Komatsu 830E-1AC Manual

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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INTRODUCTION
FOREWORD..................................................................................................................................1-2
ABOUTTHISMANUAL...................................................................................................................1-3
WARNINGS....................................................................................................................................1-4
CaliforniaProposition65Warnings.....................................................................................1-4
ALERTS.........................................................................................................................................1-5
TRUCKMODELILLUSTRATION.....................................................................................................1-6
NON-OEMPARTSINCRITICALSYSTEMS.....................................................................................1-7
STANDARDCHARTSANDTABLES
GENERALINFORMATION..............................................................................................................2-2
EffectOfSpecialLubricants...............................................................................................2-2
SuggestedSourcesForRustPreventiveGrease.................................................................2-2
STANDARDTIGHTENINGTORQUES.............................................................................................2-3
Class10.9CapscrewsAndClass10Nuts...........................................................................2-3
SAEGrade5AndGrade8Capscrews................................................................................2-4
SAEGrade9Capscrews...................................................................................................2-5
T-BoltClamps....................................................................................................................2-5
SplitFlangeClamps...........................................................................................................2-6
FlaredTubeAndHoseFittings...........................................................................................2-6
JIC37°SwivelNuts...........................................................................................................2-7
PipeThreadFittings...........................................................................................................2-8
O-RingBossFittings..........................................................................................................2-9
O-RingFaceSealFittings................................................................................................2-10
CONVERSIONMULTIPLIERS........................................................................................................2-11
MetricT oEnglish..............................................................................................................2-11
EnglishT oMetric.............................................................................................................2-12
TemperatureConversions................................................................................................2-13
GENERALSAFETY
GENERALSAFETY........................................................................................................................3-2
SafetyRules......................................................................................................................3-2
TruckSafetyFeatures........................................................................................................3-2
ClothingAndPersonalItems..............................................................................................3-2
UnauthorizedModication..................................................................................................3-2
LeavingTheOperator’sSeat..............................................................................................3-2
MountingAndDismounting................................................................................................3-2
FireExtinguishersAndFirstAidKits...................................................................................3-3
PrecautionsForHighT emperatureFluids............................................................................3-3
AsbestosDustHazardPrevention......................................................................................3-3
FirePrevention..................................................................................................................3-3
ROPSPrecautions.............................................................................................................3-3
PreventingInjuryFromWorkEquipment.............................................................................3-4
PrecautionsForOptionalAttachments................................................................................3-4
PrecautionsWhenStartingTheMachine.............................................................................3-4
PRECAUTIONSFORTRUCKOPERATION.....................................................................................3-5
SafetyIsThinkingAhead...................................................................................................3-5
SafetyAtTheWorksite......................................................................................................3-5
PreparingForOperation.....................................................................................................3-5
VentilationForEnclosedAreas...........................................................................................3-5
Mirrors,Windows,AndLights.............................................................................................3-5
BeforeStartingTheEngine................................................................................................3-5
SeatBeltsAndT ethers.......................................................................................................3-5
EmergencyEgressLadders...............................................................................................3-6
OPERATINGTHEMACHINE...........................................................................................................3-7
GeneralInformation...........................................................................................................3-7
830E-1AC3
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StartingTheEngine...........................................................................................................3-7
TravelingInTheMachine...................................................................................................3-7
TravelingInReverse..........................................................................................................3-8
TravelingOnSlopes..........................................................................................................3-8
TravelingOnSnow............................................................................................................3-8
TravelingNearHighVoltageCables....................................................................................3-8
TravelingOnLooseGround...............................................................................................3-8
EnsuringGoodVisibility.....................................................................................................3-8
AvoidDamageT oTheDumpBody.....................................................................................3-8
SafeParkingOfTheMachine.............................................................................................3-9
LoadingTheMachine........................................................................................................3-9
DumpingTheMachine.......................................................................................................3-9
TowingTheMachine..........................................................................................................3-9
EXTERIORLIGHTING...........................................................................................................3-10
FogLights.......................................................................................................................3-10
Headlights.......................................................................................................................3-10
BrakeLights....................................................................................................................3-10
RetardLights....................................................................................................................3-11
Clearance/TurnSignalLights.............................................................................................3-11
BackupLights...................................................................................................................3-11
RetardLights....................................................................................................................3-11
BrakeLights....................................................................................................................3-12
BackupAlarm..................................................................................................................3-12
BackupLamp..................................................................................................................3-12
PRECAUTIONSFORMAINTENANCE...........................................................................................3-13
BEFOREPERFORMINGMAINTENANCE...............................................................................3-13
ElectricalSystemIsolation................................................................................................3-13
SecuringTheDumpBody................................................................................................3-14
DURINGMAINTENANCE.......................................................................................................3-15
WarningT ag....................................................................................................................3-15
ProperT ools....................................................................................................................3-15
Attachments....................................................................................................................3-15
WorkingUnderTheMachine............................................................................................3-15
KeepingTheMachineClean............................................................................................3-16
AddingFuelOrOilToTheMachine..................................................................................3-16
RadiatorCoolantLevel.....................................................................................................3-16
UseOfLighting................................................................................................................3-16
HandlingHighPressureHoses.........................................................................................3-16
PrecautionsWithHighPressureOil..................................................................................3-16
MaintenanceNearHighT emperaturesAndHighPressures................................................3-17
RotatingFanAndBelts....................................................................................................3-17
WasteMaterials...............................................................................................................3-17
UseOfTie-OffAnchorDuringMaintenance.......................................................................3-17
HandlingTires.................................................................................................................3-17
TireMaintenance.............................................................................................................3-18
StoringTiresAfterRemoval..............................................................................................3-18
BatteryHazardPrevention...............................................................................................3-18
JumpStartingWithJumperCables...................................................................................3-19
JumpStartingWithReceptacles.......................................................................................3-19
WHENREPAIRSARENECESSARY.............................................................................................3-21
ObserveTheFollowingPrecautions..................................................................................3-21
SPECIALPRECAUTIONS.............................................................................................................3-22
PreliminaryProceduresBeforeWeldingOrPerformingMaintenance..................................3-22
EngineShutdownProcedureBeforeWeldingorPerformingMaintenance...........................3-22
4830E-1AC
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BeforeWeldingOnTheMachine,ObeyTheFollowingGuidelines:.....................................3-22
DischargingControlCabinetCapacitors............................................................................3-23
WARNINGANDCAUTIONS
GENERALINFORMATION..............................................................................................................4-2
PINPLATE.....................................................................................................................................4-2
GRADESPEEDCHART.................................................................................................................4-3
MACHINESAFETY.........................................................................................................................4-3
KEYSWITCH.................................................................................................................................4-5
OILFILLANDCHECK....................................................................................................................4-5
HIGHPRESSURES........................................................................................................................4-6
BATTERYANDISOLATIONBOX....................................................................................................4-9
HIGHVOLTAGE...........................................................................................................................4-12
WELDING....................................................................................................................................4-15
LIFTINGPOINTS..........................................................................................................................4-16
EMERGENCYDUMPING..............................................................................................................4-17
AUTOMATICLUBRICATIONFILL..................................................................................................4-18
ROPS/FOPS................................................................................................................................4-18
TOWING......................................................................................................................................4-18
LUBRICATIONCHART.................................................................................................................4-19
OPERATINGINSTRUCTIONS
PREPARINGFOROPERATION......................................................................................................5-2
SafetyIsThinkingAhead...................................................................................................5-2
WalkAroundInspection.....................................................................................................5-2
RETRACTABLELADDERSYSTEM(IfEquipped).............................................................................5-7
GeneralInformation...........................................................................................................5-7
LadderSystemDescription................................................................................................5-7
LadderSystemOperation...................................................................................................5-7
In-CabControlPanel.........................................................................................................5-8
GroundLevelControlBox................................................................................................5-10
EmergencyDownValve....................................................................................................5-11
PRE-SHIFTBRAKETEST.............................................................................................................5-12
Operation........................................................................................................................5-12
ServiceBrakeTest...........................................................................................................5-13
ParkingBrakeTest...........................................................................................................5-13
RetardSystemTest.........................................................................................................5-14
BrakeT estExitCriteria.....................................................................................................5-14
TRUCKOPERATION....................................................................................................................5-15
ENGINESTART-UPSAFETY.................................................................................................5-15
AfterEngineHasStarted..................................................................................................5-15
MACHINEOPERATIONSAFETYPRECAUTIONS...................................................................5-16
MachineOperationOnTheHaulRoad..............................................................................5-17
StartingOnAGradeWithALoadedTruck........................................................................5-17
RetardingOnAGrade.....................................................................................................5-17
Passing...........................................................................................................................5-18
Loading...........................................................................................................................5-18
OverloadSpeedLimitFunction.........................................................................................5-18
Dumping.........................................................................................................................5-19
LoweringTheDumpBody(WhenDumpingOnFlatGround)..............................................5-20
LoweringTheDumpBody(WhenDumpingOverABermOrIntoACrusher).......................5-20
SUDDENLOSSOFENGINEPOWERORLOSSOFDRIVESYSTEMFUNCTION...................5-21
EMERGENCYSTEERINGSYSTEM.......................................................................................5-21
Operation........................................................................................................................5-21
Pre-OperationT esting......................................................................................................5-21
AdditionalGuidelines.......................................................................................................5-22
830E-1AC5
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CAMERASYSTEM(Optional).................................................................................................5-23
General...........................................................................................................................5-23
Operation........................................................................................................................5-23
CameraMonitor...............................................................................................................5-24
CameraSelection............................................................................................................5-24
AutoBacklightControl/Day/NightSettings.........................................................................5-24
ContrastAdjustment........................................................................................................5-24
BrightnessAdjustment.....................................................................................................5-24
SaturationAdjustment......................................................................................................5-24
SingleScan/Return........................................................................................................5-24
Minus..............................................................................................................................5-24
Plus................................................................................................................................5-24
Enter...............................................................................................................................5-24
FUELDEPLETION.................................................................................................................5-25
SAFEPARKINGPROCEDURES............................................................................................5-25
NORMALENGINESHUTDOWNPROCEDURE......................................................................5-25
DISABLEDTRUCKCONNECTORS..............................................................................................5-27
GENERALINFORMATION.....................................................................................................5-27
STEERINGANDBRAKESYSTEM.........................................................................................5-27
Hookup...........................................................................................................................5-27
HOISTSYSTEM....................................................................................................................5-28
Hookup...........................................................................................................................5-28
DumpingProcedure.........................................................................................................5-29
TOWING......................................................................................................................................5-30
SPECIALWIRINGHARNESS.................................................................................................5-30
TOWINGPROCEDURE.........................................................................................................5-30
PAYLOADMETERIIISYSTEM......................................................................................................5-33
GENERALINFORMATION.....................................................................................................5-33
DataSummary................................................................................................................5-33
DataGathering................................................................................................................5-33
COMPONENTDESCRIPTION................................................................................................5-33
OperatorDisplay.............................................................................................................5-33
OperatorSwitches...........................................................................................................5-33
BrakeLockSwitch...........................................................................................................5-33
PayloadMeterModule.....................................................................................................5-33
CommunicationsPorts.....................................................................................................5-34
LoadLights.....................................................................................................................5-34
SCOREBOARD.....................................................................................................................5-34
OPERATOR’SDISPLAYANDSWITCH...................................................................................5-35
ReadingtheLoadDisplay................................................................................................5-35
SettingtheOperatorID....................................................................................................5-35
LoadandTonCounter......................................................................................................5-35
ViewingLiveSensorData................................................................................................5-35
OtherDisplayMessages..................................................................................................5-36
HAULCYCLEWARNINGFLAGS...........................................................................................5-36
HaulCycleData..............................................................................................................5-36
HaulCycleWarningFlags................................................................................................5-37
PCSOFTWAREOVERVIEW..................................................................................................5-39
SYSTEMCONFIGURATION...................................................................................................5-39
ConnectingtothePayloadMeter......................................................................................5-39
DisplayedPayloadUnits..................................................................................................5-40
ConnectionMenu............................................................................................................5-40
CongurethePayloadMeter............................................................................................5-40
SettingtheDateandTime................................................................................................5-40
6830E-1AC
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SettingtheTruckTypeandSerialNumber.........................................................................5-41
SettingtheGaugeDisplayUnits.......................................................................................5-41
SettingtheCarrybackAlarmThreshold.............................................................................5-41
SettingtheTruckNumber.................................................................................................5-42
SettingtheKomatsuDistributor........................................................................................5-42
SettingtheKomatsuCustomer.........................................................................................5-42
CleanTruckT areCalibration............................................................................................5-42
InclinometerCalibration...................................................................................................5-43
DOWNLOADINGPAYLOADDATA..........................................................................................5-43
UPLOADINGDATA................................................................................................................5-44
CreatingaQuery.............................................................................................................5-45
DetailedMulti-PageReport..............................................................................................5-45
CreatingGraphs..............................................................................................................5-46
DATAANALYSIS....................................................................................................................5-46
CreatingaQuery.............................................................................................................5-46
PayloadDetailScreen......................................................................................................5-47
CreatingReports.............................................................................................................5-47
CreatingGraphs..............................................................................................................5-47
ExportingData................................................................................................................5-48
ImportingData.................................................................................................................5-48
DeletingHaulCycleRecords............................................................................................5-49
ViewingAlarms................................................................................................................5-49
DeletingAlarmRecords...................................................................................................5-49
PatentAcknowledgment...................................................................................................5-49
AUTOMATICLUBRICATIONSYSTEM...........................................................................................5-50
GENERALINFORMATION.....................................................................................................5-50
COMPONENTDESCRIPTION................................................................................................5-50
Filter...............................................................................................................................5-51
HydraulicMotorandPump...............................................................................................5-51
GreaseReservoir............................................................................................................5-51
PressureReducingValve.................................................................................................5-51
FlowControlValve...........................................................................................................5-51
SolenoidValve.................................................................................................................5-52
VentValve.......................................................................................................................5-52
InterfaceModule..............................................................................................................5-52
Injectors..........................................................................................................................5-53
GreasePressureFailureSwitch.......................................................................................5-54
ReliefValve(unloadervalve)............................................................................................5-54
SYSTEMOPERATION...........................................................................................................5-54
FillingTheReservoir........................................................................................................5-54
PrimingTheAutomaticLubricationSystem........................................................................5-55
PREVENTIVEMAINTENANCEPROCEDURES......................................................................5-55
DailyLubricationSystemInspection..................................................................................5-55
250HourInspection.........................................................................................................5-56
1000HourInspection.......................................................................................................5-56
SYSTEMCHECKOUT............................................................................................................5-56
GeneralChecks...............................................................................................................5-56
LubricationCycleOperation.............................................................................................5-57
RESERVEENGINEOILSYSTEM(ifequipped)..............................................................................5-58
Operation........................................................................................................................5-58
LEDMonitorLight............................................................................................................5-59
ChangingOil...................................................................................................................5-59
OPERATORCABANDCONTROLS
CABINTERIOR..............................................................................................................................6-2
830E-1AC7
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STEERINGWHEELANDCONTROLS.............................................................................................6-3
HornButton.......................................................................................................................6-3
Tilt/T elescopeLever.........................................................................................................6-3
Multi-FunctionTurnSignalSwitch.......................................................................................6-3
TurnSignalOperation........................................................................................................6-3
HighBeamHeadlightOperation.........................................................................................6-3
WindshieldWiperOperation...............................................................................................6-3
PEDALS.........................................................................................................................................6-5
ServiceBrakePedal..........................................................................................................6-5
DynamicRetardPedal.......................................................................................................6-5
DynamicRetarding............................................................................................................6-5
AcceleratorPedal..............................................................................................................6-5
OVERHEADPANELANDDISPLAYS...............................................................................................6-6
RadioSpeakers.................................................................................................................6-6
WarningAlarmBuzzer.......................................................................................................6-6
CabRadio.........................................................................................................................6-6
AirCleanerVacuumGauges..............................................................................................6-6
CameraMonitor(Optional).................................................................................................6-6
CENTERCONSOLE.......................................................................................................................6-7
DirectionalControlLever....................................................................................................6-7
Override/FaultResetSwitch...............................................................................................6-7
EngineStopSwitch............................................................................................................6-7
WindowControlSwitches...................................................................................................6-8
HoistControlLever............................................................................................................6-8
RaisingTheDumpBody....................................................................................................6-8
LoweringTheDumpBody..................................................................................................6-8
RetardSpeedControl(RSC)AdjustDial.............................................................................6-8
RetardSpeedControl(RSC)Switch...................................................................................6-9
DataStoreButton..............................................................................................................6-9
12VAuxiliaryPowerOutlets...............................................................................................6-9
FireSuppressionControlOutlet..........................................................................................6-9
CommunicationRadioOutlet..............................................................................................6-9
DIAGNOSTICPORTS...................................................................................................................6-10
KOMTRAXPlus..............................................................................................................6-10
InterfaceModule(IM).......................................................................................................6-10
DriveSystemOrModularMining......................................................................................6-10
DriveSystemController(DSC).........................................................................................6-10
Engine(CENSE).............................................................................................................6-10
Engine(QUANTUM)........................................................................................................6-10
OPERATORSEAT(Standard)........................................................................................................6-11
SeatBeltsAndT ethers......................................................................................................6-11
Adjustment.......................................................................................................................6-11
PASSENGERSEAT(Standard).....................................................................................................6-13
SeatBeltsAndT ethers.....................................................................................................6-13
Adjustment......................................................................................................................6-13
OPERATORSEAT(Optional)........................................................................................................6-14
SeatBeltsAndT ethers.....................................................................................................6-14
Adjustment......................................................................................................................6-14
PASSENGERSEAT(Optional)......................................................................................................6-16
SeatBeltsAndT ethers.....................................................................................................6-16
Adjustment......................................................................................................................6-16
HEATER/AIRCONDITIONERCONTROLS...................................................................................6-17
FanSpeedControlKnob..................................................................................................6-17
TemperatureControlKnob...............................................................................................6-17
8830E-1AC
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AirFlowDirectionalKnob.................................................................................................6-17
Heater/AirConditionerVents............................................................................................6-17
INSTRUMENTPANEL..................................................................................................................6-18
ControlSymbols..............................................................................................................6-18
Heater/AirConditionerVents..........................................................................................6-19
StatusIndicatorLightPanel..............................................................................................6-19
HydraulicOilTemperatureGauge.....................................................................................6-19
CoolantT emperatureGauge............................................................................................6-19
Speedometer/DigitalDisplay............................................................................................6-19
FuelLevelGauge............................................................................................................6-19
DriveSystemTemperatureGauge....................................................................................6-20
HazardWarningLightSwitch............................................................................................6-20
Pre-ShiftBrakeTestSwitch..............................................................................................6-20
WheelBrakeLockControlSwitch.....................................................................................6-20
RestSwitch.....................................................................................................................6-20
EngineWarmUp.............................................................................................................6-21
HeatedMirrorSwitch(Optional)........................................................................................6-21
RotatingBeaconLightSwitch(Optional)...........................................................................6-21
CameraSystem(Optional)...............................................................................................6-21
KeySwitch......................................................................................................................6-21
WarningLight..................................................................................................................6-22
DigitalDisplayContrastButtons........................................................................................6-22
TurnSignalIndicators......................................................................................................6-22
PanelLightDimmer.........................................................................................................6-22
ModeSwitches................................................................................................................6-22
FogLightSwitch..............................................................................................................6-22
BackupLightSwitch........................................................................................................6-22
LadderLightSwitch.........................................................................................................6-22
Headlight/PanelIlluminationLightSwitch..........................................................................6-22
STATUSINDICATORLIGHTPANEL..............................................................................................6-24
STATUSINDICATORLIGHTSYMBOLS..................................................................................6-24
BodyUp..........................................................................................................................6-24
ParkingBrake..................................................................................................................6-24
PropelSystemNotReady................................................................................................6-24
NoPropel........................................................................................................................6-25
EngineWarmUp.............................................................................................................6-25
EngineShutdownDelay...................................................................................................6-25
RetardingGridDryer........................................................................................................6-25
WheelBrakeLock...........................................................................................................6-25
TractionControl...............................................................................................................6-25
RepairMonitor.................................................................................................................6-25
RetractableLadderDown.................................................................................................6-25
SnapshotInProgress......................................................................................................6-25
PantographEnergized.....................................................................................................6-25
PantographUp................................................................................................................6-26
ServiceBrake..................................................................................................................6-26
DynamicRetarding..........................................................................................................6-26
NoDCLinkVoltage.........................................................................................................6-26
DIGITALDISPLAYOPERATION....................................................................................................6-27
TogglingThroughMainLevelScreens...............................................................................6-27
TogglingThroughWarningScreens..................................................................................6-28
EnteringPayloadMeterData............................................................................................6-29
KOMTRAXPlus............................................................................................................................6-30
KOMTRAXPlusOPERATION.................................................................................................6-30
830E-1AC9
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BasicPrecautions............................................................................................................6-30
InterfaceModule..............................................................................................................6-31
DOWNLOADINGKOMTRAXPlusDATA.................................................................................6-31
GeneralInformation.........................................................................................................6-31
KOMTRAXPlusDownloadingProcedure..........................................................................6-32
LocationOfDownloadedFiles..........................................................................................6-32
UPLOADINGKOMTRAXPlusDATA.......................................................................................6-33
ORBCOMM..................................................................................................................................6-35
KOMATSUWIRELESSBRIDGE(Optional)....................................................................................6-36
GeneralInformation.........................................................................................................6-36
CommunicationSetup......................................................................................................6-36
SwitchingT oTheKWB_SETUPNetwork..........................................................................6-36
SettingTheComputerSubnetMaskAndIPAddress.........................................................6-37
SettingUpTheKWB........................................................................................................6-37
AddingEncryption...........................................................................................................6-38
FinalComputerSettings...................................................................................................6-38
DownloadingData...........................................................................................................6-38
ResettingTheKWB.........................................................................................................6-39
FUSESANDCIRCUITBREAKERS...............................................................................................6-40
VEHICLEELECTRICALCENTER89......................................................................................6-40
VEHICLEELECTRICALCENTER90......................................................................................6-42
VEHICLEELECTRICALCENTER91......................................................................................6-44
CIRCUITBREAKERS.............................................................................................................6-46
LUBRICATIONANDSERVICE
GENERALINFORMATION..............................................................................................................7-2
HYDRAULICSYSTEMSERVICE..............................................................................................7-2
HydraulicT ank...................................................................................................................7-2
HydraulicFilters.................................................................................................................7-3
HydraulicPumpDriveShaft................................................................................................7-3
WHEELMOTORSERVICE.......................................................................................................7-3
COOLANTLEVELSERVICE....................................................................................................7-3
RadiatorFillingProcedure..................................................................................................7-4
CoolantSpecications........................................................................................................7-4
UnacceptablePractices.....................................................................................................7-4
RESERVEENGINEOILSERVICE............................................................................................7-4
ReserveOilTankFillingProcedure(RemoteFill).................................................................7-5
InlineScreen.....................................................................................................................7-5
CABAIRFILTERSERVICE......................................................................................................7-5
FUELSYSTEMSERVICE.........................................................................................................7-6
FuelT ankCleaning............................................................................................................7-6
FuelFilterService..............................................................................................................7-6
INTAKEAIRCLEANERSERVICE.............................................................................................7-7
FRONTWHEELSERVICE.......................................................................................................7-8
OilSampling......................................................................................................................7-8
FRONTENGINEMOUNTTRUNNIONSERVICE.......................................................................7-9
QUICKFILLSERVICECENTER...............................................................................................7-9
TIERODINSPECTIONANDTORQUEPROCEDURE...............................................................7-9
LUBRICATIONCHART..................................................................................................................7-11
EVERY10HOUR(DAILY)MAINTENANCE...................................................................................7-12
INITIAL50HOURLUBRICATIONANDMAINTENANCEINSPECTION............................................7-14
INITIAL100HOURLUBRICATIONANDMAINTENANCEINSPECTION..........................................7-15
EVERY250HOURLUBRICATIONANDMAINTENANCE...............................................................7-16
EVERY500HOURLUBRICATIONANDMAINTENANCE...............................................................7-19
EVERY1000HOURSLUBRICATIONANDMAINTENANCE...........................................................7-21
10830E-1AC
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