page 8: ... 8 Lowering The Dump Body 6 8 Retard Speed Control RSC Adjust Dial 6 8 Retard Speed Control RSC Switch 6 9 Data Store Button 6 9 12V Auxiliary Power Outlets 6 9 Fire Suppression Control Outlet 6 9 Communication Radio Outlet 6 9 DIAGNOSTIC PORTS 6 10 KOMTRAX Plus 6 10 Interface Module IM 6 10 Drive System Or Modular Mining 6 10 Drive System Controller DSC 6 10 Engine CENSE 6 10 Engine QUANTUM 6 10 ...

Page 9: ... Indicators 6 22 Panel Light Dimmer 6 22 Mode Switches 6 22 Fog Light Switch 6 22 Backup Light Switch 6 22 Ladder Light Switch 6 22 Headlight Panel Illumination Light Switch 6 22 STATUS INDICATOR LIGHT PANEL 6 24 STATUS INDICATOR LIGHT SYMBOLS 6 24 Body Up 6 24 Parking Brake 6 24 Propel System Not Ready 6 24 No Propel 6 25 Engine Warm Up 6 25 Engine Shutdown Delay 6 25 Retarding Grid Dryer 6 25 Wh...

Page 10: ...raulic Tank 7 2 Hydraulic Filters 7 3 Hydraulic Pump Drive Shaft 7 3 WHEEL MOTOR SERVICE 7 3 COOLANT LEVEL SERVICE 7 3 Radiator Filling Procedure 7 4 Coolant Specifications 7 4 Unacceptable Practices 7 4 RESERVE ENGINE OIL SERVICE 7 4 Reserve Oil Tank Filling Procedure Remote Fill 7 5 Inline Screen 7 5 CAB AIR FILTER SERVICE 7 5 FUEL SYSTEM SERVICE 7 6 Fuel Tank Cleaning 7 6 Fuel Filter Service 7 ...

Page 11: ...ities 8 3 Hydraulic Systems 8 3 Service Brakes 8 4 Parking Brake 8 4 Steering 8 4 Standard Dump Body Capacities And Dimensions 8 4 Tires 8 4 Weight Distribution 8 4 Overall Truck Dimensions 8 5 RADIO RADIO OPERATION 9 2 General Radio Receiver Functions 9 2 Turning On The Power 9 2 One Hour Timer 9 2 Finding A Station 9 2 Setting The Presets 9 3 Adjusting The Receiver Audio Settings 9 3 Display 9 4...

Page 12: ...n Functions 9 9 iPod 9 11 Playing An iPod 9 11 iPod Mode Displays 9 11 Button Functions 9 11 WEATHERBAND USA Only 9 13 TROUBLESHOOTING 9 14 Tips About the Audio System 9 14 Understanding Radio Reception 9 14 Care Of The Compact Discs 9 14 12 830E 1AC ...

Page 13: ...INTRODUCTION 830E 1AC 1 1 ...

Page 14: ...ystem The product identification number vehicle serial number contains information which will identify the original manufacturing bill of material for this unit This complete number will be necessary for proper ordering of many service parts and or warranty consideration The GVW is what determines the load on the drive train frame tires and other components The vehicle design and application guide...

Page 15: ... Komatsu Dr Cartersville GA 30121 United States of America Phone 678 721 3310 Email KACTECHPUBS KOMATSUNA COM If there is ever a question regarding the information in a particular section refer to the manual form number and use the address shown above to correspond The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the ...

Page 16: ...operating or maintaining this machine This manual should be kept in or near the machine for reference and periodically reviewed by all personnel who will come into contact with it California Proposition 65 Warnings Diesel engine exhaust some of its constituents and certain vehicle components contain or emit chemicals known to the State of California to cause cancer birth defects or other reproduct...

Page 17: ...ER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken WARNING identifies a specific potential hazard WHICH COULD RESULT in either INJURY OR DEATH if proper precautions are not taken CAUTION is used for general reminders of proper safety practices OR to direct the reader s attention to avoid unsafe or improper practices which may r...

Page 18: ...TRUCK MODEL ILLUSTRATION INTRODUCTION TRUCK MODEL ILLUSTRATION A 5 0000054230 1 6 830E 1AC ...

Page 19: ...ations accordingly use of such parts may compromise the safe operation of Komatsu products and place the operator and others in danger should the part fail Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above Use of non OEM parts places fu...

Page 20: ...NON OEM PARTS IN CRITICAL SYSTEMS INTRODUCTION 1 8 830E 1AC ...

Page 21: ...STANDARD CHARTS AND TABLES 830E 1AC 2 1 ...

Page 22: ...ds of standard fasteners where standard torque values are applied The use of special friction reducing lubricants will significantly alter the clamping force being applied to fasteners during the tightening process If special friction reducing lubricants are used with the standard torque values listed in this chapter excessive stress and possible breakage of the fasteners may result Where the torq...

Page 23: ...e see list this page to achieve the same clamping forces provided below NOTE Torques are calculated to give a clamping force of approximately 75 of proof load The maximum torque tolerance shall be within 10 of the torque value shown In the following table under Capscrew Size the first number represents the shank diameter mm The second number represents thread pitch in millimeters Example M20 x 2 2...

Page 24: ...Grade 5 Torque Grade 8 N m ft lb kg m N m ft lb kg m 1 4 20 9 5 7 0 97 13 6 10 1 38 1 4 28 10 8 8 1 11 14 9 11 1 52 5 16 18 20 3 15 2 07 28 21 2 90 5 16 24 22 16 2 21 30 22 3 04 3 8 16 34 25 3 46 47 35 4 84 3 8 24 41 30 4 15 54 40 5 5 7 16 14 54 40 5 5 79 58 8 0 7 16 20 61 45 6 2 84 62 8 57 1 2 13 88 65 9 122 90 12 4 1 2 20 95 70 9 7 129 95 13 1 9 16 12 122 90 12 4 169 125 17 3 Standard Tightening...

Page 25: ...ghtening Torque for SAE Hex Head and 12 Point Grade 9 Capscrews Capscrew Size 1 Torque N m Torque ft lb Torque kg m 0 250 20 16 12 1 7 0 312 18 33 24 3 3 0 375 16 57 42 5 8 0 438 14 95 70 9 7 0 500 13 142 105 14 5 0 562 12 203 150 20 7 0 625 11 278 205 28 3 0 750 10 488 360 49 7 0 875 9 780 575 79 4 1 000 8 1166 860 119 1 000 12 1240 915 126 1 125 7 1670 1230 170 Standard Tightening Torque for SAE...

Page 26: ... Kilogram meters kg m 10 10 14 66 48 6 7 12 17 112 83 11 5 16 22 279 206 28 5 Flared Tube And Hose Fittings Table 2 6 Tightening Torque For Flared Tube And Hose Fittings Thread Diameter of Nut mm Width Across Flat mm Newton meters N m 10 Foot Pounds ft lb 10 Kilogram meters kg m 10 14 19 25 18 2 5 18 24 50 36 5 22 27 80 58 8 24 32 140 101 14 30 36 175 130 18 33 41 195 145 20 36 46 245 180 25 42 55...

Page 27: ...N m Foot Pounds ft lb 2 0 125 0 312 24 5 1 4 1 3 0 188 0 375 24 11 4 8 3 4 0 250 0 438 20 16 4 12 3 5 0 312 0 500 20 20 4 15 3 6 0 375 0 562 18 24 7 18 5 8 0 500 0 750 16 40 7 30 5 10 0 625 0 875 14 54 7 40 5 12 0 750 1 062 12 75 7 55 5 14 0 875 1 188 12 88 7 65 5 16 1 000 1 312 12 108 7 80 5 20 1 250 1 625 12 136 14 100 10 24 1 500 1 875 12 163 14 120 10 32 2 000 2 500 12 312 27 230 20 830E 1AC 2...

Page 28: ...ealant ft lb Without Sealant N m Without Sealant ft lb 2 0 125 27 20 4 15 3 27 7 20 5 4 0 250 18 27 7 20 5 34 7 25 5 6 0 375 18 34 7 25 5 48 7 35 5 8 0 500 14 48 7 35 5 61 7 45 5 12 0 750 14 61 7 45 5 75 7 55 5 16 1 000 11 50 75 7 55 5 88 7 65 5 20 1 250 11 50 95 7 70 5 108 7 80 5 24 1 500 11 50 108 7 80 5 129 14 95 10 32 2 000 11 50 129 14 95 10 163 14 120 10 2 8 830E 1AC ...

Page 29: ...t Pounds ft lb 2 0 125 0 312 24 4 3 4 2 3 0 188 0 375 24 7 3 5 2 4 0 250 0 438 20 11 4 8 3 5 0 312 0 500 20 14 4 10 3 6 0 375 0 562 18 18 4 13 3 8 0 500 0 750 16 33 7 24 5 10 0 625 0 875 14 43 7 32 5 12 0 750 1 062 12 65 7 48 5 14 0 875 1 188 12 73 7 54 5 16 1 000 1 312 12 98 7 72 5 20 1 250 1 625 12 109 7 80 5 24 1 500 1 875 12 109 7 80 5 32 2 000 2 500 12 130 14 96 10 830E 1AC 2 9 ...

Page 30: ...Fittings Size Code Tube Size O D Threads UNF 2B Newton meters N m Foot Pounds ft lb 4 0 250 0 438 20 15 1 11 1 6 0 375 0 562 18 24 3 18 2 8 0 500 0 750 16 48 5 35 4 10 0 625 0 875 14 69 7 51 5 12 0 750 1 062 12 96 10 71 7 16 1 000 1 312 12 133 8 98 6 20 1 250 1 625 12 179 10 132 7 24 1 500 1 875 12 224 20 165 15 2 10 830E 1AC ...

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