Komatsu 830E-1AC Dump Truck Shop Manual CEBM019602 PDF

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Komatsu 830E-1AC Dump Truck Shop Manual CEBM019602 – PDF DOWNLOAD

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Komatsu 830E-1AC Dump Truck Shop Manual CEBM019602 – PDF DOWNLOAD 

Language : English
Pages : 1140
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM019602 – PDF DOWNLOAD 

SERIAL NUMBERS A30109 – A30140

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION 9
MAJOR COMPONENT DESCRIPTION 11
SPECIFICATIONS 13
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
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 AN 830E-1AC 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
DISABLED TRUCK CONNECTORS 63
GENERAL 63
STEERING AND BRAKE SYSTEM 63
Hookup 63
HOIST SYSTEM 64
Hookup 65
Dumping Procedure 65
TOWING 66
Special Wiring Harness 66
Towing Procedure 66
RESERVE ENGINE OIL SYSTEM (Optional) 69
Operation 69
WARNINGS AND CAUTIONS 71
TORQUE TABLES AND CONVERSION CHARTS 83
STORAGE PROCEDURES 93
STORAGE AND IDLE MACHINE PREPARATION 95
SHORT TERM IDLE PERIODS 95
PREPARATION FOR STORAGE 96
REMOVAL FROM STORAGE 97
RECONDITIONING AN IDLE VEHICLE 99
ENGINE OPERATION 101
AFTER ENGINE HAS STARTED 102
ENGINE STORAGE 103
Engine Storage-(Short Term) 103
Engine Storage- (Long Term) 104
TRANSMISSION PRESERVATION AND STORAGE 109
Restoring Transmission to Service 109
ELECTRIC DRIVE TRUCKS 105
SECTION B STRUCTURES 111
STRUCTURAL COMPONENTS 113
STRUCTURAL COMPONENTS 115
Preparation 115
LADDERS 116
Removal 116
Installation 116
RIGHT DECK 116
Removal 116
Installation 118
LEFT DECK 118
Removal 118
Installation 119
CENTER DECK 119
DUMP BODY 121
DUMP BODY 123
Removal 123
Installation 124
BODY PADS 125
Removal 125
Installation 125
Adjustment 126
BODY GUIDE 127
BODY-UP RETENTION CABLE 128
BODY POSITION INDICATOR 128
HOIST LIMIT SWITCH 128
BODY UP SWITCH 128
ROCK EJECTORS 129
Inspection 129
FUEL TANK 131
FUEL TANK 132
Removal 132
Installation 132
Repair 134
Cleaning 134
FUEL GAUGE SENDER 134
Removal 134
Installation 134
FUEL TANK BREATHER VALVE 135
Disassembly 135
Assembly 135
FUEL RECEIVERS (WIGGINS QUICK FILL) 135
FUEL RECEIVERS (WIGGINS QUICK FILL) 136
SECTION C ENGINE 137
POWER MODULE 139
POWER MODULE 141
PREPARATION 141
Removal 141
Installation 146
COOLING SYSTEM 151
COOLING SYSTEM DESCRIPTION 153
RADIATOR 154
Removal 154
Installation 157
Radiator Filling Procedure 158
REPAIRING THE RADIATOR 159
Internal Inspection 159
External Cleaning 159
Disassembly 159
Cleaning and Inspection 160
Assembly 160
Pressure Testing 162
COOLANT SYSTEM TROUBLESHOOTING 162
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
Pulse Voltage Modulator (PMV) 240
Control Power Relay 240
Auto Lube Timer 240
Ground Level Power Relay 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 Boards 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
BATTERY CHARGING ALTERNATOR 257
BATTERY CHARGING SYSTEM 261
BATTERY CHARGING SYSTEM 261
ELECTRICAL SYSTEM DESCRIPTION 261
CHARGE VOLT AND AMP VALUES 261
BATTERY 261
Maintenance and Service 261
Troubleshooting 262
Undercharging 262
Overcharging 262
Corrosion 262
Acid Levels 262
Non-Use or Storage 262
Freezing 263
BATTERY CHARGING ALTERNATOR 264
GENERAL INFORMATION 264
General Description 264
Terminal Identification and Location 265
Battery Positive (B+) 265
Battery Negative (B-) 265
DC Output (D+) 265
AC Output (R) 265
Regulator Harness Plug Identification 265
Alternator Specifications 265
Performance Curve 265
Battery/Alternator Terminology 266
WIRING DIAGRAM 268
DIMENSIONS AND TORQUE VALUES 269
PERIODIC MAINTENANCE 270
TESTING 270
GENERAL INFORMATION 270
Troubleshooting Alternator (On-Truck) 270
Equipment Required 270
Preliminary Checks 270
Test Set-up 272
Test Procedure 273
REGULATOR TESTING 274
Regulator Bypass Test (No Output) 274
Regulator Bypass Test (Amp Rating) 275
BENCH TESTING 276
Equipment 276
Identification Record 276
Advanced Troubleshooting 276
Bench Test 1: No-Load Test 276
Bench Test 2: Full Load Test 277
Bench Test 3: Regulator Bypass Test 277
STATIC TESTING 278
Equipment 278
Identification Record 278
Regulator Tester 278
Check For Shorted Power Transistor 278
Circuit Tests 279
FIELD COIL TESTS 280
Field Coil Test 1: Check for Open or Shorted Field Coil 280
Field Coil Test 2: Check For Grounded Field Coil 280
STATOR TESTS 281
Stator Test 1: Check For Stator-To-Stator Continuity 281
Stator Test 2: Check For Grounded Stators 282
THERMAL SWITCH TEST 282
Initial Test 282
Verifying a Faulty Thermal Switch 283
TROUBLESHOOTING TIPS 284
ALTERNATOR 288
ALTERNATOR REPAIR 288
Removal 288
Installation 290
Special Tools and Lubricants 290
Epoxy Adhesive 291
Liquid Threadlockers 291
Elastoplastic Silicone Resin 291
ALTERNATOR EXPLODED VIEW 293
ALTERNATOR DISASSEMBLY 295
Regulator Removal 295
Fan Removal 296
Pulley Removal 297
Anti-Drive End Housing Removal 297
Anti-Drive End Rotor Removal 299
Drive End Housing Removal 301
Drive End Rotor Removal 307
Field Coil Removal 308
Drive End and/or Anti-Drive End Stator Removal 310
CLEANING AND INSPECTION 312
ALTERNATOR ASSEMBLY 312
Anti-Drive End Stator Installation 312
Drive End Stator Installation 314
Field Coil Installation 317
Drive End Bearing Installation 319
Drive End Rotor Installation 321
Rotor and Rotor Shaft Installation 321
Drive End Housing Installation 322
Anti-Drive End Rotor Installation 326
Anti-Drive End Housing Installation 327
Regulator Installation 330
THERMAL SWITCH 331
Removal 331
Installation 333
SUPPORT STAND 333
KOMTRAX Plus SYSTEM 335
KOMTRAX Plus COMPONENTS 337
KOMTRAX Plus BASIC FEATURES 337
Gather Data 337
Convert and Record Data 337
Communicate Data to Off-Board Systems 338
USING THE KOMTRAX Plus SYSTEM 339
Turning the KOMTRAX Plus System ON 339
Normal KOMTRAX Plus Operation 339
Turning the KOMTRAX Plus System OFF 340
Downloading from the KOMTRAX Plus Controller 340
KOMTRAX Plus DATA ITEMS 341
Fault Codes 341
Machine History 341
KOMTRAX Plus History 341
Snapshots 342
Manual Snapshots 342
Trends 344
Histogram (Load Map) Data 344
Haul Cycle Data 345
Alarm and Snapshot Triggers 346
Satellite Features 346
KOMTRAX Plus DIAGNOSTIC FEATURES 348
Fault History 348
KOMTRAX Plus LED Digits 348
KOMTRAX Plus CONTROLLER 348
Removal 349
Installation 349
KOMTRAX Plus SOFTWARE 351
NECESSARY SOFTWARE 351
NECESSARY TOOLS 351
KOMTRAX Plus SYSTEM SET UP 352
KOMTRAX Plus Controller 352
KOMTRAX Plus CONTROLLER 352
KOMTRAX Plus TOOL BOX 352
Installation 352
KOMTRAX Plus SETTING TOOL 352
Installation 352
KOMTRAX Plus INITIALIZATION PROCEDURE 353
1 KOMTRAX Plus CONTROLLER SETUP PROCEDURE 353
KOMTRAX Plus Setting Tool software program 353
Select Operation 353
KOMTRAX Plus Setting Function 354
Machine Information Setting(1) 354
Machine Information Setting(2) 354
Date & Time Setting 354
GCC Setting 355
Setting Summary 355
2 KOMTRAX Plus SNAPSHOT PROCEDURE 356
3 KOMTRAX Plus DOWNLOAD PROCEDURE 357
4 LOCATION OF DOWNLOAD FILES 357
5 KOMTRAX Plus FTP UPLOAD PROCEDURE 358
6 KOMTRAX Plus INITIALIZATION FORMS 359
WHEN REPLACING A KOMTRAX Plus CONTROLLER 360
To Set: Date & Time; Satellite; Payload Meter 362
Review Setting Information 364
KOMTRAX Plus CONTROLLER CHECKOUT 365
KOMTRAX Plus Controller 365
Necessary Equipment: 365
Preliminary 366
KOMTRAX Plus Controller Checkout Procedure 367
ORBCOMM CONTROLLER 369
Removal 369
Installation 369
INTERFACE MODULE 371
INTERFACE MODULE 373
Removal 373
Installation 373
SENSORS 374
Temperature Sensors 374
Pressure Sensors 374
INTERFACE MODULE SOFTWARE 375
NECESSARY SOFTWARE 375
NECESSARY TOOLS 375
FLASHBURN PROGRAM 376
Installation 376
INTERFACE MODULE APPLICATION CODE 376
Installation 376
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 376
Installation 376
Using The Program 376
INTERFACE MODULE CHECKOUT 377
Interface Module 377
Necessary Equipment: 377
Preliminary 378
Checking Inputs And Outputs From The Interface Module 378
Check Analog Inputs To The Interface Module 382
Check CAN RPC & J1939 Interfaces To The IM 382
Check Outputs From The Interface Module 382
KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES 385
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 387
TROUBLESHOOTING 387
GENERAL 387
Structure and Purpose 387
TROUBLESHOOTING 388
Communications Networks 388
Coaxial Cable 388
FAULT CODES 389
Fault History 389
KOMTRAX Plus LED Display Fault Codes 390
Chassis Fault Codes 391
Engine Fault Codes 395
FAULT TREE ANALYSIS 401
Unable to connect to KOMTRAX Plus from laptop PC 401
Flashing Error Code N4-23 (PLM III Communications Fault) 402
Flashing Error Code N4-22 (Engine Communications Fault) 403
No Data Received By WebCARE 404
Coaxial Cable Troubleshooting 405
KOMTRAX PLUS FORMS 407
KOMTRAX PLUS FORMS 409
KOMTRAX PLUS INITIALIZATION CHECK LIST 409
KOMTRAX PLUS DATA DOWNLOAD 410
KOMTRAX PLUS INITIALIZATION CHECK LIST 411
KOMTRAX PLUS INITIALIZATION FORM 413
SECTION E ELECTRIC PROPULSION SYSTEM 415
ELECTRIC PROPULSION SYSTEM COMPONENTS 417
ELECTRICAL PROPULSION SYSTEM COMPONENTS 419
GENERAL SYSTEM DESCRIPTION 419
SYSTEM COMPONENTS 421
Propulsion System Controller (PSC) 421
Truck Control Interface (TCI) 422
Diagnostic Information Display (DID) Panel 423
DID Panel Event Codes 423
PSC SOFTWARE FUNCTIONS 442
Input Processing 442
State Machine 442
DC Link State 445
Engine Control 446
ALTERNATOR FIELD CONTROL 446
Desired Three-Phase Voltage 446
Desired DC Link Voltage 446
Self-Load 447
Propel Torque Control 447
Retard Torque Control 447
Wheel Slide Control 448
Resistor Grid Control 448
Chopper Voltage Control 448
EVENT DETECTION AND PROCESSING 448
Power-On Tests 448
Initiated Tests 449
Periodic Tests 449
EVENT RESTRICTIONS 449
EVENT LOGGING AND STORAGE 449
Event History Buffer 450
Data Packs 450
To Record and Save a Data Pack to a Disk 450
Event Reset 451
SERIAL DATA COMMUNICATIONS 451
PSC – TCI Communications Processing 451
PSC – PTU Communications Processing 451
Inverter Communications Processing 452
OUTPUT PROCESSING 452
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 452
Fast Start 452
Engine Shutdown/Engine Not Running 452
Limp Home Mode 453
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 454
ELECTRONIC ACCELERATOR AND RETARD PEDALS 462
Removal 462
Installation 462
Disassembly 462
Assembly 462
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 463
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 465
AC DRIVE SYSTEM MAINTENANCE 465
NORMAL TRUCK SHUTDOWN PROCEDURE 466
SHUTDOWN AFTER SYSTEM FAILURE 466
SYSTEM CHECKOUT 467
Battery and Control Circuit Checks – Battery Power OFF 467
Battery and Control Circuit Checks – Battery Power ON 470
Checks with Key Switch OFF 471
Checks with Key Switch ON 471
CPU Battery Checks 471
MEMORY BACKUP BATTERY REPLACEMENT 472
TCI PROGRAMMING 472
PSC PROGRAMMING 473
INVERTER PROGRAMMING 473
CPU RESET 473
PSC CHECKOUT 474
PSC Digital Input Checks 474
PSC Digital Output Checks 478
TCI CHECKOUT 479
Modular Mining Communication Port Check 479
TCI Digital Input Checks 479
TCI Digital Output Tests 485
CALIBRATIONS 487
Speedometer 487
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 487
ERASING EVENTS 487
PSC 487
TCI 488
GATE DRIVER POWER CONVERTER TEST 488
LOAD TESTING 489
Preparation 489
Alternator Speed Sensor Checks 489
Battery Boost Check 489
Brake Circuit Switch Checks 490
Hoist & Steering Circuit Switch Checks 490
Link Energized Checks 490
Loadbox Test 492
TROUBLESHOOTING 496
PVM Optimum Load Curve Handshaking Troubleshooting 496
Phase Module and Chopper Module Troubleshooting 496
PHASE MODULE REPLACEMENT 497
Phase Module Removal 497
Phase Module Installation 497
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 499
TIRES AND RIMS 501
TIRES AND RIMS 503
FRONT TIRES AND RIMS 503
Removal 503
Installation 505
REAR TIRES AND RIMS 505
Removal 505
Installation 506
RIM AND TIRE 508
Tire Removal 508
Rim And Tire Preparation 508
Lubricants 509
Tire Installation 509
FRONT WHEEL HUB AND SPINDLES 511
FRONT WHEEL HUB AND SPINDLE 513
WHEEL HUB AND SPINDLE ASSEMBLY 513
Removal 513
Spindle Removal Procedure (Optional) (off of the truck) 516
Installation 518
Disassembly 521
Cleaning and Inspection 521
Assembly 522
Wheel Bearing Adjustment (Tire Removed) 524
Wheel Bearing Adjustment (Tire mounted) 525
OIL SAMPLING PROCEDURE 526
Oil Sampling Guidelines 527
Procedure 527
OIL DRAIN AND REFILL PROCEDURE 527
STEERING CYLINDERS 528
Spherical Bearing Wear Limits 528
Removal 529
Installation 529
Bearing Replacement (Steering cylinder and tie rod) 529
TIE ROD 531
Removal 531
Installation 531
Disassembly 531
Assembly 532
TOE-IN ADJUSTMENT 533
REAR AXLE HOUSING ATTACHMENT 535
REAR AXLE HOUSING ATTACHMENT 537
PIVOT PIN 537
Removal 537
Installation 537
PIVOT EYE BEARING 538
Disassembly 538
Assembly 538
PIVOT EYE REPAIR 539
Removal 539
Installation 539
Disassembly 539
Assembly 539
ANTI-SWAY BAR 540
Removal 540
Installation 540
Disassembly 540
Cleaning and Inspection 540
Assembly 540
REAR AXLE HOUSING 541
REAR AXLE HOUSING 543
REAR AXLE HOUSING 543
Removal 543
Installation 543
WHEEL MOTOR 544
Removal 544
Cleaning and Inspection 544
Installation 545
WHEEL MOTOR GEAR OIL 548
Change/Filter The Gear case Oil 548
Oil 548
Remove And Clean Magnetic Plugs 548
Flushing The Gearbox 548
Check Gear Case Oil Level 548
SECTION H SUSPENSIONS 549
FRONT SUSPENSION 551
FRONT SUSPENSION 553
Removal 553
Installation 554
TURN-OF-THE-NUT Tightening Procedure 556
Upper Mounting Joint – 60° Advance 556
Lower Mounting Joint – 90° Advance 558
Inspection 558
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 559
Bearing Structure Removal 559
Bearing Structure Installation 559
MAJOR SUSPENSION REBUILD 560
Disassembly 560
Assembly 561
PRESSURE TEST 563
REAR SUSPENSIONS 565
REAR SUSPENSIONS 567
Removal 567
Installation 570
ROD UP SUSPENSION 572
Disassembly 572
Cleaning and Inspection 572
Assembly 572
ROD DOWN SUSPENSION 574
Disassembly 574
Cleaning and Inspection 574
Assembly 576
PRESSURE TEST 578
Suspension pressure test 578
OILING AND CHARGING PROCEDURE 579
OILING AND CHARGING PROCEDURE 581
GENERAL 581
EQUIPMENT LIST 581
HYDRAIR® CHARGING KIT 582
Installation of Charging Kit 582
Removal of Charging Kit 582
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 583
FRONT SUSPENSION 583
Front Suspension Oiling 583
Front Suspension Nitrogen Charging 585
REAR SUSPENSION – ROD UP 587
Rear Suspension Oiling (Rod Up Only) 587
Rear Suspension Nitrogen Charging (Rod Up Only) 588
REAR SUSPENSION – ROD DOWN 590
Rear Suspension Oiling (Rod Down Only) 590
Rear Suspension Nitrogen Charging (Rod Down Only) 592
OIL AND NITROGEN SPECIFICATIONS CHART 594
SECTION J BRAKE CIRCUIT 595
BRAKE CIRCUIT 597
BRAKE CIRCUIT 599
OPERATION 599
SERVICE BRAKE CIRCUIT OPERATION 599
SECONDARY BRAKING AND AUTOMATIC APPLY 601
PARKING BRAKE CIRCUIT 601
Normal Operation (key switch on, engine running) 601
BRAKE LOCK CIRCUIT 602
WARNING CIRCUIT 602
BRAKE CIRCUIT COMPONENT SERVICE 605
BRAKE CIRCUIT COMPONENT SERVICE 607
BRAKE VALVE 607
Rebuild Criteria 607
Removal 607
Installation 609
DISASSEMBLY 611
Cleaning and Inspection 613
ASSEMBLY 613
Actuator Base Threaded Inserts 613
Boot and Cap 613
Valve Body Seal Installation 614
Regulator Sleeve O-Ring Installation 614
Actuator Plunger O-ring Installation 615
Assembly of Valve 615
VALVE BENCH TEST AND ADJUSTMENT 617
Test Set Up Procedure 618
Brake Valve Output Pressure Adjustment 618
Final Test and Adjustment 619
Installation Of Brake Pedal Actuator Assembly to Brake Valve 620
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 622
Installation of Retard Pedal To Brake Pedal 622
HYDRAULIC BRAKE ACCUMULATORS 623
Brake Accumulator Bleed Down Procedure 623
Removal 623
Installation 623
Disassembly 623
Cleaning and Inspection 625
Assembly 625
Charging Procedure 627
BRAKE MANIFOLD 628
Removal 628
Removal 628
Installation 629
Disassembly 629
Cleaning and Inspection 630
Assembly 630
BRAKE CIRCUIT CHECK-OUT PROCEDURE 631
BRAKE CIRCUIT CHECK-OUT PROCEDURE 633
EQUIPMENT REQUIRED 634
INITIAL SYSTEM SET-UP 636
PARKING BRAKE 636
BRAKE SYSTEM CHECK-OUT 637
BRAKE LOCK 637
FAILURE MODES CHECK-OUT 638
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 639
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 642
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 643
FRONT BRAKES 645
WHEEL SPEED FRONT DISC BRAKES 647
BRAKE CALIPER 647
Caliper Removal 647
Installation 648
Disassembly 649
Assembly 649
Cleaning and Inspection 650
BRAKE LINING 651
Replacement 651
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 653
GENERAL 653
Safety Precautions 653
Front Brake Conditioning 653
BRAKE BLEEDING PROCEDURES 654
ARMATURE SPEED REAR DISC BRAKES 655
ARMATURE SPEED REAR DISC BRAKES 657
REAR BRAKES 657
CALIPER AND DISC 657
Removal 657
Installation 659
PARK BRAKE ADJUSTMENT PROCEDURE 661
BRAKE BLEEDING PROCEDURE 662
Service Brake 662
Park Brake 662
CALIPER 663
Disassembly 663
PISTON SUBASSEMBLY 666
Disassembly 666
PREPARATION FOR ASSEMBLY 667
Clean Parts 667
For Rough Metal Parts 668
Dry and Inspect Parts 668
Corrosion Protection 668
INSPECTION 668
Caliper Parts 668
Shoes, Linings and End Plates 669
Inspect linings 669
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 669
Piston Assembly Adjuster Grip Force 670
Adjuster Force 672
Piston Return Spring 674
ASSEMBLY 675
Adjuster and Pin Assembly 675
Piston Subassembly 676
Brake Caliper 677
PERIODIC INSPECTIONS 683
Shoes, Linings and End Plates 683
Inspect the following areas for fluid leaks 683
Dust Boots 683
Brake Disc 683
BRAKE LINING 684
Replacement 684
BRAKE DISC 684
Inspection 684
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 685
GENERAL 685
SAFETY PRECAUTIONS 685
Rear Brake Conditioning 686
SECTION L HYDRAULIC SYSTEM 689
HYDRAULIC SYSTEM 691
HYDRAULIC SYSTEM 693
HYDRAULIC SYSTEM OPERATION 693
COMPONENT DESCRIPTION 694
Hoist Pump 694
Steering/Brake Pump 694
Tank 694
High Pressure Hydraulic Filters 694
Bleeddown Manifold 694
Steering System Accumulators 694
DISABLED TRUCK CONNECTORS 696
GENERAL 696
STEERING AND BRAKE SYSTEM 696
Hookup 696
HOIST SYSTEM 697
Hookup 697
Dumping Procedure 697
HYDRAULIC SYSTEM COMPONENT REPAIR 699
HYDRAULIC SYSTEM COMPONENT REPAIR 701
HOIST PUMP 701
Removal 701
Installation 702
Disassembly 704
Inspection Of Parts 707
Assembly 708
HYDRAULIC TANK 714
Filling Instructions 714
Removal 714
Installation 715
HYDRAULIC TANK STRAINERS 716
Removal 716
Inspect and Clean 716
Installation 717
HYDRAULIC TANK BREATHERS 717
HOIST CIRCUIT FILTERS 718
FILTER ELEMENT REPLACEMENT 719
Removal 719
Installation 719
INDICATOR SWITCH 719
STEERING CIRCUIT 721
STEERING CIRCUIT 723
STEERING CIRCUIT OPERATION 723
COMPONENT DESCRIPTION 724
STEERING CONTROL UNIT 724
FLOW AMPLIFIER 724
No Steer 726
Steering Left 728
Steering Right 730
No Steer, External Shock Load 732
BLEED DOWN MANIFOLD 734
ACCUMULATORS 735
Low Precharge Warning Switch 735
HIGH PRESSURE FILTER 735
STEERING/BRAKE PUMP 735
Operation 736
PRINCIPLE OF OPERATION 738
Full Pump Volume: 738
Half Pump Volume: 738
Neutral Position: 739
STEERING CIRCUIT COMPONENT REPAIR 741
STEERING CIRCUIT COMPONENT REPAIR 743
BLEED DOWN MANIFOLD 743
Removal 743
Installation 743
ACCUMULATOR 744
Removal 744
Installation 745
Disassembly 745
Cleaning and Inspection 746
Assembly 746
LEAK TESTING 748
STEERING ACCUMULATOR CHARGING PROCEDURE 749
Temperature During Precharge 752
ACCUMULATOR STORAGE PROCEDURES 752
Instructions For Storing Bladder Accumulators 752
Installation 753
Bladder Storage Procedures 753
FLOW AMPLIFIER 754
Removal 754
Installation 754
Disassembly 756
Reassembly 757
STEERING CONTROL UNIT 758
Removal 758
Spline Inspection 758
Installation 759
Disassembly 759
Cleaning and Inspection 760
Assembly 761
STEERING CYLINDER 765
Disassembly 765
Inspection and Cleaning 765
Assembly 765
STEERING CIRCUIT FILTER 766
Filter Element Replacement 766
Removal 767
Installation 767
Indicator Switch 767
STEERING AND BRAKE PUMP 768
Removal 768
Installation 769
Disassembly 770
Control Piston Group 770
Valve Plate Group 771
Rotating Group 771
Swashblock Group 772
Driveshaft Group 772
INSPECTION 772
Control Piston Group 772
Valve Plate Group 772
Rotating Group 772
Swashblock Group 776
Driveshaft Group 776
Compensator Block and Unloader Module 776
Stroke Adjuster Assembly 776
ASSEMBLY 776
Swashblock Group 776
Control Piston Group 778
Valve Plate Group 779
HOIST CIRCUIT 781
HOIST CIRCUIT 783
HOIST CIRCUIT OPERATION 783
COMPONENT DESCRIPTION 784
Hydraulic Tank 784
Hoist Pump 784
High Pressure Filters 784
Hoist Valve 785
Hoist Pilot Valve 786
Hoist-up Limit Solenoid 786
Pilot Operated Check Valve 786
Counterbalance Valve Manifold 787
HOIST SYSTEM OPERATION MODES 788
Float Position Of Pilot Valve And Body On Frame (Figure 7-6) 788
Power Up Operation (Figure 7-7) 790
Hold Operation (Figure 7-8) 792
Power Down Operation (Figure 7-9) 794
Float Operation (Figure 7-10) 796
HOIST CIRCUIT COMPONENT REPAIR 799
HOIST CIRCUIT COMPONENT REPAIR 801
HOIST VALVE 801
Removal 801
Installation 801
O-Ring Replacement 802
INLET SECTION 803
Disassembly 803
Cleaning and Inspection 804
Assembly 804
SPOOL SECTION 804
Disassembly 804
Cleaning and Inspection 807
Assembly 807
HOIST PILOT VALVE 808
Removal 808
Installation 808
Disassembly 809
Cleaning and Inspection 810
Assembly 811
BODY UP LIMIT SOLENOID 812
PILOT OPERATED CHECK VALVE 812
HOIST CYLINDERS 812
Removal 812
Installation 813
Disassembly 814
Cleaning and Inspection 816
ASSEMBLY OF QUILL AND CYLINDER 817
Quill Installation 817
Installation of Check Balls and Plugs in Quill 818
Assembly of Cylinder 819
Assembly of Cylinder 819
Pressure Testing 820
OVERCENTER MANIFOLD 821
HYDRAULIC CHECKOUT PROCEDURE 823
HYDRAULIC CHECKOUT PROCEDURE 825
STEERING AND BRAKE PUMP 825
Pressure Check And Adjustment Procedure 825
BLEEDDOWN MANIFOLD 827
SHOCK & SUCTION VALVES 827
Shock & Suction Valve Settings 827
LEAKAGE TESTS 829
Steering Control Unit & Flow Amplifier 829
Bleeddown Manifold 829
ACCUMULATOR BLEED DOWN PROCEDURE 831
LOW STEERING PRESSURE SWITCH 831
CHECKING HOIST SYSTEM PRESSURES 838
Hoist System Relief Pressure Adjustment 838
Power Down Relief Pressure Adjustment 839
HOIST COUNTERBALANCE VALVE 840
Preparation: 840
Counterbalance Valve Pressure Check Only: 840
Counterbalance Valve Adjustment 841
HYDRAULIC SYSTEM FLUSHING PROCEDURE 844
Hydraulic System Flushing Procedure 844
OIL CLEANLINESS CHECK 849
SECTION M SPECIAL TOOLS 851
HEATER OPTIONS 853
GENERAL INFORMATION 855
TROUBLESHOOTING 855
HEATER ELEMENT 855
Removal 855
Installation 856
GENERAL 857
Maintenance 857
HEATING ELEMENT 857
Removal 857
Installation 858
THERMOSTAT 858
Removal 858
Installation 858
GENERAL INFORMATION 859
TROUBLESHOOTING 859
HEATER ELEMENT 859
Removal 859
Installation 860
SPECIAL TOOLS 861
NITROGEN CHARGING VALVE 861
ROLL-OUT ASSEMBLY 861
EYE BOLT 861
OFFSET WRENCH 862
TORQUE ADAPTER 862
HANDLE 862
SEAL INSTALLER 862
SLEEVE ALIGNMENT TOOLS 863
QUICK DISCONNECT COUPLING 863
HARNESS 863
SEAL INSTALLATION RING 863
BELT TENSION TESTER 864
BELT ALIGNMENT TOOL 864
SOCKETS AND ADAPTERS 864
DUST CAPS 864
HYDRAULIC SYSTEM FLUSHING TOOLS 865
PAYLOAD DATA MANAGER 865
HYDRAULIC SYSTEM VACUUM PUMP 865
MISCELLANEOUS SERVICE TOOLS 866
BRAKE PISTON TOOL 867
HIGH VOLTAGE TOOLS 870
2000 VDC METER 870
GROUNDING STICKS 870
BODY PAD SPACER TOOL 871
RADIATOR SHUTTERS 873
RADIATOR SHUTTERS 875
OPERATION 875
Hydraulic Circuit 875
Electrical Circuit: 876
MAINTENANCE AND REPAIR 876
TROUBLESHOOTING 877
Hydraulic Troubleshooting 880
Electrical Troubleshooting 882
PAYLOAD METER III ™ 883
OPERATION SECTION 887
Introduction 887
Data Summary 887
Data Gathering 887
COMPONENT DESCRIPTION 888
System Diagram 888
Suspension Pressure Sensors 888
Inclinometer 888
Operator Display 888
Operator Switch 889
Speed Input 889
Body-Up Switch 889
Brake Lock Switch 889
Payload Meter 889
Communications Ports 889
Key Switch Input 890
Payload Meter Power 890
Load Lights 890
Wiring and Termination 891
TCI Outputs 891
OPERATOR’S DISPLAY AND SWITCH 892
Reading the Speedometer 892
Reading the Load Display 892
Using the Operator ID 892
Using the Load and Ton Counter 892
Total Ton Counter 892
Total Load Counter 893
Clearing the Counters 893
Viewing Live Sensor Data 893
Other Display Messages 893
PAYLOAD OPERATION & CALCULATION 894
Description of Haul Cycle States 894
Haul Cycle Description 894
Load Calculation 895
Carry Back 895
Measurement Accuracy 895
SOURCES FOR PAYLOAD ERROR 895
Payload Error 895
Loading Conditions 896
Pressure Sensors 896
Swingloads 896
Speed and Distance 896
HAUL CYCLE DATA 896
Haul Cycle Warning Flags 898
Frame Torque Data 899
Sprung Weight Data 899
Maximum Speed Data 899
Alarm Records 899
Fault Code Data 900
PC SOFTWARE OVERVIEW 901
System Configuration 901
Installing the PLMIII Software 901
DOWNLOADING DATA 902
PLM III SYSTEM CONFIGURATION 903
Starting Communications 903
Displayed Payload Units 903
Time Units 903
Connection Menu 903
Connecting to the Payload Meter 904
Configure the Payload Meter 904
Setting the Date and Time 904
Setting the Truck Type 905
Setting the Gauge Display Units 905
Setting the Frame Serial Number 905
Setting the Truck Number 905
Setting the Komatsu Distributor 905
Setting the Komatsu Customer 905
Clean Truck Tare 906
Inclinometer Calibration 906
DATA ANALYSIS 907
Creating a Query 907
Sorting on Truck Unit Number 907
Sorting on Truck Type 907
Sorting on Date Range 908
Sorting on Time Range 908
Payload Detail Screen 909
Creating Reports 909
Summary – one page report 910
Detailed – multi-page report 910
Creating Graphs 911
Exporting Data 911
CSV Export 911
Compressed 912
Importing Data 913
Deleting Haul Cycle Records 913
Viewing Alarms 914
Deleting Alarm Records 914
TROUBLESHOOTING SECTION 915
TROUBLESHOOTING 915
Viewing Active Alarms 915
Real-Time Data Display 915
Testing the Payload Lights 915
Creating Log Files of Inputs 916
Daily Inspections 916
Periodic Maintenance 916
Abnormal Displays at Power-Up 917
No Payload Display When Key Switch is Turned ON 918
No Display on Speedometer 919
No Display on Operator Display 919
No Communications With PC 920
Load Lights Don’t Light During Loading 921
Load Lights Remain ON 922
Load Lights Remain ON During Dumping 922
Display Doesn’t Clear When The Load Is Dumped 922
Calibration Problems 923
Alarm 1 – Left Front Pressure High 924
Alarm 2 – Left Front Pressure Low 924
Troubleshoot Wiring to Left Front Suspension 924
Alarm 3 – Right Front Pressure High 925
Alarm 4 – Right Front Pressure Low 925
Troubleshoot Wiring to Right Front Suspension 925
Alarm 5 -Left Rear Pressure High 926
Alarm 6 – Left Rear Pressure Low 926
Troubleshoot Wiring to Left Rear Suspension 926
Alarm 7 – Right Rear Pressure High 927
Alarm 8 – Right Rear Pressure Low 927
Troubleshoot Wiring to Right Rear Suspension 927
Alarm 9 – Inclinometer High 928
Alarm 10 – Inclinometer Low 928
Troubleshoot Inclinometer Wiring 928
Alarm 13 – Body Up Input Failure 929
Alarm 16 – Memory Write Failure 930
Alarm 17 – Memory Read Failure 930
Alarm 18 931
Alarm 19 931
Alarm 22 931
Operator Switch Doesn’t Work 932
Alarm 26 – User Switch Fault – SELECT 932
Alarm 27 – User Switch Fault – SET 932
Connector Map 933
Connectors 934
PLMIII CHECK OUT PROCEDURE 935
General Description 935
Tools Required 935
Checkout Procedure 935
PLMIII CHECKOUT PROCEDURE CONFIRMATION 939
Flashburn Programming 939
Confirmation Checklist 941
RESERVE ENGINE OIL SYSTEM 943
RESERVE ENGINE OIL SYSTEM 945
Operation 946
LED Monitor Light 946
Tank Fill Control (Optional) 947
Filling Procedure (Remote Fill Feature) 947
SERVICE 948
Every 10 Hours, or once each shift: 948
Every 500 Hours 948
Changing Oil 948
TROUBLESHOOTING 949
Circuit Fuse 949
SYSTEM ELECTRICAL SCHEMATICS 950
SECTION N OPERATOR CAB 951
TRUCK CAB AND COMPONENTS 953
TRUCK CAB AND COMPONENTS 955
TRUCK CAB 955
Description 955
Removal 956
Installation 957
CAB DOOR 958
Removal 958
Installation 958
Door Adjustment 958
Door Jamb Bolt Adjustment 959
Door Handle Plunger Adjustment 960
Replace Door Glass 961
Replace Door Window Regulator 965
Replacing the Door Handle or Latch Assembly 966
Replacing the Door and Door Hinge Seal 966
Removing the Door Opening Seal 967
Installation 967
GLASS REPLACEMENT 968
Adhesive-bonded Windows 968
Replacement Procedure 968
WINDSHIELD & REAR GLASS 970
Removal 970
Installation 970
CAB COMPONENTS 973
CAB COMPONENTS 975
WINDSHIELD WIPERS 975
WIPER MOTOR 975
Removal 975
Installation 975
WIPER ARM 975
Removal 975
Installation 976
WIPER LINKAGE 976
Removal 976
Installation 976
WINDSHIELD WASHER 977
Operation 977
Service 977
OPERATOR SEAT 978
Seat Belts 978
Adjustment 978
Inspection 979
Removal 979
Installation 979
PASSENGER SEAT 980
Inspection 980
Removal 980
Installation 980
OPERATOR COMFORT 981
OPERATOR COMFORT 983
HEATER / AIR CONDITIONER 983
Operation 983
Fan Control Knob 983
Temperature Control Knob 983
Directional Control Knob 983
Heater Vents 983
COMPONENTS 984
Circuit Breakers 984
Relays 984
Heater Core 984
Fan Motor And Speed Control 985
Actuators 985
Cab Air Filter 985
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 988
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 988
PRINCIPLES OF REFRIGERATION 988
Air Conditioning 988
Refrigeration – The Act Of Cooling 989
The Refrigeration Cycle 989
AIR CONDITIONER SYSTEM COMPONENTS 990
Compressor (Refrigerant Pump) 990
Service Valves 990
Condenser 990
Receiver-Drier 990
Expansion Block Valve 991
Accumulator 991
Evaporator 991
ELECTRICAL CIRCUIT 992
Thermostat 992
Compressor Clutch 992
Trinary™ Switch 993
SYSTEM SERVICING 994
SERVICE TOOLS AND EQUIPMENT 995
Recovery/Recycle Station 995
Leak Detector 995
Service Valves 996
Vacuum Pump 996
Manifold Gauge Set 997
Installing Manifold Gauge Set 998
Purging Air From Service Hoses 998
SYSTEM PERFORMANCE TEST 999
SYSTEM OIL 1000
Handling and Reusing PAG Oil 1000
Oil Quantity 1000
Checking System Oil 1000
REFRIGERANT 1001
Recycled Refrigerant 1001
Reclaimed Refrigerant 1001
Refrigerant Quantity 1001
R-134a Refrigerant Containers 1002
SYSTEM LEAK TESTING 1002
Electronic Leak Detector 1003
Tracer Dyes 1003
Soap and Water 1003
RECOVERING AND RECYCLING THE REFRIGERANT 1003
Performing the Recovery Cycle 1003
Performing the Recycling Procedure 1004
Evacuating and Charging the A/C System 1004
SYSTEM REPAIR 1004
System Flushing 1005
A/C DRIVE BELT CHECKOUT PROCEDURE 1006
Pulley Alignment 1006
Belt Tension Check 1006
COMPONENT REPLACEMENT 1008
Hoses and Fittings 1008
Lines 1008
Expansion Valve 1008
Receiver-Drier 1008
Thermostat 1008
Compressor 1009
Accumulator 1009
Clutch 1009
Servicing the Compressor Clutch 1010
Pulley Removal 1012
Clutch Coil Check 1013
Pulley Installation 1013
Clutch Assembly Installation 1013
EVACUATING THE SYSTEM 1015
CHARGING THE A/C SYSTEM 1017
TROUBLESHOOTING 1018
Preliminary Checks 1018
Diagnosis Of Gauge Readings And System Performance 1018
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1019
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1025
OPERATOR CAB CONTROLS 1027
OPERATOR CAB AND CONTROLS 1029
STEERING WHEEL AND CONTROLS 1030
Horn Button 1030
Tilt / Telescope Lever 1030
Multi-Function Turn Signal Switch 1030
STEERING COLUMN 1031
Removal 1031
Steering Column Inspection 1031
Installation 1031
STEERING WHEEL 1032
Removal 1032
Installation 1032
PEDALS 1034
Service Brake Pedal 1034
Dynamic Retarding 1034
Dynamic Retard Pedal 1034
Throttle/Accelerator Pedal 1034
GRADE/SPEED RETARD CHART 1035
OVERHEAD PANEL AND DISPLAYS 1036
CENTER CONSOLE 1037
Directional Control Lever 1037
Override/Fault Reset Switch 1038
Engine Stop Switch 1038
L H Window Control Switch 1038
R H Window Control Switch 1038
Hoist Control Lever 1038
Raising The Dump Body 1038
Lowering The Dump Body 1038
Retard Speed Control (RSC) Adjust Dial 1039
Retard Speed Control (RSC) Switch 1039
Data Store Button 1040
KOMTRAX Plus Snapshot In Progress Light 1040
Link Energized Light 1040
Service Engine Light 1040
DIAGNOSTIC PORTS 1040
KOMTRAX Plus Diagnostic Port 1040
Interface Module (IM) Diagnostic Port 1040
Payload Meter Diagnostic Port 1040
Truck Control Interface (TCI) Diagnostic Port 1040
Propulsion System Controller (PSC) Diagnostic Port 1040
Engine Diagnostic Port (CENSE) 1040
Engine Diagnostic Port (QUANTUM) 1040
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 1041
Fan Control Knob 1041
Temperature Control Knob 1041
Directional Control Knob 1041
Heater Vents 1041
INSTRUMENT PANEL 1042
Key Switch 1044
Starting 1044
Rotating Beacon Light Switch (Optional) 1044
Heated Mirror Switch (Optional) 1044
Rest Switch 1044
Wheel Brake Lock Control 1045
Hazard Warning Lights 1045
Cab/Air Conditioner Vents 1045
Engine Oil Pressure Gauge 1045
Right Turn Signal Indicator 1045
Tachometer 1045
High Beam Indicator 1045
Speedometer/Payload Meter Display 1046
Left Turn Signal Indicator 1046
Water Temperature Gauge 1046
Lamp Test Switch 1046
Light Switch 1046
Ladder Light Switch 1046
Manual Backup Switch 1046
Fog Lights (Optional) 1047
Payload Meter Switch 1047
Panel Light Dimmer 1047
Hydraulic Oil Temperature Gauge 1047
Hourmeter 1047
Fuel Level Gauge 1047
OVERHEAD STATUS / WARNING INDICATORS 1048
Status / Warning Indicator Light Symbols 1049
KOMTRAX Plus MONITORING SYSTEM 1055
Operation 1055
Interface Module 1056
Basic Precautions 1056
SECTION P LUBRICATION AND SERVICE 1057
LUBRICATION AND SERVICE 1059
LUBRICATION AND SERVICE 1061
GENERAL 1061
830E SERVICE CAPACITIES 1061
HYDRAULIC TANK SERVICE 1061
Adding Oil 1061
COOLING SYSTEM SERVICE 1062
Radiator Filling Procedure 1062
Coolant Specifications 1062
Unacceptable Practices 1062
WHEEL MOTOR SERVICE 1062
RESERVE ENGINE OIL SYSTEM (Optional) 1063
Reserve Oil Tank Filling Procedure (Remote fill) 1063
Inline Screen 1063
QUICK FILL SERVICE CENTER 1064
LUBRICATION CHART 1065
10 HOUR (DAILY) INSPECTION 1066
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1069
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1070
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1071
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1075
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 1077
2500 HOUR MAINTENANCE CHECKS 1078
5000 HOUR MAINTENANCE CHECKS 1078
AUTOMATIC LUBRICATION SYSTEM 1079
AUTOMATIC LUBRICATION SYSTEM 1081
GENERAL DESCRIPTION 1081
SYSTEM COMPONENTS 1083
Filter 1083
Hydraulic Motor and Pump 1083
Grease Reservoir 1083
Pressure Reducing Valve 1083
Flow Control Valve 1083
Solenoid Valve 1083
Vent Valve 1083
Lubrication Cycle Timer 1083
Over Pressure Cut Off Switch 1083
Grease Pressure Failure Switch 1083
Injectors 1083
Relief Valve 1083
SYSTEM OPERATION 1084
GENERAL INSTRUCTIONS 1085
Required Lubricant 1085
System Priming 1085
Filter Assembly 1085
LUBRICANT PUMP 1086
Pump Housing Oil Level 1086
Pump Pressure Control 1086
INJECTORS (SL-1 Series “H”) 1086
Injector Specifications 1086
Injector Adjustment 1086
INJECTOR OPERATION 1088
PREVENTIVE MAINTENANCE PROCEDURES 1089
Daily Lubrication System Inspection 1089
250 Hour Inspection 1089
1,000 Hour Inspection 1089
SYSTEM CHECKOUT 1090
Lubrication Controller Check 1090
Lubrication Controller Operation 1090
Lubrication Controller Components 1090
Lubrication Controller Adjustment 1090
SYSTEM TROUBLESHOOTING CHART 1092
SECTION Q ALPHABETICAL INDEX 1095
SECTION R SYSTEM SCHEMATICS 1099
HH360 HYDRAULIC SCHEMATIC 1101
HH366 HYDRAULIC SCHEMATIC 1102
HE484 ELECTRICAL SCHEMATIC HEATER/AC CONTROLS 1104
XS5100 ELECTRICAL SCHEMATIC 1105

DESCRIPTION:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM019602 – PDF DOWNLOAD 

SERIAL NUMBERS A30109 – A30140

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”,
  “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers
  represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an
  Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
  includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating.

S.V 12/12/24