Komatsu 830E-1AC Dump Truck Shop Manual CEBM029301 PDF

Description

Komatsu 830E-1AC Dump Truck Shop Manual CEBM029301  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM029301  – PDF DOWNLOAD

Language : English
Pages : 1434
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM029301  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40939 – A40961

FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
SECTION A2 MAJOR COMPONENTS & SPECIFICATIONS 11
MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
Traction Alternator (GTA-41) 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
SPECIFICATIONS 13
ENGINE 13
AC ELECTRIC DRIVE SYSTEM 13
DYNAMIC RETARDING 13
24 VDC ELECTRIC SYSTEM 13
SERVICE CAPACITIES 13
HYDRAULIC SYSTEMS 13
SERVICE BRAKES 13
DISC PARKING BRAKE 13
STEERING 13
DUMP BODY CAPACITIES AND DIMENSIONS 14
TIRES 14
OVERALL TRUCK DIMENSIONS 14
WEIGHT DISTRIBUTION 14
SECTION A3 GENERAL SAFETY AND OPERATING INSTRUCTIONS INDEX 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 Jumper 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
Jack Point Locations 32
If a tow bumper reinforcement group is installed, it is acceptable to place jack stands under tow hooks at locations (4) However, do not position jacks outside of the tow hooks 32
DURING MAINTENANCE 33
Personnel 33
Attachments 33
Working Under The Machine 33
Keeping The Machine Clean 33
Rules To Follow When Adding Fuel Or Oil 33
Radiator Coolant Level 33
Use Of Lighting 34
Precautions With The Battery 34
Handling High Pressure Hoses 34
Precautions With High Pressure Oil 34
Maintenance Near High Temperatures And High Pressures 34
Rotating Fan And Belts 34
Waste Materials 34
TIRES 35
Handling Tires 35
Tire Maintenance 36
Storing Tires After Removal 36
Handling 37
ADDITIONAL JOB SITE RULES 38
WHEN REPAIRS ARE NECESSARY 39
SPECIAL PRECAUTIONS FOR WORKING ON AN 830E-1AC TRUCK 40
Preliminary Procedures before Welding or Performing Maintenance 40
Engine Shutdown Procedure before Welding or Performing Maintenance 40
CAPACITOR DISCHARGE SYSTEM 42
Necessary Tools 42
Warnings And Cautions 43
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE 44
Preparation 44
CAPACITOR CHARGE LIGHTS 46
FAILURE OF DISCHARGE SYSTEM 47
Measuring DC Voltage On Capacitors 47
MANUAL DISCHARGE OF CAPACITORS 48
SHORT ISOLATED CAPACITOR TERMINALS 50
TRUCK OPERATION 52
PREPARING FOR OPERATION 52
Safety Is Thinking Ahead 52
WALK AROUND INSPECTION 52
RETRACTABLE LADDER SYSTEM (If equipped) 56
LADDER SYSTEM DESCRIPTION 56
LADDER SYSTEM OPERATION 57
Normal Operation 57
GENERAL SAFETY 57
IN-CAB CONTROL PANEL 57
IN-CAB CONTROL PANEL FEATURES 58
Digital Display Screen 58
Command Buttons 58
USING THE IN-CAB CONTROL PANEL 59
Raising the Ladder 59
Lowering the Ladder 60
USING THE GROUND LEVEL CONTROL BOX 61
Raising the Ladder 61
Lowering the Ladder 61
Emergency Operation 62
ENGINE START-UP 63
AFTER ENGINE HAS STARTED 64
PRE-SHIFT BRAKE CHECK (if equipped) 65
Events 65
OPERATION 65
Description 65
Brake Test Exit Criteria 66
PERFORMING THE BRAKE TESTS 66
Setup 66
Service Brake Test 67
Parking Brake Test 68
Retard System Test: 68
EMERGENCY STEERING SYSTEM 69
Operation 69
Pre-Operation Testing 69
Additional Guidelines 70
MACHINE OPERATION SAFETY PRECAUTIONS 70
MACHINE OPERATION ON THE HAUL ROAD 71
STARTING ON A GRADE WITH A LOADED TRUCK 72
PASSING 72
LOADING 72
Overload Speed Limit Function 72
DUMPING 73
Raising The Dump Body 73
Lowering The Dump Body 74
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION 75
FUEL DEPLETION 75
SAFE PARKING PROCEDURES 76
NORMAL ENGINE SHUTDOWN PROCEDURE 77
DISABLED TRUCK CONNECTORS 78
STEERING AND BRAKE SYSTEM 78
Hookup 78
HOIST SYSTEM 79
Hookup 79
Dumping Procedure 79
TOWING 80
Special Wiring Harness 80
Towing Procedure 81
SECTION A4 WARNINGS AND CAUTIONS 83
SECTION A5 TORQUES TABLES AND CONVERSION CHARTS 97
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 98
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 98
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 99
SECTION A7 STORAGE PROCEDURES INDEX 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
ELECTRIC DRIVE TRUCKS 119
TRANSMISSION PRESERVATION AND STORAGE 123
Restoring Transmission to Service 123
SECTION B STRUCTURES INDEX 125
SECTION B2 STRUCTURAL COMPONENTS INDEX 127
STRUCTURAL COMPONENTS 129
LADDERS 130
Removal 130
Installation 130
RIGHT DECK 131
Removal 131
Installation 131
LEFT DECK 132
Removal 132
Installation 132
CENTER DECK 133
Removal 133
Installation 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 SLING 142
BODY POSITION INDICATOR 142
HOIST LIMIT SWITCH 142
BODY UP SWITCH 142
ROCK EJECTORS 143
Inspection 143
SECTION B4 FUEL TANK INDEX 145
FUEL TANK 146
Removal 146
Installation 146
Repair 148
Cleaning 148
FUEL TANK VENT ASSEMBLY 148
Disassembly 148
Assembly 148
FUEL GAUGE SENDER (TOP) 149
Removal 149
Operation 150
Specifications: 150
QUICK FILL FUEL RECEIVERS 151
SECTION C ENGINE INDEX 153
SECTION C2 POWER MODULE INDEX 155
POWER MODULE 157
PREPARATION 157
REMOVAL 157
INSTALLATION 162
EXHAUST TUBE INSTALLATION 166
EXHAUST BLANKET INSTALLATION 166
SECTION C3 COOLING SYSTEM INDEX 167
COOLING SYSTEM DESCRIPTION 169
RADIATOR 170
Removal 170
Installation 173
Radiator Filling Procedure 174
REPAIRING THE RADIATOR 175
Internal Inspection 175
External Cleaning 175
Disassembly 175
Cleaning and Inspection 176
Pressure Testing 178
COOLANT SYSTEM TROUBLESHOOTING 178
SECTION C4 POWER TRAIN INDEX 179
POWER TRAIN 181
ALTERNATOR REMOVAL PROCEDURE 181
ALTERNATOR INSTALLATION 183
General Instructions 183
Measuring Procedure 183
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 185
ENGINE 187
Removal 187
Service 187
Installation 188
SECTION C5 AIR CLEANERS INDEX 189
AIR CLEANERS 191
OPERATION 191
SERVICING THE AIR CLEANERS 191
Replacing The Elements 192
AIR CLEANER ASSEMBLY CLEANING 193
Primary Element Cleaning 193
Precleaner Section Cleaning 195
AIR INTAKE TROUBLESHOOTING 196
SECTION C7 FAN CLUTCH INDEX 197
FAN CLUTCH 199
REMOVAL & INSTALLATION TOOLING 199
DISASSEMBLY 202
CLEANING AND INSPECTION 212
ASSEMBLY 216
TEST PROCEDURE 231
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 233
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 235
24 VDC ELECTRIC SUPPLY SYSTEM 237
ELECTRICAL SYSTEM DESCRIPTION 237
BATTERIES 237
Maintenance and Service 237
Troubleshooting 237
BATTERY SUPPLY SYSTEM 239
24VDC Battery Charging Alternator 239
Battery Box 239
Removal 239
Installation 240
Battery Control Box 240
24VDC Auxiliary Battery Receptacles 240
Engine Start Relay 240
ISOLATION BOX ASSEMBLY 240
Engine Shutdown Switch 240
Access Ladder Light Switch 240
Battery Disconnect Switches 240
Propel Lockout Lever 241
LED Lights 241
AUXILIARY CONTROL CABINET 242
24VDC to 12VDC Converter 242
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 243
Operation 243
Engine Oil Pressure Switch 243
Check Valve 243
MAINTENANCE 243
Prelube System Operation Checks 243
Check Valve 243
CRANKING MOTORS 246
Operation 246
Removal 246
Installation 246
CRANKING MOTOR TROUBLESHOOTING 247
Preliminary Inspection 247
No-Load Test 247
Interpreting Results of Tests 248
Disassembly 248
Cleaning and Inspection 249
Armature Servicing 251
Field Coil Checks 251
Field Coil Removal 251
SOLENOID CHECKS 252
Test 252
Assembly 253
Bearing Replacement: 253
Motor Assembly: 253
Pinion Clearance 254
MAGNETIC SWITCH 254
Removal 254
Installation 254
Coil Test 255
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 257
24 VDC ELECTRICAL SYSTEM COMPONENTS 259
TRUCK SHUTDOWN PROCEDURE 259
BRAKE WARNING BUZZER 259
AUXILIARY CONTROL CABINET COMPONENTS 259
Interface Module 260
Payload Meter 260
24VDC to 12VDC Converter 260
Circuit Breaker (CB60) 260
Inclinometer 260
Pump Module Service Light Timer 261
Power Distribution Terminals 261
Ground Terminal 261
Relays 262
Engine Service Light Timer 262
RTMR1 – VEC Block 263
Vehicle Electrical Centers (VEC) 263
VEC-89 264
VEC-90 266
VEC-91 268
MAGNETIC SWITCHES 270
Body position switches (With proximity switch and magnet) 270
Proximity switch operation 270
Service 270
BODY-UP SWITCH 271
Adjusting the Body-Up Switch 271
HOIST LIMIT SWITCH 272
Operation 272
Adjusting the Hoist Limit Switch 273
SECTION D11 KOMTRAX PLUS SYSTEM INDEX 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 290
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
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
KOMTRAX PLUS SNAPSHOT PROCEDURE 296
KOMTRAX PLUS DOWNLOAD PROCEDURE 297
LOCATION OF DOWNLOAD FILES 297
KOMTRAX PLUS FTP UPLOAD PROCEDURE 298
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
SECTION D12 INTERFACE MODULE INDEX 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 317
Installation 317
Using The Program 317
INTERFACE MODULE CHECKOUT 317
Interface Module 317
Necessary Equipment: 317
Preliminary 318
Checking Inputs And Outputs From The Interface Module 319
Check Analog Inputs To The Interface Module 323
Check CAN RPC & J1939 Interfaces To The IM 323
Check Outputs From The Interface Module 323
SECTION D13 KOMTRAX PLUS & INTERFACE MODULE TROUBLESHOOTING & ERROR CODES INDEX 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 336
FAULT TREE ANALYSIS 342
Unable to connect to KOMTRAX Plus from Service PC 342
Flashing Error Code N4-23 (PLM Communications Fault) 343
Flashing Error Code N4-22 (Engine Communications Fault) 344
No Data Received By WebCARE 345
Coaxial Cable Troubleshooting 346
SECTION D14 KOMTRAX PLUS FORMS INDEX 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 SYSTEM INDEX 355
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 357
ELECTRICAL PROPULSION SYSTEM COMPONENTS 359
GENERAL SYSTEM DESCRIPTION 359
SYSTEM COMPONENTS 361
Drive System Controller (DSC) 361
Diagnostic Information Display (DID) Panel 362
DID Panel Event Codes 362
DSC SOFTWARE FUNCTIONS 390
Input Processing 390
State Machine 390
DC Link State 393
Engine Control 394
ALTERNATOR FIELD CONTROL 394
Desired DC Link Voltage 394
Self-Load 394
Propel Torque Control 395
Retard Torque Control 395
Wheel Slide Control 395
Resistor Grid Control 396
Chopper Voltage Control 396
EVENT DETECTION AND PROCESSING 396
Power-On Tests 397
Initiated Tests 397
Periodic Tests 397
EVENT RESTRICTIONS 398
EVENT LOGGING AND STORAGE 398
Event History Buffer 398
Data Packs 398
Event Reset 399
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 399
Fast Start 399
Engine Shutdown/Engine Not Running 399
Limp Home Mode 400
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 401
ELECTRONIC ACCELERATOR AND RETARD PEDALS 408
Removal 408
Installation 408
Disassembly 408
Assembly 408
PHASE MODULE REPLACEMENT 409
Removal 409
Installation 409
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 411
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 413
AC DRIVE SYSTEM MAINTENANCE 413
NORMAL TRUCK SHUTDOWN PROCEDURE 414
TEST EQUIPMENT 415
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 415
REST MODE ACTIVATION 415
INITIAL CHECKOUT PROCEDURES 416
Circuit Continuity and Resistance Checks 416
Megger Test for Grounds 416
Preparation for Megger Test 417
Megger Test Procedure 418
Troubleshooting for Grounds 419
Low Voltage Power Supply Checks 420
Preparation for Power Supply Checks 420
Power Supply Check Procedure 420
Drive System Controller (DSC) Card Checks 421
Propulsion System Software Installation 421
DSC Manual Test Procedures 424
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 426
Set Truck ID Number 430
Control Cabinet Pressure Switch Check 431
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 432
Verifying DSC Software Version 432
Resetting and Erasing DSC Event Data 434
ENGINE RUNNING TESTS 435
Battery Boost Circuit Verification 435
Selector Switch Check 437
Ground Detection Network Tests 439
Self Load Engine Test (Loadbox) Procedure 443
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 445
DID Panel Display Selection 445
DID Modes Display 447
Function Key F1 – DID Events or Faults Display 448
Function Key F4 – DID Menu Display 451
DID Self Load Engine Test (Loadbox) 452
DID Link Capacitance Test 454
DID Speedometer Test 455
DID View Software Version 456
DID View Overspeed Setting 457
DID View Data Menu 458
DID Inverter Cutout Menu 463
DID Truck Configuration Menu 464
Language Selection 469
VIEWING EVENT AND STATISTICAL DATA 470
Viewing the DSC Event Summary, Trigger Data, and Data Packs 470
Viewing the Statistical Data 472
LOGIC SCREENS 473
DATALOGGER FUNCTION 475
Setting Up the Datalogger 475
Starting the Datalogger 477
UPLOADING DATA 479
Consolidated Truck Data Save 479
USB Drive 480
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A139) INDEX 481
Fault Code A001: Left front suspension pressure sensor signal is high 483
Related circuit diagram 483
Fault Code A002: Left front suspension pressure sensor signal is low 484
Related circuit diagram 484
Fault Code A003: Right front suspension pressure sensor signal is high 485
Related circuit diagram 485
Fault Code A004: Right front suspension pressure sensor signal is low 486
Related circuit diagram 486
Fault Code A005: Left rear suspension pressure sensor signal is high 487
Related circuit diagram 487
Fault Code A006: Left rear suspension pressure sensor signal is low 488
Related circuit diagram 488
Fault Code A007: Right rear suspension pressure sensor signal is high 489
Related circuit diagram 489
Fault Code A008: Right rear suspension pressure sensor signal is low 490
Related circuit diagram 490
Fault Code A009: Incline sensor signal is high 491
Related circuit diagram 491
Fault Code A010: Incline sensor signal is low 492
Related circuit diagram 492
Fault Code A011: Payload meter speed sensor signal has failed 493
Fault Code A013: Body up switch has failed 494
Related circuit diagram 494
Fault Code A014: Payload meter checksum computation has failed 495
Related circuit diagram 495
Fault Code A016: Payload meter write to flash memory has failed 496
Related circuit diagram 496
Fault Code A017: Payload meter flash memory read has failed 497
Related circuit diagram 497
Fault Code A018: Right rear flat suspension cylinder warning 498
Related circuit diagram 499
Fault Code A019: Left rear flat suspension cylinder warning 500
Related circuit diagram 501
Fault Code A022: Carryback load is excessive 502
Related circuit diagram 503
Fault Code A101: High pressure detected across a hydraulic pump filter 504
Related circuit diagram 505
Fault Code A103: Hydraulic oil tank temperature sensor is reading low 506
Related circuit diagram 506
Fault Code A104: Hydraulic oil tank temperature sensor is reading high 507
Related circuit diagram 507
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 508
Related circuit diagram 509
Fault Code A107: GE has generated a propel system caution 510
Related circuit diagram 510
Fault Code A108: GE has generated a propel system temperature caution 511
Related circuit diagram 511
Fault Code A109: GE has generated a propel system reduced level signal 512
Fault Code A111: Low steering pressure warning 514
Fault Code A115: Low steering precharge pressure is detected 516
Related circuit diagram 517
Fault Code A117: Low brake accumulator pressure warning 518
Fault Code A118: Brake pressure is low while brake lock is activated 520
Fault Code A123: GE has generated a reduced retarding caution 522
Fault Code A124: GE has generated a no propel / no retard or system not running input 524
Fault Code A125: GE has generated a no propel warning 526
Fault Code A126: Oil level in the hydraulic tank is low 527
Fault Code A127: IM furnished +5 volt output for sensors is low 528
Related circuit diagram 529
Fault Code A128: IM furnished +5 volt output for sensors is high 530
Related circuit diagram 531
Fault Code A139: Low fuel level warning 532
Related circuit diagram 533
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A246) INDEX 535
Fault Code A152: Starter failure 537
Fault Code A153: Battery voltage is low with truck in operation 538
Fault Code A154: Battery charging voltage is excessive 540
Fault Code A155: Battery charging voltage is low 541
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 542
Fault Code A184: J1939 data link is not connected 543
Fault Code A190: Auto lube control has detected an incomplete lube cycle 544
Fault Code A193: Hydraulic tank oil temperature is high 546
Fault Code A198: Hoist pressure 1 sensor is high 547
Fault Code A199: Hoist pressure 2 sensor is high 548
Fault Code A200: Steering pressure sensor is high 549
Fault Code A201: Brake pressure sensor is high 550
Fault Code A202: Hoist pressure 1 sensor is low 551
Fault Code A203: Hoist pressure 2 sensor is low 552
Fault Code A204: Steering pressure sensor is low 553
Fault Code A205: Brake pressure sensor is low 554
Fault Code A206: Ambient temperature sensor is high 555
Fault Code A207: Ambient temperature sensor is low 556
Fault Code A212: Bad truck speed signal 557
Fault Code A213: Parking brake should have applied but is detected as not having applied 558
Fault Code A214: Parking brake should have released but is detected as not having released 562
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 566
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 568
Fault Code A230: Parking brake has been requested while truck still moving 570
Fault Code A231: Dump body is up while traveling or intending to travel 572
Fault Code A233: Drive system CAN/RPC Control Link not connected 576
Fault Code A235: Steering accumulator is in the process of being bled down 578
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 580
Fault Code A237: The CAN/RPC connection to the display is open 582
Fault Code A240: The keyswitch input to the interface module is open 583
Fault Code A242: The fuel gauge within the display panel is defective 584
Fault Code A243: The engine coolant temp gauge within the display panel is defective 585
Fault Code A244: The drive system temp gauge within the display panel is defective 586
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 587
Fault Code A246: Payload meter reports truck overload 588
SECTION E5 TROUBLESHOOTING FAULT CODES (A247-A292) INDEX 589
Fault Code A247: Low steering pressure warning 591
Fault Code A248: The status indicator module within the display panel is defective 593
Fault Code A249: The red warning lamp within the display panel is shorted 594
Fault Code A250: Battery voltage is low with the truck parked 596
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 598
Fault Code A252: Start enable output circuit is either open or shorted to ground 600
Fault Code A253: Steering bleed circuit is not open while running 602
Fault Code A255: IM has detected a fault on IM output 1N 604
Fault Code A256: The red warning lamp within the display panel (driven by IM) is open 605
Fault Code A257: Payload CAN/RPC is not connected 606
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 607
Fault Code A260: Parking brake failure 608
Fault Code A261: Low brake accumulator pressure warning 610
Fault Code A262: Steering bleed valve circuit open during shutdown 612
Fault Code A264: Parking brake relay circuit is defective 614
Fault Code A265: Service brake failure 616
Fault Code A266: Selector lever was not in park while attempting to crank engine 618
Fault Code A267: Parking brake was not set while attempting to crank engine 620
Fault Code A268: Secondary engine shutdown while cranking 622
Fault Code A270: Brake lock switch power supply is not on when required 624
Fault Code A271: Shifter not in gear 626
Fault Code A272: Brake lock switch power supply is not off when required 628
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 630
Fault Code A274: A brake setting fault has been detected 632
Fault Code A275: A starter has been detected as engaged without a cranking attempt 634
Fault Code A276: The drive system data link is not connected 636
Fault Code A277: Parking brake applied while loading 638
Fault Code A278: Service brake applied while loading 640
Fault Code A279: Low steering pressure switch is defective 641
Fault Code A280: Steering accumulator Bleed Down switch is defective 642
Fault Code A281: Brake lock degradation switch is defective 644
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 646
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 648
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 650
Fault Code A285: The parking brake was not set when the key switch was turned off 652
Fault Code A286: A fault was detected in the shutdown delay relay circuit 654
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 656
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 659
Fault Code A303: Shifter is defective 661
Fault Code A304: Auto lube grease level is low 662
Fault Code A305: Auto lube circuit is defective 663
Fault Code A307: Both GE inverters are disabled 664
Fault Code A309: No brakes applied when expected 666
Fault Code A310: Low fuel level warning 668
Related circuit diagram 669
Fault Code A311: Brake lock switch is on when it should not be 670
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 672
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 673
Fault Code A315: DC-DC converter 12 volt circuit is low 674
Fault Code A316: Starter engagement has been attempted with engine running 676
Fault Code A318: Unexpected power loss to interface module 678
Fault Code A320: Propel system caution wire input not same as serial input 679
Fault Code A321: Propel system temperature caution wire input not same as serial input 680
Fault Code A322: Propel system at reduced level wire input not same as serial input 681
Fault Code A323: Propel system at reduced retard level wire input not same as serial input 682
Fault Code A324: GE link voltage wire input not same as serial input 683
Fault Code A325: No Propel/Retard wire input not same as serial input 684
Fault Code A326: No Propel wire input not same as serial input 685
Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input 686
Fault Code A328: Drive system not powered up 687
Fault Code A329: Body down wire input not same as serial input 688
Fault Code A330: Dynamic retard switch input not same as serial input 689
Fault Code A332: Seat belt not buckled 690
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 692
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 693
Fault Code A335: Manual/Auto Apply Pressure Fault 694
Fault Code A350: Overload on output 1B 695
Fault Code A351: Overload on output 1E 696
Fault Code A352: Overload on output 1H 697
Fault Code A353: Overload on output 1J 698
Fault Code A354: Overload on output 1K 699
Fault Code A355: Overload on output 1L 700
Fault Code A356: Overload on output 1M 701
Fault Code A357: Overload on output 1N 702
Fault Code A358: Overload on output 1P 703
Fault Code A359: Overload on output 1R 704
Fault Code A360: Overload on output 1S 705
Fault Code A361: Overload on output 1T 706
Fault Code A362: Overload on output 1U 707
Fault Code A363: Overload on output 1X 708
Fault Code A364: Overload on output 1Y 709
Fault Code A365: Overload on output 1Z 710
SECTION G DRIVE AXLE, SPINDLES, AND WHEELS INDEX 713
SECTION G2 TIRES AND RIMS INDEX 715
TIRES AND RIMS 717
GENERAL PRECAUTIONS 717
RIM COMPONENTS 718
Smart Rim Component Layout 718
FRONT TIRES AND RIMS 719
Removal 719
Installation 721
REAR TIRES AND RIMS 721
Removal 721
Installation 722
RIM AND TIRE 724
Tire Removal 724
Rim And Tire Preparation 724
Lubricants 725
Tire Installation 725
RIM AND TIRE SERVICE 727
Lubricants 727
Tire Inflation 727
Lock Ring Retainer Installation 727
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 728
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 729
Removal (5-Piece Standard Rim) 730
Removal (7-Piece Smart Rim) 733
Removal (5-Piece Smart Rim) 735
Preparation Before Assembly 736
Installation (5-Piece Standard Rim) 737
Installation – Horizontal Mount (Smart Rim) 739
Installation – Vertical Mount (5-Piece Smart Rim) 741
Installation – Vertical Mount (7-Piece Smart Rim) 742
SECTION G3 FRONT WHEEL HUB AND SPINDLES INDEX 743
FRONT WHEEL HUB AND SPINDLE 745
WHEEL HUB AND SPINDLE ASSEMBLY 745
Removal 745
Spindle Removal Procedure (Optional) (off of the truck) 748
Installation 750
Disassembly 753
Cleaning and Inspection 753
Assembly 754
Wheel Bearing Adjustment (Tire Removed) 756
Wheel Bearing Adjustment (Tire mounted) 757
OIL SAMPLING PROCEDURE 758
Oil Sampling Guidelines 759
Procedure 759
OIL DRAIN AND REFILL PROCEDURE 759
STEERING CYLINDERS 760
Spherical Bearing Wear Limits 760
Removal 761
Installation 761
Bearing Replacement (Steering Cylinder and Tie Rod) 761
TIE ROD 763
Removal 763
Installation 763
Disassembly 764
Assembly 764
TOE-IN ADJUSTMENT 765
TIE ROD INSPECTION AND TORQUE PROCEDURE 766
Old Style Tie Rod 766
New Style Tie Rod 767
SECTION G4 REAR AXLE HOUSING ATTACHMENT INDEX 769
REAR AXLE HOUSING ATTACHMENT 771
PIVOT PIN 771
Removal 771
Installation 771
PIVOT EYE BEARING 772
Disassembly 772
Assembly 772
PIVOT EYE REPAIR 773
Removal 773
Installation 773
Disassembly 773
Assembly 773
ANTI-SWAY BAR 774
Removal 774
Installation 774
Disassembly 774
Cleaning and Inspection 774
Assembly 775
SECTION G5 REAR AXLE HOUSING INDEX 777
REAR AXLE HOUSING 779
Removal 779
Installation 779
WHEEL MOTOR 780
Removal 780
Cleaning and Inspection 780
Installation 781
WHEEL MOTOR GEAR OIL 784
Change/Filter The Gear case Oil 784
Oil 784
Remove And Clean Magnetic Plugs 784
Flushing The Gearbox 784
Check Gear Case Oil Level 784
SECTION H SUSPENSIONS INDEX 785
SECTION H2 FRONT SUSPENSION INDEX 787
FRONT SUSPENSION 789
Removal 789
Installation 790
TURN-OF-THE-NUT Tightening Procedure 792
Upper Mounting Joint – 60° Advance 792
Lower Mounting Joint – 90° Advance 794
Inspection 794
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 795
Bearing Structure Removal 795
Bearing Structure Installation 795
MAJOR SUSPENSION REBUILD 796
Disassembly 796
Assembly 797
PRESSURE TEST 799
SECTION H3 REAR SUSPENSIONS INDEX 801
REAR SUSPENSIONS 802
Removal 802
Installation 805
ROD DOWN SUSPENSION 806
Disassembly 806
Cleaning and Inspection 806
Assembly 808
PRESSURE TEST 810
Suspension Pressure Test 810
SECTION H4 OILING AND CHARGING PROCEDURE INDEX 811
CHECKING FOR IMPROPER SUSPENSION CHARGE 813
SUSPENSION OILING AND CHARGING PROCEDURES 814
GENERAL 814
EQUIPMENT LIST 814
HYDRAIR® CHARGING KIT 815
Installation of Charging Kit 815
Removal of Charging Kit 815
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 816
FRONT SUSPENSION 817
REAR SUSPENSION 820
SUSPENSION PRESSURE TEST 823
OIL AND NITROGEN SPECIFICATIONS CHART 823
SECTION J BRAKE SYSTEMS INDEX 825
SECTION J2 BRAKE CIRCUIT INDEX 827
BRAKE CIRCUIT 829
OPERATION 829
SERVICE BRAKE CIRCUIT OPERATION 829
SECONDARY BRAKING AND AUTOMATIC APPLY 831
PARKING BRAKE CIRCUIT 831
Normal Operation (key switch on, engine running) 831
BRAKE LOCK CIRCUIT 832
WARNING CIRCUIT 832
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 835
BRAKE CIRCUIT COMPONENT SERVICE 837
BRAKE VALVE 837
Rebuild Criteria 837
Removal 837
Installation 839
DISASSEMBLY 841
Cleaning and Inspection 843
ASSEMBLY 843
Actuator Base Threaded Inserts 843
Boot and Cap 843
Valve Body Seal Installation 844
Regulator Sleeve O-Ring Installation 844
Actuator Plunger O-ring Installation 845
Assembly of Valve 845
VALVE BENCH TEST AND ADJUSTMENT 847
Test Set Up Procedure 848
Brake Valve Output Pressure Adjustment 848
Final Test and Adjustment 849
Installation Of Brake Pedal Actuator Assembly to Brake Valve 850
INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL BRAKE ASSEMBLY (Dual Function) 852
Installation of Retard Pedal To Brake Pedal 852
HYDRAULIC BRAKE ACCUMULATORS 853
Brake Accumulator Bleed Down Procedure 853
Removal 853
Installation 853
Disassembly 853
Cleaning and Inspection 855
Assembly 855
Charging Procedure 857
BRAKE MANIFOLD 858
Removal 858
Removal 858
Installation 859
Disassembly 859
Cleaning and Inspection 860
Assembly 860
SECTION J4 BRAKE CIRCUIT CHECK-OUT PROCEDURE INDEX 861
BRAKE CIRCUIT CHECK-OUT PROCEDURE 862
EQUIPMENT REQUIRED 865
INITIAL SYSTEM SET-UP 866
PARKING BRAKE 866
BRAKE SYSTEM CHECK-OUT 867
BRAKE LOCK 867
FAILURE MODES CHECK-OUT 868
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 869
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 873
SECTION J5 FRONT BRAKES INDEX 875
WHEEL SPEED FRONT DISC BRAKES 877
BRAKE CALIPER 877
Caliper Removal 877
Installation 878
Disassembly 879
Assembly 879
Cleaning and Inspection 880
BRAKE LINING 881
Replacement 881
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 883
GENERAL 883
Safety Precautions 883
Front Brake Conditioning 883
BRAKE BLEEDING PROCEDURES 884
SECTION J6 ARMATURE SPEED REAR DISC BRAKES INDEX 885
ARMATURE SPEED REAR DISC BRAKES 887
REAR BRAKES 887
CALIPER AND DISC 887
Removal 887
Inspection 889
Installation 889
PARK BRAKE ADJUSTMENT PROCEDURE 893
Service Brake 894
Park Brake 894
CALIPER 895
Disassembly 895
PISTON SUBASSEMBLY 899
Disassembly 899
PREPARATION FOR ASSEMBLY 900
Clean Parts 900
For Rough Metal Parts 900
Dry and Inspect Parts 900
Corrosion Protection 900
INSPECTION 901
Caliper Parts 901
Shoes, Linings and End Plates 901
Inspect linings 901
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 902
Piston Assembly Adjuster Grip Force 903
Adjuster Force 904
Piston Return Spring 907
ASSEMBLY 908
Adjuster and Pin Assembly 908
Piston Subassembly 909
Brake Caliper 910
PERIODIC INSPECTIONS 916
Shoes, Linings and End Plates 916
Inspect the following areas for fluid leaks 916
Dust Boots 916
Brake Disc 916
BRAKE LINING 917
Replacement 917
BRAKE DISC 917
Inspection 917
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 918
GENERAL 918
SAFETY PRECAUTIONS 918
Rear Brake Conditioning 919
SECTION L HYDRAULIC SYSTEMS INDEX 921
SECTION L2 HYDRAULIC SYSTEM OPERATION INDEX 923
HYDRAULIC SYSTEM 925
HYDRAULIC SYSTEM OPERATION 925
COMPONENT DESCRIPTION 926
Hoist Pump 926
Steering/Brake Pump 926
Tank 926
High Pressure Hydraulic Filters 926
Bleeddown Manifold 926
Steering System Accumulators 926
DISABLED TRUCK CONNECTORS 928
GENERAL 928
STEERING AND BRAKE SYSTEM 928
Hookup 928
HOIST SYSTEM 929
Hookup 929
Dumping Procedure 929
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 931
HYDRAULIC SYSTEM COMPONENT REPAIR 933
HOIST PUMP 933
Removal 933
Installation 934
Disassembly 936
Inspection Of Parts 939
Assembly 940
HYDRAULIC TANK 946
Filling Instructions 946
Removal 946
Installation 947
HYDRAULIC TANK STRAINERS 948
Removal 948
Inspect and Clean 948
Installation 949
HYDRAULIC TANK BREATHERS 949
HOIST CIRCUIT FILTERS 950
FILTER ELEMENT REPLACEMENT 951
Removal 951
Installation 951
INDICATOR SWITCH 951
SECTION L4 STEERING CIRCUIT INDEX 953
STEERING CIRCUIT 954
STEERING CIRCUIT OPERATION 955
COMPONENT DESCRIPTION 956
STEERING CONTROL UNIT 956
FLOW AMPLIFIER 956
No Steer 958
Steering Left 960
Steering Right 962
No Steer, External Shock Load 964
BLEED DOWN MANIFOLD 966
ACCUMULATORS 969
Low Precharge Warning Switch 969
HIGH PRESSURE FILTER 969
STEERING/BRAKE PUMP 969
Operation 970
PRINCIPLE OF OPERATION 972
Full Pump Volume 972
Half Pump Volume 972
Neutral Position: 973
SECTION L5 STEERING CIRCUIT COMPONENT REPAIR INDEX 975
STEERING CIRCUIT COMPONENT REPAIR 977
BLEED DOWN MANIFOLD 977
Removal 977
Installation 977
PISTON ACCUMULATOR 978
Removal 978
Installation 979
Disassembly 980
Cleaning and Inspection 981
Piston Seals Replacement 981
Assembly 982
Leak Testing 983
STEERING ACCUMULATOR CHARGING PROCEDURE 983
Temperature During Precharge 985
PISTON ACCUMULATOR STORAGE 986
FLOW AMPLIFIER 986
Removal 986
Installation 986
STEERING CONTROL UNIT 987
Removal 987
Spline Inspection 988
Installation 988
Disassembly 989
Cleaning and Inspection 990
Assembly 992
STEERING CYLINDER 994
Disassembly 994
Inspection and Cleaning 994
Assembly 994
Testing 995
STEERING CIRCUIT FILTER 996
Filter Element Replacement 996
Removal 997
Installation 997
Indicator Switch 997
STEERING AND BRAKE PUMP 998
Removal 998
Installation 999
Disassembly 1000
Inspection 1003
Assembly 1006
Driveshaft Group 1007
Rotating Group 1007
Valve Plate Group 1008
TROUBLESHOOTING 1010
STEERING CIRCUIT 1010
STEERING PUMP 1012
Basic Hydraulic System Checks 1013
System Leakage Check 1014
Steering Pump Troubleshooting Guide 1016
Pump Pressure Control Checks 1019
Pump Fails to Unload 1020
Pump Fails to Develop Pressure 1020
Pump Slow in Developing Pressure 1021
Pump Control Valve Inspection and Troubleshooting 1022
Pump Case Drain Check 1022
Setting Pump Pressure Controls 1024
Adjustment 1025
SECTION L7 HOIST CIRCUIT INDEX 1027
HOIST CIRCUIT 1029
HOIST CIRCUIT OPERATION 1029
COMPONENT DESCRIPTION 1030
Hydraulic Tank 1030
Hoist Pump 1030
High Pressure Filters 1030
Hoist Valve 1031
Hoist Pilot Valve 1032
Hoist-up Limit Solenoid 1032
Pilot Operated Check Valve 1032
Counterbalance Valve Manifold 1033
HOIST SYSTEM OPERATION MODES 1034
Float Position Of Pilot Valve And Body On Frame (Figure 7-6) 1034
Power Up Operation (Figure 7-7) 1036
Hold Operation (Figure 7-8) 1038
Power Down Operation (Figure 7-9) 1040
Float Operation (Figure 7-10) 1042
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 1045
HOIST CIRCUIT COMPONENT REPAIR 1046
HOIST VALVE 1047
Removal 1047
Installation 1047
O-Ring Replacement 1048
INLET SECTION 1049
Disassembly 1049
Cleaning and Inspection 1050
Assembly 1050
SPOOL SECTION 1051
Disassembly 1051
Cleaning and Inspection 1053
Assembly 1053
HOIST PILOT VALVE 1054
Removal 1054
Installation 1054
Disassembly 1055
Cleaning and Inspection 1056
Assembly 1057
BODY UP LIMIT SOLENOID 1058
PILOT OPERATED CHECK VALVE 1058
HOIST CYLINDERS 1058
Removal 1058
Installation 1059
Disassembly 1060
Cleaning and Inspection 1062
ASSEMBLY OF QUILL AND CYLINDER 1063
Quill Installation 1063
Installation of Check Balls and Plugs in Quill 1064
Assembly of Cylinder 1065
Pressure Testing 1066
OVERCENTER MANIFOLD 1067
SECTION L10 HYDRAULIC CHECKOUT PROCEDURE INDEX 1069
HYDRAULIC SYSTEM CHECKOUT PROCEDURE 1071
PRE-CHECKOUT ITEMS 1071
HYDRAULIC BRAKE AND STEERING ACCUMULATOR BLEED DOWN PROCEDURE 1072
ACCUMULATOR PRECHARGE PROCEDURE 1073
PRESSURE GAUGE INSTALLATION 1074
INITIAL START UP AND FLUSHING PROCEDURE 1076
COMPONENT CHECKOUT AND ADJUSTMENT PROCEDURE 1079
SYSTEM DIAGNOSTICS AND VERIFICATION 1080
HOIST COUNTERBALANCE CARTRIDGE VALVE ADJUSTMENT PROCEDURE 1081
OIL CLEANLINESS CHECK 1083
FILTER REPLACEMENT PROCEDURE 1083
TROUBLESHOOTING 1084
HYDRAULIC CHECKOUT PROCEDURE DATA SHEET 1086
SECTION M OPTIONS AND SPECIAL TOOLS INDEX 1091
SECTION M7 HEATER OPTIONS INDEX 1093
ENGINE OIL HEATERS 1095
GENERAL INFORMATION 1095
TROUBLESHOOTING 1095
HEATER ELEMENT 1096
Removal 1096
Installation 1096
ENGINE COOLANT HEATER 1097
GENERAL 1097
Maintenance 1097
HEATING ELEMENT 1097
Removal 1097
Installation 1098
THERMOSTAT 1098
Removal 1098
Installation 1098
HYDRAULIC OIL HEATERS 1099
GENERAL INFORMATION 1099
TROUBLESHOOTING 1099
HEATER ELEMENT 1100
Removal 1100
Installation 1100
SECTION M8 SPECIAL TOOLS 1101
SPECIAL TOOLS 1101
NITROGEN CHARGING VALVE 1101
ROLL-OUT ASSEMBLY 1101
EYE BOLT 1101
OFFSET WRENCH 1102
TORQUE ADAPTER 1102
HANDLE 1102
SEAL INSTALLER 1102
SLEEVE ALIGNMENT TOOLS 1103
QUICK DISCONNECT COUPLING 1103
HARNESS 1103
SEAL INSTALLATION RING 1103
SOCKETS AND ADAPTERS 1104
DUST CAPS 1104
HYDRAULIC SYSTEM FLUSHING TOOLS 1105
KOMVISION® CALIBRATION TOOLS 1106
MISCELLANEOUS SERVICE TOOLS 1107
PAYLOAD DATA MANAGER 1107
HYDRAULIC SYSTEM VACUUM PUMP 1107
BRAKE PISTON TOOL 1108
SUSPENSION OILING AND CHARGING 1109
SPINDLE REMOVAL TOOL 1109
HIGH VOLTAGE TOOLS 1110
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1110
BODY PAD SPACER TOOL 1111
SECTION M19 RADIATOR SHUTTERS INDEX 1113
RADIATOR SHUTTERS 1115
OPERATION 1115
Hydraulic Circuit 1115
Electrical Circuit: 1116
MAINTENANCE AND REPAIR 1116
TROUBLESHOOTING 1117
Hydraulic Troubleshooting 1120
Electrical Troubleshooting 1122
SECTION M20 PAYLOAD METER IV ™ INDEX 1123
INTRODUCTION 1125
Data Summary 1125
Data Gathering 1125
COMPONENT DESCRIPTION 1126
Electronic Dash Display 1126
Mode Switches 1126
Brake Lock Switch 1126
PAYLOAD METER IV SOFTWARE AND TOOLS 1127
PAYLOAD METER IV SYSTEM CONFIGURATION 1127
Connecting to the payload meter IV web server 1127
Configuring a static IP address 1127
PAYLOAD METER IV SOFTWARE INSTALLATION 1129
PLM IV SYSTEM CHECKOUT DATA SHEET 1135
DOWNLOADING PLM IV DATA AND POSSIBLE ERRORS 1136
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1139
RESERVE ENGINE OIL SYSTEM 1141
GENERAL 1141
OPERATION 1142
Pumping Unit 1142
LED Monitor Lights 1143
Tank Auto Fill Control 1144
Filling Procedure (Remote Fill Feature) 1144
SERVICE 1145
Every 10 Hours (each shift) 1145
Every 500 Hours 1145
Changing Oil 1145
TROUBLESHOOTING 1146
Circuit Fuses 1146
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1147
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1149
RETRACTABLE LADDER SYSTEM 1153
GENERAL SAFETY 1153
LADDER SYSTEM DESCRIPTION 1153
LADDER SYSTEM OPERATION 1154
Normal Operation 1154
Emergency Operation 1155
Limit Switch Operation 1155
IN-CAB CONTROL PANEL 1156
IN-CAB CONTROL PANEL FEATURES 1157
IN-CAB CONTROL PANEL FUNCTIONS 1158
Timing Control 1158
Ladder System Status 1158
Fault Code Identification 1158
Ladder System Configuration 1158
In-Cab Control Panel Lockout 1158
Automatic Raising 1158
Diagnostics 1159
Maintenance 1159
USING THE IN-CAB CONTROL PANEL 1159
Raising the Ladder 1160
Lowering the Ladder 1160
USING THE GROUND LEVEL CONTROL BOX 1161
Raising the Ladder 1161
Lowering the Ladder 1161
POWER PACK OPERATION 1162
MAINTENANCE 1165
Safety During Maintenance 1165
Unplanned Ladder Movements 1165
Automatic Ladder Raising 1165
Automatic Accumulator Recharging (Ladder in UP position) 1166
PREVENTIVE MAINTENANCE PROCEDURES 1167
Daily Inspection 1167
250 Hour Inspection 1167
5000 Hour Inspection 1167
SERVICING 1168
Check Reservoir Oil Level 1168
Changing RLS Fluid 1168
Cleaning the RLS 1169
RLS DIAGNOSTICS 1169
Description of Diagnostics Features 1169
Continuous System Monitoring 1170
Historic System Data Review 1171
Comms Integrity Monitoring 1171
Log and Service Information 1172
System Event Logs 1172
SECURITY ACCESS LEVELS 1173
Access Level 1 – NONE 1173
Access Level 2 – RESTRICTED 1173
Access Level 3 – COMPLETE 1173
User Access Privileges 1174
USER ID – PASSWORD 1175
Sequential Field Value Selection Options 1175
Password Character Table 1175
USER ID – NEW USER SETUP 1176
SYSTEM FAULTS 1176
Fault Type 1: Communications error 1177
Fault Type 2: 10A/15A fuse blown 1177
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected 1178
Fault Type 8: Power pack recharge too long 1178
Fault Type 9: Inhibit relay fail 1179
Fault Types 10, 11: Light/Siren relay failure 1179
Fault Type 12: Ladder came off upper limit 1180
Fault Type 13: Ladder did not reach limit 1180
Fault Type 14: Ladder stayed on limit 1181
Fault Type 15: Low oil level 1181
Fault Type 16: System voltage over 18V during movement 1182
Fault Type 17: System voltage under 18V 1182
Fault Type 18: System voltage over 31V 1183
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped) 1183
Fault Type 21: Accumulator recharge > than once/hour 1184
Fault Type 22: System raised by park brake 1184
Fault Types 23, 24: Levels 1 and 2 service overdue 1185
Fault Type 25: Levels 1 and 2 service complete 1185
DATA MANAGEMENT 1186
Log Files 1186
Generating Reports 1187
MENU DIAGRAMS 1193
Controller Config 1193
Contact Information 1193
Show Recent Logs 1193
System Settings 1193
Upload Logs to USB 1193
Diagnostics 1193
SECTION M33 CAMERA SYSTEM 1201
CAMERA SYSTEM 1203
CAMERA SYSTEM 1203
General 1203
Operation 1203
Camera Switch 1204
CAMERA MONITOR 1205
General 1205
CAMERA CONTROLLER 1206
General 1206
Removal 1206
Installation 1206
Camera Controller Connector Pins 1206
CAMERA SWITCHER 1207
General 1207
Removal 1207
Installation 1207
SETUP AND CHECKOUT PROCEDURE 1208
General 1208
STEP 1 – Switch Function 1208
STEP 2 – Monitor System Settings to Default 1208
STEP 4 – Monitor Settings – System Settings Unique 1210
STEP 4 – Monitor Settings – System Settings Unique – Cameras 1212
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay 1214
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode 1215
STEP 7 – Integrated Functions Check 1216
SECTION N OPERATOR CAB INDEX 1217
SECTION N2 CAB, DOORS AND WINDOWS INDEX 1219
CAB AND COMPONENTS 1222
CAB 1222
Description 1222
Removal 1223
Installation 1224
CAB DOOR 1225
Removal 1225
Installation 1225
Door Adjustment 1225
Door Jamb Bolt Adjustment 1226
Door Handle Plunger Adjustment 1227
Replace Door Glass 1228
Replace Door Window Regulator 1232
Replacing the Door Handle or Latch Assembly 1233
Replacing the Door and Door Hinge Seal 1233
Removing the Door Opening Seal 1234
Installation 1234
GLASS REPLACEMENT 1235
Adhesive-bonded Windows 1235
Replacement Procedure 1235
WINDSHIELD & REAR GLASS 1236
Removal 1236
Installation 1237
WINDSHIELD WIPERS 1238
WIPER MOTOR 1238
Removal 1238
Installation 1238
WIPER ARM 1238
Removal 1238
Installation 1239
WIPER LINKAGE 1239
Removal 1239
Installation 1239
WINDSHIELD WASHER 1240
Operation 1240
Service 1240
OPERATOR SEAT (STANDARD SEAT) 1242
Adjustment 1242
Inspection 1243
Removal 1243
Installation 1243
Replacing the Seat Compressor 1244
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1241
PASSENGER SEAT (STANDARD SEAT) 1249
Inspection 1249
Removal 1249
Installation 1249
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1250
Removal 1250
Installation 1250
SEAT BELT REPLACEMENT (STANDARD SEATS) 1252
Removal 1252
Installation 1252
OPERATOR SEAT (OPTIONAL SEAT) 1254
Seat Belts 1254
Adjustment 1254
PASSENGER SEAT (OPTIONAL SEAT) 1255
Seat Belts 1255
Adjustment 1255
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1256
General 1256
Removal 1256
SECTION N4 HEATER/AIR CONDITIONER INDEX 1261
CLIMATE CONTROL 1263
HEATER / AIR CONDITIONER 1263
Fan Speed Control Knob 1263
Temperature Control Knob 1263
Air Flow Directional Knob 1263
Heater/Air Conditioner Vents 1264
COMPONENTS 1264
Fuse and Circuit Breaker 1264
Relays 1264
Heater Core 1264
Fan Motor And Speed Control 1265
Actuators 1265
Cab Air Filter 1265
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1268
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1268
PRINCIPLES OF REFRIGERATION 1268
Air Conditioning 1268
Refrigeration – The Act Of Cooling 1269
The Refrigeration Cycle 1269
AIR CONDITIONER SYSTEM COMPONENTS 1270
Compressor (Refrigerant Pump) 1270
Service Valves 1270
Condenser 1270
Receiver-Drier 1270
Expansion Block Valve 1271
Accumulator 1271
Evaporator 1271
ELECTRICAL CIRCUIT 1272
Thermostat 1272
Compressor Clutch 1272
Trinary™ Switch 1273
SYSTEM SERVICING 1274
SERVICE TOOLS AND EQUIPMENT 1275
Recovery/Recycle Station 1275
Leak Detector 1275
Service Valves 1276
Vacuum Pump 1276
Manifold Gauge Set 1277
Installing Manifold Gauge Set 1278
Purging Air From Service Hoses 1278
SYSTEM PERFORMANCE TEST 1279
SYSTEM OIL 1280
Handling and Reusing PAG Oil 1280
Oil Quantity 1280
Checking System Oil 1281
REFRIGERANT 1282
Recycled Refrigerant 1282
Reclaimed Refrigerant 1282
Refrigerant Quantity 1282
R-134a Refrigerant Containers 1282
SYSTEM LEAK TESTING 1283
Electronic Leak Detector 1283
Tracer Dyes 1283
Soap and Water 1283
RECOVERING AND RECYCLING THE REFRIGERANT 1284
Draining Oil from the Previous Recovery Cycle 1284
Performing the Recovery Cycle 1284
Performing the Recycling Procedure 1284
Evacuating and Charging the A/C System 1284
SYSTEM REPAIR 1285
System Flushing 1285
COMPONENT REPLACEMENT 1286
Hoses and Fittings 1286
Lines 1286
Expansion Valve 1286
Receiver-Drier 1286
Thermostat 1286
Compressor 1287
Accumulator 1287
Clutch 1287
EVACUATING THE SYSTEM 1288
CHARGING THE A/C SYSTEM 1290
Preliminary Checks 1291
Diagnosis Of Gauge Readings And System Performance 1291
TROUBLESHOOTING 1291
Preliminary Checks 1291
Diagnosis Of Gauge Readings And System Performance 1291
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1292
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1298
SECTION N5 OPERATOR CAB CONTROLS INDEX 1299
OPERATOR CAB AND CONTROLS 1302
STEERING WHEEL AND CONTROLS 1304
Horn Button 1304
Tilt / Telescope Lever 1304
Multi-Function Turn Signal Switch 1304
STEERING COLUMN 1305
Removal 1305
Steering Column Inspection 1305
Installation 1306
STEERING WHEEL 1306
Removal 1306
Installation 1306
PEDALS 1308
Service Brake Pedal 1308
Dynamic Retarding 1308
Dynamic Retard Pedal 1308
Accelerator Pedal 1308
GRADE/SPEED RETARD CHART 1309
OVERHEAD PANEL AND DISPLAYS 1310
CENTER CONSOLE 1311
Directional Control Lever 1311
Override/Fault Reset Switch 1312
Engine Stop Switch 1312
L H Window Control Switch 1312
R H Window Control Switch 1312
Hoist Control Lever 1312
Raising The Dump Body 1312
Lowering The Dump Body 1313
Retard Speed Control (RSC) Adjust Dial 1313
Retard Speed Control (RSC) Switch 1313
Data Store Button 1314
12V Auxiliary Power Outlets 1314
Fire Suppression Control Outlet 1314
Communication Radio Outlet 1314
DIAGNOSTIC PORTS 1314
KOMTRAX Plus Diagnostic Port 1314
Interface Module (IM) Diagnostic Port 1314
Payload Meter Diagnostic Port 1314
Drive System Or Modular Mining 1314
Drive System Controller (DSC) Diagnostic Port 1314
Engine Diagnostic Port (CENSE) 1314
Engine Diagnostic Port (QUANTUM) 1314
HEATER / AIR CONDITIONER 1315
Fan Speed Control Knob 1315
Temperature Control Knob 1315
Air Flow Directional Knob 1315
Heater/Air Conditioner Vents 1315
INSTRUMENT PANEL 1316
Control Symbols 1316
Cab/Air Conditioner Vents 1318
Status Indicator Light Panel 1318
Hydraulic Oil Temperature Gauge 1318
Coolant Temperature Gauge 1318
Speedometer/Digital Display 1318
Fuel Level Gauge 1318
Drive System Temperature Gauge 1318
Hazard Warning Light Switch 1318
Pre-Shift Brake Test Switch 1319
Wheel Brake Lock Control 1319
Rest Switch 1319
Engine Warm Up Switch (Optional) 1320
Heated Mirror Switch (Optional) 1320
Rotating Beacon Light Switch (Optional) 1320
Camera System Switch (Optional) 1320
Key Switch 1320
Starting 1321
Warning Light 1321
Digital Display Contrast Buttons 1321
Turn Signal Indicators 1321
Panel Light Dimmer 1321
Mode Switches 1321
Fog Light Switch (Optional) 1321
Manual Backup Switch 1322
Headlight/Panel Illumination Light Switch 1322
STATUS INDICATOR LIGHT PANEL 1323
Status Indicator Light Panel 1323
DIGIT DISPLAY OPERATION 1326
Toggling Through Main Level Screens 1326
Toggling Through Warning Screens 1327
Entering Payload Meter Data 1328
KOMTRAX PLUS 1329
Operation 1329
Interface Module 1331
Basic Precautions 1331
KOMATSU WIRELESS BRIDGE (Optional) 1332
General Information 1332
Communication Setup 1332
Switching to the KWB_SETUP Network 1332
Setting the Computer Subnet Mask and IP Address 1333
Properties 1333
Setting Up the KWB 1334
Adding Encryption 1334
Final Computer Settings 1334
Data Downloading 1335
Resetting the KWB 1335
KWB Lights 1335
SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX 1337
SECTION P2 PERIODIC MAINTENANCE INDEX 1339
PERIODIC MAINTENANCE 1341
830E SERVICE CAPACITIES 1341
HYDRAULIC TANK SERVICE 1341
Adding Oil 1341
COOLANT LEVEL CHECK 1342
Radiator Filling Procedure 1342
Coolant Specifications 1342
Unacceptable Practices 1342
WHEEL MOTOR SERVICE 1342
RESERVE ENGINE OIL SYSTEM (Optional) 1343
QUICK FILL SERVICE CENTER 1343
LUBRICATION CHART 1344
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 1345
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1346
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1347
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 1348
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 1350
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 1355
EVERY 2500 HOUR MAINTENANCE 1357
EVERY 4000 HOUR MAINTENANCE 1357
EVERY 5000 HOUR MAINTENANCE 1358
EVERY 18000 HOUR MAINTENANCE 1358
INJECTOR OPERATION 1370
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1361
AUTOMATIC LUBRICATION SYSTEM 1363
GENERAL DESCRIPTION 1363
SYSTEM COMPONENTS 1365
Filter 1365
Hydraulic Motor and Pump 1365
Grease Reservoir 1365
Pressure Reducing Valve 1365
Flow Control Valve 1365
Solenoid Valve 1365
Vent Valve 1365
Grease Pressure Failure Switch 1365
Injectors 1365
Interface Module 1365
Relief Valve (unloader valve) 1365
SYSTEM OPERATION 1366
Normal Operation 1366
Lubricant Required For System 1367
Filter Assembly 1367
System Priming 1367
LUBRICANT PUMP 1368
Pump Housing Oil Level 1368
Pump Pressure Control 1368
INJECTORS (SL-1 Series “H”) 1369
Injector Specifications 1369
Injector Adjustment 1369
PREVENTIVE MAINTENANCE PROCEDURES 1371
Daily Lubrication System Inspection 1371
250 Hour Inspection 1371
1000 Hour Inspection 1371
SYSTEM CHECKOUT 1372
Pump Priming Procedure 1372
System Priming Procedure 1373
Lubrication Cycle Operation 1373
AUTOLUBE TROUBLESHOOTING CHART 1374
SECTION R SYSTEM SCHEMATICS INDEX 1377

DESCRIPTION:

Komatsu 830E-1AC Dump Truck Shop Manual CEBM029301  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40939 – A40961

• 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.
• NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable
  payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations should be
  removed as often as practical.
• Exceeding the allowable payload will reduce expected life of truck components.

G.B 20/12/24