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

Dump truck
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Operation & Maintenance
Manual
830E
DUMP TRUCK
SERIAL NUMBERS
ENGINE
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.
January 2017
-1AC
830E-1AC A40939-A40961
16V160
CEAM029701
Copyright 2017 Komatsu
Printed in U.S.A
Komatsu America Corp.

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Summary of Contents for Komatsu 830E-1AC

  • Page 1 16V160 ENGINE 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.
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 Ventilation For Enclosed Areas ................... 3-5 Mirrors, Windows, And Lights ..................... 3-5 Before Starting The Engine ....................3-5 Seat Belts And Tethers....................... 3-5 Emergency Egress Ladders ....................3-6 OPERATING THE MACHINE......................3-7 General Information ......................3-7 830E-1AC Find manuals at https://best-manuals.com...
  • Page 4 Jump Starting With Receptacles ..................3-19 WHEN REPAIRS ARE NECESSARY ..................... 3-21 Observe The Following Precautions.................. 3-21 SPECIAL PRECAUTIONS......................3-22 Preliminary Procedures Before Welding Or Performing Maintenance ........3-22 Engine Shutdown Procedure Before Welding or Performing Maintenance ......3-22 830E-1AC Find manuals at https://best-manuals.com...
  • Page 5 Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)....... 5-20 SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION ....5-21 EMERGENCY STEERING SYSTEM ..................5-21 Operation ........................5-21 Pre-Operation Testing ...................... 5-21 Additional Guidelines ....................... 5-22 830E-1AC Find manuals at https://best-manuals.com...
  • Page 6 PC SOFTWARE OVERVIEW ....................5-39 SYSTEM CONFIGURATION....................5-39 Connecting to the Payload Meter ..................5-39 Displayed Payload Units ....................5-40 Connection Menu ......................5-40 Configure the Payload Meter .................... 5-40 Setting the Date and Time ....................5-40 830E-1AC Find manuals at https://best-manuals.com...
  • Page 7 Setting the Gauge Display Units ..................5-41 Setting the Carryback Alarm Threshold ................5-41 Setting the Truck Number....................5-42 Setting the Komatsu Distributor ..................5-42 Setting the Komatsu Customer ..................5-42 Clean Truck Tare Calibration .................... 5-42 Inclinometer Calibration ....................5-43 DOWNLOADING PAYLOAD DATA ..................
  • Page 8 Seat Belts And Tethers..................... 6-14 Adjustment........................6-14 PASSENGER SEAT (Optional) ...................... 6-16 Seat Belts And Tethers..................... 6-16 Adjustment........................6-16 HEATER / AIR CONDITIONER CONTROLS................... 6-17 Fan Speed Control Knob....................6-17 Temperature Control Knob ....................6-17 830E-1AC Find manuals at https://best-manuals.com...
  • Page 9 No DC Link Voltage ......................6-26 DIGITAL DISPLAY OPERATION ....................6-27 Toggling Through Main Level Screens................6-27 Toggling Through Warning Screens .................. 6-28 Entering Payload Meter Data.................... 6-29 KOMTRAX Plus ..........................6-30 KOMTRAX Plus OPERATION ....................6-30 830E-1AC Find manuals at https://best-manuals.com...
  • Page 10 KOMTRAX Plus Downloading Procedure ................6-32 Location Of Downloaded Files ..................6-32 UPLOADING KOMTRAX Plus DATA ..................6-33 ORBCOMM ..........................6-35 KOMATSU WIRELESS BRIDGE (Optional) ..................6-36 General Information ......................6-36 Communication Setup...................... 6-36 Switching To The KWB_SETUP Network ................6-36 Setting The Computer Subnet Mask And IP Address ............
  • Page 11 Setting The Alarm......................9-5 Turning The Alarm Off......................9-6 Activating Snooze......................9-6 CD PLAYER ........................... 9-7 Playing A Compact Disc..................... 9-7 Playing An MP3 DISC ......................9-7 CD Mode Displays ......................9-7 Button Functions ....................... 9-7 MP3 PLAYER ..........................9-9 830E-1AC...
  • Page 12 ............................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 830E-1AC...
  • Page 13 INTRODUCTION 830E-1AC...
  • Page 14 (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 15: 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 Literature Services 100 Komatsu Dr.
  • Page 16 INTRODUCTION WARNINGS WARNINGS F.3-0000051687 This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization from KAC. It is the policy of the company to improve products whenever it is possible and practical to do so.
  • Page 17 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 result in damage to the machine. 830E-1AC...
  • Page 18 INTRODUCTION TRUCK MODEL ILLUSTRATION TRUCK MODEL ILLUSTRATION A.5-0000054230 830E-1AC...
  • Page 19 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.
  • Page 20 INTRODUCTION NON-OEM PARTS IN CRITICAL SYSTEMS 830E-1AC...
  • Page 21 STANDARD CHARTS AND TABLES 830E-1AC...

  • Page 22: General Information

    NOTE: This list represents the current engineering will be to one of the following tables. Do not approved sources for use in Komatsu manufacture. It use standard values to replace specific torque is not exclusive. Other products may meet the same values in assembly instructions.

  • Page 23: Standard Tightening Torques

    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 2.25 M20 = shank diameter (20 mm) 2.25 = thread pitch in millimeters 830E-1AC...
  • Page 24 3756 2770 N·m ft·lb kg·m N·m ft·lb kg·m 1/4-20 0.97 13.6 1.38 1/4-28 10.8 1.11 14.9 1.52 5/16-18 20.3 2.07 2.90 5/16-24 2.21 3.04 3/8-16 3.46 4.84 3/8-24 4.15 7/16-14 7/16-20 8.57 1/2-13 12.4 13.1 1/2-20 9/16-12 12.4 17.3 830E-1AC...
  • Page 25 0.625 - 11 28.3 8.5 ± 0.6 75 ± 5 (0.75 in.) 0.750 - 10 49.7 0.875 - 9 79.4 1.000 - 8 1166 1.000 - 12 1240 1.125 - 7 1670 1230 Shank Diameter (in) — Threads per inch 830E-1AC...
  • Page 26 28.5 Flared Tube And Hose Fittings Table 2-6 Tightening Torque For Flared Tube And Hose Fittings Kilogram Thread Width Newton Foot meters Diameter of Across meters Pounds (kg·m) ± Nut (mm) Flat (mm) (N·m) ± 10% (ft·lb) ± 10% 830E-1AC...
  • Page 27 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...
  • Page 28 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 830E-1AC...
  • Page 29 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...
  • Page 30 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...
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...