Komatsu 830E-1AC Dump Truck Shop Manual CEBM019302 – PDF DOWNLOAD

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Komatsu 830E-1AC Dump Truck Shop Manual CEBM019302 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM019302 – PDF DOWNLOAD

Language : English
Pages : 1068
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM019302 – PDF DOWNLOAD

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SPECIFICATIONS 13
GENERAL SAFETY AND OPERATING INSTRUCTIONS 15
GENERAL SAFETY 19
Safety Rules 19
Truck Safety Features 19
Clothing And Personal Items 19
Unauthorized Modification 19
Leaving The Operator’s Seat 19
Mounting And Dismounting 20
Fire Extinguishers And First Aid Kits 20
Precautions For High Temperature Fluids 20
Asbestos Dust Hazard Prevention 20
Fire Prevention For Fuel And Oil 21
ROPS Precautions 21
Preventing Injury From Work Equipment 21
Precautions For Optional Attachments 21
Precautions When Starting The Machine 21
PRECAUTIONS FOR TRUCK OPERATION 22
Safety Is Thinking Ahead 22
Safety At The Worksite 22
Fire Prevention 22
Preparing For Operation 22
Ventilation For Enclosed Areas 22
Mirrors, Windows, And Lights 23
In The Operator’s Cab – Before Starting The Engine 23
Seat Belts 23
OPERATING THE TRUCK 23
Starting The Engine 23
Truck Operation – General 23
Traveling In The Truck 24
Precautions When Traveling In Reverse 24
Traveling On Slopes 24
Ensuring Good Visibility 25
Operating On Snow 25
Avoid Damage To The Dump Body 25
Driving Near High Voltage Cables 25
When Loading The Truck 25
When Dumping 25
Working On Loose Ground 26
Parking The Machine 26
TOWING 26
WORKING NEAR BATTERIES 27
Jump Starting With Booster Cables 28
Jump Starting With Receptacles 28
PRECAUTIONS FOR MAINTENANCE 29
BEFORE PERFORMING MAINTENANCE 29
Stopping The Engine Before Service 29
Warning Tag 29
Proper Tools 29
Securing The Dump Body 30
WHILE PERFORMING MAINTENANCE 31
Personnel 31
Attachments 31
Working Under The Machine 31
Keeping The Machine Clean 31
Rules To Follow When Adding Fuel Or Oil 31
Radiator Coolant Level 31
Use Of Lighting 31
Precautions With The Battery 32
Handling High Pressure Hoses 32
Precautions With High Pressure Oil 32
Maintenance Near High Temperatures And High Pressures 32
Rotating Fan And Belts 32
Waste Materials 32
TIRES 33
Handling Tires 33
Tire Maintenance 34
Storing Tires After Removal 34
ADDITIONAL JOB SITE RULES 35
WHEN REPAIRS ARE NECESSARY 36
Use of Tie-Off Anchor During Maintenance 36
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK 37
Preliminary Procedures before Welding or Performing Maintenance 37
Engine Shutdown Procedure before Welding or Performing Maintenance 37
CAPACITOR DISCHARGE SYSTEM 39
Necessary Tools 39
Warnings And Cautions 40
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE 41
Preparation 41
CAPACITOR CHARGE LIGHTS 43
FAILURE OF DISCHARGE SYSTEM 44
Measuring Dc Voltage On Capacitors 44
MANUAL DISCHARGE OF CAPACITORS 45
SHORT ISOLATED CAPACITOR TERMINALS 47
OPERATING INSTRUCTIONS 49
PREPARING FOR OPERATION 49
Safety Is Thinking Ahead 49
WALK AROUND INSPECTION 49
ENGINE START-UP SAFETY PRACTICES 53
AFTER ENGINE HAS STARTED 54
EMERGENCY STEERING SYSTEM 55
Operation 55
Pre-Operation Testing 55
Additional Guidelines 56
MACHINE OPERATION SAFETY PRECAUTIONS 56
MACHINE OPERATION ON THE HAUL ROAD 57
STARTING ON A GRADE WITH A LOADED TRUCK 58
PASSING 58
LOADING 58
DUMPING 58
Raising The Dump Body 58
Lowering The Dump Body 59
SUDDEN LOSS OF ENGINE POWER 61
FUEL DEPLETION 61
SAFE PARKING PROCEDURES 62
NORMAL ENGINE SHUTDOWN PROCEDURE 62
DELAYED ENGINE SHUTDOWN PROCEDURE 63
DISABLED TRUCK DUMPING PROCEDURE 64
GENERAL 64
STEERING AND BRAKE SYSTEM 64
Hookup 64
HOIST SYSTEM 65
Hookup 66
Dumping Procedure 66
TOWING 67
Towing Procedure 67
RESERVE ENGINE OIL SYSTEM (Optional) 68
Operation 68
WARNINGS AND CAUTIONS 69
TORQUE TABLES AND CONVERSION CHARTS 81
STORAGE PROCEDURES 91
STORAGE AND IDLE MACHINE PREPARATION 93
SHORT TERM IDLE PERIODS 93
PREPARATION FOR STORAGE 94
REMOVAL FROM STORAGE 95
RECONDITIONING AN IDLE VEHICLE 97
ENGINE OPERATION 99
AFTER ENGINE HAS STARTED 100
ENGINE STORAGE 101
Engine Storage-(Short Term) 101
Engine Storage- (Long Term) 102
TRANSMISSION PRESERVATION AND STORAGE 107
Restoring Transmission to Service 107
ELECTRIC DRIVE TRUCKS 103
SECTION B STRUCTURES 109
STRUCTURAL COMPONENTS 111
STRUCTURAL COMPONENTS 113
Preparation 113
LADDERS 114
Removal 114
Installation 114
RIGHT DECK 114
Removal 114
Installation 116
LEFT DECK 116
Removal 116
Installation 117
CENTER DECK 117
DUMP BODY 119
DUMP BODY 121
Removal 121
Installation 122
BODY PADS 123
Removal 123
Installation 123
Adjustment 124
BODY GUIDE 125
BODY-UP RETENTION CABLE 126
BODY POSITION INDICATOR 126
HOIST LIMIT SWITCH 126
BODY UP SWITCH 126
ROCK EJECTORS 127
Inspection 127
FUEL TANK 129
FUEL TANK 130
Removal 130
Installation 130
Repair 132
Cleaning 132
FUEL GAUGE SENDER 132
Removal 132
Installation 132
FUEL TANK BREATHER VALVE 133
Disassembly 133
Assembly 133
FUEL RECEIVERS (WIGGINS QUICK FILL) 133
FUEL RECEIVERS (WIGGINS QUICK FILL) 134
SECTION C ENGINE 135
POWER MODULE 137
POWER MODULE 139
PREPARATION 139
Removal 139
Installation 144
FUEL AND COOLING SYSTEM 149
FUEL FILTERS 151
Filter replacement; 151
COOLING SYSTEM DESCRIPTION 152
RADIATOR 153
Removal 153
Installation 156
Radiator Filling Procedure 157
REPAIRING THE RADIATOR 158
Internal Inspection 158
External Cleaning 158
Disassembly 158
Cleaning and Inspection 159
Assembly 159
Pressure Testing 161
COOLANT SYSTEM TROUBLESHOOTING 161
POWER TRAIN 163
ALTERNATOR REMOVAL PROCEDURE 165
Removal (Komatsu SSDA16V160 or SDA16V160 Engine) 165
ENGINE/ALTERNATOR MATING 167
General Instructions 167
Measuring Procedure 167
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 169
ENGINE 170
Removal 170
Service 171
Installation 171
AIR CLEANERS 173
AIR CLEANERS 175
OPERATION 175
SERVICING THE AIR CLEANERS 175
Replacing The Filter Element 176
AIR CLEANER ASSEMBLY CLEANING 177
Main Filter Cleaning 177
Precleaner Section Cleaning 179
AIR INTAKE TROUBLESHOOTING 180
FAN CLUTCH 181
FAN CLUTCH 183
REMOVAL & INSTALLATION TOOLING 183
DISASSEMBLY 186
CLEANING AND INSPECTION 196
ASSEMBLY 200
TEST PROCEDURE 214
SECTION D ELECTRICAL SYSTEM (24VDC) 215
24VDC ELECTRIC SUPPLY SYSTEM 217
24VDC ELECTRIC SUPPLY SYSTEM 219
ELECTRICAL SYSTEM DESCRIPTION 219
BATTERIES 219
Maintenance and Service 219
Troubleshooting 219
BATTERY SUPPLY SYSTEM 221
24VDC Battery Charging Alternator 221
Battery Box 221
Battery Control Box 222
Battery Disconnect Switches 222
24VDC Auxiliary Battery Receptacles 222
Isolator Diode 222
Engine Start Relay 222
24VDC to 12VDC Converter 222
24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 223
Operation 223
Pressure Switch 224
Check Valve 224
Timer Solenoid 224
MAINTENANCE 224
Prelube System Operation Checks 224
Check Valve 224
Timer Solenoid 224
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 225
24 VDC ELECTRIC START SYSTEM 227
CRANKING MOTORS 227
Operation 227
Removal 227
Installation 227
CRANKING MOTOR TROUBLESHOOTING 228
Preliminary Inspection 228
No-Load Test 228
Interpreting Results of Tests 229
Disassembly 229
Cleaning and Inspection 230
Armature Servicing 232
Field Coil Checks 232
Field Coil Removal 232
SOLENOID CHECKS 233
Test 233
Assembly 234
Bearing Replacement: 234
Motor Assembly: 234
Pinion Clearance 235
MAGNETIC SWITCH 235
Removal 235
Installation 235
Coil Test 236
24VDC ELECTRICAL SYSTEM COMPONENTS 237
24 VDC ELECTRICAL SYSTEM COMPONENTS 239
TRUCK SHUTDOWN PROCEDURE 239
BRAKE WARNING BUZZER 239
AUXILIARY CONTROL CABINET COMPONENTS 239
Power Distribution Terminals 239
Engine Starter Failure Delay Timer 239
5 Minute Idle Timer 240
Pulse Voltage Modulator (PMV) 240
Control Power Relay 240
Auto Lube Timer 240
Diode Board – DB1 242
Fuse Blocks 243
Alarm Indicating Device (AID) System 243
Diode Matrix (With Sound) 244
Diode Matrix (Without Sound) 244
Hot Switch Inverter 244
Hot Switch Inverter (Not Used) 245
Temperature and Latch 245
RELAY BOARDS 246
Relay Boards RB1, RB3, RB4, RB5 246
Relay Board RB6, RB7, RB8, RB9 247
Service 247
Relay Board Functions 249
BODY-UP SWITCH 251
Operation 251
Adjustment 251
Service 251
HOIST LIMIT SWITCH 252
Operation 252
Adjustment 252
Service 252
FUSE BLOCK CHARTS 253
CIRCUIT BREAKER CHART 255
CIRCUIT BREAKERS 255
CHARGING SYSTEM 257
CHARGING SYSTEM DESCRIPTION 259
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 259
Excessive heat 259
Dirt and dust 259
Vibration 259
PREVENTIVE MAINTENANCE PROCEDURES 260
Alternator Cleanliness 260
Alternator Mounting 260
Belt Tension And Condition 260
TROUBLESHOOTING PROCEDURES 260
ALTERNATOR PERFORMANCE TEST 260
ALTERNATOR PERFORMANCE TEST – LOAD APPLIED 261
ALTERNATOR CABLE TEST 261
VOLTAGE REGULATOR ADJUSTMENT 262
ALTERNATOR 263
Removal 263
Installation 264
KOMTRAX Plus COMPONENTS 267
KOMTRAX Plus COMPONENTS 269
KOMTRAX Plus BASIC FEATURES 269
Gather Data 269
Convert and Record Data 269
Communicate Data to Off-Board Systems 270
USING THE KOMTRAX Plus SYSTEM 271
Turning the KOMTRAX Plus System ON 271
Normal KOMTRAX Plus Operation 271
Turning the KOMTRAX Plus System OFF 272
Downloading from the KOMTRAX Plus Controller 272
KOMTRAX Plus DATA ITEMS 273
Fault Codes 273
Machine History 273
KOMTRAX Plus History 273
Snapshots 274
Manual Snapshots 274
Trends 276
Histogram (Load Map) Data 276
Haul Cycle Data 277
Alarm and Snapshot Triggers 278
Satellite Features 278
KOMTRAX Plus DIAGNOSTIC FEATURES 280
Fault History 280
KOMTRAX Plus LED Digits 280
KOMTRAX Plus CONTROLLER 280
Removal 281
Installation 281
ORBCOMM CONTROLLER 282
Removal 282
Installation 282
INTERFACE MODULE 283
Removal 283
Installation 283
SENSORS 284
Temperature Sensors 284
Pressure Sensors 284
KOMTRAX Plus SOFTWARE 285
KOMTRAX Plus SOFTWARE 287
NECESSARY SOFTWARE 287
NECESSARY TOOLS 287
KOMTRAX Plus SYSTEM SET UP 288
INTERFACE MODULE 288
KOMTRAX Plus CONTROLLER 288
INTERFACE MODULE 288
FLASHBURN PROGRAM 288
Installation 288
INTERFACE MODULE APPLICATION CODE 288
Installation 288
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 289
Installation 289
Using The Program 289
KOMTRAX Plus CONTROLLER 289
KOMTRAX Plus TOOL BOX 289
Installation 289
KOMTRAX Plus SETTING TOOL 289
Installation 289
KOMTRAX Plus INITIALIZATION PROCEDURE 290
1 KOMTRAX Plus CONTROLLER SETUP PROCEDURE 290
VHMS Setting Tool software program 290
Select Operation 290
VHMS Setting Function 291
Machine Information Setting(1) 291
Machine Information Setting(2) 291
Date & Time Setting 291
GCC Setting 292
Setting Summary 292
2 KOMTRAX Plus SNAPSHOT PROCEDURE 293
3 KOMTRAX Plus DOWNLOAD PROCEDURE 294
4 LOCATION OF DOWNLOAD FILES 294
5 KOMTRAX Plus FTP UPLOAD PROCEDURE 295
6 KOMTRAX Plus INITIALIZATION FORMS 296
WHEN REPLACING A KOMTRAX Plus CONTROLLER 297
To Set: Date & Time; Satellite; Payload Meter 299
Review Setting Information 301
KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING 303
INTERFACE MODULE AND KOMTRAX Plus CHECKOUT & TROUBLESHOOTING 305
GENERAL 305
Structure and Purpose 305
INTERFACE MODULE CHECKOUT 306
Interface Module 306
Necessary Equipment: 306
Preliminary 307
Checking Inputs And Outputs From The Interface Module 307
Check Analog Inputs To The Interface Module 310
Check CAN RPC & J1939 Interfaces To The IM 311
Check Outputs From The Interface Module 311
KOMTRAX Plus CONTROLLER CHECKOUT 312
KOMTRAX Plus Controller 312
Necessary Equipment: 312
Preliminary 313
KOMTRAX Plus Controller Checkout Procedure 314
ORBCOMM CONTROLLER 316
TROUBLESHOOTING 316
Communications Networks 316
Coaxial Cable 316
FAULT CODES 317
Fault History 317
KOMTRAX Plus LED Display Fault Codes 318
Chassis Fault Codes 319
Engine Fault Codes 322
FAULT TREE ANALYSIS 328
Unable to connect to KOMTRAX Plus from laptop PC 328
Flashing Error Code N4-23 (PLM III Communications Fault) 329
Flashing Error Code N4-22 (Engine Communications Fault) 330
No Data Received By WebCARE 331
Coaxial Cable Troubleshooting 332
KOMTRAX PLUS FORMS 333
KOMTRAX PLUS FORMS 335
KOMTRAX PLUS INITIALIZATION CHECK LIST 335
KOMTRAX PLUS DATA DOWNLOAD 336
KOMTRAX PLUS INITIALIZATION CHECK LIST 337
KOMTRAX PLUS INITIALIZATION FORM 339
SECTION E ELECTRIC PROPULSION SYSTEM 341
ELECTRIC PROPULSION SYSTEM COMPONENTS 343
ELECTRICAL PROPULSION SYSTEM COMPONENTS 345
GENERAL SYSTEM DESCRIPTION 345
SYSTEM COMPONENTS 347
Propulsion System Controller (PSC) 347
Truck Control Interface (TCI) 348
Diagnostic Information Display (DID) Panel 349
DID Panel Event Codes 349
PSC SOFTWARE FUNCTIONS 368
Input Processing 368
State Machine 368
DC Link State 371
Engine Control 372
ALTERNATOR FIELD CONTROL 372
Desired Three-Phase Voltage 372
Desired DC Link Voltage 372
Self-Load 373
Propel Torque Control 373
Retard Torque Control 373
Wheel Slide Control 374
Resistor Grid Control 374
Chopper Voltage Control 374
EVENT DETECTION AND PROCESSING 374
Power-On Tests 374
Initiated Tests 375
Periodic Tests 375
EVENT RESTRICTIONS 375
EVENT LOGGING AND STORAGE 375
Event History Buffer 376
Data Packs 376
To Record and Save a Data Pack to a Disk 376
Event Reset 377
SERIAL DATA COMMUNICATIONS 377
PSC – TCI Communications Processing 377
PSC – PTU Communications Processing 377
Inverter Communications Processing 378
OUTPUT PROCESSING 378
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 378
Fast Start 378
Engine Shutdown/Engine Not Running 378
Limp Home Mode 379
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 380
ELECTRONIC ACCELERATOR AND RETARD PEDALS 388
Removal 388
Installation 388
Disassembly 388
Assembly 388
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 389
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 391
AC DRIVE SYSTEM MAINTENANCE 391
NORMAL TRUCK SHUTDOWN PROCEDURE 392
SHUTDOWN AFTER SYSTEM FAILURE 392
SYSTEM CHECKOUT 393
Battery and Control Circuit Checks – Battery Power OFF 393
Battery and Control Circuit Checks – Battery Power ON 396
Checks with Key Switch OFF 397
Checks with Key Switch ON 397
CPU Battery Checks 397
MEMORY BACKUP BATTERY REPLACEMENT 398
TCI PROGRAMMING 398
PSC PROGRAMMING 399
INVERTER PROGRAMMING 399
CPU RESET 399
PSC CHECKOUT 400
PSC Digital Input Checks 400
PSC Digital Output Checks 404
TCI CHECKOUT 405
Modular Mining Communication Port Check 405
TCI Digital Input Checks 405
TCI Digital Output Tests 411
CALIBRATIONS 413
Speedometer 413
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 413
ERASING EVENTS 413
PSC 413
TCI 414
GATE DRIVER POWER CONVERTER TEST 414
LOAD TESTING 415
Preparation 415
Alternator Speed Sensor Checks 415
Battery Boost Check 415
Brake Circuit Switch Checks 416
Hoist & Steering Circuit Switch Checks 416
Link Energized Checks 416
Loadbox Test 418
TROUBLESHOOTING 422
PVM Optimum Load Curve Handshaking Troubleshooting 422
Phase Module and Chopper Module Troubleshooting 422
PHASE MODULE REPLACEMENT 423
Phase Module Removal 423
Phase Module Installation 423
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 425
TIRES AND RIMS 427
TIRES AND RIMS 429
FRONT TIRES AND RIMS 429
Removal 429
Installation 431
REAR TIRES AND RIMS 431
Removal 431
Installation 432
RIM AND TIRE 434
Tire Removal 434
Rim And Tire Preparation 434
Lubricants 435
Tire Installation 435
FRONT WHEEL HUB AND SPINDLES 437
FRONT WHEEL HUB AND SPINDLE 439
WHEEL HUB AND SPINDLE ASSEMBLY 439
Removal 439
Spindle Removal Procedure (Optional) (off of the truck) 442
Installation 444
Disassembly 447
Cleaning and Inspection 447
Assembly 448
Wheel Bearing Adjustment (Tire Removed) 450
Wheel Bearing Adjustment (Tire mounted) 451
OIL SAMPLING PROCEDURE 452
Oil Sampling Guidelines 453
Procedure 453
OIL DRAIN AND REFILL PROCEDURE 453
STEERING CYLINDERS AND TIE ROD 454
Spherical Bearing Wear Limits 454
Installation 455
Bearing Replacement (Steering cylinder and tie rod) 455
TIE ROD 457
Removal 457
Installation 457
Assembly 458
TOE-IN ADJUSTMENT 459
REAR AXLE HOUSING ATTACHMENT 461
REAR AXLE HOUSING ATTACHMENT 463
PIVOT PIN 463
Removal 463
Installation 463
PIVOT EYE BEARING 464
Disassembly 464
Assembly 464
PIVOT EYE REPAIR 465
Removal 465
Installation 465
Disassembly 465
Assembly 465
ANTI-SWAY BAR 466
Removal 466
Installation 466
Disassembly 466
Cleaning and Inspection 466
Assembly 466
REAR AXLE HOUSING 467
REAR AXLE HOUSING 469
REAR AXLE HOUSING 469
Removal 469
Installation 469
WHEEL MOTOR 470
Removal 470
Cleaning and Inspection 470
Installation 471
WHEEL MOTOR GEAR OIL 474
Change/Filter The Gear case Oil 474
Oil 474
Remove And Clean Magnetic Plugs 474
Flushing The Gearbox 474
Check Gear Case Oil Level 474
SECTION H SUSPENSIONS 475
FRONT SUSPENSION 477
FRONT SUSPENSION 479
Removal 479
Installation 480
TURN-OF-THE-NUT Tightening Procedure 482
Upper Mounting Joint – 60° Advance 482
Lower Mounting Joint – 90° Advance 484
Inspection 484
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 485
Bearing Structure Removal 485
Bearing Structure Installation 485
MAJOR SUSPENSION REBUILD 486
Disassembly 486
Assembly 487
PRESSURE TEST 489
REAR SUSPENSIONS 491
REAR SUSPENSIONS 493
Removal 493
Installation 496
ROD UP SUSPENSION 498
Disassembly 498
Cleaning and Inspection 498
Assembly 498
ROD DOWN SUSPENSION 500
Disassembly 500
Cleaning and Inspection 500
Assembly 502
PRESSURE TEST 504
Suspension pressure test 504
OILING AND CHARGING PROCEDURE 505
OILING AND CHARGING PROCEDURE 507
GENERAL 507
EQUIPMENT LIST 507
HYDRAIR® CHARGING KIT 508
Installation of Charging Kit 508
Removal of Charging Kit 508
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 509
FRONT SUSPENSION 509
Front Suspension Oiling 509
Front Suspension Nitrogen Charging 511
REAR SUSPENSION – ROD UP 513
Rear Suspension Oiling (Rod Up Only) 513
Rear Suspension Nitrogen Charging (Rod Up Only) 514
REAR SUSPENSION – ROD DOWN 516
Rear Suspension Oiling (Rod Down Only) 516
Rear Suspension Nitrogen Charging (Rod Down Only) 518
OIL AND NITROGEN SPECIFICATIONS CHART 520
SECTION J BRAKE CIRCUIT 521
BRAKE CIRCUIT 523
BRAKE CIRCUIT 525
OPERATION 525
SERVICE BRAKE CIRCUIT OPERATION 525
SECONDARY BRAKING AND AUTOMATIC APPLY 527
PARKING BRAKE CIRCUIT 527
Normal Operation (key switch on, engine running) 527
BRAKE LOCK CIRCUIT 528
WARNING CIRCUIT 528
BRAKE CIRCUIT COMPONENT SERVICE 531
BRAKE CIRCUIT COMPONENT SERVICE 533
BRAKE VALVE 533
Rebuild Criteria 533
Removal 533
Installation 535
DISASSEMBLY 537
Cleaning and Inspection 539
ASSEMBLY 539
Actuator Base Threaded Inserts 539
Boot and Cap 539
Valve Body Seal Installation 540
Regulator Sleeve O-Ring Installation 540
Actuator Plunger O-ring Installation 541
Assembly of Valve 541
VALVE BENCH TEST AND ADJUSTMENT 543
Test Set Up Procedure 544
Brake Valve Output Pressure Adjustment 544
Final Test and Adjustment 545
Installation Of Brake Pedal Actuator Assembly to Brake Valve 546
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 548
Installation of Retard Pedal To Brake Pedal 548
HYDRAULIC BRAKE ACCUMULATORS 549
Brake Accumulator Bleed Down Procedure 549
Removal 549
Installation 549
Disassembly 549
Cleaning and Inspection 551
Assembly 551
Charging Procedure 553
BRAKE MANIFOLD 554
Removal 554
Removal 554
Installation 555
Disassembly 555
Cleaning and Inspection 556
Assembly 556
BRAKE CIRCUIT CHECK-OUT PROCEDURE 557
BRAKE CIRCUIT CHECK-OUT PROCEDURE 559
EQUIPMENT REQUIRED 560
INITIAL SYSTEM SET-UP 562
PARKING BRAKE 562
BRAKE SYSTEM CHECK-OUT 563
BRAKE LOCK 563
FAILURE MODES CHECK-OUT 564
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 565
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 568
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 569
FRONT BRAKES 571
WHEEL SPEED FRONT DISC BRAKES 573
BRAKE CALIPER 573
Caliper Removal 573
Installation 574
Disassembly 575
Assembly 575
Cleaning and Inspection 576
BRAKE LINING 577
Replacement 577
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 579
GENERAL 579
Safety Precautions 579
Front Brake Conditioning 579
BRAKE BLEEDING PROCEDURES 580
ARMATURE SPEED REAR DISC BRAKES 581
ARMATURE SPEED REAR DISC BRAKES 583
REAR BRAKES 583
CALIPER AND DISC 583
Removal 583
Installation 585
PARK BRAKE ADJUSTMENT PROCEDURE 587
BRAKE BLEEDING PROCEDURE 588
Service Brake 588
Park Brake 588
CALIPER 589
Disassembly 589
PISTON SUBASSEMBLY 592
Disassembly 592
PREPARATION FOR ASSEMBLY 593
Clean Parts 593
For Rough Metal Parts 594
Dry and Inspect Parts 594
Corrosion Protection 594
INSPECTION 594
Caliper Parts 594
Shoes, Linings and End Plates 595
Inspect linings 595
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 595
Piston Assembly Adjuster Grip Force 596
Adjuster Force 598
Piston Return Spring 600
ASSEMBLY 601
Adjuster and Pin Assembly 601
Piston Subassembly 602
Brake Caliper 603
PERIODIC INSPECTIONS 609
Shoes, Linings and End Plates 609
Inspect the following areas for fluid leaks 609
Dust Boots 609
Brake Disc 609
BRAKE LINING 610
Replacement 610
BRAKE DISC 610
Inspection 610
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 611
GENERAL 611
SAFETY PRECAUTIONS 611
Rear Brake Conditioning 612
SECTION L HYDRAULIC SYSTEM 615
HYDRAULIC SYSTEM 617
HYDRAULIC SYSTEM 619
HYDRAULIC SYSTEM OPERATION 619
COMPONENT DESCRIPTION 620
Hoist Pump 620
Steering/Brake Pump 620
Tank 620
High Pressure Hydraulic Filters 620
Bleeddown Manifold 620
Steering System Accumulators 620
DISABLED TRUCK CONNECTORS 622
GENERAL 622
STEERING AND BRAKE SYSTEM 622
Hookup 622
HOIST SYSTEM 623
Hookup 623
Dumping Procedure 623
HYDRAULIC SYSTEM COMPONENT REPAIR 625
HYDRAULIC SYSTEM COMPONENT REPAIR 627
HOIST PUMP 627
Removal 627
Installation 628
Disassembly 630
Inspection Of Parts 633
Assembly 634
HYDRAULIC TANK 640
Filling Instructions 640
Removal 640
Installation 641
HYDRAULIC TANK STRAINERS 642
Removal 642
Inspect and Clean 642
Installation 643
HYDRAULIC TANK BREATHERS 643
HOIST CIRCUIT FILTERS 644
FILTER ELEMENT REPLACEMENT 645
Removal 645
Installation 645
INDICATOR SWITCH 645
STEERING CIRCUIT 647
STEERING CIRCUIT 649
STEERING CIRCUIT OPERATION 649
COMPONENT DESCRIPTION 650
STEERING CONTROL UNIT 650
FLOW AMPLIFIER 650
No Steer 652
Steering Left 654
Steering Right 656
No Steer, External Shock Load 658
BLEED DOWN MANIFOLD 660
ACCUMULATORS 661
Low Precharge Warning Switch 661
HIGH PRESSURE FILTER 661
STEERING/BRAKE PUMP 661
Operation 662
PRINCIPLE OF OPERATION 664
Full Pump Volume: 664
Half Pump Volume: 664
Neutral Position: 665
STEERING CIRCUIT COMPONENT REPAIR 667
STEERING CIRCUIT COMPONENT REPAIR 669
BLEED DOWN MANIFOLD 669
Removal 669
Installation 669
ACCUMULATOR 670
Removal 670
Installation 671
Disassembly 671
Cleaning and Inspection 672
Assembly 672
LEAK TESTING 674
STEERING ACCUMULATOR CHARGING PROCEDURE 675
Temperature During Precharge 678
ACCUMULATOR STORAGE PROCEDURES 678
Instructions For Storing Bladder Accumulators 678
Installation 679
Bladder Storage Procedures 679
FLOW AMPLIFIER 680
Removal 680
Installation 680
Disassembly 682
Reassembly 683
STEERING CONTROL UNIT 684
Removal 684
Spline Inspection 684
Installation 685
Disassembly 685
Cleaning and Inspection 686
Assembly 687
STEERING CYLINDER 691
Disassembly 691
Inspection and Cleaning 691
Assembly 691
STEERING CIRCUIT FILTER 692
Filter Element Replacement 692
Removal 693
Installation 693
Indicator Switch 693
STEERING AND BRAKE PUMP 694
Removal 694
Installation 695
Disassembly 696
Control Piston Group 696
Valve Plate Group 697
Rotating Group 697
Swashblock Group 698
Driveshaft Group 698
INSPECTION 698
Control Piston Group 698
Valve Plate Group 698
Rotating Group 698
Swashblock Group 702
Driveshaft Group 702
Compensator Block and Unloader Module 702
Stroke Adjuster Assembly 702
ASSEMBLY 702
Swashblock Group 702
Control Piston Group 704
Valve Plate Group 705
HOIST CIRCUIT 707
HOIST CIRCUIT 709
HOIST CIRCUIT OPERATION 709
COMPONENT DESCRIPTION 710
Hydraulic Tank 710
Hoist Pump 710
High Pressure Filters 710
Hoist Valve 711
Hoist Pilot Valve 712
Hoist-up Limit Solenoid 712
Pilot Operated Check Valve 712
Counterbalance Valve Manifold 713
HOIST SYSTEM OPERATION MODES 714
Float Position Of Pilot Valve And Body On Frame (Figure 7-6) 714
Power Up Operation (Figure 7-7) 716
Hold Operation (Figure 7-8) 718
Power Down Operation (Figure 7-9) 720
Float Operation (Figure 7-10) 722
HOIST CIRCUIT COMPONENT REPAIR 725
HOIST CIRCUIT COMPONENT REPAIR 727
HOIST VALVE 727
Removal 727
Installation 727
O-Ring Replacement 728
INLET SECTION 729
Disassembly 729
Cleaning and Inspection 730
Assembly 730
SPOOL SECTION 730
Disassembly 730
Cleaning and Inspection 733
Assembly 733
HOIST PILOT VALVE 734
Removal 734
Installation 734
Disassembly 735
Cleaning and Inspection 736
Assembly 737
BODY UP LIMIT SOLENOID 738
PILOT OPERATED CHECK VALVE 738
HOIST CYLINDERS 738
Removal 738
Installation 739
Disassembly 740
Cleaning and Inspection 742
ASSEMBLY OF QUILL AND CYLINDER 743
Quill Installation 743
Installation of Check Balls and Plugs in Quill 744
Assembly of Cylinder 745
Assembly of Cylinder 745
Pressure Testing 746
OVERCENTER MANIFOLD 747
HYDRAULIC CHECKOUT PROCEDURE 749
HYDRAULIC CHECKOUT PROCEDURE 751
STEERING AND BRAKE PUMP 751
Pressure Check And Adjustment Procedure 751
BLEEDDOWN MANIFOLD 753
SHOCK & SUCTION VALVES 753
Shock & Suction Valve Settings 753
LEAKAGE TESTS 755
Steering Control Unit & Flow Amplifier 755
Bleeddown Manifold 755
ACCUMULATOR BLEED DOWN PROCEDURE 757
LOW STEERING PRESSURE SWITCH 757
CHECKING HOIST SYSTEM PRESSURES 764
Hoist System Relief Pressure Adjustment 764
Power Down Relief Pressure Adjustment 765
HOIST COUNTERBALANCE VALVE 766
Preparation: 766
Counterbalance Valve Pressure Check Only: 766
Counterbalance Valve Adjustment 767
HYDRAULIC SYSTEM FLUSHING PROCEDURE 770
Hydraulic System Flushing Procedure 770
OIL CLEANLINESS CHECK 775
SECTION M SPECIAL TOOLS 777
HEATER OPTIONS 779
GENERAL INFORMATION 781
TROUBLESHOOTING 781
HEATER ELEMENT 781
Removal 781
Installation 782
GENERAL 783
Maintenance 783
HEATING ELEMENT 783
Removal 783
Installation 784
THERMOSTAT 784
Removal 784
Installation 784
GENERAL INFORMATION 785
TROUBLESHOOTING 785
HEATER ELEMENT 785
Removal 785
Installation 786
SPECIAL TOOLS 787
NITROGEN CHARGING VALVE 787
ROLL-OUT ASSEMBLY 787
EYE BOLT 787
OFFSET WRENCH 788
TORQUE ADAPTER 788
HANDLE 788
SEAL INSTALLER 788
SLEEVE ALIGNMENT TOOLS 789
QUICK DISCONNECT COUPLING 789
HARNESS 789
SEAL INSTALLATION RING 789
BELT TENSION TESTER 790
BELT ALIGNMENT TOOL 790
SOCKETS AND ADAPTERS 790
DUST CAPS 790
HYDRAULIC SYSTEM FLUSHING TOOLS 791
PAYLOAD DATA MANAGER 791
HYDRAULIC SYSTEM VACUUM PUMP 791
MISCELLANEOUS SERVICE TOOLS 792
BRAKE PISTON TOOL 793
HIGH VOLTAGE TOOLS 796
2000 VDC METER 796
GROUNDING STICKS 796
BODY PAD SPACER TOOL 797
RADIATOR SHUTTERS 799
RADIATOR SHUTTERS 801
OPERATION 801
Hydraulic Circuit 801
Electrical Circuit: 802
MAINTENANCE AND REPAIR 802
TROUBLESHOOTING 803
Hydraulic Troubleshooting 806
Electrical Troubleshooting 808
PAYLOAD METER III ™ 809
OPERATION SECTION 813
Introduction 813
Data Summary 813
Data Gathering 813
COMPONENT DESCRIPTION 814
System Diagram 814
Suspension Pressure Sensors 814
Inclinometer 814
Operator Display 814
Operator Switch 815
Speed Input 815
Body-Up Switch 815
Brake Lock Switch 815
Payload Meter 815
Communications Ports 815
Key Switch Input 816
Payload Meter Power 816
Load Lights 816
Wiring and Termination 817
TCI Outputs 817
OPERATOR’S DISPLAY AND SWITCH 818
Reading the Speedometer 818
Reading the Load Display 818
Using the Operator ID 818
Using the Load and Ton Counter 818
Total Ton Counter 818
Total Load Counter 819
Clearing the Counters 819
Viewing Live Sensor Data 819
Other Display Messages 819
PAYLOAD OPERATION & CALCULATION 820
Description of Haul Cycle States 820
Haul Cycle Description 820
Load Calculation 821
Carry Back 821
Measurement Accuracy 821
SOURCES FOR PAYLOAD ERROR 821
Payload Error 821
Loading Conditions 822
Pressure Sensors 822
Swingloads 822
Speed and Distance 822
HAUL CYCLE DATA 822
Haul Cycle Warning Flags 824
Frame Torque Data 825
Sprung Weight Data 825
Maximum Speed Data 825
Alarm Records 825
Fault Code Data 826
PC SOFTWARE OVERVIEW 827
System Configuration 827
Installing the PLMIII Software 827
DOWNLOADING DATA 828
PLM III SYSTEM CONFIGURATION 829
Starting Communications 829
Displayed Payload Units 829
Time Units 829
Connection Menu 829
Connecting to the Payload Meter 830
Configure the Payload Meter 830
Setting the Date and Time 830
Setting the Truck Type 831
Setting the Gauge Display Units 831
Setting the Frame Serial Number 831
Setting the Truck Number 831
Setting the Komatsu Distributor 831
Setting the Komatsu Customer 831
Clean Truck Tare 832
Inclinometer Calibration 832
DATA ANALYSIS 833
Creating a Query 833
Sorting on Truck Unit Number 833
Sorting on Truck Type 833
Sorting on Date Range 834
Sorting on Time Range 834
Payload Detail Screen 835
Creating Reports 835
Summary – one page report 836
Detailed – multi-page report 836
Creating Graphs 837
Exporting Data 837
CSV Export 837
Compressed 838
Importing Data 839
Deleting Haul Cycle Records 839
Viewing Alarms 840
Deleting Alarm Records 840
TROUBLESHOOTING SECTION 841
TROUBLESHOOTING 841
Viewing Active Alarms 841
Real-Time Data Display 841
Testing the Payload Lights 841
Creating Log Files of Inputs 842
Daily Inspections 842
Periodic Maintenance 842
Abnormal Displays at Power-Up 843
No Payload Display When Key Switch is Turned ON 844
No Display on Speedometer 845
No Display on Operator Display 845
No Communications With PC 846
Load Lights Don’t Light During Loading 847
Load Lights Remain ON 848
Load Lights Remain ON During Dumping 848
Display Doesn’t Clear When The Load Is Dumped 848
Calibration Problems 849
Alarm 1 – Left Front Pressure High 850
Alarm 2 – Left Front Pressure Low 850
Troubleshoot Wiring to Left Front Suspension 850
Alarm 3 – Right Front Pressure High 851
Alarm 4 – Right Front Pressure Low 851
Troubleshoot Wiring to Right Front Suspension 851
Alarm 5 -Left Rear Pressure High 852
Alarm 6 – Left Rear Pressure Low 852
Troubleshoot Wiring to Left Rear Suspension 852
Alarm 7 – Right Rear Pressure High 853
Alarm 8 – Right Rear Pressure Low 853
Troubleshoot Wiring to Right Rear Suspension 853
Alarm 9 – Inclinometer High 854
Alarm 10 – Inclinometer Low 854
Troubleshoot Inclinometer Wiring 854
Alarm 13 – Body Up Input Failure 855
Alarm 16 – Memory Write Failure 856
Alarm 17 – Memory Read Failure 856
Alarm 18 857
Alarm 19 857
Alarm 22 857
Operator Switch Doesn’t Work 858
Alarm 26 – User Switch Fault – SELECT 858
Alarm 27 – User Switch Fault – SET 858
Connector Map 859
Connectors 860
PLMIII CHECK OUT PROCEDURE 861
General Description 861
Tools Required 861
Checkout Procedure 861
PLMIII CHECKOUT PROCEDURE CONFIRMATION 865
Flashburn Programming 865
Confirmation Checklist 867
RESERVE ENGINE OIL SYSTEM 869
RESERVE ENGINE OIL SYSTEM 871
Operation 872
LED Monitor Light 872
Tank Fill Control (Optional) 873
Filling Procedure (Remote Fill Feature) 873
SERVICE 874
Every 10 Hours, or once each shift: 874
Every 500 Hours 874
Changing Oil 874
TROUBLESHOOTING 875
Circuit Fuse 875
SYSTEM ELECTRICAL SCHEMATICS 876
SECTION N OPERATOR CAB 877
TRUCK CAB AND COMPONENTS 879
TRUCK CAB AND COMPONENTS 881
TRUCK CAB 881
Description 881
Removal 882
Installation 883
CAB DOOR 884
Removal 884
Installation 884
Door Adjustment 884
Door Jamb Bolt Adjustment 885
Door Handle Plunger Adjustment 886
Replace Door Glass 887
Replace Door Window Regulator 891
Replacing the Door Handle or Latch Assembly 892
Replacing the Door and Door Hinge Seal 892
Removing the Door Opening Seal 893
Installation 893
GLASS REPLACEMENT 894
Adhesive-bonded Windows 894
Replacement Procedure 894
WINDSHIELD & REAR GLASS 896
Removal 896
Installation 896
CAB COMPONENTS 899
CAB COMPONENTS 901
WINDSHIELD WIPERS 901
WIPER MOTOR 901
Removal 901
Installation 901
WIPER ARM 901
Removal 901
Installation 902
WIPER LINKAGE 902
Removal 902
Installation 902
WINDSHIELD WASHER 903
Operation 903
Service 903
OPERATOR SEAT 904
Seat Belts 904
Adjustment 904
Inspection 905
Removal 905
Installation 905
PASSENGER SEAT 906
Inspection 906
Removal 906
Installation 906
OPERATOR COMFORT 907
OPERATOR COMFORT 909
HEATER / AIR CONDITIONER 909
Operation 909
Fan Control Knob 909
Temperature Control Knob 909
Directional Control Knob 909
Heater Vents 909
COMPONENTS 910
Circuit Breakers 910
Relays 910
Heater Core 910
Fan Motor And Speed Control 911
Actuators 911
Cab Air Filter 911
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 914
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 914
PRINCIPLES OF REFRIGERATION 914
Air Conditioning 914
Refrigeration – The Act Of Cooling 915
The Refrigeration Cycle 915
AIR CONDITIONER SYSTEM COMPONENTS 916
Compressor (Refrigerant Pump) 916
Service Valves 916
Condenser 916
Receiver-Drier 916
Expansion Block Valve 917
Accumulator 917
Evaporator 917
ELECTRICAL CIRCUIT 918
Thermostat 918
Compressor Clutch 918
Trinary™ Switch 919
SYSTEM SERVICING 920
SERVICE TOOLS AND EQUIPMENT 921
Recovery/Recycle Station 921
Leak Detector 921
Service Valves 922
Vacuum Pump 922
Manifold Gauge Set 923
Installing Manifold Gauge Set 924
Purging Air From Service Hoses 924
SYSTEM PERFORMANCE TEST 925
SYSTEM OIL 926
Handling and Reusing PAG Oil 926
Oil Quantity 926
Checking System Oil 926
REFRIGERANT 927
Recycled Refrigerant 927
Reclaimed Refrigerant 927
Refrigerant Quantity 927
R-134a Refrigerant Containers 928
SYSTEM LEAK TESTING 928
Electronic Leak Detector 929
Tracer Dyes 929
Soap and Water 929
RECOVERING AND RECYCLING THE REFRIGERANT 929
Performing the Recovery Cycle 929
Performing the Recycling Procedure 930
Evacuating and Charging the A/C System 930
SYSTEM REPAIR 930
System Flushing 931
A/C DRIVE BELT CHECKOUT PROCEDURE 932
Pulley Alignment 932
Belt Tension Check 932
COMPONENT REPLACEMENT 934
Hoses and Fittings 934
Lines 934
Expansion Valve 934
Receiver-Drier 934
Thermostat 934
Compressor 935
Accumulator 935
Clutch 935
Servicing the Compressor Clutch 936
Pulley Removal 938
Clutch Coil Check 939
Pulley Installation 939
Clutch Assembly Installation 939
EVACUATING THE SYSTEM 941
CHARGING THE A/C SYSTEM 943
TROUBLESHOOTING 944
Preliminary Checks 944
Diagnosis Of Gauge Readings And System Performance 944
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 945
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 951
OPERATOR CAB CONTROLS 953
OPERATOR CAB AND CONTROLS 955
STEERING WHEEL AND CONTROLS 956
Horn Button 956
Tilt / Telescope Lever 956
Multi-Function Turn Signal Switch 956
STEERING COLUMN 957
Removal 957
Steering Column Inspection 957
Installation 957
STEERING WHEEL 958
Removal 958
Installation 958
PEDALS 960
Service Brake Pedal 960
Dynamic Retarding 960
Dynamic Retard Pedal 960
Throttle/Accelerator Pedal 960
GRADE/SPEED RETARD CHART 961
OVERHEAD PANEL AND DISPLAYS 962
CENTER CONSOLE 963
Directional Control Lever 963
Override/Fault Reset Switch 964
Engine Stop Switch 964
LH Window Control Switch 964
RH Window Control Switch 964
Hoist Control Lever 964
Raising The Dump Body 964
Lowering The Dump Body 964
Retard Speed Control (RSC) Adjust Dial 965
Retard Speed Control (RSC) Switch 965
Data Store Button 966
KOMTRAX Plus Snapshot In Progress Light 966
Link Energized Light 966
Service Engine Light 966
DIAGNOSTIC PORTS 966
KOMTRAX Plus Diagnostic Port 966
Interface Module (IM) Diagnostic Port 966
Payload Meter Diagnostic Port 966
Truck Control Interface (TCI) Diagnostic Port 966
Propulsion System Controller (PSC) Diagnostic Port 966
Engine Diagnostic Port (CENSE) 966
Engine Diagnostic Port (QUANTUM) 966
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 967
Fan Control Knob 967
Temperature Control Knob 967
Directional Control Knob 967
Heater Vents 967
INSTRUMENT PANEL 968
Key Switch 970
Starting 970
Engine Stop Switch with Five Minute Idle Timer Delay 970
Rotating Beacon Light Switch (Optional) 971
Heated Mirror Switch (Optional) 971
Rest Switch 971
Wheel Brake Lock Control 971
Hazard Warning Lights 971
Cab/Air Conditioner Vents 971
Engine Oil Pressure Gauge 972
Right Turn Signal Indicator 972
Tachometer 972
High Beam Indicator 972
Speedometer/Payload Meter Display 972
Left Turn Signal Indicator 972
Water Temperature Gauge 972
Lamp Test Switch 972
Light Switch 972
Ladder Light Switch 973
Manual Backup Switch 973
Fog Lights (Optional) 973
Payload Meter Switch 973
Panel Light Dimmer 973
Hydraulic Oil Temperature Gauge 974
Hourmeter 974
Fuel Level Gauge 974
OVERHEAD STATUS / WARNING INDICATORS 975
Status / Warning Indicator Light Symbols 976
KOMTRAX Plus MONITORING SYSTEM 982
Operation 982
Interface Module 983
Basic Precautions 983
SECTION P LUBRICATION AND SERVICE 985
LUBRICATION AND SERVICE 987
LUBRICATION AND SERVICE 989
830E SERVICE CAPACITIES 989
HYDRAULIC TANK SERVICE 989
Adding Oil 989
COOLING SYSTEM SERVICE 990
Radiator Filling Procedure 990
Coolant Specifications 990
Unacceptable Practices 990
WHEEL MOTOR SERVICE 990
RESERVE ENGINE OIL SYSTEM (Optional) 991
Reserve Oil Tank Filling Procedure (Remote fill) 991
Inline Screen 991
QUICK FILL SERVICE CENTER 992
LUBRICATION CHART 993
10 HOUR (DAILY) INSPECTION 994
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 997
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 998
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 999
500 HOUR LUBRICATION AND MAINTENANCE CHECKS1003
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS1005
2500 HOUR MAINTENANCE CHECKS1006
5000 HOUR MAINTENANCE CHECKS1006
AUTOMATIC LUBRICATION SYSTEM 1007
AUTOMATIC LUBRICATION SYSTEM1009
GENERAL DESCRIPTION1009
SYSTEM COMPONENTS1011
Filter1011
Hydraulic Motor and Pump1011
Grease Reservoir1011
Pressure Reducing Valve1011
Flow Control Valve1011
Solenoid Valve1011
Vent Valve1011
Lubrication Cycle Timer1011
Over Pressure Cut Off Switch1011
Grease Pressure Failure Switch1011
Injectors1011
Relief Valve1011
SYSTEM OPERATION1012
GENERAL INSTRUCTIONS1013
Required Lubricant1013
System Priming1013
Filter Assembly1013
LUBRICANT PUMP1014
Pump Housing Oil Level1014
Pump Pressure Control1014
INJECTORS (SL-1 Series “H”)1014
Injector Specifications1014
Injector Adjustment1014
INJECTOR OPERATION1016
PREVENTIVE MAINTENANCE PROCEDURES1017
Daily Lubrication System Inspection1017
250 Hour Inspection1017
1,000 Hour Inspection1017
SYSTEM CHECKOUT1018
Lubrication Controller Check1018
Lubrication Controller Operation1018
Lubrication Controller Components1018
Lubrication Controller Adjustment1018
SYSTEM TROUBLESHOOTING CHART1020
SECTION Q ALPHABETICAL INDEX 1023
SECTION R SYSTEM SCHEMATICS 1027
HH360 HYDRAULIC SCHEMATIC 1029
HH366 HYDRAULIC SCHEMATIC 1030
HE484 ELECTRICAL SCHEMATIC HEATER/AC CONTROLS 1032
XS3800 ELECTRICAL SCHEMATIC 1033

DESCRIPTION:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM019302 – PDF DOWNLOAD

G.B 13/12/24