Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM032802 PDF

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM032802  – PDF DOWNLOAD

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Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM032802  – PDF DOWNLOAD

Language : English
Pages : 1494
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM032802  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40987 – A40994 A40996 and up
• ENGINE 16V160

SECTION A GENERAL INFORMATION 9
SECTION A2 MAJOR COMPONENT DESCRIPTION 11
Truck And Engine 11
Main Control Cabinet 11
AC Induction Traction Motorized Wheels 11
Suspension 11
Operator’s Cab 11
Power Steering 11
Dynamic Retarding 11
Brake System 11
SECTION A2 SPECIFICATIONS 13
SECTION A3 SAFETY 15
GENERAL 15
PRECAUTIONS BEFORE OPERATION 18
OPERATING THE TRUCK 20
WORKING NEAR BATTERIES 23
BEFORE PERFORMING MAINTENANCE 25
WHILE PERFORMING MAINTENANCE 29
TIRES 31
WHEN REPAIRS ARE NECESSARY 34
SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS 35
CAPACITOR DISCHARGE SYSTEM 37
SECTION A3 OPERATING INSTRUCTIONS 45
PREPARING FOR OPERATION 45
WALK AROUND INSPECTION 45
RETRACTABLE LADDER SYSTEM (Optional) 49
IN-CAB CONTROL PANEL 50
USING THE IN-CAB CONTROL PANEL 52
USING THE GROUND LEVEL CONTROL BOX 54
EMERGENCY OPERATION 55
ENGINE START-UP 56
AFTER ENGINE HAS STARTED 57
PRE-SHIFT BRAKE CHECK 58
OPERATION 58
PERFORMING THE BRAKE TESTS 60
EMERGENCY STEERING SYSTEM 62
MACHINE OPERATION SAFETY PRECAUTIONS 63
OPERATING ON THE HAUL ROAD 64
STARTING ON A GRADE WITH A LOADED TRUCK 65
PASSING 65
LOADING 65
DUMPING 66
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
HOIST SYSTEM 72
TOWING 73
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
TRANSMISSION PRESERVATION AND STORAGE 115
ELECTRIC DRIVE TRUCKS 111
SECTION B STRUCTURES 117
SECTION B2 STRUCTURAL COMPONENTS INDEX 119
STRUCTURAL COMPONENTS 121
LADDERS 122
RIGHT DECK 123
LEFT DECK 125
CENTER DECK 126
SECTION B3 DUMP BODY INDEX 127
DUMP BODY 129
BODY PADS 131
BODY GUIDE 133
BODY-UP RETENTION SLING 134
BODY POSITION INDICATOR 134
HOIST LIMIT SWITCH 134
BODY UP SWITCH 134
ROCK EJECTORS 135
SECTION B4 FUEL TANK INDEX 137
FUEL TANK 138
FUEL TANK VENT ASSEMBLY 140
FUEL GAUGE SENDER (TOP) 141
QUICK FILL FUEL RECEIVERS 143
SECTION C ENGINE 145
SECTION C2 POWER MODULE INDEX 147
POWER MODULE 149
PREPARATION 149
REMOVAL 149
INSTALLATION 154
EXHAUST TUBE INSTALLATION 158
EXHAUST BLANKET INSTALLATION 158
SECTION C3 COOLING SYSTEM INDEX 161
COOLING SYSTEM DESCRIPTION 163
RADIATOR 164
REPAIRING THE RADIATOR 169
COOLANT SYSTEM TROUBLESHOOTING 172
SECTION C4 POWER TRAIN INDEX 173
POWER TRAIN 175
ALTERNATOR REMOVAL PROCEDURE 175
ALTERNATOR INSTALLATION 177
ENGINE 181
SECTION C5 AIR CLEANERS INDEX 183
AIR CLEANERS 185
OPERATION 185
SERVICING THE AIR CLEANERS 185
AIR CLEANER ASSEMBLY CLEANING 187
AIR INTAKE TROUBLESHOOTING 190
SECTION C7 FAN CLUTCH INDEX 191
FAN CLUTCH 193
REMOVAL & INSTALLATION TOOLING 193
DISASSEMBLY 196
CLEANING AND INSPECTION 206
ASSEMBLY 210
TEST PROCEDURE 224
SECTION D ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 225
SECTION D2 24VDC ELECTRIC SUPPLY SYSTEM INDEX 227
24VDC ELECTRIC SUPPLY SYSTEM 229
ELECTRICAL SYSTEM DESCRIPTION 229
BATTERIES 229
BATTERY SUPPLY SYSTEM 231
ISOLATION BOX ASSEMBLY 232
AUXILIARY CONTROL CABINET 234
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE) 235
MAINTENANCE 235
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT 236
24VDC ELECTRIC START SYSTEM 238
CRANKING MOTORS 238
CRANKING MOTOR TROUBLESHOOTING 239
SOLENOID CHECKS 244
MAGNETIC SWITCH 246
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
MAGNETIC SWITCHES 262
Body position switches (With proximity switch and magnet) 262
BODY-UP SWITCH 263
HOIST LIMIT SWITCH 264
SECTION D11 KOMTRAX PLUS SYSTEM INDEX 267
KOMTRAX PLUS COMPONENTS 269
KOMTRAX PLUS BASIC FEATURES 269
USING THE KOMTRAX PLUS SYSTEM 271
KOMTRAX PLUS DATA ITEMS 273
KOMTRAX PLUS DIAGNOSTIC FEATURES 280
KOMTRAX PLUS CONTROLLER 280
KOMTRAX PLUS SOFTWARE 283
KOMTRAX PLUS SYSTEM SET UP 284
KOMTRAX PLUS CONTROLLER 284
KOMTRAX PLUS TOOL BOX 284
KOMTRAX PLUS SETTING TOOL 284
KOMTRAX PLUS INITIALIZATION PROCEDURE 285
KOMTRAX PLUS CONTROLLER SETUP PROCEDURE 285
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
KOMTRAX PLUS CONTROLLER CHECKOUT 297
ORBCOMM CONTROLLER 301
SECTION D12 INTERFACE MODULE INDEX 303
INTERFACE MODULE 305
SENSORS 306
INTERFACE MODULE SOFTWARE 307
FLASHBURN PROGRAM 308
INTERFACE MODULE APPLICATION CODE 308
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM 309
INTERFACE MODULE CHECKOUT 309
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
TROUBLESHOOTING 320
FAULT CODES 321
FAULT TREE ANALYSIS 334
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 347
SECTION E2 ELECTRIC PROPULSION SYSTEM COMPONENTS INDEX 349
ELECTRICAL PROPULSION SYSTEM COMPONENTS 351
GENERAL SYSTEM DESCRIPTION 351
SYSTEM COMPONENTS 353
DSC SOFTWARE FUNCTIONS 382
ALTERNATOR FIELD CONTROL 386
EVENT DETECTION AND PROCESSING 388
EVENT RESTRICTIONS 389
EVENT LOGGING AND STORAGE 389
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS 391
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS 392
ELECTRONIC ACCELERATOR AND RETARD PEDALS 399
PHASE MODULE REPLACEMENT 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
CHECKS PRIOR TO SELF LOAD ENGINE TEST (LOADBOX) 422
ENGINE RUNNING TESTS 425
DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL 435
VIEWING EVENT AND STATISTICAL DATA 460
LOGIC SCREENS 463
DATALOGGER FUNCTION 465
UPLOADING DATA 469
SECTION E5 TROUBLESHOOTING FAULT CODES (A001-A139) INDEX 471
Fault Code A001: Left front suspension pressure sensor signal is high 473
Fault Code A002: Left front suspension pressure sensor signal is low 474
Fault Code A003: Right front suspension pressure sensor signal is high 475
Fault Code A004: Right front suspension pressure sensor signal is low 476
Fault Code A005: Left rear suspension pressure sensor signal is high 477
Fault Code A006: Left rear suspension pressure sensor signal is low 478
Fault Code A007: Right rear suspension pressure sensor signal is high 479
Fault Code A008: Right rear suspension pressure sensor signal is low 480
Fault Code A009: Incline sensor signal is high 481
Fault Code A010: Incline sensor signal is low 482
Fault Code A011: Payload meter speed sensor signal has failed 483
Fault Code A013: Body up switch has failed 484
Fault Code A014: Payload meter checksum computation has failed 485
Fault Code A016: Payload meter write to flash memory has failed 486
Fault Code A017: Payload meter flash memory read has failed 487
Fault Code A018: Right rear flat suspension cylinder warning 488
Fault Code A019: Left rear flat suspension cylinder warning 490
Fault Code A022: Carryback load is excessive 492
Fault Code A101: High pressure detected across a hydraulic pump filter 494
Fault Code A103: Hydraulic oil tank temperature sensor is reading low 496
Fault Code A104: Hydraulic oil tank temperature sensor is reading high 497
Fault Code A105: Fuel level sensor is shorted to ground, indicating a false high fuel level 498
Fault Code A107: GE has generated a propel system caution 500
Fault Code A108: GE has generated a propel system temperature caution 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
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
Fault Code A128: IM furnished +5 volt output for sensors is high 520
Fault Code A139: Low fuel level warning 522
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 (A248-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
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 703
SECTION G2 TIRES AND RIMS INDEX 705
TIRES AND RIMS 707
GENERAL PRECAUTIONS 707
RIM COMPONENTS 708
FRONT TIRES AND RIMS 709
REAR TIRES AND RIMS 711
RIM AND TIRE 714
RIM AND TIRE SERVICE 717
SECTION G3 FRONT WHEEL HUB AND SPINDLES INDEX 733
FRONT WHEEL HUB AND SPINDLE 735
WHEEL HUB AND SPINDLE ASSEMBLY 735
OIL SAMPLING PROCEDURE 748
OIL DRAIN AND REFILL PROCEDURE 749
STEERING CYLINDERS 750
TIE ROD 753
TOE-IN ADJUSTMENT 755
TIE ROD INSPECTION AND TORQUE PROCEDURE 756
SECTION G4 REAR AXLE HOUSING ATTACHMENT INDEX 759
REAR AXLE HOUSING ATTACHMENT 761
PIVOT PIN 761
PIVOT EYE BEARING 762
PIVOT EYE REPAIR 762
ANTI-SWAY BAR 763
SECTION G5 REAR AXLE HOUSING INDEX 765
REAR AXLE HOUSING 767
REAR AXLE HOUSING 767
WHEEL MOTOR 768
WHEEL MOTOR GEAR OIL 772
SECTION H SUSPENSIONS 773
SECTION H2 FRONT SUSPENSION INDEX 775
FRONT SUSPENSION 777
TURN-OF-THE-NUT Tightening Procedure 780
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 783
MAJOR SUSPENSION REBUILD 784
PRESSURE TEST 787
SECTION H3 REAR SUSPENSIONS INDEX 789
REAR SUSPENSIONS 790
ROD DOWN SUSPENSION 794
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
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 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
BRAKE LOCK CIRCUIT 820
WARNING CIRCUIT 820
SECTION J3 BRAKE CIRCUIT COMPONENT SERVICE INDEX 823
BRAKE CIRCUIT COMPONENT SERVICE 825
BRAKE VALVE 825
DISASSEMBLY 829
ASSEMBLY 831
VALVE BENCH TEST AND ADJUSTMENT 835
INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL BRAKE ASSEMBLY (Dual Function) 840
HYDRAULIC BRAKE ACCUMULATORS 841
BRAKE MANIFOLD 846
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 867
SECTION J5 FRONT BRAKES INDEX 875
WHEEL SPEED FRONT DISC BRAKES 877
BRAKE CALIPER 877
BRAKE LINING 881
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 883
GENERAL 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
PARK BRAKE ADJUSTMENT PROCEDURE 893
CALIPER 895
PISTON SUBASSEMBLY 898
PREPARATION FOR ASSEMBLY 899
INSPECTION 900
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC) 901
ASSEMBLY 907
PERIODIC INSPECTIONS 915
BRAKE LINING 916
BRAKE DISC 916
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 917
GENERAL 917
SAFETY PRECAUTIONS 917
SECTION L HYDRAULIC SYSTEMS 921
SECTION L2 HYDRAULIC SYSTEM OPERATION INDEX 923
HYDRAULIC SYSTEM 925
HYDRAULIC SYSTEM OPERATION 925
COMPONENT DESCRIPTION 926
DISABLED TRUCK CONNECTORS 928
GENERAL 928
STEERING AND BRAKE SYSTEM 928
HOIST SYSTEM 929
SECTION L3 HYDRAULIC SYSTEM COMPONENT REPAIR INDEX 931
HYDRAULIC SYSTEM COMPONENT REPAIR 933
HOIST PUMP 933
HYDRAULIC TANK 946
HYDRAULIC TANK STRAINERS 948
HYDRAULIC TANK BREATHERS 949
HOIST CIRCUIT FILTERS 950
FILTER ELEMENT REPLACEMENT 951
INDICATOR SWITCH 951
SECTION L4 STEERING CIRCUIT INDEX 953
STEERING CIRCUIT 955
STEERING CIRCUIT OPERATION 955
COMPONENT DESCRIPTION 956
STEERING CONTROL UNIT 956
FLOW AMPLIFIER 956
BLEED DOWN MANIFOLD 966
ACCUMULATORS 969
HIGH PRESSURE FILTER 969
STEERING/BRAKE PUMP 969
PRINCIPLE OF OPERATION 972
SECTION L5 STEERING CIRCUIT COMPONENT REPAIR INDEX 975
STEERING CIRCUIT COMPONENT REPAIR 977
BLEED DOWN MANIFOLD 977
PISTON ACCUMULATOR 978
STEERING ACCUMULATOR CHARGING PROCEDURE 983
PISTON ACCUMULATOR STORAGE 986
FLOW AMPLIFIER 986
STEERING CONTROL UNIT 987
STEERING CYLINDER 994
STEERING CIRCUIT FILTER 996
STEERING AND BRAKE PUMP 998
TROUBLESHOOTING 1010
STEERING CIRCUIT 1010
STEERING PUMP 1012
SECTION L7 HOIST CIRCUIT INDEX 1027
HOIST CIRCUIT 1029
HOIST CIRCUIT OPERATION 1029
COMPONENT DESCRIPTION 1030
HOIST SYSTEM OPERATION MODES 1034
SECTION L8 HOIST CIRCUIT COMPONENT REPAIR INDEX 1045
HOIST CIRCUIT COMPONENT REPAIR 1047
HOIST VALVE 1047
INLET SECTION 1049
SPOOL SECTION 1050
HOIST PILOT VALVE 1054
BODY UP LIMIT SOLENOID 1058
PILOT OPERATED CHECK VALVE 1058
HOIST CYLINDERS 1058
ASSEMBLY OF QUILL AND CYLINDER 1063
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 1087
SECTION M OPTIONSAND SPECIAL TOOLS 1091
SECTION M7 HEATER OPTIONS INDEX 1093
GENERAL INFORMATION 1095
TROUBLESHOOTING 1095
HEATER ELEMENT 1095
GENERAL 1097
HEATING ELEMENT 1097
THERMOSTAT 1098
GENERAL INFORMATION 1099
TROUBLESHOOTING 1099
HEATER ELEMENT 1099
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
SLEEVE ALIGNMENT TOOLS 1103
QUICK DISCONNECT COUPLING 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
HIGH VOLTAGE TOOLS 1111
0-2000 VDC CUSTOM METER KIT (58B-06-00800) 1111
BODY PAD SPACER TOOL 1112
RADIATOR SHUTTERS 1115
OPERATION 1115
MAINTENANCE AND REPAIR 1116
TROUBLESHOOTING 1117
SECTION M19 RADIATOR SHUTTERS INDEX 1113
SECTION M20 PAYLOAD METER IV ™ INDEX 1123
INTRODUCTION 1125
COMPONENT DESCRIPTION 1126
USING THE ELECTRONIC DASH DISPLAY 1128
HAUL CYCLE WARNINGS 1130
SYSTEM CONFIGURATION 1134
SECTION M31 RESERVE ENGINE OIL SYSTEM INDEX 1145
RESERVE ENGINE OIL SYSTEM 1147
GENERAL 1147
OPERATION 1148
SERVICE 1151
TROUBLESHOOTING 1152
AUTO FILL SYSTEM ELECTRICAL SCHEMATIC 1153
SECTION M32 RETRACTABLE LADDER SYSTEM INDEX 1155
RETRACTABLE LADDER SYSTEM 1159
GENERAL SAFETY 1159
LADDER SYSTEM DESCRIPTION 1159
LADDER SYSTEM OPERATION 1160
IN-CAB CONTROL PANEL 1162
IN-CAB CONTROL PANEL FEATURES 1163
IN-CAB CONTROL PANEL FUNCTIONS 1164
USING THE IN-CAB CONTROL PANEL 1165
USING THE GROUND LEVEL CONTROL BOX 1167
POWER PACK OPERATION 1168
MAINTENANCE 1171
PREVENTIVE MAINTENANCE PROCEDURES 1173
SERVICING 1174
RLS DIAGNOSTICS 1175
SECURITY ACCESS LEVELS 1179
USER ID – PASSWORD 1181
USER ID – NEW USER SETUP 1182
SYSTEM FAULTS 1182
DATA MANAGEMENT 1192
MENU DIAGRAMS 1199
SECTION M33 KOMVISION® INDEX 1207
KomVision® 1209
KomVision® SYSTEM PRECAUTIONS 1209
COMPONENT LOCATIONS 1210
MONITOR PANEL 1214
MONITOR DISPLAY 1216
RADAR SYSTEM 1220
START-UP INSPECTION 1224
CLEANING 1225
KomVision® SYSTEM SETUP AND CALIBRATION 1226
MAINTENANCE SCREEN EXPLANATION 1243
RADAR DETAIL 1247
TESTING AND ADJUSTING 1250
CALIBRATION SHEET LAYOUT AND ASSEMBLAGE 1251
6 CAMERA CALIBRATION SHEET CONSTRUCTION 1256
CALIBRATING CAMERAS 1257
RADAR SETTING 1266
SECTION N OPERATOR CAB 1277
SECTION N2 CAB, DOORS AND WINDOWS INDEX 1279
CAB AND COMPONENTS 1282
CAB 1282
CAB DOOR 1285
GLASS REPLACEMENT 1295
WINDSHIELD & REAR GLASS 1296
WINDSHIELD WIPERS 1298
WIPER MOTOR 1298
WIPER ARM 1298
WIPER LINKAGE 1299
WINDSHIELD WASHER 1300
SECTION N3 OPERATOR AND PASSENGER SEATS INDEX 1301
OPERATOR SEAT (STANDARD SEAT) 1302
PASSENGER SEAT (STANDARD SEAT) 1309
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230) 1310
SEAT BELT REPLACEMENT (STANDARD SEATS) 1312
OPERATOR SEAT (OPTIONAL SEAT) 1314
PASSENGER SEAT (OPTIONAL SEAT) 1315
SEAT BELT REPLACEMENT (OPTIONAL SEATS) 1316
SECTION N4 HEATER/AIR CONDITIONER INDEX 1321
CLIMATE CONTROL 1323
HEATER / AIR CONDITIONER 1323
COMPONENTS 1324
ENVIRONMENTAL IMPACT OF AIR CONDITIONING 1328
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES 1328
PRINCIPLES OF REFRIGERATION 1328
AIR CONDITIONER SYSTEM COMPONENTS 1330
ELECTRICAL CIRCUIT 1332
SYSTEM SERVICING 1334
SERVICE TOOLS AND EQUIPMENT 1335
SYSTEM PERFORMANCE TEST 1339
SYSTEM OIL 1340
REFRIGERANT 1342
SYSTEM LEAK TESTING 1343
RECOVERING AND RECYCLING THE REFRIGERANT 1343
SYSTEM REPAIR 1344
COMPONENT REPLACEMENT 1346
EVACUATING THE SYSTEM 1348
CHARGING THE A/C SYSTEM 1350
TROUBLESHOOTING 1351
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1352
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM 1358
SECTION N5 OPERATOR CAB CONTROLS INDEX 1359
OPERATOR CAB AND CONTROLS 1362
STEERING WHEEL AND CONTROLS 1363
STEERING COLUMN 1364
STEERING WHEEL 1365
PEDALS 1367
GRADE/SPEED RETARD CHART 1368
CENTER CONSOLE 1370
DIAGNOSTIC PORTS 1373
HEATER / AIR CONDITIONER 1374
INSTRUMENT PANEL 1375
STATUS INDICATOR LIGHT PANEL 1382
DIGITAL DISPLAY OPERATION 1385
KOMTRAX PLUS 1388
KOMATSU WIRELESS BRIDGE (Bullet 2) 1391
SECTION P LUBRICATION AND PERIODIC MAINTENANCE 1397
SECTION P2 PERIODIC MAINTENANCE INDEX 1399
PERIODIC MAINTENANCE 1401
830E SERVICE CAPACITIES 1401
HYDRAULIC TANK SERVICE 1401
COOLANT LEVEL CHECK 1402
WHEEL MOTOR SERVICE 1402
RESERVE ENGINE OIL SYSTEM (Optional) 1403
QUICK FILL SERVICE CENTER 1403
LUBRICATION CHART 1404
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 1405
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1406
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 1407
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 1408
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 1410
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 1415
EVERY 2500 HOUR MAINTENANCE 1417
EVERY 4000 HOUR MAINTENANCE 1417
EVERY 5000 HOUR MAINTENANCE 1418
EVERY 18000 HOUR MAINTENANCE 1418
SECTION P3 AUTOMATIC LUBRICATION SYSTEM INDEX 1421
AUTOMATIC LUBRICATION SYSTEM 1423
GENERAL DESCRIPTION 1423
SYSTEM COMPONENTS 1425
SYSTEM OPERATION 1426
LUBRICANT PUMP 1428
INJECTORS (SL-1 Series “H”) 1429
PREVENTIVE MAINTENANCE PROCEDURES 1431
SYSTEM CHECKOUT 1432
Autolube troubleshooting chart 1434
SECTION R SYSTEM SCHEMATICS 1437

DESCRIPTION:

Komatsu 830E-1AC DUMP TRUCK Shop Manual CEBM032802  – PDF DOWNLOAD

• SERIAL NUMBERS 830E-1AC A40987 – A40994 A40996 and up
• ENGINE 16V160

• 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