Komatsu 830E-1AC Dump Truck Operation & Maintenance Manual
225 pages · Publication CEAM024404
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- Models
- 830E-1AC
- Serial coverage
- A30561 - A30850
- Manual type
- Operation & Maintenance Manual
- Pages
- 225
- Publication
- CEAM024404
- Condition
- Brand new
What's inside
From the manual's own table of contents: 105 sections, 488 entries. See sample pages (PDF, 664 KB)
FOREWORD
ABOUT THIS MANUAL
WARNINGS1 topic
- California Proposition 65 Warnings
ALERTS
TRUCK MODEL ILLUSTRATION
PARTS IN CRITICAL SYSTEMS
GENERAL INFORMATION2 topics
- Effect Of Special Lubricants
- Suggested Sources For Rust Preventive Grease
STANDARD TIGHTENING TORQUES10 topics
- Class 10.9 Capscrews And Class 10 Nuts
- SAE Grade 5 And Grade 8 Capscrews
- SAE Grade 9 Capscrews
- T-Bolt Clamps
- Split Flange Clamps
- Flared Tube And Hose Fittings
- JIC 37° Swivel Nuts
- Pipe Thread Fittings
- O-Ring Boss Fittings
- O-Ring Face Seal Fittings
CONVERSION MULTIPLIERS3 topics
- Metric To English
- English To Metric
- Temperature Conversions
GENERAL SAFETY14 topics
- Safety Rules
- Truck Safety Features
- Clothing And Personal Items
- Unauthorized Modification
- Leaving The Operator’s Seat
- Mounting And Dismounting
- Fire Extinguishers And First Aid Kits
- Precautions For High Temperature Fluids
- Asbestos Dust Hazard Prevention
- Fire Prevention
- ROPS Precautions
- Preventing Injury From Work Equipment
- Precautions For Optional Attachments
- Precautions When Starting The Machine
PRECAUTIONS FOR TRUCK OPERATION8 topics
- Safety Is Thinking Ahead
- Safety At The Worksite
- Preparing For Operation
- Ventilation For Enclosed Areas
- Mirrors, Windows, And Lights
- Before Starting The Engine
- Seat Belts And Tethers
- Emergency Egress Ladders
OPERATING THE MACHINE14 topics
- General Information
- Starting The Engine
- Traveling In The Machine
- Traveling In Reverse
- Traveling On Slopes
- Traveling On Snow
- Traveling Near High Voltage Cables
- Traveling On Loose Ground
- Ensuring Good Visibility
- Avoid Damage To The Dump Body
- Safe Parking Of The Machine
- Loading The Machine
- Dumping The Machine
- Towing The Machine
EXTERIOR LIGHTING8 topics
- Fog Lights
- Headlights
- Brake Lights
- Retard Lights
- Clearance/Turn Signal Lights
- Backup Lights
- Backup Alarm
- HID Backup Light
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE2 topics
- Electrical System Isolation
- Securing The Dump Body
DURING MAINTENANCE20 topics
- Warning Tag
- Proper Tools
- Attachments
- Working Under The Machine
- Keeping The Machine Clean
- Adding Fuel Or Oil To The Machine
- Radiator Coolant Level
- Use Of Lighting
- Handling High Pressure Hoses
- Precautions With High Pressure Oil
- Maintenance Near High Temperatures And High Pressures
- Rotating Fan And Belts
- Waste Materials
- Use Of Tie-Off Anchor During Maintenance
- Handling Tires
- Tire Maintenance
- Storing Tires After Removal
- Battery Hazard Prevention
- Jump Starting With Jumper Cables
- Jump Starting With Receptacles
WHEN REPAIRS ARE NECESSARY1 topic
- Observe The Following Precautions
SPECIAL PRECAUTIONS4 topics
- Preliminary Procedures Before Welding Or Performing Maintenance
- Engine Shutdown Procedure Before Welding or Performing Maintenance
- Before Welding On The Machine, Obey The Following Guidelines
- Discharging Control Cabinet Capacitors
PIN PLATE
GRADE SPEED CHART
MACHINE SAFETY
KEY SWITCH
OIL FILL AND CHECK
HIGH PRESSURES
Show all 105 sections
BATTERY AND ISOLATION BOX
HIGH VOLTAGE
WELDING
LIFTING POINTS
EMERGENCY DUMPING
AUTOMATIC LUBRICATION FILL
ROPS/FOPS
TOWING
LUBRICATION CHART
PREPARING FOR OPERATION2 topics
- Safety Is Thinking Ahead
- Walk Around Inspection
RETRACTABLE LADDER SYSTEM (If Equipped)6 topics
- General Information
- Ladder System Description
- Ladder System Operation
- In-Cab Control Panel
- Ground Level Control Box
- Emergency Down Valve
BRAKE TEST5 topics
- OPERATION
- Service Brake Test
- Parking Brake Test
- Retard System Test
- Brake Test Exit Criteria
TRUCK OPERATION17 topics
- ENGINE START-UP SAFETY
- After Engine Has Started
- MACHINE OPERATION SAFETY PRECAUTIONS
- Machine Operation On The Haul Road
- Starting On A Grade With A Loaded Truck
- Retarding On A Grade
- Passing
- Loading
- Overload Speed Limit Function
- Dumping
- Lowering The Dump Body (When Dumping On Flat Ground)
- Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)
- SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
- EMERGENCY STEERING SYSTEM
- Operation
- Pre-Operation Testing
- Additional Guidelines
CAMERA SYSTEM (Optional)12 topics
- General
- Operation
- Camera Monitor
- Camera Selection
- Auto Backlight Control/Day/Night Settings
- Contrast Adjustment
- Brightness Adjustment
- Saturation Adjustment
- Single Scan / Return
- Minus
- Plus
- Enter
FUEL DEPLETION
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DISABLED TRUCK CONNECTORS
STEERING AND BRAKE SYSTEM1 topic
- Hookup
HOIST SYSTEM1 topic
- Dumping Procedure
SPECIAL WIRING HARNESS
TOWING PROCEDURE
PAYLOAD METER III SYSTEM2 topics
- Data Summary
- Data Gathering
COMPONENT DESCRIPTION6 topics
- Operator Display
- Operator Switch
- Brake Lock Switch
- Payload Meter Module
- Communications Ports
- Load Lights
OPERATOR’S DISPLAY AND SWITCH5 topics
- Reading the Load Display
- Setting the Operator ID
- Load and Ton Counter
- Viewing Live Sensor Data
- Other Display Messages
HAUL CYCLE WARNING FLAGS2 topics
- Haul Cycle Data
- Haul Cycle Warning Flags
PC SOFTWARE OVERVIEW
SYSTEM CONFIGURATION26 topics
- Connecting to the Payload Meter
- Displayed Payload Units
- Connection Menu
- Configure the Payload Meter
- Setting the Date and Time
- Setting the Truck Type and Serial Number
- Setting the Gauge Display Units
- Setting the Carryback Alarm Threshold
- Setting the Truck Number
- Setting the Komatsu Distributor
- Setting the Komatsu Customer
- Clean Truck Tare Calibration
- Inclinometer Calibration
- DOWNLOADING PAYLOAD DATA
- UPLOADING DATA
- DATA ANALYSIS
- Creating a Query
- Payload Detail Screen
- Creating Reports
- Creating Graphs
- Exporting Data
- Importing Data
- Deleting Haul Cycle Records
- Viewing Alarms
- Deleting Alarm Records
- Patent Acknowledgment
AUTOMATIC LUBRICATION SYSTEM23 topics
- GENERAL INFORMATION
- COMPONENT DESCRIPTION
- Filter
- Hydraulic Motor and Pump
- Grease Reservoir
- Pressure Reducing Valve
- Flow Control Valve
- Solenoid Valve
- Vent Valve
- Lubrication Cycle Timer
- Pressure Cut Off Switch
- Injectors
- Grease Pressure Failure Switch
- Relief Valve (unloader valve)
- SYSTEM OPERATION
- Filling The Reservoir
- Priming The Automatic Lubrication System
- PREVENTIVE MAINTENANCE PROCEDURES
- Daily Lubrication System Inspection
- Hour Inspection
- SYSTEM CHECKOUT
- General Checks
- Lubrication Controller Components
RESERVE ENGINE OIL SYSTEM (If Equipped)3 topics
- Operation
- LED Monitor Light
- Changing Oil
CAB INTERIOR
STEERING WHEEL AND CONTROLS6 topics
- Horn Button
- Tilt / Telescope Lever
- Multi-Function Turn Signal Switch
- Turn Signal Operation
- High Beam Headlight Operation
- Windshield Wiper Operation
PEDALS4 topics
- Service Brake Pedal
- Dynamic Retard Pedal
- Dynamic Retarding
- Accelerator Pedal
OVERHEAD PANEL AND DISPLAYS7 topics
- Radio Speakers
- Warning Alarm Buzzer
- Cab Radio
- Warning Light Dimmer Control
- Status/Warning Indicator Light Panel
- Air Cleaner Vacuum Gauges
- Camera Monitor (Optional)
CENTER CONSOLE16 topics
- DIRECTIONAL CONTROL LEVER
- OVERRIDE/FAULT RESET SWITCH
- ENGINE STOP SWITCH
- WINDOW CONTROL SWITCHES
- HOIST CONTROL LEVER
- Raising The Dump Body
- Lowering The Dump Body
- RETARD SPEED CONTROL (RSC) ADJUST DIAL
- RETARD SPEED CONTROL (RSC) SWITCH
- DATA STORE BUTTON
- KOMTRAX Plus SNAPSHOT IN PROGRESS LIGHT
- LINK ENERGIZED LIGHT
- SERVICE ENGINE LIGHT
- 12V AUXILIARY POWER OUTLETS
- 24V FIRE CONTROL CONNECTOR
- 24V/12V RADIO CONNECTOR
DIAGNOSTIC PORTS6 topics
- KOMTRAX Plus
- Interface Module (IM)
- Truck Control Interface (TCI)
- Propulsion System Controller (PSC)
- Engine (CENSE)
- Engine (QUANTUM)
OPERATOR SEAT (Standard, Older)2 topics
- SEAT BELTS
- ADJUSTMENT
OPERATOR SEAT (Standard)1 topic
- Seat Belts And Tethers
PASSENGER SEAT (Standard)
OPERATOR SEAT (Optional)
PASSENGER SEAT (Optional)2 topics
- Seat Belts And Tethers
- Adjustment
HEATER / AIR CONDITIONER CONTROLS4 topics
- Fan Speed Control Knob
- Temperature Control Knob
- Air Flow Directional Knob
- Heater/Air Conditioner Vents
INSTRUMENT PANEL27 topics
- CONTROL SYMBOLS
- Key Switch
- Engine Warm Up (Optional)
- Camera System (Optional)
- Rotating Beacon Light Switch (Optional)
- Heated Mirror Switch (Optional)
- Rest Switch
- Wheel Brake Lock Control Switch
- Hazard Warning Light Switch
- Cab/Air Conditioner Vents
- Engine Oil Pressure Gauge
- Right Turn Signal Indicator
- Tachometer
- High Beam Indicator
- Speedometer/Payload Meter Display
- Left Turn Signal Indicator
- Coolant Temperature Gauge
- Lamp Test Switch
- Light Switch
- Ladder Light Switch
- Manual Backup Switch
- Fog Light Switch (Optional)
- Payload Meter Switch
- Panel Light Dimmer
- Hydraulic Oil Temperature Gauge
- Hourmeter
- Fuel Level Gauge
OVERHEAD STATUS/WARNING INDICATOR33 topics
- STATUS / WARNING INDICATOR LIGHT SYMBOLS
- High Hydraulic Oil Temperature
- Low Steering Pressure
- Low Accumulator Precharge Pressure
- Low Brake Pressure
- Low Hydraulic Tank Level
- Automatic Lubrication System Pressure
- Circuit Breaker Tripped
- Hydraulic Oil Filter Monitor
- Low Fuel
- Parking Brake
- Service Brake
- Body Up
- Dynamic Retarding
- Stop Engine
- Cranking Motor Failure
- Manual Backup Lights
- Engine Shutdown Delay
- Retard Speed Control (RSC) Indicator
- Check Engine
- No Power
- Propulsion System Warning
- Propulsion System Temperature
- System/Component Failure
- Battery Charging System Failure
- No Propel
- Propel System at Rest
- Propel System Not Ready
- Reduced Propulsion
- Retard at Continuous Level
- Brake Test Light (If Equipped)
- Maintenance Monitor
- Brake Test Switch (If Equipped)
KOMTRAX Plus
KOMTRAX Plus OPERATION2 topics
- Basic Precautions
- Interface Module
DOWNLOADING KOMTRAX Plus DATA2 topics
- KOMTRAX Plus Downloading Procedure
- Location Of Downloaded Files
UPLOADING KOMTRAX Plus DATA
ORBCOMM
KOMATSU WIRELESS BRIDGE (Optional)8 topics
- Communication Setup
- Switching To The KWB_SETUP Network
- Setting The Computer Subnet Mask And IP Address
- Setting Up The KWB
- Adding Encryption
- Final Computer Settings
- Downloading Data
- Resetting The KWB
FUSES AND CIRCUIT BREAKERS
FUSE BLOCK #1
FUSE BLOCK #2
FUSE BLOCK #3
FUSE BLOCK #4
FUSE HOLDERS
CIRCUIT BREAKERS
HYDRAULIC SYSTEM SERVICE3 topics
- Hydraulic Tank
- Hydraulic Filters
- Hydraulic Pump Drive Shaft
WHEEL MOTOR SERVICE
COOLANT LEVEL SERVICE3 topics
- Radiator Filling Procedure
- Coolant Specifications
- Unacceptable Practices
RESERVE ENGINE OIL SERVICE12 topics
- Reserve Oil Tank Filling Procedure (Remote Fill)
- Inline Screen
- CAB AIR FILTER SERVICE
- FUEL SYSTEM SERVICE
- Fuel Tank Cleaning
- Fuel Filter Service
- INTAKE AIR CLEANER SERVICE
- FRONT WHEEL SERVICE
- Oil Sampling
- FRONT ENGINE MOUNT TRUNNION SERVICE
- QUICK FILL SERVICE CENTER
- TIE ROD INSPECTION AND TORQUE PROCEDURE
EVERY 10 HOUR (DAILY) MAINTENANCE
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 250 HOUR LUBRICATION AND MAINTENANCE
EVERY 500 HOUR LUBRICATION AND MAINTENANCE
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
EVERY 2500 HOUR MAINTENANCE
EVERY 4000 HOUR MAINTENANCE
EVERY 5000 HOUR MAINTENANCE
EVERY 10,000 HOUR MAINTENANCE
EVERY 18,000 HOUR MAINTENANCE
MAJOR COMPONENT DESCRIPTION9 topics
- Truck And Engine
- Traction Alternator
- Main Control Cabinet
- AC Induction Traction Motorized Wheels
- Suspension
- Operator's Cab
- Power Steering
- Dynamic Retarding Grid
- Brake System
SPECIFICATIONS12 topics
- Engine
- AC Electric Drive System
- Battery Electric System
- Service Capacities
- Hydraulic Systems
- Service Brakes
- Parking Brake
- Steering
- Standard Dump Body Capacities And Dimensions
- Tires
- Weight Distribution
- Overall Truck Dimensions
RADIO OPERATION10 topics
- General Radio Receiver Functions
- Turning On The Power
- One-Hour Timer
- Finding A Station
- Setting The Presets
- Adjusting The Receiver Audio Settings
- Display
- Adjusting The Receiver Menu Settings
- Front Auxiliary Mode
- Rear Auxiliary Mode
CLOCK5 topics
- Clock/Alarm Button
- Setting The Clock
- Setting The Alarm
- Turning The Alarm Off
- Activating Snooze
CD PLAYER4 topics
- Playing A Compact Disc
- Playing An MP3 DISC
- CD Mode Displays
- Button Functions
MP3 PLAYER2 topics
- Playing MP3 Files
- MP3 Mode Displays
iPod ®2 topics
- Playing An iPod ®
- iPod ® Mode Displays
WEATHERBAND (USA Only)
TROUBLESHOOTING3 topics
- Tips About the Audio System
- Understanding Radio Reception
- Care Of The Compact Discs
Inside this manual
Real pages from this operation & maintenance manual (225 pages). Open the sample pages (PDF, 662 KB)
- Controls and operation, page 141: CENTER CONSOLE
- Maintenance, page 195: EVERY 250 HOUR LUBRICATION AND
- Specifications, page 207: MAJOR COMPONENT DESCRIPTION
- Color page, page 185: GENERAL INFORMATION
- Color page, page 131: AUTOMATIC LUBRICATION SYSTEM
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 830E-1AC are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Operation & Maintenance Manual CEAM024404$69.53
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This is an operator's manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
This manual
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 225 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).