Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM029902 PDF

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM029902 –  PDF DOWNLOAD

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM029902 –  PDF DOWNLOAD

Language : English
Pages : 1488
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM029902 –  PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40962 – A40986

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 CAPACITITES 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 SAFETY AND OPERATING INSTRUCTIONS 15
SAFETY 15
GENERAL 15
Safety Rules 15
Safety Features 15
Fire Extinguisher And First Aid Kit 15
Clothing And Personal Items 15
Leaving The Operator’s Seat 16
Mounting And Dismounting 16
Fire Prevention For Fuel And Oil 16
Precautions With High Temperature Fluids 17
Asbestos Dust Hazard Prevention 17
Prevention Of Injury By Work Equipment 17
Unauthorized Modification 17
Precautions When Using ROPS 17
Precautions For Attachments 18
Precautions For Starting The Truck 18
PRECAUTIONS BEFORE OPERATION 18
Safety At The Worksite 18
Fire Prevention 19
Ventilation In Enclosed Areas 19
Preparing For Operation 19
Mirrors, Windows And Lights 19
In The Operator Cab (Before Starting The Engine) 19
Seat Belts 19
OPERATING THE TRUCK 20
When Starting The Engine 20
General Truck Operation 20
Ensuring Good Visibility 20
Traveling 21
Traveling In Reverse 21
Traveling On Slopes 21
Operating On Snow Or Ice 21
Avoid Damage To Dump Body 21
Driving Near High Voltage Cables 22
Working On Loose Ground 22
When Dumping 22
When Loading 22
Parking The Truck 22
Towing 22
WORKING NEAR BATTERIES 23
Battery Hazard Prevention 23
Jump Starting With Jumper Cables 24
Jump Starting With Receptacles 24
BEFORE PERFORMING MAINTENANCE 25
Stopping The Engine Before Service 25
Electrical Systems Isolation 25
Warning Tag 27
Proper Tools 27
Use of Tie-Off Anchor During Maintenance and Repair 27
Securing The Dump Body 27
Jack Point Locations 28
WHILE PERFORMING MAINTENANCE 29
Keep The Truck Clean 29
Attachments 29
Working Under The Truck 29
Rotating Fan And Belts 29
Waste Materials 29
Adding Fuel Or Oil 30
Radiator Coolant Level 30
Use Of Lighting 30
Precautions With The Battery 30
Handling High Pressure Hoses 30
Precautions With High Pressure Oil 30
Performing Maintenance Near High Temperature Or High Pressure 30
TIRES 31
Inspection 31
Maintenance 31
Storage 32
Handling 33
WHEN REPAIRS ARE NECESSARY 34
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 35
Preliminary Procedures Before Welding or Performing Maintenance 35
Engine Shutdown Procedure Before Welding or Performing Maintenance 35
CAPACITOR DISCHARGE SYSTEM 37
Necessary Tools 37
Warnings And Cautions 38
Manual DC Link Capacitor Discharge Procedure 39
Failure of the Discharge System 41
Manual Discharge of Capacitors 42
Short Isolated Capacitor Terminals 44
OPERATING INSTRUCTIONS 44
PREPARING FOR OPERATION 45
WALK AROUND INSPECTION 45
RETRACTABLE LADDER SYSTEM (Optional) 49
Description 49
Normal Operation 50
General Safety 50
IN-CAB CONTROL PANEL 50
Digital Display Screen 51
Command Buttons 51
USING THE IN-CAB CONTROL PANEL 52
Raising the Ladder 53
Lowering the Ladder 53
USING THE GROUND LEVEL CONTROL BOX 54
Raising the Ladder 54
Lowering the Ladder 54
EMERGENCY OPERATION 55
ENGINE START-UP 56
AFTER ENGINE HAS STARTED 57
PRE-SHIFT BRAKE CHECK 58
Events 58
OPERATION 58
Description 58
Brake Test Exit Criteria 59
PERFORMING THE BRAKE TESTS 60
Setup 60
Service Brake Test 60
Parking Brake Test 61
Retard System Test 62
EMERGENCY STEERING SYSTEM 62
Operation 62
Pre-Operation Testing 62
Additional Guidelines 63
MACHINE OPERATION SAFETY PRECAUTIONS 63
OPERATING ON THE HAUL ROAD 64
STARTING ON A GRADE WITH A LOADED TRUCK 65
PASSING 65
LOADING 65
Overload Speed Limit Function 65
DUMPING 66
Raising The Dump Body 66
Lowering The Dump Body (When dumping on flat ground) 67
Lowering The Dump Body (When dumping over a berm or into a crusher) 67
Sudden loss of engine power or loss of drive system function 68
FUEL DEPLETION 68
SAFE PARKING PROCEDURES 69
NORMAL ENGINE SHUTDOWN PROCEDURE 69
DISABLED TRUCK DUMPING PROCEDURE 71
Hookup 71
Raising the Body 71
Lowering the Body 71
HOIST SYSTEM 72
Hookup 72
Dumping Procedure 73
TOWING 73
Special Wiring Harness 74
Towing Procedure 74
SECTION A4 WARNINGS AND CAUTIONS 77
GRADE/SPEED CHART 77
KEY SWITCH 77
ROPS/FOPS 77
BATTERIES 78
ISOLATION BOX 79
PROPEL LOCKOUT LEVER 79
CAPACITORS 80
CRUSHING HAZARD 80
CYLINDER PRESSURE 81
FILLING THE HYDRAULIC TANK 81
HYDRAULIC OIL PRESSURE 82
HOT OIL SPRAY 82
WHEEL MOTOR OIL LEVEL 82
HOT EXHAUST 82
RADIATOR 83
ORGANIC ACID TECHNOLOGY (OAT) COOLANT 83
EMERGENCY LADDER 83
ACCUMULATOR DRAIN VALVES 83
EMERGENCY DUMP PROCEDURE 83
EMERGENCY TOWING PROCEDURE 84
WELDING 84
EMERGENCY SHUTDOWN 84
INFORMATION DISPLAY 84
WIRELESS SIGNALS 85
HIGH VOLTAGE 85
LIFTING INSTRUCTIONS 86
TOW SOCKET 87
PRODUCT IDENTIFICATION PLATE 87
LUBRICATION CHART 88
SECTION A5 TORQUE TABLES AND CONVERSION CHARTS 89
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 90
STANDARD TIGHTENING TORQUES For Class 10 9 Capscrews & Class 10 Nuts 90
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews 91
STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews 92
SECTION A7 STORAGE PROCEDURES INDEX 99
STORAGE AND IDLE MACHINE PREPARATION 101
SHORT TERM IDLE PERIODS 101
PREPARATION FOR STORAGE 102
REMOVAL FROM STORAGE 103
RECONDITIONING AN IDLE VEHICLE 105
ENGINE OPERATION 107
AFTER ENGINE HAS STARTED 108
ENGINE STORAGE 109
Engine Storage-(Short Term) 109
Engine Storage- (Long Term) 110
TRANSMISSION PRESERVATION AND STORAGE 115
Restoring Transmission to Service 115
ELECTRIC DRIVE TRUCKS 111
SECTION B STRUCTURES INDEX 117
SECTION B2 STRUCTURAL COMPONENTS INDEX 119
STRUCTURAL COMPONENTS 121
LADDERS 122
Removal 123
Installation 123
RIGHT DECK 123
Removal 123
Installation 124
LEFT DECK 125
Removal 125
Installation 125
CENTER DECK 126
Removal 126
Installation 126
Removal 129
Installation 130
SECTION B3 DUMP BODY INDEX 127
DUMP BODY 129
BODY PADS 131
Removal 131
Installation 131
Adjustment 132
BODY GUIDE 133
BODY-UP RETENTION SLING 134
BODY POSITION INDICATOR 134
HOIST LIMIT SWITCH 134
BODY UP SWITCH 134
ROCK EJECTORS 135
Inspection 135
Removal 138
Installation 138
Repair 140
Cleaning 140
SECTION B4 FUEL TANK INDEX 137
FUEL TANK 138
FUEL TANK VENT ASSEMBLY 140
Disassembly 140
Assembly 140
FUEL GAUGE SENDER (TOP) 141
Removal 141
Operation 142
Specifications: 142
QUICK FILL FUEL RECEIVERS 143
SECTION C ENGINE INDEX 145
SECTION C2 POWER MODULE INDEX 147
POWER MODULE 148
PREPARATION 149
REMOVAL 149
INSTALLATION 154
EXHAUST TUBE INSTALLATION 158
EXHAUST BLANKET INSTALLATION 158
SECTION C4 POWER TRAIN INDEX 173
POWER TRAIN 174
ALTERNATOR REMOVAL PROCEDURE 175
ALTERNATOR INSTALLATION 177
General Instructions 177
Measuring Procedure 177
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 179
ENGINE 181
Removal 181
Service 182
Installation 182
SECTION C5 AIR CLEANERS INDEX 183
AIR CLEANERS 185
OPERATION 185
SERVICING THE AIR CLEANERS 185
Replacing The Elements 186
AIR CLEANER ASSEMBLY CLEANING 187
Primary Element Cleaning 187
Precleaner Section Cleaning 189
AIR INTAKE TROUBLESHOOTING 190
SECTION C7 FAN CLUTCH INDEX 191
FAN CLUTCH 192
REMOVAL & INSTALLATION TOOLING 193
DISASSEMBLY 196
CLEANING AND INSPECTION 206
ASSEMBLY 210
TEST PROCEDURE 224
SECTION C3 COOLING SYSTEM INDEX 161
COOLING SYSTEM DESCRIPTION 163
RADIATOR 164
Removal 164
Installation 167
Radiator Filling Procedure 168
REPAIRING THE RADIATOR 169
Internal Inspection 169
External Cleaning 169
Disassembly 169
Cleaning and Inspection 170
Assembly 170
Pressure Testing 172
COOLANT SYSTEM TROUBLESHOOTING 172
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) INDEX 225
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 226
24VDC ELECTRIC SUPPLY SYSTEM 229
ELECTRICAL SYSTEM DESCRIPTION 229
BATTERIES 229
Maintenance and Service 229
Troubleshooting 229
BATTERY SUPPLY SYSTEM 231
24VDC Battery Charging Alternator 231
Battery Box 231
Removal 231
Installation 232
Battery Control Box 232
24VDC Auxiliary Battery Receptacles 232
Engine Start Relay 232
ISOLATION BOX ASSEMBLY 232
Engine Shutdown Switch 232
Access Ladder Light Switch 232
Battery Disconnect Switches 232
Propel Lockout Lever 233
LED Lights 233
AUXILIARY CONTROL CABINET 234
24VDC to 12VDC Converter 234
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 235
Operation 235
Engine Oil Pressure Switch 235
Check Valve 235
MAINTENANCE 235
Prelube System Operation Checks 235
Check Valve 235
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 236
24VDC ELECTRIC START SYSTEM 238
CRANKING MOTORS 238
Operation 238
Removal 238
Installation 238
CRANKING MOTOR TROUBLESHOOTING 239
Preliminary Inspection 239
No-Load Test 239
Interpreting Results of Tests 240
Disassembly 240
Cleaning and Inspection 241
Armature Servicing 241
Field Coil Checks 243
Field Coil Removal 243
SOLENOID CHECKS 244
Test 244
Assembly 245
Bearing Replacement: 245
Motor Assembly: 245
Pinion Clearance 246
MAGNETIC SWITCH 246
Removal 246
Installation 246
Coil Test 247
SECTION D3 24VDC ELECTRICAL SYSTEM COMPONENTS INDEX 249
24 VDC ELECTRICAL SYSTEM COMPONENTS 251
TRUCK SHUTDOWN PROCEDURE 251
BRAKE WARNING BUZZER 251
AUXILIARY CONTROL CABINET COMPONENTS 251
Interface Module 252
Payload Meter 252
24VDC to 12VDC Converter 252
Circuit Breaker (CB60) 252
Communication Interface Module 252
Pump Module Service Light Timer 253
Power Distribution Terminals 253
Ground Terminal 253
Relays 254
Engine Service Light Timer 254
RTMR1 – VEC Block 255
Vehicle Electrical Centers (VEC) 255
VEC-89 256
VEC-90 258
VEC-91 260
MAGNETIC SWITCHES 262
Body position switches (With proximity switch and magnet) 262
Proximity switch operation 262
Service 262
BODY-UP SWITCH 263
Adjusting the Body-Up Switch 263
HOIST LIMIT SWITCH 264
Operation 264
Adjusting the Hoist Limit Switch 265
SECTION D11 KOMTRAX PLUS SYSTEM INDEX 266
KOMTRAX PLUS COMPONENTS 268
KOMTRAX PLUS BASIC FEATURES 269
Gather Data 269
Convert and Record Data 269
Communicate Data to Off-Board Systems 270
USING THE KOMTRAX PLUS SYSTEM 271
Turning the KOMTRAX Plus System ON 271
Normal KOMTRAX Plus Operation 271
Turning the KOMTRAX Plus System OFF 272
Downloading from the KOMTRAX Plus Controller 272
KOMTRAX PLUS DATA ITEMS 273
Fault Codes 273
Machine History 273
KOMTRAX Plus History 273
Snapshots 274
Manual Snapshots 274
Trends 276
Histogram (Load Map) Data 276
Haul Cycle Data 277
Alarm and Snapshot Triggers 278
Satellite Features 278
KOMTRAX PLUS DIAGNOSTIC FEATURES 280
Fault History 280
KOMTRAX Plus LED Digits 280
KOMTRAX PLUS CONTROLLER 280
Removal 281
Installation 281
NECESSARY SOFTWARE 283
NECESSARY TOOLS 283
KOMTRAX PLUS SOFTWARE 283
KOMTRAX PLUS SYSTEM SET UP 284
KOMTRAX Plus Controller 284
KOMTRAX PLUS CONTROLLER 284
KOMTRAX PLUS TOOL BOX 284
Installation 284
KOMTRAX PLUS SETTING TOOL 284
Installation 284
KOMTRAX PLUS INITIALIZATION PROCEDURE 285
KOMTRAX PLUS CONTROLLER SETUP PROCEDURE 285
KOMTRAX Plus Setting Tool software program 285
Select Operation 285
KOMTRAX Plus Setting Function 286
Machine Information Setting(1) 286
Machine Information Setting(2) 286
Date & Time Setting 286
GCC Setting 287
Setting Summary 287
KOMTRAX PLUS SNAPSHOT PROCEDURE 288
KOMTRAX PLUS DOWNLOAD PROCEDURE 289
LOCATION OF DOWNLOAD FILES 289
KOMTRAX PLUS FTP UPLOAD PROCEDURE 290
KOMTRAX Plus INITIALIZATION FORMS 291
WHEN REPLACING A KOMTRAX PLUS CONTROLLER 292
To Set: Date & Time; Satellite; Payload Meter 294
Review Setting Information 296
KOMTRAX PLUS CONTROLLER CHECKOUT 297
KOMTRAX Plus Controller 297
Necessary Equipment: 297
Preliminary 298
KOMTRAX Plus Controller Checkout Procedure 299
ORBCOMM CONTROLLER 301
Removal 301
Installation 301
SECTION D12 INTERFACE MODULE INDEX 303
INTERFACE MODULE 305
Removal 305
Installation 305
SENSORS 306
Temperature Sensors 306
Pressure Sensors 306
INTERFACE MODULE SOFTWARE 307
NECESSARY SOFTWARE 307
NECESSARY TOOLS 307
FLASHBURN PROGRAM 308
Installation 308
INTERFACE MODULE APPLICATION CODE 308
Installation 308
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 309
Installation 309
Using The Program 309
INTERFACE MODULE CHECKOUT 309
Interface Module 309
Necessary Equipment: 309
Preliminary 310
Checking Inputs And Outputs From The Interface Module 311
Check Analog Inputs To The Interface Module 315
Check CAN RPC & J1939 Interfaces To The IM 315
Check Outputs From The Interface Module 315
SECTION D13 KOMTRAX PLUS & INTERFACE MODULE TROUBLESHOOTING & ERROR CODES INDEX 317
KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING 319
TROUBLESHOOTING 319
GENERAL 319
Structure and Purpose 319
TROUBLESHOOTING 320
Communications Networks 320
Coaxial Cable 320
FAULT CODES 321
Fault History 321
KOMTRAX Plus LED Display Fault Codes 322
Chassis Fault Codes 323
Engine Fault Codes 328
FAULT TREE ANALYSIS 334
Unable to connect to KOMTRAX Plus from Service PC 334
Flashing Error Code N4-23 (PLM Communications Fault) 335
Flashing Error Code N4-22 (Engine Communications Fault) 336
No Data Received By WebCARE 337
Coaxial Cable Troubleshooting 338
SECTION D14 KOMTRAX PLUS FORMS INDEX 339
KOMTRAX PLUS FORMS 341
KOMTRAX PLUS INITIALIZATION CHECK LIST 341
KOMTRAX PLUS DATA DOWNLOAD 342
KOMTRAX PLUS INITIALIZATION CHECK LIST 343
KOMTRAX PLUS INITIALIZATION FORM 345
SECTION E ELECTRIC PROPULSION SYSTEM INDEX 347
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 348
ELECTRICAL PROPULSION SYSTEM COMPONENTS 351
GENERAL SYSTEM DESCRIPTION 351
SYSTEM COMPONENTS 353
Drive System Controller (DSC) 353
Diagnostic Information Display (DID) Panel 354
DID Panel Event Codes 354
DSC SOFTWARE FUNCTIONS 382
Input Processing 382
State Machine 382
DC Link State 385
Engine Control 386
ALTERNATOR FIELD CONTROL 386
Desired DC Link Voltage 386
Self-Load 386
Propel Torque Control 387
Retard Torque Control 387
Wheel Slide Control 387
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
Event Reset 390
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 391
Fast Start 391
Engine Shutdown/Engine Not Running 391
Limp Home Mode 391
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 392
ELECTRONIC ACCELERATOR AND RETARD PEDALS 399
Removal 399
Installation 399
Disassembly 399
Assembly 399
PHASE MODULE REPLACEMENT 400
Removal 400
Installation 400
SECTION E3 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE INDEX 401
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE 403
AC DRIVE SYSTEM MAINTENANCE 403
NORMAL TRUCK SHUTDOWN PROCEDURE 404
TEST EQUIPMENT 405
HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS 405
REST MODE ACTIVATION 405
INITIAL CHECKOUT PROCEDURES 406
Circuit Continuity and Resistance Checks 406
Megger Test for Grounds 406
Preparation for Megger Test 407
Megger Test Procedure 408
Troubleshooting for Grounds 409
Low Voltage Power Supply Checks 410
Preparation for Power Supply Checks 410
Power Supply Check Procedure 410
Drive System Controller (DSC) Card Checks 411
Propulsion System Software Installation 411
DSC Manual Test Procedures 414
Accelerator Pedal, Retarder Pedal, and Retarder Lever Calibration and Checks 416
Set Truck ID Number 420
Control Cabinet Pressure Switch Check 421
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 422
Verifying DSC Software Version 422
Resetting and Erasing DSC Event Data 424
ENGINE RUNNING TESTS 425
Battery Boost Circuit Verification 425
Selector Switch Check 427
Ground Detection Network Tests 429
Self Load Engine Test (Loadbox) Procedure 433
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 435
DID Panel Display Selection 435
DID Modes Display 437
Function Key F1 – DID Events or Faults Display 438
Function Key F4 – DID Menu Display 441
DID Self Load Engine Test (Loadbox) 442
DID Link Capacitance Test 444
DID Speedometer Test 445
DID View Software Version 446
DID View Overspeed Setting 447
DID View Data Menu 448
DID Inverter Cutout Menu 453
DID Truck Configuration Menu 454
Language Selection 459
VIEWING EVENT AND STATISTICAL DATA 460
Viewing the DSC Event Summary, Trigger Data, and Data Packs 460
Viewing the Statistical Data 462
LOGIC SCREENS 463
DATALOGGER FUNCTION 465
Setting Up the Datalogger 465
Starting the Datalogger 467
UPLOADING DATA 469
Consolidated Truck Data Save 469
USB Drive 470
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A139) INDEX 471
Fault Code A001: Left front suspension pressure sensor signal is high 473
Related circuit diagram 473
Fault Code A002: Left front suspension pressure sensor signal is low 474
Related circuit diagram 474
Fault Code A003: Right front suspension pressure sensor signal is high 475
Related circuit diagram 475
Fault Code A004: Right front suspension pressure sensor signal is low 476
Related circuit diagram 476
Fault Code A005: Left rear suspension pressure sensor signal is high 477
Related circuit diagram 477
Fault Code A006: Left rear suspension pressure sensor signal is low 478
Related circuit diagram 478
Fault Code A007: Right rear suspension pressure sensor signal is high 479
Related circuit diagram 479
Fault Code A008: Right rear suspension pressure sensor signal is low 480
Related circuit diagram 480
Fault Code A009: Incline sensor signal is high 481
Related circuit diagram 481
Fault Code A010: Incline sensor signal is low 482
Related circuit diagram 482
Fault Code A011: Payload meter speed sensor signal has failed 483
Fault Code A013: Body up switch has failed 484
Related circuit diagram 484
Fault Code A014: Payload meter checksum computation has failed 485
Related circuit diagram 485
Fault Code A016: Payload meter write to flash memory has failed 486
Related circuit diagram 486
Fault Code A017: Payload meter flash memory read has failed 487
Related circuit diagram 487
Fault Code A018: Right rear flat suspension cylinder warning 488
Related circuit diagram 489
Fault Code A019: Left rear flat suspension cylinder warning 490
Related circuit diagram 491
Fault Code A022: Carryback load is excessive 492
Related circuit diagram 493
Fault Code A101: High pressure detected across a hydraulic pump filter 494
Related circuit diagram 495
Fault Code A103: Hydraulic oil tank temperature sensor is reading low 496
Related circuit diagram 496
Fault Code A104: Hydraulic oil tank temperature sensor is reading high 497
Related circuit diagram 497
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 498
Related circuit diagram 499
Fault Code A107: GE has generated a propel system caution 500
Related circuit diagram 500
Fault Code A108: GE has generated a propel system temperature caution 501
Related circuit diagram 501
Fault Code A109: GE has generated a propel system reduced level signal 502
Fault Code A111: Low steering pressure warning 504
Fault Code A115: Low steering precharge pressure is detected 506
Related circuit diagram 507
Fault Code A117: Low brake accumulator pressure warning 508
Fault Code A118: Brake pressure is low while brake lock is activated 510
Fault Code A123: GE has generated a reduced retarding caution 512
Fault Code A124: GE has generated a no propel / no retard or system not running input 514
Fault Code A125: GE has generated a no propel warning 516
Fault Code A126: Oil level in the hydraulic tank is low 517
Fault Code A127: IM furnished +5 volt output for sensors is low 518
Related circuit diagram 519
Fault Code A128: IM furnished +5 volt output for sensors is high 520
Related circuit diagram 521
Fault Code A139: Low fuel level warning 522
Related circuit diagram 523
SECTION E5 TROUBLESHOOTING FAULT CODES (A152-A246) INDEX 525
Fault Code A152: Starter failure 527
Fault Code A153: Battery voltage is low with truck in operation 528
Fault Code A154: Battery charging voltage is excessive 530
Fault Code A155: Battery charging voltage is low 531
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 532
Fault Code A184: J1939 data link is not connected 533
Fault Code A190: Auto lube control has detected an incomplete lube cycle 534
Fault Code A193: Hydraulic tank oil temperature is high 536
Fault Code A198: Hoist pressure 1 sensor is high 537
Fault Code A199: Hoist pressure 2 sensor is high 538
Fault Code A200: Steering pressure sensor is high 539
Fault Code A201: Brake pressure sensor is high 540
Fault Code A202: Hoist pressure 1 sensor is low 541
Fault Code A203: Hoist pressure 2 sensor is low 542
Fault Code A204: Steering pressure sensor is low 543
Fault Code A205: Brake pressure sensor is low 544
Fault Code A206: Ambient temperature sensor is high 545
Fault Code A207: Ambient temperature sensor is low 546
Fault Code A212: Bad truck speed signal 547
Fault Code A213: Parking brake should have applied but is detected as not having applied 548
Fault Code A214: Parking brake should have released but is detected as not having released 552
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 556
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 558
Fault Code A230: Parking brake has been requested while truck still moving 560
Fault Code A231: Dump body is up while traveling or intending to travel 562
Fault Code A233: Drive system CAN/RPC Control Link not connected 566
Fault Code A235: Steering accumulator is in the process of being bled down 568
Fault Code A236: Steering accumulator has not properly bled down after 90 seconds 570
Fault Code A237: The CAN/RPC connection to the display is open 572
Fault Code A240: The keyswitch input to the interface module is open 573
Fault Code A242: The fuel gauge within the display panel is defective 574
Fault Code A243: The engine coolant temp gauge within the display panel is defective 575
Fault Code A244: The drive system temp gauge within the display panel is defective 576
Fault Code A245: The hydraulic oil temp gauge within the display panel is defective 577
Fault Code A246: Payload meter reports truck overload 578
SECTION E5 TROUBLESHOOTING FAULT CODES (A247-A292) INDEX 579
Fault Code A247: Low steering pressure warning 581
Fault Code A248: The status indicator module within the display panel is defective 583
Fault Code A249: The red warning lamp within the display panel is shorted 584
Fault Code A250: Battery voltage is low with the truck parked 586
Fault Code A251: The sonalert used with the display panel (driven by IM) is open or shorted to ground 588
Fault Code A252: Start enable output circuit is either open or shorted to ground 590
Fault Code A253: Steering bleed circuit is not open while running 592
Fault Code A255: IM has detected a fault on IM output 1N 594
Fault Code A256: The red warning lamp within the display panel (driven by IM) is open 595
Fault Code A257: Payload CAN/RPC is not connected 596
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 597
Fault Code A260: Parking brake failure 598
Fault Code A261: Low brake accumulator pressure warning 600
Fault Code A262: Steering bleed valve circuit open during shutdown 602
Fault Code A264: Parking brake relay circuit is defective 604
Fault Code A265: Service brake failure 606
Fault Code A266: Selector lever was not in park while attempting to crank engine 608
Fault Code A267: Parking brake was not set while attempting to crank engine 610
Fault Code A268: Secondary engine shutdown while cranking 612
Fault Code A270: Brake lock switch power supply is not on when required 614
Fault Code A271: Shifter not in gear 616
Fault Code A272: Brake lock switch power supply is not off when required 618
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 620
Fault Code A274: A brake setting fault has been detected 622
Fault Code A275: A starter has been detected as engaged without a cranking attempt 624
Fault Code A276: The drive system data link is not connected 626
Fault Code A277: Parking brake applied while loading 628
Fault Code A278: Service brake applied while loading 630
Fault Code A279: Low steering pressure switch is defective 631
Fault Code A280: Steering accumulator Bleed Down switch is defective 632
Fault Code A281: Brake lock degradation switch is defective 634
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 636
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 638
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 640
Fault Code A285: The parking brake was not set when the key switch was turned off 642
Fault Code A286: A fault was detected in the shutdown delay relay circuit 644
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 646
SECTION E5 TROUBLESHOOTING FAULT CODES (A303-A365) INDEX 649
Fault Code A303: Shifter is defective 651
Fault Code A304: Auto lube grease level is low 652
Fault Code A305: Auto lube circuit is defective 653
Fault Code A307: Both GE inverters are disabled 654
Fault Code A309: No brakes applied when expected 656
Fault Code A310: Low fuel level warning 658
Related circuit diagram 659
Fault Code A311: Brake lock switch is on when it should not be 660
Fault Code A312: DC-DC converter 12 volt circuit sensing is producing low readings 662
Fault Code A313: DC-DC converter 12 volt circuit sensing is producing high readings 663
Fault Code A315: DC-DC converter 12 volt circuit is low 664
Fault Code A316: Starter engagement has been attempted with engine running 666
Fault Code A318: Unexpected power loss to interface module 668
Fault Code A320: Propel system caution wire input not same as serial input 669
Fault Code A321: Propel system temperature caution wire input not same as serial input 670
Fault Code A322: Propel system at reduced level wire input not same as serial input 671
Fault Code A323: Propel system at reduced retard level wire input not same as serial input 672
Fault Code A324: GE link voltage wire input not same as serial input 673
Fault Code A325: No Propel/Retard wire input not same as serial input 674
Fault Code A326: No Propel wire input not same as serial input 675
Fault Code A327: GE Propel System at Rest or Not Ready wire input not same as serial input 676
Fault Code A328: Drive system not powered up 677
Fault Code A329: Body down wire input not same as serial input 678
Fault Code A330: Dynamic retard switch input not same as serial input 679
Fault Code A332: Seat belt not buckled 680
Fault Code A333: The hydraulic ladder controller has declared a ladder fault 682
Fault Code A334: Selector lever not in park when propel was either not ready or at rest 683
Fault Code A335: Manual/Auto Apply Pressure Fault 684
Fault Code A350: Overload on output 1B 685
Fault Code A351: Overload on output 1E 686
Fault Code A352: Overload on output 1H 687
Fault Code A353: Overload on output 1J 688
Fault Code A354: Overload on output 1K 689
Fault Code A355: Overload on output 1L 690
Fault Code A356: Overload on output 1M 691
Fault Code A357: Overload on output 1N 692
Fault Code A358: Overload on output 1P 693
Fault Code A359: Overload on output 1R 694
Fault Code A360: Overload on output 1S 695
Fault Code A361: Overload on output 1T 696
Fault Code A362: Overload on output 1U 697
Fault Code A363: Overload on output 1X 698
Fault Code A364: Overload on output 1Y 699
Fault Code A365: Overload on output 1Z 700
SECTION G DRIVE AXLE, SPINDLES, AND WHEELS INDEX 703
SECTION G2 TIRES AND RIMS INDEX 705
TIRES AND RIMS 706
GENERAL PRECAUTIONS 707
RIM COMPONENTS 708
Smart Rim Component Layout 708
FRONT TIRES AND RIMS 709
Removal 709
Installation 711
REAR TIRES AND RIMS 711
Removal 711
Installation 712
RIM AND TIRE 714
Tire Removal 714
Rim And Tire Preparation 714
Lubricants 715
Tire Installation 715
RIM AND TIRE SERVICE 717
Lubricants 717
Tire Inflation 717
Lock Ring Retainer Installation 717
Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual 718
Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual 719
Removal (5-Piece Standard Rim) 720
Removal (7-Piece Smart Rim) 723
Removal (5-Piece Smart Rim) 725
Preparation Before Assembly 726
Installation (5-Piece Standard Rim) 727
Installation – Horizontal Mount (Smart Rim) 729
Installation – Vertical Mount (5-Piece Smart Rim) 731
Installation – Vertical Mount (7-Piece Smart Rim) 732
SECTION G3 FRONT WHEEL HUB AND SPINDLES INDEX 733
FRONT WHEEL HUB AND SPINDLE 735
WHEEL HUB AND SPINDLE ASSEMBLY 735
Removal 735
Spindle Removal Procedure (Optional) (off of the truck) 738
Installation 740
Disassembly 742
Cleaning and Inspection 742
Assembly 744
Wheel Bearing Adjustment (Tire Removed) 746
Wheel Bearing Adjustment (Tire mounted) 747
OIL SAMPLING PROCEDURE 748
Oil Sampling Guidelines 749
Procedure 749
OIL DRAIN AND REFILL PROCEDURE 749
STEERING CYLINDERS 750
Spherical Bearing Wear Limits 750
Removal 751
Installation 751
Bearing Replacement (Steering Cylinder and Tie Rod) 751
TIE ROD 753
Removal 753
Installation 753
Disassembly 754
Assembly 754
TOE-IN ADJUSTMENT 755
TIE ROD INSPECTION AND TORQUE PROCEDURE 756
Old Style Tie Rod 756
New Style Tie Rod 757
SECTION G4 REAR AXLE HOUSING ATTACHMENT INDEX 759
REAR AXLE HOUSING ATTACHMENT 761
PIVOT PIN 761
Removal 761
Installation 761
PIVOT EYE BEARING 762
Disassembly 762
Assembly 762
PIVOT EYE REPAIR 762
Removal 762
Installation 763
Disassembly 763
Assembly 763
ANTI-SWAY BAR 763
Removal 763
Installation 764
Disassembly 764
Cleaning and Inspection 764
Assembly 764
SECTION G5 REAR AXLE HOUSING INDEX 765
REAR AXLE HOUSING 767
REAR AXLE HOUSING 767
Removal 767
Installation 767
WHEEL MOTOR 768
Removal 768
Cleaning and Inspection 768
Installation 769
WHEEL MOTOR GEAR OIL 772
Change/Filter The Gear case Oil 772
Oil 772
Remove And Clean Magnetic Plugs 772
Flushing The Gearbox 772
Check Gear Case Oil Level 772
Removal 777
Installation 778
SECTION H SUSPENSIONS INDEX 773
SECTION H2 FRONT SUSPENSION INDEX 775
FRONT SUSPENSION 776
TURN-OF-THE-NUT Tightening Procedure 780
Upper Mounting Joint – 60° Advance 780
Lower Mounting Joint – 90° Advance 782
Inspection 782
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 783
Bearing Structure Removal 783
Bearing Structure Installation 783
MAJOR SUSPENSION REBUILD 784
Disassembly 784
Assembly 785
PRESSURE TEST 787
Removal 790
Installation 793
SECTION H3 REAR SUSPENSIONS INDEX 789
REAR SUSPENSIONS 789
ROD DOWN SUSPENSION 794
Disassembly 794
Cleaning and Inspection 794
Assembly 796
PRESSURE TEST 798
Suspension Pressure Test 798
SECTION H4 OILING AND CHARGING PROCEDURE INDEX 799
CHECKING FOR IMPROPER SUSPENSION CHARGE 801
SUSPENSION OILING AND CHARGING PROCEDURES 802
GENERAL 802
EQUIPMENT LIST 802
HYDRAIR® CHARGING KIT 803
Installation of Charging Kit 803
Removal of Charging Kit 803
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 804
FRONT SUSPENSION 805
REAR SUSPENSION 808
SUSPENSION PRESSURE TEST 811
OIL AND NITROGEN SPECIFICATIONS CHART 812
SECTION J BRAKE SYSTEMS INDEX 813
SECTION J2 BRAKE CIRCUIT INDEX 815
BRAKE CIRCUIT 817
OPERATION 817
SERVICE BRAKE CIRCUIT OPERATION 817
SECONDARY BRAKING AND AUTOMATIC APPLY 819
PARKING BRAKE CIRCUIT 819
Normal Operation (key switch on, engine running) 819
BRAKE LOCK CIRCUIT 820
WARNING CIRCUIT 820
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 823
BRAKE CIRCUIT COMPONENT SERVICE 825
BRAKE VALVE 825
Rebuild Criteria 825
Removal 825
Installation 827
DISASSEMBLY 829
Cleaning and Inspection 831
ASSEMBLY 831
Actuator Base Threaded Inserts 831
Boot and Cap 831
Valve Body Seal Installation 832
Regulator Sleeve O-Ring Installation 832
Actuator Plunger O-ring Installation 833
Assembly of Valve 833
VALVE BENCH TEST AND ADJUSTMENT 835
Test Set Up Procedure 836
Brake Valve Output Pressure Adjustment 836
Final Test and Adjustment 837
Installation Of Brake Pedal Actuator Assembly to Brake Valve 838
INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL BRAKE ASSEMBLY (Dual Function) 840
Installation of Retard Pedal To Brake Pedal 840
HYDRAULIC BRAKE ACCUMULATORS 841
Brake Accumulator Bleed Down Procedure 841
Removal 841
Installation 841
Disassembly 841
Cleaning and Inspection 843
Assembly 843
Charging Procedure 845
BRAKE MANIFOLD 846
Removal 846
Removal 846
Installation 847
Disassembly 847
Cleaning and Inspection 848
Assembly 848
SECTION J4 BRAKE SYSTEM CHECKOUT PROCEDURE INDEX 849
BRAKE SYSTEM CHECKOUT PROCEDURE 851
EQUIPMENT REQUIRED 853
PRE-CHECKOUT ITEMS 854
CHECKOUT PROCEDURE SET-UP 855
INITIAL SYSTEM SET-UP 856
BRAKE LOCK SYSTEM CHECK 858
PARKING BRAKE SYSTEM 859
LOW BRAKE PRESSURE AND AUTO APPLY 860
BRAKE REAPPLICATIONS (STORED ENERGY CHECK) 861
PARK BRAKE CONTROL LOGIC CHECK 861
BRAKE LOCK CONTROL LOGIC CHECK 862
BRAKE SYSTEM TROUBLESHOOTING 865
BRAKE SYSTEM CHECKOUT DATA SHEET 866
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 898
Disassembly 898
PREPARATION FOR ASSEMBLY 899
Clean Parts 899
For Rough Metal Parts 900
Dry and Inspect Parts 900
Corrosion Protection 900
INSPECTION 900
Caliper Parts 900
Shoes, Linings and End Plates 901
Inspect linings 901
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 901
Piston Assembly Adjuster Grip Force 902
Adjuster Force 904
Piston Return Spring 906
ASSEMBLY 907
Adjuster and Pin Assembly 907
Piston Subassembly 908
Brake Caliper 909
PERIODIC INSPECTIONS 915
Shoes, Linings and End Plates 915
Inspect the following areas for fluid leaks 915
Dust Boots 915
Brake Disc 915
BRAKE LINING 916
Replacement 916
BRAKE DISC 916
Inspection 916
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 917
GENERAL 917
SAFETY PRECAUTIONS 917
Rear Brake Conditioning 918
SECTION L HYDRAULIC SYSTEMS INDEX 921
SECTION L2 HYDRAULIC SYSTEM OPERATION INDEX 922
HYDRAULIC SYSTEM 924
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
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
STEERING CIRCUIT OPERATION 955
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 931
HYDRAULIC SYSTEM COMPONENT REPAIR 933
HOIST PUMP 933
HYDRAULIC TANK 946
HYDRAULC TANK STRAINERS 948
HYDRAULIC TANK BREATHERS 948
HOIST CIRCUIT FILTERS 950
FILTER ELEMENT REPLACEMENT 950
INDICATOR SWITCH 951
SECTION L4 STEERING CIRCUIT INDEX 953
STEERING CIRCUIT 955
STEERING CIRCUIT OPERATION 955
COMPONENT DESCRIPTION 957
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 976
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
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 1028
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 1047
HOIST VALVE 1047
Removal 1047
Installation 1048
O-Ring Replacement 1048
INLET SECTION 1049
Cleaning and Inspection 1050
Assembly 1050
REAR SPOOL SECTION (Work Ports) 1051
Disassembly 1051
Cleaning and Inspection 1051
Assembly 1053
FRONT SPOOL SECTION (Tank Ports) 1054
Disassembly 1054
Cleaning and Inspection 1054
Assembly 1054
HOIST PILOT VALVE 1056
Removal 1056
Installation 1056
Disassembly 1057
Cleaning and Inspection 1058
Assembly 1058
HOIST CYLINDERS 1059
Removal 1059
Installation 1060
Disassembly 1062
Cleaning and Inspection 1063
Assembly – Quill 1064
Assembly – Cylinder 1066
Testing 1066
OVERCENTER VALVE 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 1087
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 1095
Removal 1095
Installation 1096
GENERAL 1097
Maintenance 1097
HEATING ELEMENT 1097
Removal 1097
Installation 1098
THERMOSTAT 1098
Removal 1098
Installation 1098
GENERAL INFORMATION 1099
TROUBLESHOOTING 1099
HEATER ELEMENT 1099
Removal 1099
Installation 1100
SECTION M8 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
SOCKETS AND ADAPTERS 1104
DUST CAPS 1104
HYDRAULIC SYSTEM FLUSHING TOOLS 1105
BATTERY JUMP STARTING 1105
SMART RIM TOOLS 1105
KOMVISION® CALIBRATION TOOLS 1106
MISCELLANEOUS SERVICE TOOLS 1107
PAYLOAD DATA MANAGER 1107
HYDRAULIC SYSTEM VACUUM PUMP 1107
BRAKE PISTON TOOL 1108
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 1124
Data Summary 1124
Data Gathering 1124
COMPONENT DESCRIPTION 1125
Electronic Dash Display 1125
Mode Switches 1125
Brake Lock Switch 1125
Payload meter IV software and tools 1126
Payload meter IV system configuration 1126
Connecting to the payload meter IV web server 1126
Configuring a static IP address 1126
Payload meter IV software installation 1128
PLM IV system checkout data sheet 1134
Downloading PLM IV data and possible errors 1135
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 KomVision® INDEX 1201
KomVision® 1203
KomVision® SYSTEM PRECAUTIONS 1203
COMPONENT LOCATIONS 1204
MONITOR PANEL 1208
Brightness Switches 1208
System Power Status Indicator 1208
Force Display Switch 1208
Camera Switches 1209
Monitor Display Mode Switch 1209
Reference Line Display Switch 1209
Lower Body Display Switch 1209
Object Clear Switch 1209
MONITOR DISPLAY 1210
Camera Display Modes 1210
Bird’s Eye Views 1212
Reference Lines 1212
Dump Body Status Display 1212
Error Code Display 1213
Initial Setting Screen 1214
RADAR SYSTEM 1214
Object Detection Range 1214
Object Detection Warnings 1215
Object Clear 1218
START-UP INSPECTION 1218
Camera Inspections 1218
Verify the Radar System is Operational 1218
CLEANING 1219
Monitor Panel And Controller 1219
Cameras 1219
KomVision® SYSTEM SETUP AND CALIBRATION 1220
Password Mode 1220
Maintenance Mode 1221
Main Setting Display 1222
6 Camera Calibration Display 1223
Camera Setting 1233
System State 1235
Error Log Screen 1236
Check Disk Display 1236
MAINTENANCE SCREEN EXPLANATION 1237
Area 1237
Threshold 1238
All Radar Position 1238
RADAR DETAIL 1241
Integration 1241
Explanation of Terms 1242
System I/O Explanation 1243
TESTING AND ADJUSTING 1244
System Adjustment 1244
Initial Setting 1244
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1245
6 Camera Calibration Preparation 1245
Calibration Sheet Unfolding 1248
Folding a Camera Calibration Sheet 1249
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1250
Placement of Front Calibration Sheet 1250
Placement of Left and Right Calibration Sheet 1250
Placement of Rear Calibration Sheet and Adjustment of Left and Right Calibration Sheets 1251
CALIBRATING CAMERAS 1251
Automatic 6 Camera Calibration Operation 1251
Manual 6 Camera Calibration 1255
6 Camera Calibration Outgoing Message, and Screen Correspondence 1257
1 Camera Calibration 1258
1 Camera Calibration Outgoing Message, and Screen Correspondence 1260
RADAR SETTING 1260
Radar Zone Preparation and System Calibration 1260
SECTION N OPERATOR CAB INDEX 1271
SECTION N2 CAB, DOORS AND WINDOWS INDEX 1273
CAB AND COMPONENTS 1275
CAB 1276
Description 1276
Removal 1277
Installation 1278
CAB DOOR 1279
Removal 1279
Installation 1279
Door Adjustment 1279
Door Jamb Bolt Adjustment 1280
Door Handle Plunger Adjustment 1281
Replace Door Glass 1282
Replace Door Window Regulator 1286
Replacing the Door Handle or Latch Assembly 1287
Replacing the Door and Door Hinge Seal 1287
Removing the Door Opening Seal 1288
Installation 1288
GLASS REPLACEMENT 1289
Adhesive-bonded Windows 1289
Replacement Procedure 1289
WINDSHIELD & REAR GLASS 1290
Removal 1290
Installation 1291
WINDSHIELD WIPERS 1292
WIPER MOTOR 1292
Removal 1292
Installation 1292
WIPER ARM 1292
Removal 1292
Installation 1293
WIPER LINKAGE 1293
Removal 1293
Installation 1293
WINDSHIELD WASHER 1294
Operation 1294
Service 1294
OPERATOR SEAT (STANDARD SEAT) 1296
Adjustment 1296
Inspection 1297
Removal 1297
Installation 1297
Replacing the Seat Compressor 1298
PASSENGER SEAT (STANDARD SEAT) 1303
Inspection 1303
Removal 1303
Installation 1303
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1304
Removal 1304
Installation 1304
SEAT BELT REPLACEMENT (STANDARD SEATS) 1306
Removal 1306
Installation 1306
OPERATOR SEAT (OPTIONAL SEAT) 1308
Seat Belts 1308
Adjustment 1308
PASSENGER SEAT (OPTIONAL SEAT) 1309
Seat Belts 1309
Adjustment 1309
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1295
OPERATOR SEAT (STANDARD SEAT) 1296
Adjustment 1296
Inspection 1296
Removal 1297
Installation 1297
Replacing the Seat Compressor 1297
PASSENGER SEAT (STANDARD SEAT) 1303
Inspection 1303
Removal 1303
Installation 1303
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1303
Removal 1304
Installation 1304
SEAT BELT REPLACEMENT (STANDARD SEATS) 1306
Removal 1306
Installation 1306
OPERATOR SEAT (OPTIONAL SEAT) 1308
Seat Belts 1308
Adjustment 1308
PASSENGER SEAT (OPTIONAL SEAT) 1309
Seat Belts 1309
Adjustment 1309
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1309
General 1310
Removal 1310
SECTION N4 HEATER/AIR CONDITIONER INDEX 1315
CLIMATE CONTROL 1317
HEATER / AIR CONDITIONER 1317
Fan Speed Control Knob 1317
Temperature Control Knob 1317
Air Flow Directional Knob 1317
Heater/Air Conditioner Vents 1318
COMPONENTS 1318
Fuse and Circuit Breaker 1318
Relays 1318
Heater Core 1318
Fan Motor And Speed Control 1319
Actuators 1319
Cab Air Filter 1319
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1322
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1322
PRINCIPLES OF REFRIGERATION 1322
Air Conditioning 1322
Refrigeration – The Act Of Cooling 1323
The Refrigeration Cycle 1323
AIR CONDITIONER SYSTEM COMPONENTS 1324
Compressor (Refrigerant Pump) 1324
Service Valves 1324
Condenser 1324
Receiver-Drier 1324
Expansion Block Valve 1325
Accumulator 1325
Evaporator 1325
ELECTRICAL CIRCUIT 1326
Thermostat 1326
Compressor Clutch 1326
Trinary™ Switch 1327
SYSTEM SERVICING 1328
SERVICE TOOLS AND EQUIPMENT 1329
Recovery/Recycle Station 1329
Leak Detector 1329
Service Valves 1330
Vacuum Pump 1330
Manifold Gauge Set 1331
Installing Manifold Gauge Set 1332
Purging Air From Service Hoses 1332
SYSTEM PERFORMANCE TEST 1333
SYSTEM OIL 1334
Handling and Reusing PAG Oil 1334
Oil Quantity 1334
Checking System Oil 1335
REFRIGERANT 1336
Recycled Refrigerant 1336
Reclaimed Refrigerant 1336
Refrigerant Quantity 1336
R-134a Refrigerant Containers 1336
SYSTEM LEAK TESTING 1337
Electronic Leak Detector 1337
Tracer Dyes 1337
Soap and Water 1337
RECOVERING AND RECYCLING THE REFRIGERANT 1337
Draining Oil from the Previous Recovery Cycle 1337
Performing the Recovery Cycle 1338
Performing the Recycling Procedure 1338
Evacuating and Charging the A/C System 1338
SYSTEM REPAIR 1338
System Flushing 1339
COMPONENT REPLACEMENT 1340
Hoses and Fittings 1340
Lines 1340
Expansion Valve 1340
Receiver-Drier 1340
Thermostat 1340
Compressor 1341
Accumulator 1341
Clutch 1341
EVACUATING THE SYSTEM 1342
CHARGING THE A/C SYSTEM 1344
Preliminary Checks 1345
Diagnosis Of Gauge Readings And System Performance 1345
TROUBLESHOOTING 1345
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1345
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1351
SECTION N5 OPERATOR CAB CONTROLS INDEX 1353
OPERATOR CAB AND CONTROLS 1356
STEERING WHEEL AND CONTROLS 1357
Horn Button 1357
Tilt / Telescope Lever 1357
Multi-Function Turn Signal Switch 1357
STEERING COLUMN 1358
Removal 1358
Steering Column Inspection 1358
Installation 1359
STEERING WHEEL 1359
Removal 1359
Installation 1359
PEDALS 1361
Service Brake Pedal 1361
Dynamic Retarding 1361
Dynamic Retard Pedal 1361
Accelerator Pedal 1361
GRADE/SPEED RETARD CHART 1362
Radio Speakers 1363
Warning Alarm Buzzer 1363
Cab Radio 1363
Air Cleaner Vacuum Gauges 1363
KomVisionTM Panel 1363
CENTER CONSOLE 1364
Directional Control Lever 1364
Override/Fault Reset Switch 1365
Engine Stop Switch 1365
LH Window Control Switch 1365
RH Window Control Switch 1365
Hoist Control Lever 1365
Raising The Dump Body 1365
Lowering The Dump Body 1366
Retard Speed Control (RSC) Adjust Dial 1366
Retard Speed Control (RSC) Switch 1366
Data Store Button 1367
12V Auxiliary Power Outlets 1367
Fire Suppression Control Outlet 1367
Communication Radio Outlet 1367
DIAGNOSTIC PORTS 1367
KOMTRAX Plus Diagnostic Port 1367
Interface Module (IM) Diagnostic Port 1367
Payload Meter Diagnostic Port 1367
Drive System Controller (DSC) Diagnostic Port 1367
Engine Diagnostic Port (CENSE) 1367
Engine Diagnostic Port (QUANTUM) 1367
HEATER / AIR CONDITIONER 1368
Fan Speed Control Knob 1368
Temperature Control Knob 1368
Air Flow Directional Knob 1368
Heater/Air Conditioner Vents 1368
INSTRUMENT PANEL 1369
Control Symbols 1369
Cab/Air Conditioner Vents 1371
Status Indicator Light Panel 1371
Hydraulic Oil Temperature Gauge 1371
Coolant Temperature Gauge 1371
Speedometer/Digital Display 1371
Fuel Level Gauge 1371
Drive System Temperature Gauge 1371
Hazard Warning Light Switch 1371
Pre-Shift Brake Test Switch 1372
Wheel Brake Lock Control 1372
Rest Switch 1372
Engine Warm Up Switch (Optional) 1373
Heated Mirror Switch (Optional) 1373
Rotating Beacon Light Switch (Optional) 1373
Key Switch 1373
Starting 1373
Warning Light 1374
Digital Display Contrast Buttons 1374
Turn Signal Indicators 1374
Panel Light Dimmer 1374
Mode Switches 1374
Fog Light Switch (Optional) 1374
Manual Backup Switch 1374
Headlight/Panel Illumination Light Switch 1375
STATUS INDICATOR LIGHT PANEL 1376
Status Indicator Light Panel 1376
DIGITAL DISPLAY OPERATION 1379
Toggling Through Main Level Screens 1379
Toggling Through Warning Screens 1380
Entering Payload Meter Data 1381
KOMTRAX PLUS 1382
Operation 1382
Interface Module 1384
Basic Precautions 1384
KOMATSU WIRELESS BRIDGE (Bullet 2) 1385
General Information 1385
Communication Setup 1385
Setting The Computer Subnet Mask And IP Address 1387
Windows 2000® 1387
Windows XP® 1387
Windows Vista® 1387
Windows 7® 1388
Adding Encryption 1389
Downloading Data 1389
Resetting the KWB 1390
SECTION P LUBRICATION AND PERIODIC MAINTENANCE INDEX 1391
SECTION P2 PERIODIC MAINTENANCE INDEX 1393
PERIODIC MAINTENANCE 1395
830E SERVICE CAPACITIES 1395
HYDRAULIC TANK SERVICE 1395
Adding Oil 1395
COOLANT LEVEL CHECK 1396
Radiator Filling Procedure 1396
Coolant Specifications 1396
Unacceptable Practices 1396
WHEEL MOTOR SERVICE 1396
RESERVE ENGINE OIL SYSTEM (Optional) 1397
QUICK FILL SERVICE CENTER 1397
LUBRICATION CHART 1398
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 1399
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1400
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1401
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 1402
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 1404
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 1409
EVERY 2500 HOUR MAINTENANCE 1411
EVERY 4000 HOUR MAINTENANCE 1411
EVERY 5000 HOUR MAINTENANCE 1412
EVERY 18000 HOUR MAINTENANCE 1412
INJECTOR OPERATION 1424
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1415
AUTOMATIC LUBRICATION SYSTEM 1417
GENERAL DESCRIPTION 1417
SYSTEM COMPONENTS 1419
Filter 1419
Hydraulic Motor and Pump 1419
Grease Reservoir 1419
Pressure Reducing Valve 1419
Flow Control Valve 1419
Solenoid Valve 1419
Vent Valve 1419
Grease Pressure Failure Switch 1419
Injectors 1419
Interface Module 1419
Relief Valve (unloader valve) 1419
SYSTEM OPERATION 1420
Normal Operation 1420
Lubricant Required For System 1421
Filter Assembly 1421
System Priming 1421
LUBRICANT PUMP 1422
Pump Housing Oil Level 1422
Pump Pressure Control 1422
INJECTORS (SL-1 Series “H”) 1423
Injector Specifications 1423
Injector Adjustment 1423
PREVENTIVE MAINTENANCE PROCEDURES 1425
Daily Lubrication System Inspection 1425
250 Hour Inspection 1425
1000 Hour Inspection 1425
SYSTEM CHECKOUT 1426
Pump Priming Procedure 1426
System Priming Procedure 1427
Lubrication Cycle Operation 1427
Autolube troubleshooting chart 1428
SECTION R SYSTEM SCHEMATICS INDEX 1431
58E-06-02006_05 Aug 20 pdf 0
830E (58E) 0
Schematics 0
58E-06-02006 0
58E-06-02006:05:WIRING DIAGRAM – 830E-1AC 0
Diagram1 1436
Diagram2 1437
Diagram3 1438
Diagram4 1439
Diagram5 1440
Diagram6 1441
Diagram7 1442
Diagram8 1443
Diagram9 1444
Diagram10 1445
Diagram11 1446
Diagram12 1447
Diagram13 1448
Diagram14 1449
Diagram15 1450
Diagram16 1451
Diagram17 1452
Diagram18 1453
Diagram19 1454
Diagram20 1455

DESCRIPTION:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM029902 –  PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40962 – A40986

• 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