🏷️ Basic Information Identification Make: Komatsu Model: 830E-AC Type: Dump Truck Body Style: Mining/Heavy Duty Dump Truck 👋 Introduction Market Position Segment: Heavy-duty mining and construction equipment Application: Designed for high-capacity material transport in surface mining and heavy construction environments. Competitive Analysis Competitors: Caterpillar (e.g., 777 series), Liebherr (e.g., T 284), Hitachi. Key Features Payload Capacity: High, typically in the range of 220-250 tons (nominal). Engine Power: Powerful, industrial-grade diesel engine. Durability: Built for extreme operating conditions and long service life. Articulation: Typically rigid frame with independent front suspension and robust rear axle. 📋 Manual Details Coverage Manual Type: Workshop Service Manual / Repair Manual Language: English File Format: PDF Delivery: Instant Download Printability: Full Printable Zoom Capability: Yes Software Requirements: Adobe PDF Reader, WinRAR Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Engine System: Comprehensive overhaul, maintenance, diagnostics, troubleshooting, component specifications, torque values, timing procedures, fuel system, lubrication system, cooling system. Transmission System: Repair, maintenance, diagnostics, troubleshooting, component identification, fluid specifications, control system operation. Electrical System: Detailed wiring diagrams, component testing, troubleshooting guides, circuit descriptions, sensor data, ECU functions. Hydraulic System: Troubleshooting, maintenance, component repair (pumps, cylinders, valves), system schematics, pressure specifications. Braking System: Maintenance, repair, troubleshooting, component specifications, hydraulic and pneumatic system details. Steering System: Repair, maintenance, troubleshooting, hydraulic components, steering linkage. Cooling System: Maintenance, troubleshooting, component replacement (radiator, fans, thermostats), fluid capacities. Exhaust System: Component identification, installation, maintenance. Chassis And Frame: Inspection, repair procedures for frame damage, suspension components. Dump Body And Hoist: Maintenance, inspection, troubleshooting of hydraulic hoist system, body components. Operator Station: Component identification, controls, instrumentation, maintenance of cabin systems. Procedures Routine Maintenance: Periodic maintenance charts, lubrication points, fluid checks, filter replacement, pre-operation inspections. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, common issue identification and resolution. Repair Instructions: Step-by-step repair procedures for all major systems, including disassembly, cleaning, inspection, reassembly, and adjustment. Overhaul Procedures: Detailed instructions for complete engine, transmission, and hydraulic component overhauls. Diagnostics: Procedures for identifying faults, reading error codes, and testing system components using specialized tools. Wiring Diagrams: Comprehensive and detailed electrical wiring schematics for all vehicle systems. Component Replacement: Detailed guidance on replacing all major components, including torque specifications and critical clearances. Technical Depth Depth: Professional technician level, suitable for advanced DIY mechanics. Target Audience: Professional technicians, service mechanics, experienced DIY enthusiasts. 📊 Manual Specifications File Attributes File Type: PDF Print Quality: High Resolution, suitable for professional printing Searchable Text: Likely (typical for PDF service manuals) Production Manual Source: Manufacturer (Komatsu) Manual Authenticity: Original Workshop Manual Manual Completeness: Full Service Repair Manual ⚙️ Engine Specifications Primary Engine Manufacturer: Cummins (likely, common in Komatsu mining trucks) Model: Cummins K50 (common for this class, specific model may vary by exact build) Configuration: V18 Cylinder, Turbocharged, Intercooled Diesel Displacement: Approximately 50.3 Liters (3070 cubic inches) Performance Horsepower: Typically around 1500-1600 HP (net) Torque: High, in the range of 4000-4500 lb-ft. Fuel System Injection Type: High-pressure common rail or advanced mechanical injection. Fuel Type: Diesel Fuel Engine Management Control System: Electronic Engine Control Unit (ECU) 🔧 Transmission Standard Type: Heavy-duty automatic/planetary gear transmission, likely with electronic control. Manufacturer: Allison Transmission (common for this class) Features Gear Selection: Electronically controlled automatic shifting, with manual override capability. Retarder: Integrated engine or transmission retarder for downhill speed control. Fluid Specifications Fluid Type: Manufacturer-specified heavy-duty automatic transmission fluid (e.g., Dexron-III, or specific Komatsu/Allison fluid). 📐 Dimensions Exterior Length: Approximately 10.5 - 11 meters (34.5 - 36 ft) Width: Approximately 5 - 5.5 meters (16.5 - 18 ft) Height: Approximately 4.5 - 5 meters (15 - 16.5 ft) Cargo Body Capacity Cubic Meters: Approximately 60-70 m³ (heaped) Payload Capacity Tons: Nominal 220 US Tons (approx. 200 Metric Tons) Weights Operating Weight Kg: Typically 160,000 - 180,000 kg (350,000 - 400,000 lbs) Gross Vehicle Weight Rating Kg: Exceeds 370,000 kg (815,000 lbs) 🛡️ Safety Features Ratings Rollover Protection: ROPS (Roll-Over Protective Structure) certified cabin Active Features Braking System: Multiple redundant braking systems (service, parking, secondary), often wet-disk type. Steering System: Hydrostatic power steering with emergency steering capability. Visibility: Large operator cabin with excellent visibility, advanced lighting systems. Passive Features Operator Cabin: Pressurized, sound-suppressed cabin with safety glass and ergonomic controls. Fire Suppression: Optional automatic fire suppression systems. 💡 Technology Features Infotainment Operator Interface: Modern operator interface with digital displays for engine status, diagnostics, and truck parameters. Driver Assistance Telematics: Often equipped with Komatsu telematics (e.g., Komtrax) for remote monitoring and diagnostics. Payload Monitoring: On-board payload weighing system for accurate load management. Connectivity Diagnostic Ports: Standardized diagnostic ports for connection to service laptops and diagnostic tools. 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 250-500 operating hours (refer to manual for exact specification). Fuel Filter Replacement: Varies by operating conditions, generally based on hours or indicated by fuel system diagnostics. Hydraulic Oil Filter Replacement: Scheduled replacement based on operating hours...