Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM024002 PDF

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM024002  – PDF DOWNLOAD

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM024002  – PDF DOWNLOAD

Language : English
Pages : 1154
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM024002  – PDF DOWNLOAD

• SERIAL NUMBERS A30561 & UP

COVER 1
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 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 MACHINE 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
Electrical Systems Isolation 29
Warning Tag 31
Proper Tools 31
Securing The Dump Body 31
DURING MAINTENANCE 32
Personnel 32
Attachments 32
Working Under The Machine 32
Keeping The Machine Clean 32
Rules To Follow When Adding Fuel Or Oil 32
Radiator Coolant Level 32
Use Of Lighting 33
Precautions With The Battery 33
Handling High Pressure Hoses 33
Precautions With High Pressure Oil 33
Maintenance Near High Temperatures And High Pressures 33
Rotating Fan And Belts 33
Waste Materials 33
TIRES 34
Handling Tires 34
Tire Maintenance 35
Storing Tires After Removal 35
ADDITIONAL JOB SITE RULES 36
WHEN REPAIRS ARE NECESSARY 37
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK 38
Preliminary Procedures before Welding or Performing Maintenance 38
Engine Shutdown Procedure before Welding or Performing Maintenance 38
CAPACITOR DISCHARGE SYSTEM 40
Necessary Tools 40
Warnings And Cautions 41
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE 42
Preparation 42
CAPACITOR CHARGE LIGHTS 44
FAILURE OF DISCHARGE SYSTEM 45
Measuring Dc Voltage On Capacitors 45
MANUAL DISCHARGE OF CAPACITORS 46
SHORT ISOLATED CAPACITOR TERMINALS 48
TRUCK OPERATION 50
PREPARING FOR OPERATION 50
Safety Is Thinking Ahead 50
WALK AROUND INSPECTION 50
RETRACTABLE LADDER SYSTEM (If equipped) 54
LADDER SYSTEM DESCRIPTION 54
LADDER SYSTEM OPERATION 55
Normal Operation 55
GENERAL SAFETY 55
IN-CAB CONTROL PANEL 55
IN-CAB CONTROL PANEL FEATURES 56
Digital Display Screen 56
Command Buttons 56
USING THE IN-CAB CONTROL PANEL 57
Raising the Ladder 57
Lowering the Ladder 58
USING THE GROUND LEVEL CONTROL BOX 59
Raising the Ladder 59
Lowering the Ladder 59
Emergency Operation 60
ENGINE START-UP SAFETY PRACTICES 61
AFTER ENGINE HAS STARTED 62
PRE-SHIFT BRAKE CHECK (if equipped) 63
Events 63
OPERATION 63
Description 63
Brake Test Exit Criteria 64
PERFORMING THE BRAKE TESTS 64
Setup 64
Service Brake Test 65
Parking Brake Test 66
Retard System Test: 66
EMERGENCY STEERING SYSTEM 67
Operation 67
Pre-Operation Testing 67
Additional Guidelines 68
MACHINE OPERATION SAFETY PRECAUTIONS 68
MACHINE OPERATION ON THE HAUL ROAD 69
STARTING ON A GRADE WITH A LOADED TRUCK 70
PASSING 70
LOADING 70
DUMPING 70
Raising The Dump Body 70
Lowering The Dump Body 71
SUDDEN LOSS OF ENGINE POWER 72
FUEL DEPLETION 73
SAFE PARKING PROCEDURES 73
NORMAL ENGINE SHUTDOWN PROCEDURE 74
DISABLED TRUCK CONNECTORS 75
GENERAL 75
STEERING AND BRAKE SYSTEM 75
Hookup 75
HOIST SYSTEM 76
Hookup 76
Dumping Procedure 76
TOWING 78
Special Wiring Harness 78
Towing Procedure 78
RESERVE ENGINE OIL SYSTEM (Optional) 81
WARNINGS AND CAUTIONS 83
TORQUE TABLES AND CONVERSION CHARTS 97
STORAGE PROCEDURES 107
STORAGE AND IDLE MACHINE PREPARATION 109
SHORT TERM IDLE PERIODS 109
PREPARATION FOR STORAGE 110
REMOVAL FROM STORAGE 111
RECONDITIONING AN IDLE VEHICLE 113
ENGINE OPERATION 115
AFTER ENGINE HAS STARTED 116
ENGINE STORAGE 117
Engine Storage-(Short Term) 117
Engine Storage- (Long Term) 118
TRANSMISSION PRESERVATION AND STORAGE 123
Restoring Transmission to Service 123
ELECTRIC DRIVE TRUCKS 119
SECTION B STRUCTURES 125
STRUCTURAL COMPONENTS 127
STRUCTURAL COMPONENTS 129
Preparation 129
LADDERS 130
Removal 130
Installation 130
RIGHT DECK 130
Removal 130
Installation 132
LEFT DECK 132
Removal 132
Installation 133
CENTER DECK 133
SECTION B3 DUMP BODY INDEX 135
DUMP BODY 137
Removal 137
Installation 138
BODY PADS 139
Removal 139
Installation 139
Adjustment 140
BODY GUIDE 141
BODY-UP RETENTION CABLE 142
BODY POSITION INDICATOR 142
HOIST LIMIT SWITCH 142
BODY UP SWITCH 142
ROCK EJECTORS 143
Inspection 143
FUEL TANK 145
FUEL TANK 146
Removal 146
Installation 146
Repair 148
Cleaning 148
FUEL GAUGE SENDER 148
Removal 148
Installation 148
FUEL TANK BREATHER VALVE 149
Disassembly 149
Assembly 149
FUEL RECEIVERS (WIGGINS QUICK FILL) 150
SECTION C ENGINE 151
POWER MODULE 153
POWER MODULE 155
PREPARATION 155
Removal 155
Installation 160
COOLING SYSTEM 165
COOLING SYSTEM DESCRIPTION 167
RADIATOR 168
Removal 168
Installation 171
Radiator Filling Procedure 172
REPAIRING THE RADIATOR 173
Internal Inspection 173
External Cleaning 173
Disassembly 173
Cleaning and Inspection 174
Assembly 174
Pressure Testing 176
COOLANT SYSTEM TROUBLESHOOTING 176
POWER TRAIN 177
ALTERNATOR REMOVAL PROCEDURE 179
Removal (Komatsu SSDA16V160 or SDA16V160 Engine) 179
ENGINE/ALTERNATOR MATING 181
General Instructions 181
Measuring Procedure 181
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 183
ENGINE 184
Removal 184
Service 185
Installation 185
AIR CLEANERS 187
AIR CLEANERS 189
OPERATION 189
SERVICING THE AIR CLEANERS 189
Replacing The Elements 190
AIR CLEANER ASSEMBLY CLEANING 191
Primary Element Cleaning 191
Precleaner Section Cleaning 193
AIR INTAKE TROUBLESHOOTING 194
FAN CLUTCH 195
REMOVAL & INSTALLATION TOOLING 197
DISASSEMBLY 200
CLEANING AND INSPECTION 210
ASSEMBLY 214
TEST PROCEDURE 228
SECTION D ELECTRICAL SYSTEM (24VDC) 229
24VDC ELECTRIC SUPPLY SYSTEM 231
24VDC ELECTRIC SUPPLY SYSTEM 233
ELECTRICAL SYSTEM DESCRIPTION 233
BATTERIES 233
Maintenance and Service 233
Troubleshooting 233
BATTERY SUPPLY SYSTEM 235
24VDC Battery Charging Alternator 235
Battery Box 235
Removal 236
Installation 236
Battery Control Box 237
24VDC Auxiliary Battery Receptacles 237
Isolator Diode 237
Engine Start Relay 237
Isolation Box Assembly 237
Engine Shutdown Switch 238
Access Ladder Light Switch 238
Battery Disconnect Switches 238
Propel Lockout Lever 238
LED Lights 238
24VDC to 12VDC Converter 238
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 239
Operation 239
Pressure Switch 240
Check Valve 240
Timer Solenoid 240
MAINTENANCE 240
Prelube System Operation Checks 240
Check Valve 240
Timer Solenoid 240
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 241
24VDC ELECTRIC START SYSTEM 243
CRANKING MOTORS 243
Operation 243
Removal 243
Installation 243
CRANKING MOTOR TROUBLESHOOTING 244
Preliminary Inspection 244
No-Load Test 244
Interpreting Results of Tests 245
Disassembly 245
Cleaning and Inspection 246
Armature Servicing 248
Field Coil Checks 248
Field Coil Removal 248
SOLENOID CHECKS 249
Test 249
Assembly 250
Bearing Replacement: 250
Motor Assembly: 250
Pinion Clearance 251
MAGNETIC SWITCH 251
Removal 251
Installation 251
Coil Test 252
24VDC ELECTRICAL SYSTEM COMPONENTS 253
24 VDC ELECTRICAL SYSTEM COMPONENTS 255
TRUCK SHUTDOWN PROCEDURE 255
BRAKE WARNING BUZZER 255
AUXILIARY CONTROL CABINET COMPONENTS 255
Power Distribution Terminals 255
Pulse Voltage Modulator (PMV) 256
Control Power Relay 256
Auto Lube Timer 256
Ground Level Power Relay 256
Diode Board – DB1 258
Fuse Blocks 259
Alarm Indicating Device (AID) System 259
Diode Matrix (With Sound) 260
Diode Matrix (Without Sound) 260
Hot Switch Inverter 260
Hot Switch Inverter (Not Used) 261
Temperature and Latch 261
RELAY BOARDS 262
Relay Boards RB1, RB3, RB4, RB5 262
Relay Boards RB6, RB7, RB8, RB9 263
Service 263
Relay Board Functions 265
MAGNETIC SWITCHES 267
Body position switches (With proximity switch and magnet) 267
Proximity switch operation 267
Service 267
BODY-UP SWITCH 268
Adjust the body up switch 268
HOIST LIMIT SWITCH 269
Operation 269
Adjust the hoist limit switch 270
FUSE BLOCK CHARTS 272
CIRCUIT BREAKER CHART 274
CIRCUIT BREAKERS 274
KOMTRAX Plus SYSTEM 275
KOMTRAX Plus COMPONENTS 277
KOMTRAX Plus BASIC FEATURES 277
Gather Data 277
Convert and Record Data 277
Communicate Data to Off-Board Systems 278
USING THE KOMTRAX Plus SYSTEM 279
Turning the KOMTRAX Plus System ON 279
Normal KOMTRAX Plus Operation 279
Turning the KOMTRAX Plus System OFF 280
Downloading from the KOMTRAX Plus Controller 280
KOMTRAX Plus DATA ITEMS 281
Fault Codes 281
Machine History 281
KOMTRAX Plus History 281
Snapshots 282
Manual Snapshots 282
Trends 284
Histogram (Load Map) Data 284
Haul Cycle Data 285
Alarm and Snapshot Triggers 286
Satellite Features 286
KOMTRAX Plus DIAGNOSTIC FEATURES 288
Fault History 288
KOMTRAX Plus LED Digits 288
KOMTRAX Plus CONTROLLER 288
Removal 289
Installation 289
KOMTRAX Plus SOFTWARE 291
NECESSARY SOFTWARE 291
NECESSARY TOOLS 291
KOMTRAX Plus SYSTEM SET UP 292
KOMTRAX Plus Controller 292
KOMTRAX Plus CONTROLLER 292
KOMTRAX Plus TOOL BOX 292
Installation 292
KOMTRAX Plus SETTING TOOL 292
Installation 292
KOMTRAX Plus INITIALIZATION PROCEDURE 293
1 KOMTRAX Plus CONTROLLER SETUP PROCEDURE 293
KOMTRAX Plus Setting Tool software program 293
Select Operation 293
KOMTRAX Plus Setting Function 294
Machine Information Setting(1) 294
Machine Information Setting(2) 294
Date & Time Setting 294
GCC Setting 295
Setting Summary 295
2 KOMTRAX Plus SNAPSHOT PROCEDURE 296
3 KOMTRAX Plus DOWNLOAD PROCEDURE 297
4 LOCATION OF DOWNLOAD FILES 297
5 KOMTRAX Plus FTP UPLOAD PROCEDURE 298
6 KOMTRAX Plus INITIALIZATION FORMS 299
WHEN REPLACING A KOMTRAX Plus CONTROLLER 300
To Set: Date & Time; Satellite; Payload Meter 302
Review Setting Information 304
KOMTRAX Plus CONTROLLER CHECKOUT 305
KOMTRAX Plus Controller 305
Necessary Equipment: 305
Preliminary 306
KOMTRAX Plus Controller Checkout Procedure 307
ORBCOMM CONTROLLER 309
Removal 309
Installation 309
INTERFACE MODULE 311
INTERFACE MODULE 313
Removal 313
Installation 313
SENSORS 314
Temperature Sensors 314
Pressure Sensors 314
INTERFACE MODULE SOFTWARE 315
NECESSARY SOFTWARE 315
NECESSARY TOOLS 315
FLASHBURN PROGRAM 316
Installation 316
INTERFACE MODULE APPLICATION CODE 316
Installation 316
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 316
Installation 316
Using The Program 316
INTERFACE MODULE CHECKOUT 317
Interface Module 317
Necessary Equipment: 317
Preliminary 318
Checking Inputs And Outputs From The Interface Module 318
Check Analog Inputs To The Interface Module 322
Check CAN RPC & J1939 Interfaces To The IM 322
Check Outputs From The Interface Module 322
KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES 325
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 327
TROUBLESHOOTING 327
GENERAL 327
Structure and Purpose 327
TROUBLESHOOTING 328
Communications Networks 328
Coaxial Cable 328
FAULT CODES 329
Fault History 329
KOMTRAX Plus LED Display Fault Codes 330
Chassis Fault Codes 331
Engine Fault Codes 335
FAULT TREE ANALYSIS 341
Unable to connect to KOMTRAX Plus from laptop PC 341
Flashing Error Code N4-23 (PLM III Communications Fault) 342
Flashing Error Code N4-22 (Engine Communications Fault) 343
No Data Received By WebCARE 344
Coaxial Cable Troubleshooting 345
KOMTRAX PLUS FORMS 347
KOMTRAX PLUS FORMS 349
KOMTRAX PLUS INITIALIZATION CHECK LIST 349
KOMTRAX PLUS DATA DOWNLOAD 350
KOMTRAX PLUS INITIALIZATION CHECK LIST 351
KOMTRAX PLUS INITIALIZATION FORM 353
SECTION E ELECTRIC PROPULSION 355
ELECTRIC PROPULSION SYSTEM COMPONENTS 357
ELECTRICAL PROPULSION SYSTEM COMPONENTS 359
GENERAL SYSTEM DESCRIPTION 359
SYSTEM COMPONENTS 361
Propulsion System Controller (PSC) 361
Truck Control Interface (TCI) 362
Diagnostic Information Display (DID) Panel 363
DID Panel Event Codes 363
PSC SOFTWARE FUNCTIONS 382
Input Processing 382
State Machine 382
DC Link State 385
Engine Control 386
ALTERNATOR FIELD CONTROL 386
Desired Three-Phase Voltage 386
Desired DC Link Voltage 386
Self-Load 387
Propel Torque Control 387
Retard Torque Control 387
Wheel Slide Control 388
Resistor Grid Control 388
Chopper Voltage Control 388
EVENT DETECTION AND PROCESSING 388
Power-On Tests 388
Initiated Tests 389
Periodic Tests 389
EVENT RESTRICTIONS 389
EVENT LOGGING AND STORAGE 389
Event History Buffer 390
Data Packs 390
To Record and Save a Data Pack to a Disk 390
Event Reset 391
SERIAL DATA COMMUNICATIONS 391
PSC – TCI Communications Processing 391
PSC – PTU Communications Processing 391
Inverter Communications Processing 392
OUTPUT PROCESSING 392
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 392
Fast Start 392
Engine Shutdown/Engine Not Running 392
Limp Home Mode 393
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 394
ELECTRONIC ACCELERATOR AND RETARD PEDALS 402
Removal 402
Installation 402
Disassembly 402
Assembly 402
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 403
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 405
AC DRIVE SYSTEM MAINTENANCE 405
NORMAL TRUCK SHUTDOWN PROCEDURE 406
SHUTDOWN AFTER SYSTEM FAILURE 406
SYSTEM CHECKOUT 407
Battery and Control Circuit Checks – Battery Power OFF 407
Battery and Control Circuit Checks – Battery Power ON 410
Checks with Key Switch OFF 411
Checks with Key Switch ON 411
CPU Battery Checks 411
MEMORY BACKUP BATTERY REPLACEMENT 412
TCI PROGRAMMING 412
PSC PROGRAMMING 413
INVERTER PROGRAMMING 413
CPU RESET 413
PSC CHECKOUT 414
PSC Digital Input Checks 414
PSC Digital Output Checks 418
TCI CHECKOUT 419
Modular Mining Communication Port Check 419
TCI Digital Input Checks 419
TCI Digital Output Tests 425
CALIBRATIONS 428
Speedometer 428
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial 428
ERASING EVENTS 428
PSC 428
TCI 429
GATE DRIVER POWER CONVERTER TEST 429
LOAD TESTING 430
Preparation 430
Alternator Speed Sensor Checks 430
Battery Boost Check 430
Brake Circuit Switch Checks 431
Hoist & Steering Circuit Switch Checks 431
Link Energized Checks 431
Loadbox Test 433
TROUBLESHOOTING 437
PVM Optimum Load Curve Handshaking Troubleshooting 437
Phase Module and Chopper Module Troubleshooting 437
PHASE MODULE REPLACEMENT 438
Phase Module Removal 438
Phase Module Installation 438
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 439
TIRES AND RIMS 441
TIRES AND RIMS 443
FRONT TIRES AND RIMS 443
Removal 443
Installation 445
REAR TIRES AND RIMS 445
Removal 445
Installation 446
RIM AND TIRE 448
Tire Removal 448
Rim And Tire Preparation 448
Lubricants 449
Tire Installation 449
FRONT WHEEL HUB AND SPINDLES 451
FRONT WHEEL HUB AND SPINDLE 453
WHEEL HUB AND SPINDLE ASSEMBLY 453
Removal 453
Spindle Removal Procedure (Optional) (off of the truck) 456
Installation 458
Disassembly 461
Cleaning and Inspection 461
Assembly 462
Wheel Bearing Adjustment (Tire Removed) 464
Wheel Bearing Adjustment (Tire mounted) 465
OIL SAMPLING PROCEDURE 466
Oil Sampling Guidelines 467
Procedure 467
OIL DRAIN AND REFILL PROCEDURE 467
STEERING CYLINDERS 468
Spherical Bearing Wear Limits 468
Removal 469
Installation 469
Bearing Replacement (Steering cylinder and tie rod) 469
TIE ROD 471
Removal 471
Installation 471
Disassembly 472
Assembly 472
TOE-IN ADJUSTMENT 473
REAR AXLE HOUSING ATTACHMENT 475
REAR AXLE HOUSING ATTACHMENT 477
PIVOT PIN 477
Removal 477
Installation 477
PIVOT EYE BEARING 478
Disassembly 478
Assembly 478
PIVOT EYE REPAIR 479
Removal 479
Installation 479
Disassembly 479
Assembly 479
ANTI-SWAY BAR 480
Removal 480
Installation 480
Disassembly 480
Cleaning and Inspection 480
Assembly 480
REAR AXLE HOUSING 481
REAR AXLE HOUSING 483
REAR AXLE HOUSING 483
Removal 483
Installation 483
WHEEL MOTOR 484
Removal 484
Cleaning and Inspection 484
Installation 485
WHEEL MOTOR GEAR OIL 488
Change/Filter The Gear case Oil 488
Oil 488
Remove And Clean Magnetic Plugs 488
Flushing The Gearbox 488
Check Gear Case Oil Level 488
SECTION H SUSPENSIONS 489
FRONT SUSPENSION 491
FRONT SUSPENSION 493
Removal 493
Installation 494
TURN-OF-THE-NUT Tightening Procedure 496
Upper Mounting Joint – 60° Advance 496
Lower Mounting Joint – 90° Advance 498
Inspection 498
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 499
Bearing Structure Removal 499
Bearing Structure Installation 499
MAJOR SUSPENSION REBUILD 500
Disassembly 500
Assembly 501
PRESSURE TEST 502
REAR SUSPENSIONS 503
REAR SUSPENSIONS 504
Removal 504
Installation 507
ROD DOWN SUSPENSION 508
Disassembly 508
Cleaning and Inspection 508
Assembly 510
PRESSURE TEST 512
Suspension pressure test 512
OILING AND CHARGING PROCEDURE 513
OILING AND CHARGING PROCEDURE 515
GENERAL 515
EQUIPMENT LIST 515
HYDRAIR® CHARGING KIT 516
Installation of Charging Kit 516
Removal of Charging Kit 516
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 517
FRONT SUSPENSION 517
Front Suspension Oiling 517
Front Suspension Nitrogen Charging 519
REAR SUSPENSION – ROD DOWN 521
Rear Suspension Oiling (Rod Down Only) 521
Rear Suspension Nitrogen Charging (Rod Down Only) 523
OIL AND NITROGEN SPECIFICATIONS CHART 525
SECTION J BRAKE CIRCUIT 527
BRAKE CIRCUIT 529
BRAKE CIRCUIT 531
OPERATION 531
SERVICE BRAKE CIRCUIT OPERATION 531
SECONDARY BRAKING AND AUTOMATIC APPLY 533
PARKING BRAKE CIRCUIT 533
Normal Operation (key switch on, engine running) 533
BRAKE LOCK CIRCUIT 534
WARNING CIRCUIT 534
BRAKE CIRCUIT COMPONENT SERVICE 537
BRAKE CIRCUIT COMPONENT SERVICE 539
BRAKE VALVE 539
Rebuild Criteria 539
Removal 539
Installation 541
DISASSEMBLY 543
Cleaning and Inspection 545
ASSEMBLY 545
Actuator Base Threaded Inserts 545
Boot and Cap 545
Valve Body Seal Installation 546
Regulator Sleeve O-Ring Installation 546
Actuator Plunger O-ring Installation 547
Assembly of Valve 547
VALVE BENCH TEST AND ADJUSTMENT 549
Test Set Up Procedure 550
Brake Valve Output Pressure Adjustment 550
Final Test and Adjustment 551
Installation Of Brake Pedal Actuator Assembly to Brake Valve 552
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 554
Installation of Retard Pedal To Brake Pedal 554
HYDRAULIC BRAKE ACCUMULATORS 555
Brake Accumulator Bleed Down Procedure 555
Removal 555
Installation 555
Disassembly 555
Cleaning and Inspection 557
Assembly 557
Charging Procedure 559
BRAKE MANIFOLD 560
Removal 560
Removal 560
Installation 561
Disassembly 561
Cleaning and Inspection 562
Assembly 562
BRAKE CIRCUIT CHECK-OUT PROCEDURE 563
BRAKE CIRCUIT CHECK-OUT PROCEDURE 565
EQUIPMENT REQUIRED 567
INITIAL SYSTEM SET-UP 568
PARKING BRAKE 568
BRAKE SYSTEM CHECK-OUT 569
BRAKE LOCK 569
FAILURE MODES CHECK-OUT 570
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 571
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 574
WHEEL SPEED FRONT DISC BRAKES 577
BRAKE CALIPER 579
Caliper Removal 579
Installation 580
Disassembly 581
Assembly 581
Cleaning and Inspection 582
BRAKE LINING 583
Replacement 583
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 585
GENERAL 585
Safety Precautions 585
Front Brake Conditioning 585
BRAKE BLEEDING PROCEDURES 586
ARMATURE SPEED REAR DISC BRAKES 587
ARMATURE SPEED REAR DISC BRAKES 589
REAR BRAKES 589
CALIPER AND DISC 589
Removal 589
Installation 591
PARK BRAKE ADJUSTMENT PROCEDURE 593
BRAKE BLEEDING PROCEDURE 594
Service Brake 594
Park Brake 594
CALIPER 595
Disassembly 595
PISTON SUBASSEMBLY 598
Disassembly 598
PREPARATION FOR ASSEMBLY 599
Clean Parts 599
For Rough Metal Parts 600
Dry and Inspect Parts 600
Corrosion Protection 600
INSPECTION 600
Caliper Parts 600
Shoes, Linings and End Plates 601
Inspect linings 601
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 601
Piston Assembly Adjuster Grip Force 602
Adjuster Force 604
Piston Return Spring 606
ASSEMBLY 607
Adjuster and Pin Assembly 607
Piston Subassembly 608
Brake Caliper 609
PERIODIC INSPECTIONS 615
Shoes, Linings and End Plates 615
Inspect the following areas for fluid leaks 615
Dust Boots 615
Brake Disc 615
BRAKE LINING 616
Replacement 616
BRAKE DISC 616
Inspection 616
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 617
GENERAL 617
SAFETY PRECAUTIONS 617
Rear Brake Conditioning 618
SECTION L HYDRAULIC SYSTEM 621
HYDRAULIC SYSTEM 623
HYDRAULIC SYSTEM 625
HYDRAULIC SYSTEM OPERATION 625
COMPONENT DESCRIPTION 626
Hoist Pump 626
Steering/Brake Pump 626
Tank 626
High Pressure Hydraulic Filters 626
Bleeddown Manifold 626
Steering System Accumulators 626
DISABLED TRUCK CONNECTORS 628
GENERAL 628
STEERING AND BRAKE SYSTEM 628
Hookup 628
HOIST SYSTEM 629
Hookup 629
Dumping Procedure 629
HYDRAULIC SYSTEM COMPONENT REPAIR 631
HYDRAULIC SYSTEM COMPONENT REPAIR 633
HOIST PUMP 633
Removal 633
Installation 634
Disassembly 636
Inspection Of Parts 639
Assembly 640
HYDRAULIC TANK 646
Filling Instructions 646
Removal 646
Installation 647
HYDRAULIC TANK STRAINERS 648
Removal 648
Inspect and Clean 648
Installation 649
HYDRAULIC TANK BREATHERS 649
HOIST CIRCUIT FILTERS 650
FILTER ELEMENT REPLACEMENT 651
Removal 651
Installation 651
INDICATOR SWITCH 651
STEERING CIRCUIT 653
STEERING CIRCUIT 655
STEERING CIRCUIT OPERATION 655
COMPONENT DESCRIPTION 656
STEERING CONTROL UNIT 656
FLOW AMPLIFIER 656
No Steer 658
Steering Left 660
Steering Right 662
No Steer, External Shock Load 664
BLEED DOWN MANIFOLD 666
ACCUMULATORS 669
Low Precharge Warning Switch 669
HIGH PRESSURE FILTER 669
STEERING/BRAKE PUMP 669
Operation 670
PRINCIPLE OF OPERATION 672
Full Pump Volume: 672
Half Pump Volume: 672
Neutral Position: 673
STEERING CIRCUIT COMPONENT REPAIR 675
STEERING CIRCUIT COMPONENT REPAIR 677
BLEED DOWN MANIFOLD 677
Removal 677
Installation 677
ACCUMULATOR 678
Removal 678
Installation 679
Disassembly 679
Cleaning and Inspection 680
Assembly 680
LEAK TESTING 682
STEERING ACCUMULATOR CHARGING PROCEDURE 683
Temperature During Precharge 686
ACCUMULATOR STORAGE PROCEDURES 686
Instructions For Storing Bladder Accumulators 686
Installation 687
Bladder Storage Procedures 687
FLOW AMPLIFIER 688
Removal 688
Installation 688
Disassembly 690
Reassembly 691
STEERING CONTROL UNIT 692
Removal 692
Spline Inspection 692
Installation 693
Disassembly 693
Cleaning and Inspection 694
Assembly 695
STEERING CYLINDER 699
Disassembly 699
Inspection and Cleaning 699
Assembly 699
Testing 699
STEERING CIRCUIT FILTER 700
Filter Element Replacement 700
Removal 701
Installation 701
Indicator Switch 701
STEERING AND BRAKE PUMP 702
Removal 702
Installation 703
Disassembly 704
Control Piston Group 704
Valve Plate Group 705
Rotating Group 705
Swashblock Group 706
Driveshaft Group 706
INSPECTION 706
Control Piston Group 706
Valve Plate Group 706
Rotating Group 706
Swashblock Group 710
Driveshaft Group 710
Compensator Block and Unloader Module 710
Stroke Adjuster Assembly 710
ASSEMBLY 710
Swashblock Group 710
Driveshaft Group 711
Rotating Group 712
Control Piston Group 712
Valve Plate Group 713
HOIST CIRCUIT 715
HOIST CIRCUIT 717
HOIST CIRCUIT OPERATION 717
COMPONENT DESCRIPTION 718
Hydraulic Tank 718
Hoist Pump 718
High Pressure Filters 718
Hoist Valve 719
Hoist Pilot Valve 720
Hoist-up Limit Solenoid 720
Pilot Operated Check Valve 720
Counterbalance Valve Manifold 721
HOIST SYSTEM OPERATION MODES 722
Float Position Of Pilot Valve And Body On Frame (Figure 7-6) 722
Power Up Operation (Figure 7-7) 724
Hold Operation (Figure 7-8) 726
Power Down Operation (Figure 7-9) 728
Float Operation (Figure 7-10) 730
HOIST CIRCUIT COMPONENT REPAIR 733
HOIST CIRCUIT COMPONENT REPAIR 735
HOIST VALVE 735
Removal 735
Installation 735
O-Ring Replacement 736
INLET SECTION 737
Disassembly 737
Cleaning and Inspection 738
Assembly 738
SPOOL SECTION 738
Disassembly 738
Cleaning and Inspection 741
Assembly 741
HOIST PILOT VALVE 742
Removal 742
Installation 742
Disassembly 743
Cleaning and Inspection 744
Assembly 745
BODY UP LIMIT SOLENOID 746
PILOT OPERATED CHECK VALVE 746
HOIST CYLINDERS 746
Removal 746
Installation 747
Disassembly 748
Cleaning and Inspection 750
ASSEMBLY OF QUILL AND CYLINDER 751
Quill Installation 751
Installation of Check Balls and Plugs in Quill 752
Assembly of Cylinder 753
Pressure Testing 754
OVERCENTER MANIFOLD 755
HYDRAULIC CHECKOUT PROCEDURE 757
HYDRAULIC CHECKOUT PROCEDURE 759
STEERING AND BRAKE PUMP 759
Pressure Check And Adjustment Procedure 759
BLEEDDOWN MANIFOLD 761
SHOCK & SUCTION VALVES 761
Shock & Suction Valve Settings 761
LEAKAGE TESTS 763
Steering Control Unit & Flow Amplifier 763
Bleeddown Manifold 763
ACCUMULATOR BLEED DOWN PROCEDURE 764
LOW STEERING PRESSURE SWITCH 766
CHECKING HOIST SYSTEM PRESSURES 773
Hoist System Relief Pressure Adjustment 773
Power Down Relief Pressure Adjustment 774
HOIST COUNTERBALANCE VALVE 775
Preparation: 775
Counterbalance Valve Pressure Check Only: 775
Counterbalance Valve Adjustment 776
OIL CLEANLINESS CHECK 779
SECTION M OPTIONS AND SPECIAL TOOLS 781
HEATER OPTIONS 783
GENERAL INFORMATION 785
TROUBLESHOOTING 785
HEATER ELEMENT 785
Removal 785
Installation 786
GENERAL 787
Maintenance 787
HEATING ELEMENT 787
Removal 787
Installation 788
THERMOSTAT 788
Removal 788
Installation 788
GENERAL INFORMATION 789
TROUBLESHOOTING 789
HEATER ELEMENT 789
Removal 789
Installation 790
SPECIAL TOOLS 791
NITROGEN CHARGING VALVE 791
ROLL-OUT ASSEMBLY 791
EYE BOLT 791
OFFSET WRENCH 792
TORQUE ADAPTER 792
HANDLE 792
SEAL INSTALLER 792
SLEEVE ALIGNMENT TOOLS 793
QUICK DISCONNECT COUPLING 793
HARNESS 793
SEAL INSTALLATION RING 793
BELT TENSION TESTER 794
BELT ALIGNMENT TOOL 794
SOCKETS AND ADAPTERS 794
DUST CAPS 794
HYDRAULIC SYSTEM FLUSHING TOOLS 795
PAYLOAD DATA MANAGER 795
HYDRAULIC SYSTEM VACUUM PUMP 795
MISCELLANEOUS SERVICE TOOLS 796
BRAKE PISTON TOOL 797
HIGH VOLTAGE TOOLS 800
2000 VDC METER 800
GROUNDING STICKS 800
BODY PAD SPACER TOOL 801
RADIATOR SHUTTERS 803
RADIATOR SHUTTERS 805
OPERATION 805
Hydraulic Circuit 805
Electrical Circuit: 806
MAINTENANCE AND REPAIR 806
TROUBLESHOOTING 807
Hydraulic Troubleshooting 810
Electrical Troubleshooting 812
PAYLOAD METER III ™ 813
OPERATION SECTION 817
Introduction 817
Data Summary 817
Data Gathering 817
COMPONENT DESCRIPTION 818
System Diagram 818
Suspension Pressure Sensors 818
Inclinometer 818
Operator Display 818
Operator Switch 819
Speed Input 819
Body-Up Switch 819
Brake Lock Switch 819
Payload Meter 819
Communications Ports 819
Key Switch Input 820
Payload Meter Power 820
Load Lights 820
Wiring and Termination 821
TCI Outputs 821
OPERATOR’S DISPLAY AND SWITCH 822
Reading the Speedometer 822
Reading the Load Display 822
Using the Operator ID 822
Using the Load and Ton Counter 822
Total Ton Counter 822
Total Load Counter 823
Clearing the Counters 823
Viewing Live Sensor Data 823
Other Display Messages 823
PAYLOAD OPERATION & CALCULATION 824
Description of Haul Cycle States 824
Haul Cycle Description 824
Load Calculation 825
Carry Back 825
Measurement Accuracy 825
SOURCES FOR PAYLOAD ERROR 825
Payload Error 825
Loading Conditions 826
Pressure Sensors 826
Swingloads 826
Speed and Distance 826
HAUL CYCLE DATA 826
Haul Cycle Warning Flags 828
Frame Torque Data 829
Sprung Weight Data 829
Maximum Speed Data 829
Alarm Records 829
Fault Code Data 830
PC SOFTWARE OVERVIEW 831
System Configuration 831
Installing the PLMIII Software 831
DOWNLOADING DATA 832
PLM III SYSTEM CONFIGURATION 833
Starting Communications 833
Displayed Payload Units 833
Time Units 833
Connection Menu 833
Connecting to the Payload Meter 834
Configure the Payload Meter 834
Setting the Date and Time 834
Setting the Truck Type 835
Setting the Gauge Display Units 835
Setting the Frame Serial Number 835
Setting the Truck Number 835
Setting the Komatsu Distributor 835
Setting the Komatsu Customer 835
Clean Truck Tare 836
Inclinometer Calibration 836
DATA ANALYSIS 837
Creating a Query 837
Sorting on Truck Unit Number 837
Sorting on Truck Type 837
Sorting on Date Range 838
Sorting on Time Range 838
Payload Detail Screen 839
Creating Reports 839
Summary – one page report 840
Detailed – multi-page report 840
Creating Graphs 841
Exporting Data 841
CSV Export 841
Compressed 842
Importing Data 843
Deleting Haul Cycle Records 843
Viewing Alarms 844
Deleting Alarm Records 844
TROUBLESHOOTING SECTION 845
TROUBLESHOOTING 845
Viewing Active Alarms 845
Real-Time Data Display 845
Testing the Payload Lights 845
Creating Log Files of Inputs 846
Daily Inspections 846
Periodic Maintenance 846
Abnormal Displays at Power-Up 847
No Payload Display When Key Switch is Turned ON 848
No Display on Speedometer 849
No Display on Operator Display 849
No Communications With PC 850
Load Lights Don’t Light During Loading 851
Load Lights Remain ON 852
Load Lights Remain ON During Dumping 852
Display Doesn’t Clear When The Load Is Dumped 852
Calibration Problems 853
Alarm 1 – Left Front Pressure High 854
Alarm 2 – Left Front Pressure Low 854
Troubleshoot Wiring to Left Front Suspension 854
Alarm 3 – Right Front Pressure High 855
Alarm 4 – Right Front Pressure Low 855
Troubleshoot Wiring to Right Front Suspension 855
Alarm 5 -Left Rear Pressure High 856
Alarm 6 – Left Rear Pressure Low 856
Troubleshoot Wiring to Left Rear Suspension 856
Alarm 7 – Right Rear Pressure High 857
Alarm 8 – Right Rear Pressure Low 857
Troubleshoot Wiring to Right Rear Suspension 857
Alarm 9 – Inclinometer High 858
Alarm 10 – Inclinometer Low 858
Troubleshoot Inclinometer Wiring 858
Alarm 13 – Body Up Input Failure 859
Alarm 16 – Memory Write Failure 860
Alarm 17 – Memory Read Failure 860
Alarm 18 861
Alarm 19 861
Alarm 22 861
Operator Switch Doesn’t Work 862
Alarm 26 – User Switch Fault – SELECT 862
Alarm 27 – User Switch Fault – SET 862
Connector Map 863
Connectors 864
PLMIII CHECK OUT PROCEDURE 865
General Description 865
Tools Required 865
Checkout Procedure 865
PLMIII CHECKOUT PROCEDURE CONFIRMATION 869
Flashburn Programming 869
Confirmation Checklist 871
RESERVE ENGINE OIL SYSTEM 873
RESERVE ENGINE OIL SYSTEM 875
Operation 876
LED Monitor Light 876
Tank Fill Control (Optional) 877
Filling Procedure (Remote Fill Feature) 877
SERVICE 878
Every 10 Hours, or once each shift: 878
Every 500 Hours 878
Changing Oil 878
TROUBLESHOOTING 879
Circuit Fuse 879
SYSTEM ELECTRICAL SCHEMATICS 880
RETRACTABLE LADDER SYSTEM 881
RETRACTABLE LADDER SYSTEM 886
GENERAL SAFETY 886
LADDER SYSTEM DESCRIPTION 886
LADDER SYSTEM OPERATION 886
Normal Operation 886
Emergency Operation 888
Limit Switch Operation 888
IN-CAB CONTROL PANEL 888
IN-CAB CONTROL PANEL FEATURES 890
Digital Display Screen 890
Command Buttons 890
IN-CAB CONTROL PANEL FUNCTIONS 892
Timing Control 892
Ladder System Status 892
Fault Code Identification 892
Ladder System Configuration 893
In-Cab Control Panel Lockout 893
Automatic Raising 893
Diagnostics 893
Maintenance 893
USING THE IN-CAB CONTROL PANEL 894
Raising the Ladder 894
Lowering the Ladder 895
USING THE GROUND LEVEL CONTROL BOX 896
Raising the Ladder 896
Lowering the Ladder 896
POWER PACK OPERATION 897
MAINTENANCE 901
Safety During Maintenance 901
Unplanned Ladder Movements 901
Automatic Ladder Raising 901
Automatic Accumulator Recharging (Ladder in UP position) 902
PREVENTIVE MAINTENANCE PROCEDURES 903
Daily Inspection 903
250 Hour Inspection 903
5000 Hour Inspection 903
SERVICING 904
Check Reservoir Oil Level 904
Changing RLS Fluid 904
Cleaning the RLS 905
RLS DIAGNOSTICS 905
Description of Diagnostics Features 905
Continuous System Monitoring 906
Historic System Data Review 907
Comms Integrity Monitoring 907
Log and Service Information 907
System Event Logs 908
SECURITY ACCESS LEVELS 909
Access Level 1 – NONE 909
Access Level 2 – RESTRICTED 909
Access Level 3 – COMPLETE 909
User Access Privileges 910
USER ID – PASSWORD 911
Sequential Field Value Selection Options 911
Password Character Table 911
USER ID – NEW USER SETUP 912
SYSTEM FAULTS 912
Fault Type 1: Communications error 913
Fault Type 2: 10A/15A fuse blown 913
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 914
Fault Type 8: Power pack recharge too long 914
Fault Type 9: Inhibit relay fail 915
Fault Types 10, 11: Light/Siren relay failure 915
Fault Type 12: Ladder came off upper limit 916
Fault Type 13: Ladder did not reach limit 916
Fault Type 14: Ladder stayed on limit 917
Fault Type 15: Low oil level 917
Fault Type 16: System voltage over 18V during movement 918
Fault Type 17: System voltage under 18V 918
Fault Type 18: System voltage over 31V 919
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 919
Fault Type 21: Accumulator recharge > than once/hour 920
Fault Type 22: System raised by park brake 920
Fault Types 23, 24: Levels 1 and 2 service overdue 921
Fault Type 25: Levels 1 and 2 service complete 921
DATA MANAGEMENT 922
Log Files 922
Generating Reports 923
MENU DIAGRAMS 929
Controller Config 929
Contact Information 929
Show Recent Logs 929
System Settings 929
Upload Logs to USB 929
Diagnostics 929
CAMERA SYSTEM 937
CAMERA SYSTEM 938
CAMERA SYSTEM 938
General 938
Operation 938
Camera Switch 939
CAMERA MONITOR 940
General 940
CAMERA CONTROLLER 941
General 941
Removal 941
Installation 941
Camera Controller Pins 941
CAMERA SWITCHER 942
General 942
Removal 942
Installation 942
SETUP AND CHECKOUT PROCEDURE 943
General 943
STEP 1 – Switch Function 943
STEP 2 – Monitor System Settings to Default 943
STEP 4 – Monitor Settings – System Settings Unique 945
STEP 4 – Monitor Settings – System Settings Unique – Cameras 947
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay 949
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode 950
STEP 7 – Integrated Functions Check 951
SECTION N OPERATOR CAB 953
TRUCK CAB AND COMPONENTS 955
TRUCK CAB AND COMPONENTS 957
TRUCK CAB 957
Description 957
Removal 958
Installation 959
CAB DOOR 960
Removal 960
Installation 960
Door Adjustment 960
Door Jamb Bolt Adjustment 961
Door Handle Plunger Adjustment 962
Replace Door Glass 963
Replace Door Window Regulator 967
Replacing the Door Handle or Latch Assembly 968
Replacing the Door and Door Hinge Seal 968
Removing the Door Opening Seal 969
Installation 969
GLASS REPLACEMENT 970
Adhesive-bonded Windows 970
Replacement Procedure 970
WINDSHIELD & REAR GLASS 972
Removal 972
Installation 972
CAB COMPONENTS 975
CAB COMPONENTS 977
WINDSHIELD WIPERS 977
WIPER MOTOR 977
Removal 977
Installation 977
WIPER ARM 977
Removal 977
Installation 978
WIPER LINKAGE 978
Removal 978
Installation 978
WINDSHIELD WASHER 979
Operation 979
Service 979
OPERATOR SEAT (STANDARD SEAT) 980
Adjustment 980
Inspection 981
Removal 981
Installation 981
PASSENGER SEAT (STANDARD SEAT) 982
Inspection 982
Removal 982
Installation 982
SEAT BELT REPLACEMENT (STANDARD SEATS) 983
Removal 983
Installation 983
OPERATOR’S SEAT (OPTIONAL SEAT) 985
Seat Belts 985
Adjustment 985
PASSENGER SEAT (OPTIONAL SEAT) 986
Seat Belts 986
Adjustment 986
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 987
General 987
Removal 987
OPERATOR COMFORT 991
OPERATOR COMFORT 993
HEATER / AIR CONDITIONER 993
Fan Speed Control Knob 993
Temperature Control Knob 993
Air Flow Directional Knob 993
Heater/Air Conditioner Vents 994
COMPONENTS 994
Fuse and Circuit Breaker 994
Relays 994
Heater Core 994
Fan Motor And Speed Control 995
Actuators 995
Cab Air Filter 995
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 998
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 998
PRINCIPLES OF REFRIGERATION 998
Air Conditioning 998
Refrigeration – The Act Of Cooling 999
The Refrigeration Cycle 999
AIR CONDITIONER SYSTEM COMPONENTS 1000
Compressor (Refrigerant Pump) 1000
Service Valves 1000
Condenser 1000
Receiver-Drier 1000
Expansion Block Valve 1001
Accumulator 1001
Evaporator 1001
ELECTRICAL CIRCUIT 1002
Thermostat 1002
Compressor Clutch 1002
Trinary™ Switch 1003
SYSTEM SERVICING 1004
SERVICE TOOLS AND EQUIPMENT 1005
Recovery/Recycle Station 1005
Leak Detector 1005
Service Valves 1006
Vacuum Pump 1006
Manifold Gauge Set 1007
Installing Manifold Gauge Set 1008
Purging Air From Service Hoses 1008
SYSTEM PERFORMANCE TEST 1009
SYSTEM OIL 1010
Handling and Reusing PAG Oil 1010
Oil Quantity 1010
Checking System Oil 1011
REFRIGERANT 1012
Recycled Refrigerant 1012
Reclaimed Refrigerant 1012
Refrigerant Quantity 1012
R-134a Refrigerant Containers 1012
SYSTEM LEAK TESTING 1013
Electronic Leak Detector 1013
Tracer Dyes 1013
Soap and Water 1013
RECOVERING AND RECYCLING THE REFRIGERANT 1013
Draining Oil from the Previous Recovery Cycle 1013
Performing the Recovery Cycle 1014
Performing the Recycling Procedure 1014
Evacuating and Charging the A/C System 1014
SYSTEM REPAIR 1014
System Flushing 1015
A/C DRIVE BELT CHECKOUT PROCEDURE 1016
Pulley Alignment 1016
Belt Tension Check 1016
COMPONENT REPLACEMENT 1018
Hoses and Fittings 1018
Lines 1018
Expansion Valve 1018
Receiver-Drier 1018
Thermostat 1018
Compressor 1019
Accumulator 1019
Clutch 1019
EVACUATING THE SYSTEM 1020
CHARGING THE A/C SYSTEM 1022
TROUBLESHOOTING 1023
Preliminary Checks 1023
Diagnosis Of Gauge Readings And System Performance 1023
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1024
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1030
OPERATOR CAB CONTROLS 1031
OPERATOR CAB AND CONTROLS 1035
STEERING WHEEL AND CONTROLS 1036
Horn Button 1036
Tilt / Telescope Lever 1036
Multi-Function Turn Signal Switch 1036
STEERING COLUMN 1037
Removal 1037
Steering Column Inspection 1037
Installation 1038
STEERING WHEEL 1038
Removal 1038
Installation 1038
PEDALS 1040
Service Brake Pedal 1040
Dynamic Retarding 1040
Dynamic Retard Pedal 1040
Throttle/Accelerator Pedal 1040
GRADE/SPEED RETARD CHART 1041
OVERHEAD PANEL AND DISPLAYS 1042
CENTER CONSOLE 1043
Directional Control Lever 1043
Override/Fault Reset Switch 1044
Engine Stop Switch 1044
L H Window Control Switch 1044
R H Window Control Switch 1044
Hoist Control Lever 1044
Raising The Dump Body 1044
Lowering The Dump Body 1044
Retard Speed Control (RSC) Adjust Dial 1045
Retard Speed Control (RSC) Switch 1045
Data Store Button 1046
KOMTRAX Plus Snapshot In Progress Light 1046
Link Energized Light 1046
Service Engine Light 1046
DIAGNOSTIC PORTS 1046
KOMTRAX Plus Diagnostic Port 1046
Interface Module (IM) Diagnostic Port 1046
Payload Meter Diagnostic Port 1046
Truck Control Interface (TCI) Diagnostic Port 1046
Propulsion System Controller (PSC) Diagnostic Port 1046
Engine Diagnostic Port (CENSE) 1046
Engine Diagnostic Port (QUANTUM) 1046
HEATER / AIR CONDITIONER 1047
Fan Speed Control Knob 1047
Temperature Control Knob 1047
Air Flow Directional Knob 1047
Heater/Air Conditioner Vents 1047
INSTRUMENT PANEL 1048
Control Symbols 1048
Key Switch 1050
Starting 1050
Grid Dryer (Optional) 1050
Camera System (Optional) 1050
Rotating Beacon Light Switch (Optional) 1050
Heated Mirror Switch (Optional) 1050
Rest Switch 1051
Wheel Brake Lock Control 1051
Hazard Warning Lights 1051
Cab/Air Conditioner Vents 1052
Engine Oil Pressure Gauge 1052
Right Turn Signal Indicator 1052
Tachometer 1052
High Beam Indicator 1052
Speedometer/Payload Meter Display 1052
Left Turn Signal Indicator 1052
Water Temperature Gauge 1052
Lamp Test Switch 1053
Light Switch 1053
Ladder Light Switch 1053
Manual Backup Switch 1053
Fog Lights (Optional) 1053
Payload Meter Switch 1053
Panel Light Dimmer 1054
Hydraulic Oil Temperature Gauge 1054
Hourmeter 1054
Fuel Level Gauge 1054
OVERHEAD STATUS / WARNING INDICATORS 1055
Status / Warning Indicator Light Symbols 1056
REAR AXLE LIGHT BAR 1062
Backup Lights 1062
Retard Lights 1062
Brake Light 1062
Backup Alarm 1062
KOMTRAX PLUS 1063
Operation 1063
Interface Module 1065
Basic Precautions 1065
KOMATSU WIRELESS BRIDGE (Optional) 1066
General Information 1066
Communication Setup 1066
Switching to the KWB_SETUP Network 1066
Setting the Computer Subnet Mask and IP Address 1067
Properties 1067
Setting Up the KWB 1068
Adding Encryption 1068
Final Computer Settings 1068
Data Downloading 1069
Resetting the KWB 1069
KWB Lights 1069
SECTION P LUBRICATION AND SERVICE 1071
LUBRICATION AND SERVICE 1073
LUBRICATION AND SERVICE 1075
830E SERVICE CAPACITIES 1075
HYDRAULIC TANK SERVICE 1075
Adding Oil 1075
COOLANT LEVEL CHECK 1076
Radiator Filling Procedure 1076
Coolant Specifications 1076
Unacceptable Practices 1076
WHEEL MOTOR SERVICE 1076
RESERVE ENGINE OIL SYSTEM (Optional) 1077
Reserve Oil Tank Filling Procedure (Remote fill) 1077
Inline Screen 1077
QUICK FILL SERVICE CENTER 1078
LUBRICATION CHART 1079
10 HOUR (DAILY) INSPECTION 1080
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS 1083
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS 1084
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 1085
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 1089
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS 1091
2500 HOUR MAINTENANCE CHECKS 1092
5000 HOUR MAINTENANCE CHECKS 1092
AUTOMATIC LUBRICATION SYSTEM 1093
AUTOMATIC LUBRICATION SYSTEM 1095
GENERAL DESCRIPTION 1095
SYSTEM COMPONENTS 1097
Filter 1097
Hydraulic Motor and Pump 1097
Grease Reservoir 1097
Pressure Reducing Valve 1097
Flow Control Valve 1097
Solenoid Valve 1097
Vent Valve 1097
Lubrication Cycle Timer 1097
Over Pressure Cut Off Switch 1097
Grease Pressure Failure Switch 1097
Injectors 1097
Relief Valve (unloader valve) 1097
SYSTEM OPERATION 1098
Normal Operation 1098
Lubricant Required For System 1099
System Priming 1099
Filter Assembly 1099
LUBRICANT PUMP 1100
Pump Housing Oil Level 1100
Pump Pressure Control 1100
INJECTORS (SL-1 Series “H”) 1101
Injector Specifications 1101
Injector Adjustment 1101
PREVENTIVE MAINTENANCE PROCEDURES 1103
Daily Lubrication System Inspection 1103
250 Hour Inspection 1103
1000 Hour Inspection 1103
SYSTEM CHECKOUT 1104
Lubrication Controller Check 1104
Lubrication Controller Components 1104
Lubrication Controller Adjustment 1104
SYSTEM TROUBLESHOOTING CHART 1106
SECTION Q ALPHABETICAL INDEX 1109
SECTION R SYSTEM SCHEMATICS 1113
HE484 ELECTRICAL SCHEMATIC 1115
HH360 HYDRAULIC BRAKE SCHEMATIC 1116
EM7611 HYDRAULIC SCHEMATIC 1117
HH364 SCHEMATIC RETRACTABLE LADDER SYSTEM 1118
XS6800 ELECTRICAL SCHEMATIC 1119
XS6801-2 1119
XS6802-0 1120
XS6803-0 1121
XS6804-0 1122
XS6805-0 1123
XS6806-0 1124
XS6807-1 1125
XS6808-1 1126
XS6809-0 1127
XS6810-2 1128
XS6811-0 1129
XS6812-1 1130
XS6813-0 1131
XS6814-0 1132
XS6815-1 1133
XS6816-0 1134
XS6817-1 1135
XS6818-1 1136
XS6819-1 1137
XS6820-1 1138
XS6821-0 1139
XS6822-1 1140
XS6823-0 1141
XS6824-1 1142
XS6825-2 1143
XS6826-3 1144
XS6827-2 1145
XS6828-0 1146
XS6829-1 1147
XS6830-0 1148
XS6831-0 1149
XS6832-2 1150
XS6833-1 1151
XS6834-0 1152
XS6835-0 1153

DESCRIPTION:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM024002  – PDF DOWNLOAD

• SERIAL NUMBERS A30561 & UP

• 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 metric (SI) and U.S. standard 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 135 N·m (100 ft lbs) torque. All torque specifications have ±10%
  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. 830E). The three numbers
  represent the basic truck model. 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. The result is the allowable payload.

G.B  21/12/24