Komatsu 830E-1AC Dump Truck Parts Manual CEBM037701 – PDF DOWNLOAD

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Komatsu 830E-1AC Dump Truck Parts Manual CEBM037701 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E-1AC Dump Truck Parts Manual CEBM037701 – PDF DOWNLOAD

Language : English
Pages : 1449
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC Dump Truck Parts Manual CEBM037701 – PDF DOWNLOAD

• SERIAL NUMBERS   830E-1AC A41140 and up

COVER 1
SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
Main Control Cabinet 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SECTION A2 SPECIFICATIONS 13
SECTION A3 SAFETY 15
GENERAL 15
PRECAUTIONS BEFORE OPERATION 18
OPERATING THE TRUCK 20
WORKING NEAR BATTERIES 23
BEFORE PERFORMING MAINTENANCE 25
WHILE PERFORMING MAINTENANCE 30
TIRES 32
WHEN REPAIRS ARE NECESSARY 35
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 36
CAPACITOR DISCHARGE SYSTEM 38
SECTION A3 OPERATING INSTRUCTIONS 46
PREPARING FOR OPERATION 46
WALK AROUND INSPECTION 46
RETRACTABLE LADDER SYSTEM (Optional) 50
IN-CAB CONTROL PANEL 51
USING THE IN-CAB CONTROL PANEL 53
USING THE GROUND LEVEL CONTROL BOX 55
EMERGENCY OPERATION 56
ENGINE START-UP 57
AFTER ENGINE HAS STARTED 58
PRE-SHIFT BRAKE CHECK 59
OPERATION 59
PERFORMING THE BRAKE TESTS 61
EMERGENCY STEERING SYSTEM 63
MACHINE OPERATION SAFETY PRECAUTIONS 64
OPERATING ON THE HAUL ROAD 65
STARTING ON A GRADE WITH A LOADED TRUCK 66
PASSING 66
LOADING 66
DUMPING 67
Sudden loss of engine power or loss of drive system function 69
FUEL DEPLETION 70
SAFE PARKING PROCEDURES 70
NORMAL ENGINE SHUTDOWN PROCEDURE 71
DISABLED TRUCK DUMPING PROCEDURE 72
HOIST SYSTEM 73
TOWING 74
SECTION A4 WARNINGS AND CAUTIONS 77
GRADE/SPEED CHART 77
KEY SWITCH 77
ROPS/FOPS 77
BATTERIES 78
ISOLATION BOX 79
PROPEL LOCKOUT LEVER 79
CAPACITORS 80
CRUSHING HAZARD 80
CYLINDER PRESSURE 81
FILLING THE HYDRAULIC TANK 81
HYDRAULIC OIL PRESSURE 82
HOT OIL SPRAY 82
WHEEL MOTOR OIL LEVEL 82
HOT EXHAUST 82
RADIATOR 83
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 83
EMERGENCY LADDER 83
ACCUMULATOR DRAIN VALVES 83
EMERGENCY DUMP PROCEDURE 83
EMERGENCY TOWING PROCEDURE 84
WELDING 84
EMERGENCY SHUTDOWN 84
INFORMATION DISPLAY 84
WIRELESS SIGNALS 85
HIGH VOLTAGE 85
LIFTING INSTRUCTIONS 86
TOW SOCKET 87
PRODUCT IDENTIFICATION PLATE 87
LUBRICATION CHART 88
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 89
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 90
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 90
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 91
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 92
SECTION A7 STORAGE PROCEDURES 99
STORAGE AND IDLE MACHINE PREPARATION 101
SHORT TERM IDLE PERIODS 101
PREPARATION FOR STORAGE 102
REMOVAL FROM STORAGE 103
RECONDITIONING AN IDLE VEHICLE 105
ENGINE OPERATION 107
AFTER ENGINE HAS STARTED 108
ENGINE STORAGE 109
TRANSMISSION PRESERVATION AND STORAGE 115
ELECTRIC DRIVE TRUCKS 111
SECTION B STRUCTURES 117
SECTION B2 STRUCTURAL COMPONENTS 119
STRUCTURAL COMPONENTS 121
LADDERS 122
RIGHT DECK 123
LEFT DECK 124
CENTER DECK 125
SECTION B3 DUMP BODY 127
DUMP BODY 129
BODY PADS 131
BODY GUIDE 133
BODY-UP RETENTION SLING 134
BODY POSITION INDICATOR 134
HOIST LIMIT SWITCH 134
BODY UP SWITCH 134
ROCK EJECTORS 135
SECTION B4 FUEL TANK 137
FUEL TANK 138
FUEL TANK VENT ASSEMBLY 140
FUEL GAUGE SENDER (TOP) 141
QUICK FILL FUEL RECEIVERS 143
SECTION C ENGINE 145
SECTION C2 POWER MODULE INDEX 147
POWER MODULE 149
PREPARATION 149
EXHAUST TUBE INSTALLATION 158
EXHAUST BLANKET INSTALLATION 158
SECTION C3 COOLING SYSTEM INDEX 159
COOLING SYSTEM DESCRIPTION 161
RADIATOR 162
REPAIRING THE RADIATOR 167
COOLANT SYSTEM TROUBLESHOOTING 170
SECTION C4 POWER TRAIN INDEX 171
POWER TRAIN 173
ALTERNATOR REMOVAL PROCEDURE 173
ALTERNATOR INSTALLATION 175
ENGINE 179
SECTION C5 AIR CLEANERS INDEX 181
AIR CLEANERS 183
OPERATION 183
SERVICING THE AIR CLEANERS 183
AIR CLEANER ASSEMBLY CLEANING 185
AIR INTAKE TROUBLESHOOTING 188
SECTION C7 FAN CLUTCH INDEX 189
FAN CLUTCH 191
REMOVAL & INSTALLATION TOOLING 191
DISASSEMBLY 194
CLEANING AND INSPECTION 204
ASSEMBLY 208
TEST PROCEDURE 223
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 225
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM 227
24VDC ELECTRIC SUPPLY SYSTEM 229
ELECTRICAL SYSTEM DESCRIPTION 229
BATTERIES 229
BATTERY SUPPLY SYSTEM 231
ISOLATION BOX ASSEMBLY 232
AUXILIARY CONTROL CABINET 234
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 235
MAINTENANCE 235
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 236
24VDC ELECTRIC START SYSTEM 238
CRANKING MOTORS 238
CRANKING MOTOR TROUBLESHOOTING 239
SOLENOID CHECKS 244
MAGNETIC SWITCH 246
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 249
24 VDC ELECTRICAL SYSTEM COMPONENTS 251
TRUCK SHUTDOWN PROCEDURE 251
BRAKE WARNING BUZZER 251
AUXILIARY CONTROL CABINET COMPONENTS 251
MAGNETIC SWITCHES 262
Body position switches (With proximity switch and magnet) 262
BODY-UP SWITCH 263
HOIST LIMIT SWITCH 264
SECTION D11 KOMTRAX PLUS SYSTEM 267
KOMTRAX PLUS COMPONENTS 269
KOMTRAX PLUS BASIC FEATURES 269
USING THE KOMTRAX PLUS SYSTEM 271
KOMTRAX PLUS DATA ITEMS 273
KOMTRAX PLUS DIAGNOSTIC FEATURES 280
KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS SOFTWARE 283
KOMTRAX PLUS SYSTEM SET UP 284
KOMTRAX PLUS CONTROLLER 284
KOMTRAX PLUS TOOL BOX 284
KOMTRAX PLUS SETTING TOOL 284
KOMTRAX PLUS INITIALIZATION PROCEDURE 285
KOMTRAX PLUS CONTROLLER SETUP PROCEDURE 285
KOMTRAX PLUS SNAPSHOT PROCEDURE 288
KOMTRAX PLUS DOWNLOAD PROCEDURE 289
LOCATION OF DOWNLOAD FILES 289
KOMTRAX PLUS FTP UPLOAD PROCEDURE 290
KOMTRAX Plus INITIALIZATION FORMS 291
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 292
KOMTRAX PLUS CONTROLLER CHECKOUT 297
ORBCOMM CONTROLLER 301
SECTION D12 INTERFACE MODULE 2 (IM2) 303
REQUIRED TOOLS 305
PROGRAMMING THE IM2 305
INTERFACE MODULE CHECKOUT PROCEDURES 307
IM CHECKOUT SHEET 312
SECTION D13 KOMTRAX PLUS & INTERFACE MODULE TROUBLESHOOTING & ERROR CODES 315
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 317
TROUBLESHOOTING 317
GENERAL 317
TROUBLESHOOTING 318
FAULT CODES 319
FAULT TREE ANALYSIS 332
SECTION E ELECTRIC PROPULSION SYSTEM 337
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 339
ELECTRICAL PROPULSION SYSTEM COMPONENTS 341
GENERAL SYSTEM DESCRIPTION 341
SYSTEM COMPONENTS 343
DSC SOFTWARE FUNCTIONS 372
ALTERNATOR FIELD CONTROL 376
EVENT DETECTION AND PROCESSING 379
EVENT RESTRICTIONS 380
EVENT LOGGING AND STORAGE 380
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 382
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 383
ELECTRONIC ACCELERATOR AND RETARD PEDALS 390
PHASE MODULE REPLACEMENT 391
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 393
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 395
AC DRIVE SYSTEM MAINTENANCE 395
NORMAL TRUCK SHUTDOWN PROCEDURE 396
TEST EQUIPMENT 397
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 397
REST MODE ACTIVATION 397
INITIAL CHECKOUT PROCEDURES 398
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 415
ENGINE RUNNING TESTS 417
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 427
VIEWING EVENT AND STATISTICAL DATA 452
LOGIC SCREENS 455
DATALOGGER FUNCTION 457
UPLOADING DATA 461
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A139) 463
Fault Code A001: Left front suspension pressure sensor signal is high 465
Fault Code A002: Left front suspension pressure sensor signal is low 466
Fault Code A003: Right front suspension pressure sensor signal is high 467
Fault Code A004: Right front suspension pressure sensor signal is low 468
Fault Code A005: Left rear suspension pressure sensor signal is high 469
Fault Code A006: Left rear suspension pressure sensor signal is low 470
Fault Code A007: Right rear suspension pressure sensor signal is high 471
Fault Code A008: Right rear suspension pressure sensor signal is low 472
Fault Code A009: Incline sensor signal is high 473
Fault Code A010: Incline sensor signal is low 474
Fault Code A011: Payload meter speed sensor signal has failed 475
Fault Code A013: Body up switch has failed 476
Fault Code A014: Payload meter checksum computation has failed 477
Fault Code A016: Payload meter write to flash memory has failed 478
Fault Code A017: Payload meter flash memory read has failed 479
Fault Code A018: Right rear flat suspension cylinder warning 480
Fault Code A019: Left rear flat suspension cylinder warning 482
Fault Code A022: Carryback load is excessive 484
Fault Code A101: High pressure detected across a hydraulic pump filter 486
Fault Code A103: Hydraulic oil tank temperature sensor is reading low 488
Fault Code A104: Hydraulic oil tank temperature sensor is reading high 489
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 490
Fault Code A107: GE has generated a propel system caution 492
Fault Code A108: GE has generated a propel system temperature caution 493
Fault Code A109: GE has generated a propel system reduced level signal 494
Fault Code A111: Low steering pressure warning 496
Fault Code A115: Low steering precharge pressure is detected 498
Fault Code A117: Low brake accumulator pressure warning 500
Fault Code A118: Brake pressure is low while brake lock is activated 502
Fault Code A123: GE has generated a reduced retarding caution 504
Fault Code A124: GE has generated a no propel / no retard or system not running input 506
Fault Code A125: GE has generated a no propel warning 508
Fault Code A126: Oil level in the hydraulic tank is low 509
Fault Code A127: IM furnished +5 volt output for sensors is low 510
Fault Code A128: IM furnished +5 volt output for sensors is high 512
Fault Code A139: Low fuel level warning 514
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A246) 517
Fault Code A152: Starter failure 519
Fault Code A153: Battery voltage is low with truck in operation 520
Fault Code A154: Battery charging voltage is excessive 522
Fault Code A155: Battery charging voltage is low 523
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 524
Fault Code A184: J1939 data link is not connected 525
Fault Code A190: Auto lube control has detected an incomplete lube cycle 526
Fault Code A193: Hydraulic tank oil temperature is high 528
Fault Code A198: Hoist pressure 1 sensor is high 529
Fault Code A199: Hoist pressure 2 sensor is high 530
Fault Code A200: Steering pressure sensor is high 531
Fault Code A201: Brake pressure sensor is high 532
Fault Code A202: Hoist pressure 1 sensor is low 533
Fault Code A203: Hoist pressure 2 sensor is low 534
Fault Code A204: Steering pressure sensor is low 535
Fault Code A205: Brake pressure sensor is low 536
Fault Code A206: Ambient temperature sensor is high 537
Fault Code A207: Ambient temperature sensor is low 538
Fault Code A212: Bad truck speed signal 539
Fault Code A213: Parking brake should have applied but is detected as not having applied 540
Fault Code A214: Parking brake should have released but is detected as not having released 544
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 548
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 550
Fault Code A230: Parking brake has been requested while truck still moving 552
Fault Code A231: Dump body is up while traveling or intending to travel 554
Fault Code A233: Drive system CAN/RPC Control Link not connected 558
Fault Code A235: Steering accumulator is in the process of being bled down 560
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 562
Fault Code A237: The CAN/RPC connection to the display is open 564
Fault Code A240: The keyswitch input to the interface module is open 565
Fault Code A242: The fuel gauge within the display panel is defective 566
Fault Code A243: The engine coolant temp gauge within the display panel is defective 567
Fault Code A244: The drive system temp gauge within the display panel is defective 568
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 569
Fault Code A246: Payload meter reports truck overload 570
SECTION E5 TROUBLESHOOTING FAULT CODES (A247-A292) 571
Fault Code A247: Low steering pressure warning 573
Fault Code A248: The status indicator module within the display panel is defective 575
Fault Code A249: The red warning lamp within the display panel is shorted 576
Fault Code A250: Battery voltage is low with the truck parked 578
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 580
Fault Code A252: Start enable output circuit is either open or shorted to ground 582
Fault Code A253: Steering bleed circuit is not open while running 584
Fault Code A255: IM has detected a fault on IM output 1N 586
Fault Code A256: The red warning lamp within the display panel (driven by IM) is open 587
Fault Code A257: Payload CAN/RPC is not connected 588
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 589
Fault Code A260: Parking brake failure 590
Fault Code A261: Low brake accumulator pressure warning 592
Fault Code A262: Steering bleed valve circuit open during shutdown 594
Fault Code A264: Parking brake relay circuit is defective 596
Fault Code A265: Service brake failure 598
Fault Code A266: Selector lever was not in park while attempting to crank engine 600
Fault Code A267: Parking brake was not set while attempting to crank engine 602
Fault Code A268: Secondary engine shutdown while cranking 604
Fault Code A270: Brake lock switch power supply is not on when required 606
Fault Code A271: Shifter not in gear 608
Fault Code A272: Brake lock switch power supply is not off when required 610
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 612
Fault Code A274: A brake setting fault has been detected 614
Fault Code A275: A starter has been detected as engaged without a cranking attempt 616
Fault Code A276: The drive system data link is not connected 618
Fault Code A277: Parking brake applied while loading 620
Fault Code A278: Service brake applied while loading 622
Fault Code A279: Low steering pressure switch is defective 623
Fault Code A280: Steering accumulator Bleed Down switch is defective 624
Fault Code A281: Brake lock degradation switch is defective 626
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 628
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 630
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 632
Fault Code A285: The parking brake was not set when the key switch was turned off 634
Fault Code A286: A fault was detected in the shutdown delay relay circuit 636
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 638
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) 641
Fault Code A303: Shifter is defective 643
Fault Code A304: Auto lube grease level is low 644
Fault Code A305: Auto lube circuit is defective 645
Fault Code A307: Both GE inverters are disabled 646
Fault Code A309: No brakes applied when expected 648
Fault Code A310: Low fuel level warning 650
Fault Code A311: Brake lock switch is on when it should not be 652
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 654
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 655
Fault Code A315: DC-DC converter 12 volt circuit is low 656
Fault Code A316: Starter engagement has been attempted with engine running 658
Fault Code A318: Unexpected power loss to interface module 660
Fault Code A320: Propel system caution wire input not same as serial input 661
Fault Code A321: Propel system temperature caution wire input not same as serial input 662
Fault Code A322: Propel system at reduced level wire input not same as serial input 663
Fault Code A323: Propel system at reduced retard level wire input not same as serial input 664
Fault Code A324: GE link voltage wire input not same as serial input 665
Fault Code A325: No Propel/Retard wire input not same as serial input 666
Fault Code A326: No Propel wire input not same as serial input 667
Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input 668
Fault Code A328: Drive system not powered up 669
Fault Code A329: Body down wire input not same as serial input 670
Fault Code A330: Dynamic retard switch input not same as serial input 671
Fault Code A332: Seat belt not buckled 672
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 674
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 675
Fault Code A335: Manual/Auto Apply Pressure Fault 676
Fault Code A350: Overload on output 1B 677
Fault Code A351: Overload on output 1E 678
Fault Code A352: Overload on output 1H 679
Fault Code A353: Overload on output 1J 680
Fault Code A354: Overload on output 1K 681
Fault Code A355: Overload on output 1L 682
Fault Code A356: Overload on output 1M 683
Fault Code A357: Overload on output 1N 684
Fault Code A358: Overload on output 1P 685
Fault Code A359: Overload on output 1R 686
Fault Code A360: Overload on output 1S 687
Fault Code A361: Overload on output 1T 688
Fault Code A362: Overload on output 1U 689
Fault Code A363: Overload on output 1X 690
Fault Code A364: Overload on output 1Y 691
Fault Code A365: Overload on output 1Z 692
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 693
SECTION G2 TIRES AND RIMS 695
TIRES AND RIMS 697
GENERAL PRECAUTIONS 697
WHEEL STUD MAINTENANCE 698
REAR OUTER WHEEL STUD INSTALLATION 699
FRONT TIRES AND RIMS 700
REAR TIRES AND RIMS 702
RIM AND TIRE 705
RIM COMPONENTS 708
RIM AND TIRE SERVICE 709
SECTION G3 FRONT WHEEL HUB AND SPINDLES 725
FRONT WHEEL HUB AND SPINDLE 727
WHEEL HUB AND SPINDLE ASSEMBLY 727
OIL SAMPLING PROCEDURE 740
OIL DRAIN AND REFILL PROCEDURE 741
STEERING CYLINDERS 742
TIE ROD 745
TOE-IN ADJUSTMENT 747
TIE ROD INSPECTION AND TORQUE PROCEDURE 748
SECTION G4 REAR AXLE HOUSING ATTACHMENT 751
REAR AXLE HOUSING ATTACHMENT 753
PIVOT PIN 753
PIVOT EYE BEARING 754
PIVOT EYE REPAIR 756
ANTI-SWAY BAR 757
SECTION G5 REAR AXLE HOUSING 759
REAR AXLE HOUSING 761
REAR AXLE HOUSING 761
WHEEL MOTOR 762
WHEEL MOTOR GEAR OIL 766
SECTION H SUSPENSIONS 767
SECTION H2 FRONT SUSPENSION 769
FRONT SUSPENSION 771
TURN-OF-THE-NUT Tightening Procedure 774
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 777
MAJOR SUSPENSION REBUILD 778
PRESSURE TEST 781
SECTION H3 REAR SUSPENSIONS 783
REAR SUSPENSIONS 784
ROD DOWN SUSPENSION 788
PRESSURE TEST 792
SECTION H4 SUSPENSION OILING AND CHARGING PROCEDURES 793
SUSPENSION OILING AND CHARGING PROCEDURES 795
GENERAL 797
HYDRAIR® CHARGING KIT 798
OIL AND NITROGEN SPECIFICATIONS CHARTS 809
SECTION J BRAKE SYSTEMS 811
SECTION J2 BRAKE CIRCUIT 813
BRAKE CIRCUIT 815
OPERATION 815
SERVICE BRAKE CIRCUIT OPERATION 815
SECONDARY BRAKING AND AUTOMATIC APPLY 817
PARKING BRAKE CIRCUIT 817
BRAKE LOCK CIRCUIT 818
WARNING CIRCUIT 818
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 821
BRAKE CIRCUIT COMPONENT SERVICE 823
BRAKE VALVE 823
BRAKE VALVE/PEDAL ASSEMBLY 826
VALVE BENCH TEST AND ADJUSTMENT 829
INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL BRAKE ASSEMBLY (Dual Function) 835
HYDRAULIC BRAKE ACCUMULATORS 836
BRAKE MANIFOLD 841
SECTION J4 BRAKE SYSTEM CHECKOUT PROCEDURE 845
BRAKE SYSTEM CHECKOUT PROCEDURE 847
EQUIPMENT REQUIRED 849
PRE-CHECKOUT ITEMS 850
CHECKOUT PROCEDURE SET-UP 851
INITIAL SYSTEM SET-UP 852
BRAKE LOCK SYSTEM CHECK 854
PARKING BRAKE SYSTEM 855
LOW BRAKE PRESSURE AND AUTO APPLY 856
BRAKE REAPPLICATIONS (STORED ENERGY CHECK) 857
PARK BRAKE CONTROL LOGIC CHECK 857
BRAKE LOCK CONTROL LOGIC CHECK 858
BRAKE SYSTEM TROUBLESHOOTING 861
BRAKE SYSTEM CHECKOUT DATA SHEET 863
SECTION J5 FRONT BRAKES 869
WHEEL SPEED FRONT DISC BRAKES 871
BRAKE CALIPER 871
BRAKE LINING 875
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 877
GENERAL 877
BRAKE BLEEDING PROCEDURES 878
SECTION J6 ARMATURE SPEED REAR DISC BRAKES 879
ARMATURE SPEED REAR DISC BRAKES 881
REAR BRAKES 881
CALIPER AND DISC 881
PARK BRAKE ADJUSTMENT PROCEDURE 887
BRAKE BLEEDING PROCEDURE 888
CALIPER 889
PISTON SUBASSEMBLY 893
PREPARATION FOR ASSEMBLY 894
INSPECTION 895
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 896
ASSEMBLY 902
PERIODIC INSPECTIONS 910
BRAKE LINING 911
BRAKE DISC 911
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 912
GENERAL 912
SAFETY PRECAUTIONS 912
SECTION L HYDRAULIC SYSTEMS 915
SECTION L2 HYDRAULIC SYSTEM OPERATION 917
HYDRAULIC SYSTEM 919
HYDRAULIC SYSTEM OPERATION 919
COMPONENT DESCRIPTION 920
DISABLED TRUCK CONNECTORS 922
GENERAL 922
STEERING AND BRAKE SYSTEM 922
HOIST SYSTEM 923
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 925
HYDRAULIC SYSTEM COMPONENT REPAIR 927
HOIST PUMP 927
HYDRAULIC TANK 940
HYDRAULIC TANK STRAINERS 942
HYDRAULIC TANK BREATHERS 943
HOIST CIRCUIT FILTERS 944
FILTER ELEMENT REPLACEMENT 945
INDICATOR SWITCH 945
SECTION L4 STEERING CIRCUIT 947
STEERING CIRCUIT 949
STEERING CIRCUIT OPERATION 949
COMPONENT DESCRIPTION 950
STEERING CONTROL UNIT 950
FLOW AMPLIFIER 950
BLEED DOWN MANIFOLD 960
ACCUMULATORS 963
HIGH PRESSURE FILTER 963
STEERING/BRAKE PUMP 963
PRINCIPLE OF OPERATION 966
SECTION L5 STEERING CIRCUIT COMPONENT REPAIR 969
STEERING CIRCUIT COMPONENT REPAIR 971
BLEED DOWN MANIFOLD 971
PISTON ACCUMULATOR 972
STEERING ACCUMULATOR CHARGING PROCEDURE 977
PISTON ACCUMULATOR STORAGE 980
FLOW AMPLIFIER 980
STEERING CONTROL UNIT 982
STEERING CYLINDER 988
STEERING CIRCUIT FILTER 990
STEERING AND BRAKE PUMP 992
TROUBLESHOOTING 1004
STEERING CIRCUIT 1004
STEERING PUMP 1006
System Leakage Check 1009
Setting Pump Pressure Controls 1019
SECTION L7 HOIST CIRCUIT 1021
HOIST CIRCUIT 1023
HOIST CIRCUIT OPERATION 1023
COMPONENT DESCRIPTION 1024
HOIST SYSTEM OPERATION MODES 1028
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 1039
HOIST CIRCUIT COMPONENT REPAIR 1041
HOIST VALVE 1041
INLET SECTION 1043
SPOOL SECTION 1045
HOIST PILOT VALVE 1048
BODY UP LIMIT SOLENOID 1052
PILOT OPERATED CHECK VALVE 1052
HOIST CYLINDERS 1052
ASSEMBLY OF QUILL AND CYLINDER 1057
OVERCENTER MANIFOLD 1061
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE 1063
HYDRAULIC SYSTEM CHECKOUT PROCEDURE 1065
PRE-CHECKOUT ITEMS 1065
HYDRAULIC BRAKE AND STEERING ACCUMULATOR BLEED DOWN PROCEDURE 1066
ACCUMULATOR PRECHARGE PROCEDURE 1067
PRESSURE GAUGE INSTALLATION 1068
INITIAL START UP AND FLUSHING PROCEDURE 1070
COMPONENT CHECKOUT AND ADJUSTMENT PROCEDURE 1073
SYSTEM DIAGNOSTICS AND VERIFICATION 1074
HOIST COUNTERBALANCE CARTRIDGE VALVE ADJUSTMENT PROCEDURE 1075
OIL CLEANLINESS CHECK 1077
FILTER REPLACEMENT PROCEDURE 1078
TROUBLESHOOTING 1079
HYDRAULIC CHECKOUT PROCEDURE DATA SHEET 1081
SECTION M OPTIONS AND SPECIAL TOOLS 1085
SECTION M7 HEATER OPTIONS 1087
ENGINE COOLANT HEATER 1091
GENERAL 1091
HEATING ELEMENT 1091
THERMOSTAT 1092
GENERAL INFORMATION 1093
TROUBLESHOOTING 1093
HEATER ELEMENT 1094
GENERAL INFORMATION 1089
TROUBLESHOOTING 1089
HEATER ELEMENT 1090
SECTION M8 SPECIAL TOOLS 1095
NITROGEN CHARGING VALVE 1095
ROLL-OUT ASSEMBLY 1095
EYE BOLT 1095
OFFSET WRENCH 1096
TORQUE ADAPTER 1096
HANDLE 1096
SEAL INSTALLER 1096
SLEEVE ALIGNMENT TOOLS 1097
QUICK DISCONNECT COUPLING 1097
SEAL INSTALLATION RING 1097
SOCKETS AND ADAPTERS 1098
DUST CAPS 1098
HYDRAULIC SYSTEM FLUSHING TOOLS 1099
BATTERY JUMP STARTING 1099
SMART RIM TOOLS 1099
KOMVISION® CALIBRATION TOOLS 1100
MISCELLANEOUS SERVICE TOOLS 1101
PAYLOAD DATA MANAGER 1101
HYDRAULIC SYSTEM VACUUM PUMP 1101
BRAKE PISTON TOOL 1102
SUSPENSION OILING AND CHARGING 1103
SPINDLE REMOVAL TOOL 1103
HIGH VOLTAGE TOOLS 1104
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1104
BODY PAD SPACER TOOL 1105
RADIATOR SHUTTERS 1109
OPERATION 1109
MAINTENANCE AND REPAIR 1110
TROUBLESHOOTING 1111
SECTION M19 RADIATOR SHUTTERS 1107
SECTION M20 PAYLOAD METER IV ™ 1117
PAYLOAD METER IV ™ 1119
INTRODUCTION 1119
COMPONENT DESCRIPTION 1120
PAYLOAD METER IV SOFTWARE AND TOOLS 1121
PAYLOAD METER IV SYSTEM CONFIGURATION 1121
PAYLOAD METER IV SOFTWARE INSTALLATION 1123
INCLINOMETER CALIBRATION AND CLEAN TRUCK TARE 1123
PLM IV SYSTEM CHECKOUT DATA SHEET 1129
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1130
SECTION M31 RESERVE ENGINE OIL SYSTEM 1133
RESERVE ENGINE OIL SYSTEM 1135
GENERAL 1135
OPERATION 1136
SERVICE 1139
TROUBLESHOOTING 1140
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1141
SECTION M32 RETRACTABLE LADDER SYSTEM 1143
RETRACTABLE LADDER SYSTEM 1147
GENERAL SAFETY 1147
LADDER SYSTEM DESCRIPTION 1147
LADDER SYSTEM OPERATION 1148
IN-CAB CONTROL PANEL 1150
IN-CAB CONTROL PANEL FEATURES 1151
IN-CAB CONTROL PANEL FUNCTIONS 1152
USING THE IN-CAB CONTROL PANEL 1153
USING THE GROUND LEVEL CONTROL BOX 1155
POWER PACK OPERATION 1156
MAINTENANCE 1159
PREVENTIVE MAINTENANCE PROCEDURES 1161
SERVICING 1162
RLS DIAGNOSTICS 1163
SECURITY ACCESS LEVELS 1167
USER ID – PASSWORD 1169
USER ID – NEW USER SETUP 1170
SYSTEM FAULTS 1170
DATA MANAGEMENT 1180
MENU DIAGRAMS 1187
SECTION M33 KomVision® 1195
KomVision® 1197
KomVision® SYSTEM PRECAUTIONS 1197
COMPONENT LOCATIONS 1198
MONITOR PANEL 1202
MONITOR DISPLAY 1204
RADAR SYSTEM 1208
START-UP INSPECTION 1212
CLEANING 1213
KomVision® SYSTEM SETUP AND CALIBRATION 1214
MAINTENANCE SCREEN EXPLANATION 1231
RADAR DETAIL 1235
TESTING AND ADJUSTING 1238
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1239
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1244
CALIBRATING CAMERAS 1245
RADAR SETTING 1254
SECTION N OPERATOR CAB 1265
SECTION N2 CAB, DOORS AND WINDOWS 1267
CAB AND COMPONENTS 1270
CAB 1270
CAB DOOR 1273
GLASS REPLACEMENT 1283
WINDSHIELD & REAR GLASS 1284
WINDSHIELD WIPERS 1286
WIPER MOTOR 1286
WIPER ARM 1286
WIPER LINKAGE 1287
WINDSHIELD WASHER 1288
SECTION N3 OPERATOR AND PASSENGER SEATS 1289
OPERATOR AND PASSENGER SEATS 1290
OPERATOR SEAT (STANDARD SEAT) 1290
PASSENGER SEAT (STANDARD SEAT) 1297
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1298
SEAT BELT REPLACEMENT (STANDARD SEATS) 1300
OPERATOR SEAT (OPTIONAL SEAT) 1302
PASSENGER SEAT (OPTIONAL SEAT) 1303
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1304
SECTION N4 HEATER/AIR CONDITIONER 1309
CLIMATE CONTROL 1311
HEATER / AIR CONDITIONER 1311
COMPONENTS 1312
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1316
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1316
PRINCIPLES OF REFRIGERATION 1316
AIR CONDITIONER SYSTEM COMPONENTS 1318
ELECTRICAL CIRCUIT 1320
SYSTEM SERVICING 1322
SERVICE TOOLS AND EQUIPMENT 1323
SYSTEM PERFORMANCE TEST 1327
SYSTEM OIL 1328
REFRIGERANT 1330
SYSTEM LEAK TESTING 1331
RECOVERING AND RECYCLING THE REFRIGERANT 1332
SYSTEM REPAIR 1333
COMPONENT REPLACEMENT 1334
EVACUATING THE SYSTEM 1336
CHARGING THE A/C SYSTEM 1338
TROUBLESHOOTING 1339
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1340
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1346
SECTION N5 OPERATOR CAB CONTROLS 1347
OPERATOR CAB AND CONTROLS 1350
STEERING WHEEL AND CONTROLS 1351
STEERING COLUMN 1352
STEERING WHEEL 1353
PEDALS 1355
GRADE/SPEED RETARD CHART 1356
CENTER CONSOLE 1358
DIAGNOSTIC PORTS 1361
HEATER / AIR CONDITIONER 1362
INSTRUMENT PANEL 1363
STATUS INDICATOR LIGHT PANEL 1370
DIGITAL DISPLAY OPERATION 1373
KOMTRAX PLUS 1376
KOMATSU WIRELESS BRIDGE (Bullet 2) 1379
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1385
SECTION P2 PERIODIC MAINTENANCE 1387
PERIODIC MAINTENANCE 1389
830E SERVICE CAPACITIES 1389
HYDRAULIC TANK SERVICE 1389
COOLANT LEVEL CHECK 1390
WHEEL MOTOR SERVICE 1390
RESERVE ENGINE OIL SYSTEM (Optional) 1391
QUICK FILL SERVICE CENTER 1391
LUBRICATION CHART 1392
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 1393
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1394
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1395
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 1396
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 1398
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 1403
EVERY 2500 HOUR MAINTENANCE 1405
EVERY 4000 HOUR MAINTENANCE 1405
EVERY 5000 HOUR MAINTENANCE 1406
EVERY 18000 HOUR MAINTENANCE 1406
SECTION P3 AUTOMATIC LUBRICATION SYSTEM 1409
AUTOMATIC LUBRICATION SYSTEM 1411
GENERAL DESCRIPTION 1411
SYSTEM COMPONENTS 1413
SYSTEM OPERATION 1414
LUBRICANT PUMP 1416
INJECTORS (SL-1 Series “H”) 1417
PREVENTIVE MAINTENANCE PROCEDURES 1419
SYSTEM CHECKOUT 1420
AUTOLUBE TROUBLESHOOTING CHART 1422
SECTION R SYSTEM SCHEMATICS 1425

DESCRIPTION:

Komatsu 830E-1AC Dump Truck Parts Manual CEBM037701 – PDF DOWNLOAD

• SERIAL NUMBERS   830E-1AC A41140 and up

G.B 18/12/24