Komatsu 830E-AC User manual

830E-AC
MAXIMUM GVW
385848 kg 850,650 lb
GROSS HORSEPOWER
1865 kW 2,500 HP
ELECTRIC DRIVE TRUCK
Photo may include optional equipment.

830E-AC ELECTRIC DRIVE TRUCK
SERVICE CAPACITIES
Cooling system . . . . . . . . . . . . . . . . . . . . . . . .568 L 150 U.S. gal
*Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . .280 L 74 U.S. gal
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . .946 L 250 U.S. gal
Motor gear box . . . . . . . . . . . . . . . . . . . . . . . . .38 L 10 U.S. gal
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4542 L 1200 U.S. gal
* Includes lube oil filters
ENGINE
*Make and model . . . . . . . . . . . . . . . . . . . . . . Komatsu SDA16V160
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diesel
Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Operating cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 cycle
**Rated brake power . . . . . . . . . . . 1865 kW 2,500 HP @ 1900 rpm
***Flywheel power . . . . . . . . . . . . . 1761 kW 2,360 HP @ 1900 rpm
Weight (wet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9608 kg 21,182 lb
*Tier 2 emissions certified. Tier 1 emissions engine is optional outside of North America.
**Rated brake power is the output of the engine as installed in this machine, at governed rpm and
with engine manufacturer’s approved fuel setting. Accessory losses included are water pump, fuel
pump and oil pump
***Flywheel power is the rated power at the engine flywheel minus the average accessory losses.
Accessories include fan and charging alternator. Rating(s) represent gross engine performance in
accordance with SAE J1349 conditions.
ELECTRIC DRIVE
AC/DC CURRENT
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.E. GTA-41
Dual impeller in-line blower . . . . . . . . . . . . 255 m3/min 9,000 cfm
Control. . . . . . . . . . . . . . . . . . . . . . . . . . AC torque control system
*Motorized wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GEB25
*Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.875:1
Speed (maximum). . . . . . . . . . . . . . . . . . . . . . . . . 64 kph 40 mph
* Wheel motor application depends upon gross vehicle weight, haul road grade, haul road length,
rolling resistance and other parameters. Komatsu and G.E. must analyze each job condition to
assure proper application.
TIRES AND RIMS
Rock service, tubeless, tires (bias ply or radial)
Standard tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.00R57
*Optional tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46/90R57
Standard five (5) piece rim
737 mm x 1488 mm x 152 mm 29'' x 57'' x 6'' rims.
Typical tire weight . . . . . . . . . . . . . . . . . . . . . . .21081 kg 46,476 lbs
* Fitment of optional 46/90R57 tire shall increase nominal GVW rating to 392357 kg 865,000 lbs
Tires should meet application requirements for tkph/tmph, tread, compound, inflation pressure, ply rating or
equivalent, etc.
BODY
All-welded steel flat floor body with horizontal bolsters and full canopy.
Rear wheel rock ejectors,body up sling and rubber mounts on frame
are standard. Pivot exhaust heating optional.
Floor sheet . . . . . . . . . . . . . . 19 mm 0.75'' 1379 mPa 200,000 psi
tensile strength steel (two-piece)
Front sheet . . . . . . . . . . . . . . 12 mm 0.47'' 1379 mPa 200,000 psi
tensile strength steel
Side sheet . . . . . . . . . . . . . . . 8 mm 0.31'' 1379 mPa 200,000 psi
tensile strength steel
Canopy sheet . . . . . . . . . . . . . 5 mm 0.19'' 690 mPa 100,000 psi
Struck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 m3 153 yd3
Standard SAE heaped 2:1 . . . . . . . . . . . . . . . . . . . 147 m3 193 yd3
Standard Komatsu body weight . . . . . . . . . . 27669 kg 61,000 lbs
CAB
Advanced Operator Environment with integral 4-post ROPS/FOPS
Level 2, (SAE J1040/ISO 3449) adjustable air suspension seat
w/lumbar support and arm rests, passenger seat, maximum R-value
insulation, tilt and telescoping steering wheel, electric windshield
wipers w/washer, tinted glass, power windows, Komatsu Payload
Weighing System, 55,000 Btu/hr heater and defroster, 21,600 Btu/hr
air conditioning (HFC - 134A refrigerant).
FRAME
Advanced technology, full butt-welded box-sectional ladder-type
frame with integral ROPS supports, integral front bumper, rear
tubular cross members, steel castings at all critical stress transition
zones, rugged continuous horsecollar.
Plate material. . . . . . . . . . . . . . . . . . . . . . . . 482.6 mPa 70,000 psi
tensile strength steel
Casting material. . . . . . . . . . . . . . . . . . . . . . 620.5 mPa 90,000 psi
tensile strength steel
Rail width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 mm 12''
Rail depth (minimum). . . . . . . . . . . . . . . . . . . . . . . . . . 864 mm 34''
Top and bottom plate thickness . . . . . . . . . . . . . . . . . 32 mm 1.25''
Side plate thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mm 0.62''
Drive axle mounting . . . . . . . . . . . . . . . . Pin and spherical bushing
Drive axle alignment . . . . . . . . . . . Swing link between frame and axle
BRAKING SYSTEM
System meets ISO 3450/1996.
Service brakes: all-hydraulic actuated.
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel speed disc.
Three calipers on a 1213 mm 47.75" O.D. disc.
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Dual disc armature speed.
Two 635 mm 25" O.D. discs per side.
One caliper per disc.
Emergency brakes . . . . . . . . . . . . . . . . . . .Automatically applied prior
to hydraulic system pressure dropping below level
required to meet secondary stopping requirements.
Wheel brake locks . . . . . . . . . . . . . . . . . . . . . . . . . . . .Switch-activated
Parking brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Spring-applied,
hydraulically released, with speed application protection.
Electric dynamic retarder (max.) . . . . . . . . . . . . . . .2983 kW 4000 hp
Continuously rated high-density blown grids w/retard at engine idle
and retard in reverse propulsion.
SUSPENSION
HYDRAIR®II
Variable rate hydro-pneumatic with integral rebound control.
Max. front stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . 335 mm 13.2''
Max. rear stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 mm 11.0''
Max. rear axle oscillation . . . . . . . . . . . . . . . . . . . . . . . . . . . ±10.3º
COOLING SYSTEM
L&M radiator assembly, split-flow, with deareation-type top tank.
Radiator frontal area ..................................................6.24 m2 67.2 ft2
SPECIFICATIONS

830E-AC
ELECTRIC DRIVE TRUCK
ELECTRICAL SYSTEM
4 x 8D 1450 CCA, 12 volt batteries, in series/parallel, bumper
mounted with disconnect switch.
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt, 140 amp
Lighting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt
Cranking motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two/24 volt
WEIGHT DISTRIBUTION
Empty Vehicle Weight kg lb %
(Wet, 100% fuel, no options, standard Komatsu body, standard tires)
Front axle . . . . . . . . . . . . . . . . . . . . . . . 81279 179,190 50
Rear axle . . . . . . . . . . . . . . . . . . . . . . . .82921 182,810 50
Total EVW . . . . . . . . . . . . . . . . . . . . . .164200 362,000
Gross Vehicle Weight (Nominal)
Front axle . . . . . . . . . . . . . . . . . . . . . . .127330 280,715 33
Rear axle . . . . . . . . . . . . . . . . . . . . . . .258519 569,936 67
Total . . . . . . . . . . . . . . . . . . . . . . . . . . .385848 850,650
Nominal Payload* . . . . . . . . . . . . . . . .221648 488,650
244 U.S. ton
*Nominal payload is as defined within Komatsu America Corporation’s payload policy documentation. In
general, the nominal payload must be adjusted for the specific vehicle configuration and site application. The
figures above are provided for basic product description purposes. Please contact your Komatsu Corp.
distributor for specific application requirements.
HYDRAULIC SYSTEM
Steering . . . . . . . . . . . . Accumulator-assisted twin cylinders provide
constant rate steering. Emergency steering
automatically supplied by accumulator.
Turning circle diameter (SAE). . . . . . . . . . . . . . . . . . . . . 28.4 m 93 ft
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 901 L 238 U.S. gal
Filtration. . . . . . . . . . . . . . . . . . . . . . . . . In-line replaceable elements
Suction . . . . . . . . . . . . . . . . . . . . . . . . . Single, full-flow, 100 mesh
Hoist and steering . . . . . . . . . . . . . . . Dual, in-line, high-pressure.
Brake component cabinet . . . . . . . . . Above-deck, easily accessible
with diagnostic test connections.
Hoist . . . . . . . . . . . . . . . Two 3-stage dual-acting outboard cylinders,
internal cushion valve, over-center damping.
Hoist times
Power-up loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 sec
Power-down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 sec
Float-down empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 sec
Pumps
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tandem gear-type pump
with output of 851 lpm 225 gpm@1900 rpm
and 17240 kPa 2,500 psi
Steering and brake . . . . . . . Pressure compensating piston pump
with output of 246 lpm 65 gpm
@ 1900 rpm and 18961 kPa 2,750 psi
System relief pressures
Hoist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17240 kPa 2,500 psi
Steering and Brake. . . . . . . . . . . . . . . . . . . . 27580 kPa 4,000 psi
Quick disconnects standard for powering disabled truck and for
system diagnostics.
8.87 m 29'1" 3.83 m 12'6"
6.71 m
22'0''
EMPTY
6.88 m
22'7"
EMPTY
13.41 m
44'0"
RAISED
1.28m 4'2"
1.84 m
6'0"
6.35 m 20'10"3.99 m 13'1" 4.06 m 13'4"
2.97m
9'9"
45°
14.4 m 47'3"
2.79 m
9'2''
830 E-AC
830E-AC
DIMENSIONS
All dimensions are with 147 m3193 yd3body.
Body Struck 2:1 Heap Loading
Height*
Standard 117 m3153 yd3147 m3193 yd36.71 m 22'
* Exact load may vary due to tire make, type and inflation pressure.

STANDARD EQUIPMENT
•Air cleaners, Donaldson SSG with dust
evacuators
•Alternator (24 volt/140A)
•Auto lubrication system –90 lbs.
•Batteries (4 x 8D, 1450 CCA 12 volt)
•Battery charging receptacle, 24 V
•Body down indicator/body up buzzer
•Body over center device
•Brakes: Front: Wheel speed disc; Rear:
dual disc armature speed
•Electric start
•Filters, high pressure hydraulic
•Gate valves on hydraulic tank
•Komatsu IGBT control cabinet
•Komatsu Payload Weighing System-PLM III
•Mirrors, LH flat and RH rectangular convex
•Mud flaps
•Muffled exhaust, deck-mounted
•On-board load box
•Quick disconnects (steering and hoist)
•Radiator sight gauge
•Removable power module unit (radiator,
engine, alternator, blower)
•Retard grids, continuous rated, 14 element
•Retard speed control
•Reverse retarding
•Rock ejectors
•Thermostatic Fan Clutch
•Fast-Fill Fuel System (in-tank)
•Service Center (radiator, engine,
hydraulics)
OPERATOR ENVIRONMENT AND
CONTROL:
•All-hydraulic service brakes with
emergency auto apply
•Battery disconnect switch
•Body up cable
•Brake lock and drive system interlock
•Circuit breakers, 24 volt
•Diagonal staircase across grill
•Dynamic retarding with continuous
rated grids
•Engine shutdown at ground level
•Hoist interlock
•Horns (electric, center of steering wheel)
•Integral roll-over protection ROPS/FOPS
Level 2
•Maintenance & power lock-out
•Parking brake with warning light and speed
application protection
•Power steering w/auto emergency steering
•Protective deck rails
•Pump drive guard
•Radiator fan guard
•Seat belts 76 mm 3" wide retractable
•Skid-resistant coating on walkways
STANDARD HIGHVISIBILITY DELUXE
CAB:
Instrumentation
•Alarm System warning lights (red)
-Accumulator pre-charge
- Coolant low level w/alarm
- Coolant high temperature w/alarm
- Electric drive system cooling blower
w/alarm
- Electric system fault w/alarm
- Engine coolant temperature gauge
- Hydraulic oil level w/alarm
- Hydraulic oil temperature w/alarm
- Low engine oil pressure w/alarm
- Low brake pressure w/alarm
- Motorized wheel temperature stop
engine w/alarm
- Steering pressure w/alarm
•Air cleaner vacuum indicators
•Air conditioner HFC 134a
•AM/FM cassette radio, CD player
•Blower pressure indicator light
•
Digital tachometer and speedometer
•Dome light
•Engine hourmeter
•Engine shutdown
•Floor mat
•Fuel gauge in cab and on tank
•Fuel low level warning
•Gauges (backlighted)
•Headlight switch
•Heater and defroster (heavy-duty)
•Heater switch
•High beam selector and indicator
•Indicator lights (amber):
-5-minute idler timer
- Auto lube alarm
- Check engine w/alarm
- Circuit breaker tripped
- Dynamic retarding
- Dump body up
-Hydraulic oil filter
- Low fuel level
- Manual back-up lights
- Park brakes applied
- Retard speed control
- Service brakes
- Starter circuit
•Insulation (Max R-Value)
•Oil pressure gauge (engine)
•Operator seat, adjustable w/air
suspension, lumbar support and arm rests
•Panel lighting (adjustable)
•Passenger seat
•Power windows
•Pressurized cab air system
•RS232 port–PLM III
•Starter key switch
•Steering system warning light and buzzer
•Sunvisor (adjustable)
•Tilt and telescoping steering wheel
•VHMS with ORBCOMM
•Windshield (tinted)
•Windshield wipers and washer (electric)
LIGHTING:
•Back-up lights (2)
•Brake and retard lights on top of cab
•Clearance lights
•Control cabinet service light
•Dynamic retarding, rear (2)
•Headlights—(4) halogen
•Ladder lights
•Manual back-up light, switch and indicator
•Service light in rear axle
•Stop and tail lights (2)
•Turn signals
•Under-hood service lights
OPTIONAL EQUIPMENT
*Available factory installed or non-installed. All other options and accessories listed are available factory installed only.
•Additional high-mounted headlights
•
Air cleaner dust evacuators
•Arctic protection package (suspensions,
antifreeze/lube below -40º C)
• Back-up lights, deck-mounted
•Body liners*
• Eliminator, Centinel, Reserve
• Engine: SDA16V160 Tier 1 emissions
package is optional outisde North America
• Fire extinguisher 9 kg 20 lb
•
Fog lights
• Hot starts (engine oil, coolant, hydraulic tank)
• Hubodometer
• Mufflers between frame rails
•Pivot exhaust (heated body)
•Pressure fueling remote LH
•
Radiator shutters
•Special language decals
•Tires 46/90R57
(Optional equipment may change operating weight).
AESS672-03 ©2009 Komatsu America Corp. Printed in USA K04(1M)C 04/09 (EV-3)
www.KomatsuAmerica.com Komatsu America Corp. is an authorized licensee of Komatsu Ltd.
Materials and specifications are subject to change without notice
is a registered trademark of Komatsu Ltd., Japan