Komatsu 830E-1AC Dump Truck Shop Manual CEBM027402 PDF

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Komatsu 830E-1AC Dump Truck Shop Manual CEBM027402 –  PDF DOWNLOAD

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Komatsu 830E-1AC Dump Truck Shop Manual CEBM027402  – PDF DOWNLOAD

Language : English
Pages : 1440
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM027402  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40851 – A40938 A40995

SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
Main Control Cabinet 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SECTION A2 SPECIFICATIONS 13
SECTION A3 GENERAL SAFETY AND OPERATING INSTRUCTIONS 15
GENERAL SAFETY 20
PRECAUTIONS FOR TRUCK OPERATION 23
OPERATING THE MACHINE 24
TOWING 27
WORKING NEAR BATTERIES 28
PRECAUTIONS FOR MAINTENANCE 30
BEFORE PERFORMING MAINTENANCE 30
DURING MAINTENANCE 34
TIRES 36
ADDITIONAL JOB SITE RULES 40
WHEN REPAIRS ARE NECESSARY 41
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK 43
CAPACITOR DISCHARGE SYSTEM 45
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE 47
CAPACITOR CHARGE LIGHTS 49
FAILURE OF DISCHARGE SYSTEM 50
MANUAL DISCHARGE OF CAPACITORS 51
SHORT ISOLATED CAPACITOR TERMINALS 53
TRUCK OPERATION 55
PREPARING FOR OPERATION 55
WALK AROUND INSPECTION 55
RETRACTABLE LADDER SYSTEM (If equipped) 59
LADDER SYSTEM DESCRIPTION 59
LADDER SYSTEM OPERATION 60
GENERAL SAFETY 60
IN-CAB CONTROL PANEL 60
IN-CAB CONTROL PANEL FEATURES 61
USING THE IN-CAB CONTROL PANEL 62
USING THE GROUND LEVEL CONTROL BOX 64
ENGINE START-UP 66
AFTER ENGINE HAS STARTED 67
PRE-SHIFT BRAKE CHECK (if equipped) 68
OPERATION 68
PERFORMING THE BRAKE TESTS 69
EMERGENCY STEERING SYSTEM 72
MACHINE OPERATION SAFETY PRECAUTIONS 73
MACHINE OPERATION ON THE HAUL ROAD 74
STARTING ON A GRADE WITH A LOADED TRUCK 75
PASSING 75
LOADING 75
DUMPING 76
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION 78
FUEL DEPLETION 78
SAFE PARKING PROCEDURES 79
NORMAL ENGINE SHUTDOWN PROCEDURE 80
DISABLED TRUCK CONNECTORS 81
STEERING AND BRAKE SYSTEM 81
HOIST SYSTEM 82
TOWING 83
WARNINGS AND CAUTIONS 87
SECTION A4 WARNINGS AND CAUTIONS 87
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 101
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 102
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 102
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 103
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 104
SECTION A7 STORAGE PROCEDURES 111
STORAGE AND IDLE MACHINE PREPARATION 113
SHORT TERM IDLE PERIODS 113
PREPARATION FOR STORAGE 114
REMOVAL FROM STORAGE 115
RECONDITIONING AN IDLE VEHICLE 117
ENGINE OPERATION 119
AFTER ENGINE HAS STARTED 120
ENGINE STORAGE 121
ELECTRIC DRIVE TRUCKS 123
TRANSMISSION PRESERVATION AND STORAGE 127
SECTION B STRUCTURES 129
SECTION B2 STRUCTURAL COMPONENTS 131
STRUCTURAL COMPONENTS 133
LADDERS 134
RIGHT DECK 135
LEFT DECK 136
CENTER DECK 137
SECTION B3 DUMP BODY 139
DUMP BODY 141
BODY PADS 143
BODY GUIDE 145
BODY-UP RETENTION SLING 146
BODY POSITION INDICATOR 146
HOIST LIMIT SWITCH 146
BODY UP SWITCH 146
ROCK EJECTORS 147
SECTION B4 FUEL TANK 149
FUEL TANK 150
FUEL TANK VENT ASSEMBLY 152
FUEL GAUGE SENDER (TOP) 153
QUICK FILL FUEL RECEIVERS 155
SECTION C ENGINE 157
SECTION C2 POWER MODULE 159
POWER MODULE 161
PREPARATION 161
REMOVAL 161
INSTALLATION 166
EXHAUST TUBE INSTALLATION 170
EXHAUST BLANKET INSTALLATION 170
SECTION C3 COOLING SYSTEM 171
COOLING SYSTEM DESCRIPTION 173
RADIATOR 174
REPAIRING THE RADIATOR 179
COOLANT SYSTEM TROUBLESHOOTING 182
SECTION C4 POWER TRAIN 183
POWER TRAIN 185
ALTERNATOR REMOVAL PROCEDURE 185
ALTERNATOR INSTALLATION 187
ENGINE 191
SECTION C5 AIR CLEANERS 193
AIR CLEANERS 195
OPERATION 195
SERVICING THE AIR CLEANERS 195
AIR CLEANER ASSEMBLY CLEANING 197
AIR INTAKE TROUBLESHOOTING 200
SECTION C7 FAN CLUTCH 201
FAN CLUTCH 203
REMOVAL & INSTALLATION TOOLING 203
DISASSEMBLY 206
CLEANING AND INSPECTION 216
ASSEMBLY 220
TEST PROCEDURE 235
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 237
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM 239
24VDC ELECTRIC SUPPLY SYSTEM 241
ELECTRICAL SYSTEM DESCRIPTION 241
BATTERIES 241
BATTERY SUPPLY SYSTEM 243
ISOLATION BOX ASSEMBLY 244
AUXILIARY CONTROL CABINET 246
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 247
MAINTENANCE 247
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 248
24VDC ELECTRIC START SYSTEM 250
CRANKING MOTORS 250
CRANKING MOTOR TROUBLESHOOTING 251
SOLENOID CHECKS 256
MAGNETIC SWITCH 258
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS 261
24 VDC ELECTRICAL SYSTEM COMPONENTS 263
TRUCK SHUTDOWN PROCEDURE 263
BRAKE WARNING BUZZER 263
AUXILIARY CONTROL CABINET COMPONENTS 263
MAGNETIC SWITCHES 274
BODY-UP SWITCH 275
HOIST LIMIT SWITCH 276
SECTION D11 KOMTRAX PLUS SYSTEM 279
KOMTRAX PLUS COMPONENTS 281
KOMTRAX PLUS BASIC FEATURES 281
USING THE KOMTRAX PLUS SYSTEM 283
KOMTRAX PLUS DATA ITEMS 285
KOMTRAX PLUS DIAGNOSTIC FEATURES 292
KOMTRAX PLUS CONTROLLER 292
KOMTRAX PLUS SOFTWARE 295
NECESSARY SOFTWARE 295
NECESSARY TOOLS 295
KOMTRAX PLUS TOOL BOX 296
KOMTRAX PLUS SETTING TOOL 296
KOMTRAX PLUS CONTROLLER SETUP PROCEDURE 297
KOMTRAX PLUS SNAPSHOT PROCEDURE 300
KOMTRAX PLUS DOWNLOAD PROCEDURE 301
LOCATION OF DOWNLOAD FILES 301
KOMTRAX PLUS FTP UPLOAD PROCEDURE 302
KOMTRAX Plus INITIALIZATION FORMS 303
KOMTRAX PLUS CONTROLLER CHECKOUT 309
ORBCOMM CONTROLLER 313
SECTION D12 INTERFACE MODULE 315
INTERFACE MODULE 317
SENSORS 318
INTERFACE MODULE SOFTWARE 319
NECESSARY SOFTWARE 319
NECESSARY TOOLS 319
FLASHBURN PROGRAM 320
INTERFACE MODULE APPLICATION CODE 320
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 321
INTERFACE MODULE CHECKOUT 321
SECTION D13 KOMTRAX PLUS & INTERFACE MODULE TROUBLESHOOTING & ERROR CODES 329
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 331
TROUBLESHOOTING 331
GENERAL 331
TROUBLESHOOTING 332
FAULT CODES 333
FAULT TREE ANALYSIS 346
SECTION D14 KOMTRAX PLUS FORMS 351
KOMTRAX PLUS FORMS 353
KOMTRAX PLUS INITIALIZATION CHECK LIST 353
KOMTRAX PLUS DATA DOWNLOAD 354
KOMTRAX PLUS INITIALIZATION CHECK LIST 355
KOMTRAX PLUS INITIALIZATION FORM 357
SECTION E ELECTRIC PROPULSION SYSTEM 359
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS 361
ELECTRICAL PROPULSION SYSTEM COMPONENTS 363
GENERAL SYSTEM DESCRIPTION 363
SYSTEM COMPONENTS 365
DSC SOFTWARE FUNCTIONS 394
ALTERNATOR FIELD CONTROL 398
EVENT DETECTION AND PROCESSING 400
EVENT RESTRICTIONS 402
EVENT LOGGING AND STORAGE 402
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 403
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 405
ELECTRONIC ACCELERATOR AND RETARD PEDALS 412
PHASE MODULE REPLACEMENT 413
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 415
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 417
AC DRIVE SYSTEM MAINTENANCE 417
NORMAL TRUCK SHUTDOWN PROCEDURE 418
TEST EQUIPMENT 419
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 419
REST MODE ACTIVATION 419
INITIAL CHECKOUT PROCEDURES 420
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 436
ENGINE RUNNING TESTS 439
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 449
VIEWING EVENT AND STATISTICAL DATA 474
LOGIC SCREENS 477
DATALOGGER FUNCTION 479
UPLOADING DATA 483
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A139) 485
Fault Code A001: Left front suspension pressure sensor signal is high 487
Fault Code A002: Left front suspension pressure sensor signal is low 488
Fault Code A003: Right front suspension pressure sensor signal is high 489
Fault Code A004: Right front suspension pressure sensor signal is low 490
Fault Code A005: Left rear suspension pressure sensor signal is high 491
Fault Code A006: Left rear suspension pressure sensor signal is low 492
Fault Code A007: Right rear suspension pressure sensor signal is high 493
Fault Code A008: Right rear suspension pressure sensor signal is low 494
Fault Code A009: Incline sensor signal is high 495
Fault Code A010: Incline sensor signal is low 496
Fault Code A011: Payload meter speed sensor signal has failed 497
Fault Code A013: Body up switch has failed 498
Fault Code A014: Payload meter checksum computation has failed 499
Fault Code A016: Payload meter write to flash memory has failed 500
Fault Code A017: Payload meter flash memory read has failed 501
Fault Code A018: Right rear flat suspension cylinder warning 502
Fault Code A019: Left rear flat suspension cylinder warning 504
Fault Code A022: Carryback load is excessive 506
Fault Code A101: High pressure detected across a hydraulic pump filter 508
Fault Code A103: Hydraulic oil tank temperature sensor is reading low 510
Fault Code A104: Hydraulic oil tank temperature sensor is reading high 511
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 512
Fault Code A107: GE has generated a propel system caution 514
Fault Code A108: GE has generated a propel system temperature caution 515
Fault Code A109: GE has generated a propel system reduced level signal 516
Fault Code A111: Low steering pressure warning 518
Fault Code A115: Low steering precharge pressure is detected 520
Fault Code A117: Low brake accumulator pressure warning 522
Fault Code A118: Brake pressure is low while brake lock is activated 524
Fault Code A123: GE has generated a reduced retarding caution 526
Fault Code A124: GE has generated a no propel / no retard or system not running input 528
Fault Code A125: GE has generated a no propel warning 530
Fault Code A126: Oil level in the hydraulic tank is low 531
Fault Code A127: IM furnished +5 volt output for sensors is low 532
Fault Code A128: IM furnished +5 volt output for sensors is high 534
Fault Code A139: Low fuel level warning 536
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A246) 539
Fault Code A152: Starter failure 541
Fault Code A153: Battery voltage is low with truck in operation 542
Fault Code A154: Battery charging voltage is excessive 544
Fault Code A155: Battery charging voltage is low 545
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 546
Fault Code A184: J1939 data link is not connected 547
Fault Code A190: Auto lube control has detected an incomplete lube cycle 548
Fault Code A193: Hydraulic tank oil temperature is high 550
Fault Code A198: Hoist pressure 1 sensor is high 551
Fault Code A199: Hoist pressure 2 sensor is high 552
Fault Code A200: Steering pressure sensor is high 553
Fault Code A201: Brake pressure sensor is high 554
Fault Code A202: Hoist pressure 1 sensor is low 555
Fault Code A203: Hoist pressure 2 sensor is low 556
Fault Code A204: Steering pressure sensor is low 557
Fault Code A205: Brake pressure sensor is low 558
Fault Code A206: Ambient temperature sensor is high 559
Fault Code A207: Ambient temperature sensor is low 560
Fault Code A212: Bad truck speed signal 561
Fault Code A213: Parking brake should have applied but is detected as not having applied 562
Fault Code A214: Parking brake should have released but is detected as not having released 566
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 570
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 572
Fault Code A230: Parking brake has been requested while truck still moving 574
Fault Code A231: Dump body is up while traveling or intending to travel 576
Fault Code A233: Drive system CAN/RPC Control Link not connected 580
Fault Code A235: Steering accumulator is in the process of being bled down 582
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 584
Fault Code A237: The CAN/RPC connection to the display is open 586
Fault Code A240: The keyswitch input to the interface module is open 587
Fault Code A242: The fuel gauge within the display panel is defective 588
Fault Code A243: The engine coolant temp gauge within the display panel is defective 589
Fault Code A244: The drive system temp gauge within the display panel is defective 590
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 591
Fault Code A246: Payload meter reports truck overload 592
SECTION E5 TROUBLESHOOTING FAULT CODES (A247-A292) 593
Fault Code A247: Low steering pressure warning 595
Fault Code A248: The status indicator module within the display panel is defective 597
Fault Code A249: The red warning lamp within the display panel is shorted 598
Fault Code A250: Battery voltage is low with the truck parked 600
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 602
Fault Code A252: Start enable output circuit is either open or shorted to ground 604
Fault Code A253: Steering bleed circuit is not open while running 606
Fault Code A255: IM has detected a fault on IM output 1N 608
Fault Code A256: The red warning lamp within the display panel (driven by IM) is open 609
Fault Code A257: Payload CAN/RPC is not connected 610
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 611
Fault Code A260: Parking brake failure 612
Fault Code A261: Low brake accumulator pressure warning 614
Fault Code A262: Steering bleed valve circuit open during shutdown 616
Fault Code A264: Parking brake relay circuit is defective 618
Fault Code A265: Service brake failure 620
Fault Code A266: Selector lever was not in park while attempting to crank engine 622
Fault Code A267: Parking brake was not set while attempting to crank engine 624
Fault Code A268: Secondary engine shutdown while cranking 626
Fault Code A270: Brake lock switch power supply is not on when required 628
Fault Code A271: Shifter not in gear 630
Fault Code A272: Brake lock switch power supply is not off when required 632
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 634
Fault Code A274: A brake setting fault has been detected 636
Fault Code A275: A starter has been detected as engaged without a cranking attempt 638
Fault Code A276: The drive system data link is not connected 640
Fault Code A277: Parking brake applied while loading 642
Fault Code A278: Service brake applied while loading 644
Fault Code A279: Low steering pressure switch is defective 645
Fault Code A280: Steering accumulator Bleed Down switch is defective 646
Fault Code A281: Brake lock degradation switch is defective 648
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 650
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 652
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 654
Fault Code A285: The parking brake was not set when the key switch was turned off 656
Fault Code A286: A fault was detected in the shutdown delay relay circuit 658
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 660
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) 663
Fault Code A303: Shifter is defective 665
Fault Code A304: Auto lube grease level is low 666
Fault Code A305: Auto lube circuit is defective 667
Fault Code A307: Both GE inverters are disabled 668
Fault Code A309: No brakes applied when expected 670
Fault Code A310: Low fuel level warning 672
Fault Code A311: Brake lock switch is on when it should not be 674
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 676
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 677
Fault Code A315: DC-DC converter 12 volt circuit is low 678
Fault Code A316: Starter engagement has been attempted with engine running 680
Fault Code A318: Unexpected power loss to interface module 682
Fault Code A320: Propel system caution wire input not same as serial input 683
Fault Code A321: Propel system temperature caution wire input not same as serial input 684
Fault Code A322: Propel system at reduced level wire input not same as serial input 685
Fault Code A323: Propel system at reduced retard level wire input not same as serial input 686
Fault Code A324: GE link voltage wire input not same as serial input 687
Fault Code A325: No Propel/Retard wire input not same as serial input 688
Fault Code A326: No Propel wire input not same as serial input 689
Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input 690
Fault Code A328: Drive system not powered up 691
Fault Code A329: Body down wire input not same as serial input 692
Fault Code A330: Dynamic retard switch input not same as serial input 693
Fault Code A332: Seat belt not buckled 694
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 696
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 697
Fault Code A335: Manual/Auto Apply Pressure Fault 698
Fault Code A350: Overload on output 1B 699
Fault Code A351: Overload on output 1E 700
Fault Code A352: Overload on output 1H 701
Fault Code A353: Overload on output 1J 702
Fault Code A354: Overload on output 1K 703
Fault Code A355: Overload on output 1L 704
Fault Code A356: Overload on output 1M 705
Fault Code A357: Overload on output 1N 706
Fault Code A358: Overload on output 1P 707
Fault Code A359: Overload on output 1R 708
Fault Code A360: Overload on output 1S 709
Fault Code A361: Overload on output 1T 710
Fault Code A362: Overload on output 1U 711
Fault Code A363: Overload on output 1X 712
Fault Code A364: Overload on output 1Y 713
Fault Code A365: Overload on output 1Z 714
SECTION G DRIVE AXLE, SPINDLE, AND WHEELS 717
SECTION G2 TIRES AND RIMS 719
TIRES AND RIMS 721
GENERAL PRECAUTIONS 721
RIM COMPONENTS 722
WHEEL STUD MAINTENANCE 723
FRONT TIRES AND RIMS 724
REAR TIRES AND RIMS 727
RIM AND TIRE 730
RIM AND TIRE SERVICE 733
SECTION G3 FRONT WHEEL HUB AND SPINDLES 749
FRONT WHEEL HUB AND SPINDLE 751
WHEEL HUB AND SPINDLE ASSEMBLY 751
OIL SAMPLING PROCEDURE 764
OIL DRAIN AND REFILL PROCEDURE 765
STEERING CYLINDERS 766
TIE ROD 769
TOE-IN ADJUSTMENT 771
TIE ROD INSPECTION AND TORQUE PROCEDURE 772
SECTION G4 REAR AXLE HOUSING ATTACHMENT 775
REAR AXLE HOUSING ATTACHMENT 777
PIVOT PIN 777
PIVOT EYE BEARING 778
PIVOT EYE REPAIR 779
ANTI-SWAY BAR 780
SECTION G5 REAR AXLE HOUSING 783
REAR AXLE HOUSING 785
REAR AXLE HOUSING 785
WHEEL MOTOR 786
WHEEL MOTOR GEAR OIL 790
SECTION H SUSPENSIONS 791
SECTION H2 FRONT SUSPENSION 793
FRONT SUSPENSION 795
TURN-OF-THE-NUT Tightening Procedure 798
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 801
MAJOR SUSPENSION REBUILD 802
PRESSURE TEST 805
SECTION H3 REAR SUSPENSIONS 807
REAR SUSPENSIONS 808
ROD DOWN SUSPENSION 812
PRESSURE TEST 816
SECTION H4 OILING AND CHARGING PROCEDURE 817
CHECKING FOR IMPROPER SUSPENSION CHARGE 819
SUSPENSION OILING AND CHARGING PROCEDURES 820
GENERAL 820
EQUIPMENT LIST 820
HYDRAIR® CHARGING KIT 821
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 822
FRONT SUSPENSION 823
REAR SUSPENSION 826
SUSPENSION PRESSURE TEST 829
OIL AND NITROGEN SPECIFICATIONS CHART 830
SECTION J BRAKE SYSTEMS 831
SECTION J2 BRAKE CIRCUIT 833
BRAKE CIRCUIT 835
OPERATION 835
SERVICE BRAKE CIRCUIT OPERATION 835
SECONDARY BRAKING AND AUTOMATIC APPLY 837
PARKING BRAKE CIRCUIT 837
BRAKE LOCK CIRCUIT 838
WARNING CIRCUIT 838
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE 841
BRAKE CIRCUIT COMPONENT SERVICE 843
BRAKE VALVE 843
BRAKE VALVE/PEDAL ASSEMBLY 846
VALVE BENCH TEST AND ADJUSTMENT 849
INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL BRAKE ASSEMBLY (Dual Function) 855
HYDRAULIC BRAKE ACCUMULATORS 856
BRAKE MANIFOLD 861
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE 865
BRAKE CIRCUIT CHECK-OUT PROCEDURE 867
EQUIPMENT REQUIRED 869
INITIAL SYSTEM SET-UP 870
PARKING BRAKE 870
BRAKE SYSTEM CHECK-OUT 871
BRAKE LOCK 871
FAILURE MODES CHECK-OUT 872
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 873
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 876
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 877
SECTION J5 FRONT BRAKES 879
WHEEL SPEED FRONT DISC BRAKES 881
BRAKE CALIPER 881
BRAKE LINING 885
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 887
GENERAL 887
BRAKE BLEEDING PROCEDURES 888
SECTION J6 ARMATURE SPEED REAR DISC BRAKES 889
ARMATURE SPEED REAR DISC BRAKES 891
REAR BRAKES 891
CALIPER AND DISC 891
PARK BRAKE ADJUSTMENT PROCEDURE 897
BRAKE BLEEDING PROCEDURE 898
CALIPER 899
PISTON SUBASSEMBLY 903
PREPARATION FOR ASSEMBLY 904
INSPECTION 905
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 906
ASSEMBLY 912
PERIODIC INSPECTIONS 920
BRAKE LINING 921
BRAKE DISC 921
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 922
GENERAL 922
SAFETY PRECAUTIONS 922
SECTION L HYDRAULIC SYSTEMS 925
SECTION L2 HYDRAULIC SYSTEM OPERATION 927
HYDRAULIC SYSTEM 929
HYDRAULIC SYSTEM OPERATION 929
COMPONENT DESCRIPTION 930
DISABLED TRUCK CONNECTORS 932
GENERAL 932
STEERING AND BRAKE SYSTEM 932
HOIST SYSTEM 933
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR 935
HYDRAULIC SYSTEM COMPONENT REPAIR 937
HOIST PUMP 937
HYDRAULIC TANK 950
HYDRAULIC TANK STRAINERS 952
HYDRAULIC TANK BREATHERS 953
HOIST CIRCUIT FILTERS 954
FILTER ELEMENT REPLACEMENT 955
INDICATOR SWITCH 955
SECTION L4 STEERING CIRCUIT 957
STEERING CIRCUIT 959
STEERING CIRCUIT OPERATION 959
COMPONENT DESCRIPTION 960
STEERING CONTROL UNIT 960
FLOW AMPLIFIER 960
BLEED DOWN MANIFOLD 970
ACCUMULATORS 973
HIGH PRESSURE FILTER 973
STEERING/BRAKE PUMP 973
PRINCIPLE OF OPERATION 976
SECTION L5 STEERING CIRCUIT COMPONENT REPAIR 979
STEERING CIRCUIT COMPONENT REPAIR 982
BLEED DOWN MANIFOLD 982
ACCUMULATOR 983
LEAK TESTING 987
STEERING ACCUMULATOR CHARGING PROCEDURE 988
ACCUMULATOR STORAGE PROCEDURES 991
FLOW AMPLIFIER 993
STEERING CONTROL UNIT 995
STEERING CYLINDER 1002
STEERING CIRCUIT FILTER 1003
STEERING AND BRAKE PUMP 1005
INSPECTION 1011
ASSEMBLY 1014
TROUBLESHOOTING 1018
STEERING CIRCUIT 1018
STEERING PUMP 1020
SECTION L7 HOIST CIRCUIT 1035
HOIST CIRCUIT 1037
HOIST CIRCUIT OPERATION 1037
COMPONENT DESCRIPTION 1038
HOIST SYSTEM OPERATION MODES 1042
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR 1053
HOIST CIRCUIT COMPONENT REPAIR 1055
HOIST VALVE 1055
INLET SECTION 1057
SPOOL SECTION 1059
HOIST PILOT VALVE 1062
BODY UP LIMIT SOLENOID 1066
PILOT OPERATED CHECK VALVE 1066
HOIST CYLINDERS 1066
ASSEMBLY OF QUILL AND CYLINDER 1071
OVERCENTER MANIFOLD 1075
SECTION L10 HYDRAULIC CHECKOUT 1077
HYDRAULIC SYSTEM CHECKOUT PROCEDURE 1079
PRE-CHECKOUT ITEMS 1079
HYDRAULIC BRAKE AND STEERING ACCUMULATOR BLEED DOWN PROCEDURE 1080
ACCUMULATOR PRECHARGE PROCEDURE 1081
PRESSURE GAUGE INSTALLATION 1082
INITIAL START UP AND FLUSHING PROCEDURE 1084
COMPONENT CHECKOUT AND ADJUSTMENT PROCEDURE 1087
SYSTEM DIAGNOSTICS AND VERIFICATION 1088
HOIST COUNTERBALANCE CARTRIDGE VALVE ADJUSTMENT PROCEDURE 1089
OIL CLEANLINESS CHECK 1091
FILTER REPLACEMENT PROCEDURE 1092
TROUBLESHOOTING 1093
HYDRAULIC CHECKOUT PROCEDURE DATA SHEET 1095
SECTION M OPTIONS AND SPECIAL TOOLS 1099
SECTION M7 HEATER OPTIONS 1101
ENGINE OIL HEATERS 1103
GENERAL INFORMATION 1103
TROUBLESHOOTING 1103
HEATER ELEMENT 1104
ENGINE COOLANT HEATER 1105
GENERAL 1105
HEATING ELEMENT 1105
THERMOSTAT 1106
HYDRAULIC OIL HEATERS 1107
GENERAL INFORMATION 1107
TROUBLESHOOTING 1107
HEATER ELEMENT 1108
SECTION M8 SPECIAL TOOLS 1109
NITROGEN CHARGING VALVE 1109
ROLL-OUT ASSEMBLY 1109
EYE BOLT 1109
OFFSET WRENCH 1110
TORQUE ADAPTER 1110
HANDLE 1110
SEAL INSTALLER 1110
SLEEVE ALIGNMENT TOOLS 1111
QUICK DISCONNECT COUPLING 1111
HARNESS 1111
SEAL INSTALLATION RING 1111
SOCKETS AND ADAPTERS 1112
DUST CAPS 1112
HYDRAULIC SYSTEM FLUSHING TOOLS 1113
BATTERY JUMP STARTING 1113
KOMVISION® CALIBRATION TOOLS 1114
MISCELLANEOUS SERVICE TOOLS 1115
PAYLOAD DATA MANAGER 1115
HYDRAULIC SYSTEM VACUUM PUMP 1115
BRAKE PISTON TOOL 1116
SUSPENSION OILING AND CHARGING 1117
SPINDLE REMOVAL TOOL 1117
HIGH VOLTAGE TOOLS 1118
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1118
BODY PAD SPACER TOOL 1119
SECTION M19 RADIATOR SHUTTERS 1121
RADIATOR SHUTTERS 1123
OPERATION 1123
MAINTENANCE AND REPAIR 1124
TROUBLESHOOTING 1125
SECTION M20 PAYLOAD METER IV ™ 1131
PAYLOAD METER IV ™ 1133
INTRODUCTION 1133
COMPONENT DESCRIPTION 1134
PAYLOAD METER IV SOFTWARE AND TOOLS 1135
PAYLOAD METER IV SYSTEM CONFIGURATION 1135
PAYLOAD METER IV SOFTWARE INSTALLATION 1137
PLM IV SYSTEM CHECKOUT DATA SHEET 1143
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1144
SECTION M31 RESERVE ENGINE OIL SYSTEM 1147
RESERVE ENGINE OIL SYSTEM 1149
SERVICE 1152
TROUBLESHOOTING 1153
SYSTEM ELECTRICAL SCHEMATICS 1154
SECTION M32 RETRACTABLE LADDER SYSTEM 1155
RETRACTABLE LADDER SYSTEM 1159
GENERAL SAFETY 1159
LADDER SYSTEM DESCRIPTION 1159
LADDER SYSTEM OPERATION 1160
IN-CAB CONTROL PANEL 1162
IN-CAB CONTROL PANEL FEATURES 1163
IN-CAB CONTROL PANEL FUNCTIONS 1164
USING THE IN-CAB CONTROL PANEL 1165
USING THE GROUND LEVEL CONTROL BOX 1167
POWER PACK OPERATION 1168
MAINTENANCE 1171
PREVENTIVE MAINTENANCE PROCEDURES 1173
SERVICING 1174
RLS DIAGNOSTICS 1175
SECURITY ACCESS LEVELS 1179
USER ID – PASSWORD 1181
USER ID – NEW USER SETUP 1182
SYSTEM FAULTS 1182
DATA MANAGEMENT 1192
MENU DIAGRAMS 1199
SECTION M33 CAMERA SYSTEM 1207
CAMERA SYSTEM 1209
CAMERA SYSTEM 1209
CAMERA MONITOR 1211
CAMERA CONTROLLER 1212
CAMERA SWITCHER 1213
SETUP AND CHECKOUT PROCEDURE 1214
SECTION N OPERATOR CAB 1223
SECTION N2 CAB, DOORS AND WINDOWS 1225
CAB AND COMPONENTS 1228
CAB 1228
CAB DOOR 1231
GLASS REPLACEMENT 1241
WINDSHIELD & REAR GLASS 1242
WINDSHIELD WIPERS 1244
WIPER MOTOR 1244
WIPER ARM 1244
WIPER LINKAGE 1245
WINDSHIELD WASHER 1246
SECTION N3 OPERATOR AND PASSENGER SEATS 1247
OPERATOR AND PASSENGER SEATS 1248
OPERATOR SEAT (STANDARD SEAT) 1248
PASSENGER SEAT (STANDARD SEAT) 1255
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1256
SEAT BELT REPLACEMENT (STANDARD SEATS) 1258
OPERATOR SEAT (OPTIONAL SEAT) 1260
PASSENGER SEAT (OPTIONAL SEAT) 1261
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1262
SECTION N4 HEATER/AIR CONDITIONER 1267
CLIMATE CONTROL 1269
HEATER / AIR CONDITIONER 1269
COMPONENTS 1270
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1274
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1274
PRINCIPLES OF REFRIGERATION 1274
AIR CONDITIONER SYSTEM COMPONENTS 1276
ELECTRICAL CIRCUIT 1278
SYSTEM SERVICING 1280
SERVICE TOOLS AND EQUIPMENT 1281
SYSTEM PERFORMANCE TEST 1285
SYSTEM OIL 1286
REFRIGERANT 1288
SYSTEM LEAK TESTING 1289
RECOVERING AND RECYCLING THE REFRIGERANT 1290
SYSTEM REPAIR 1291
COMPONENT REPLACEMENT 1292
EVACUATING THE SYSTEM 1294
CHARGING THE A/C SYSTEM 1296
TROUBLESHOOTING 1297
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1298
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1304
SECTION N5 OPERATOR CAB CONTROLS 1305
OPERATOR CAB AND CONTROLS 1309
STEERING WHEEL AND CONTROLS 1310
STEERING COLUMN 1311
STEERING WHEEL 1312
PEDALS 1314
GRADE/SPEED RETARD CHART 1315
OVERHEAD PANEL AND DISPLAYS 1316
CENTER CONSOLE 1317
DIAGNOSTIC PORTS 1320
HEATER / AIR CONDITIONER 1321
INSTRUMENT PANEL 1322
STATUS INDICATOR LIGHT PANEL 1329
DIGIT DISPLAY OPERATION 1332
KOMTRAX PLUS 1335
KOMATSU WIRELESS BRIDGE (Optional) 1338
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1343
SECTION P2 PERIODIC MAINTENANCE 1345
PERIODIC MAINTENANCE 1347
830E SERVICE CAPACITIES 1347
HYDRAULIC TANK SERVICE 1347
COOLANT LEVEL CHECK 1348
WHEEL MOTOR SERVICE 1348
RESERVE ENGINE OIL SYSTEM (Optional) 1349
QUICK FILL SERVICE CENTER 1349
LUBRICATION CHART 1350
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 1351
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1352
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1353
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 1354
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 1356
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 1361
EVERY 2500 HOUR MAINTENANCE 1363
EVERY 4000 HOUR MAINTENANCE 1363
EVERY 5000 HOUR MAINTENANCE 1364
EVERY 18000 HOUR MAINTENANCE 1364
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1367
AUTOMATIC LUBRICATION SYSTEM 1369
GENERAL DESCRIPTION 1369
SYSTEM COMPONENTS 1371
SYSTEM OPERATION 1372
LUBRICANT PUMP 1374
INJECTORS (SL-1 Series “H”) 1375
INJECTOR OPERATION 1376
PREVENTIVE MAINTENANCE PROCEDURES 1377
SYSTEM CHECKOUT 1378
AUTOLUBE TROUBLESHOOTING CHART 1380
SECTION R SYSTEM SCHEMATICS 1383
HYDRAULIC BRAKE SCHEMATIC – HH360 1384
HYDRAULIC SCHEMATIC – 58E-60-11000 1385
RETRACTABLE LADDER SYSTEM – HH364 1386
ELECTRICAL SCHEMATICS (STANDARD) – 58F-06-02000 1387
ELECTRICAL Subsystem SCHEMATIC – 58E-06-08502 1407

DESCRIPTION:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM027402  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40851 – A40938 A40995

• 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 20/12/24