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KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30072 – A30078 – PDF DOWNLOAD
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KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual
SERIAL NUMBERS:A30072 – A30078
PUBLICATION NUMBER:CEBM019302
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Description
KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30072 – A30078
KOMATSU 830E-1AC DUMP TRUCK SHOP REPAIR MANUAL SERIAL NUMBERS A30072 – A30078 – PDF DOWNLOAD:
SCREENSHOOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30072 – A30078
- 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
TABLE OF CONTENTS:
KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30072 – A30078
COVER .............................................................................................. 1 FOREWORD ........................................................................................... 5 TABLE OF CONTENTS .................................................................................. 7 SECTION A GENERAL INFORMATION ...................................................................... 9 MAJOR COMPONENT DESCRIPTION..................................................................... 11 Truck And Engine............................................................................ 11 AC Induction Traction Motorized Wheels...................................................... 11 Suspension.................................................................................. 11 Operator's Cab.............................................................................. 11 Power Steering.............................................................................. 11 Dynamic Retarding........................................................................... 11 Brake System................................................................................ 11 SPECIFICATIONS.............................................................................. 13 GENERAL SAFETY AND OPERATING INSTRUCTIONS....................................................... 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 TRUCK..................................................................... 23 Starting The Engine................................................................. 23 Truck Operation - General........................................................... 23 Traveling In The Truck.............................................................. 24 Precautions When Traveling In Reverse............................................... 24 Traveling On Slopes................................................................. 24 Ensuring Good Visibility............................................................ 25 Operating On Snow................................................................... 25 Avoid Damage To The Dump Body....................................................... 25 Driving Near High Voltage Cables.................................................... 25 When Loading The Truck.............................................................. 25 When Dumping........................................................................ 25 Working On Loose Ground............................................................. 26 Parking The Machine................................................................. 26 TOWING.................................................................................. 26 WORKING NEAR BATTERIES.................................................................. 27 Jump Starting With Booster Cables................................................... 28 Jump Starting With Receptacles...................................................... 28 PRECAUTIONS FOR MAINTENANCE................................................................. 29 BEFORE PERFORMING MAINTENANCE........................................................... 29 Stopping The Engine Before Service.................................................. 29 Warning Tag......................................................................... 29 Proper Tools........................................................................ 29 Securing The Dump Body.............................................................. 30 WHILE PERFORMING MAINTENANCE............................................................ 31 Personnel........................................................................... 31 Attachments......................................................................... 31 Working Under The Machine........................................................... 31 Keeping The Machine Clean........................................................... 31 Rules To Follow When Adding Fuel Or Oil............................................. 31 Radiator Coolant Level.............................................................. 31 Use Of Lighting..................................................................... 31 Precautions With The Battery........................................................ 32 Handling High Pressure Hoses........................................................ 32 Precautions With High Pressure Oil.................................................. 32 Maintenance Near High Temperatures And High Pressures............................... 32 Rotating Fan And Belts.............................................................. 32 Waste Materials..................................................................... 32 TIRES................................................................................... 33 Handling Tires...................................................................... 33 Tire Maintenance.................................................................... 34 Storing Tires After Removal......................................................... 34 ADDITIONAL JOB SITE RULES................................................................... 35 WHEN REPAIRS ARE NECESSARY.................................................................. 36 Use of Tie-Off Anchor During Maintenance................................................ 36 SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK...................................... 37 Preliminary Procedures before Welding or Performing Maintenance..................... 37 Engine Shutdown Procedure before Welding or Performing Maintenance.................. 37 CAPACITOR DISCHARGE SYSTEM.................................................................. 39 Necessary Tools......................................................................... 39 Warnings And Cautions................................................................... 40 MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE............................................ 41 Preparation......................................................................... 41 CAPACITOR CHARGE LIGHTS................................................................. 43 FAILURE OF DISCHARGE SYSTEM............................................................. 44 Measuring Dc Voltage On Capacitors.................................................. 44 MANUAL DISCHARGE OF CAPACITORS.......................................................... 45 SHORT ISOLATED CAPACITOR TERMINALS...................................................... 47 OPERATING INSTRUCTIONS...................................................................... 49 PREPARING FOR OPERATION................................................................. 49 Safety Is Thinking Ahead............................................................ 49 WALK AROUND INSPECTION.................................................................. 49 ENGINE START-UP SAFETY PRACTICES........................................................ 53 AFTER ENGINE HAS STARTED................................................................ 54 EMERGENCY STEERING SYSTEM............................................................... 55 Operation........................................................................... 55 Pre-Operation Testing............................................................... 55 Additional Guidelines............................................................... 56 MACHINE OPERATION SAFETY PRECAUTIONS.................................................... 56 MACHINE OPERATION ON THE HAUL ROAD...................................................... 57 STARTING ON A GRADE WITH A LOADED TRUCK................................................. 58 PASSING................................................................................. 58 LOADING................................................................................. 58 DUMPING................................................................................. 58 Raising The Dump Body............................................................... 58 Lowering The Dump Body.............................................................. 59 SUDDEN LOSS OF ENGINE POWER............................................................. 61 FUEL DEPLETION.......................................................................... 61 SAFE PARKING PROCEDURES................................................................. 62 NORMAL ENGINE SHUTDOWN PROCEDURE........................................................ 62 DELAYED ENGINE SHUTDOWN PROCEDURE....................................................... 63 DISABLED TRUCK DUMPING PROCEDURE........................................................ 64 GENERAL................................................................................. 64 STEERING AND BRAKE SYSTEM............................................................... 64 Hookup.............................................................................. 64 HOIST SYSTEM............................................................................ 65 Hookup.............................................................................. 66 Dumping Procedure................................................................... 66 TOWING.................................................................................. 67 Towing Procedure.................................................................... 67 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 68 Operation........................................................................... 68 WARNINGS AND CAUTIONS........................................................................... 69 TORQUE TABLES AND CONVERSION CHARTS ............................................................ 81 STORAGE PROCEDURES.............................................................................. 91 STORAGE AND IDLE MACHINE PREPARATION........................................................ 93 SHORT TERM IDLE PERIODS................................................................. 93 PREPARATION FOR STORAGE................................................................. 94 REMOVAL FROM STORAGE.................................................................... 95 RECONDITIONING AN IDLE VEHICLE.......................................................... 97 ENGINE OPERATION........................................................................ 99 AFTER ENGINE HAS STARTED................................................................ 100 ENGINE STORAGE.......................................................................... 101 Engine Storage-(Short Term)......................................................... 101 Engine Storage- (Long Term)......................................................... 102 TRANSMISSION PRESERVATION AND STORAGE................................................... 107 Restoring Transmission to Service................................................... 107 ELECTRIC DRIVE TRUCKS................................................................... 103 SECTION B STRUCTURES ............................................................................... 109 STRUCTURAL COMPONENTS........................................................................... 111 STRUCTURAL COMPONENTS....................................................................... 113 Preparation............................................................................. 113 LADDERS................................................................................. 114 Removal............................................................................. 114 Installation........................................................................ 114 RIGHT DECK.............................................................................. 114 Removal............................................................................. 114 Installation........................................................................ 116 LEFT DECK............................................................................... 116 Removal............................................................................. 116 Installation........................................................................ 117 CENTER DECK............................................................................. 117 DUMP BODY....................................................................................... 119 DUMP BODY................................................................................... 121 Removal................................................................................. 121 Installation............................................................................ 122 BODY PADS............................................................................... 123 Removal............................................................................. 123 Installation........................................................................ 123 Adjustment.......................................................................... 124 BODY GUIDE.............................................................................. 125 BODY-UP RETENTION CABLE................................................................. 126 BODY POSITION INDICATOR................................................................. 126 HOIST LIMIT SWITCH...................................................................... 126 BODY UP SWITCH.......................................................................... 126 ROCK EJECTORS........................................................................... 127 Inspection.......................................................................... 127 FUEL TANK....................................................................................... 129 FUEL TANK................................................................................... 130 Removal................................................................................. 130 Installation............................................................................ 130 Repair.................................................................................. 132 Cleaning................................................................................ 132 FUEL GAUGE SENDER....................................................................... 132 Removal............................................................................. 132 Installation........................................................................ 132 FUEL TANK BREATHER VALVE................................................................ 133 Disassembly......................................................................... 133 Assembly............................................................................ 133 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 133 FUEL RECEIVERS (WIGGINS QUICK FILL)..................................................... 134 SECTION C ENGINE ................................................................................... 135 POWER MODULE.................................................................................... 137 POWER MODULE................................................................................ 139 PREPARATION............................................................................. 139 Removal............................................................................. 139 Installation........................................................................ 144 FUEL AND COOLING SYSTEM......................................................................... 149 FUEL FILTERS................................................................................ 151 Filter replacement;..................................................................... 151 COOLING SYSTEM DESCRIPTION.................................................................. 152 RADIATOR................................................................................ 153 Removal............................................................................. 153 Installation........................................................................ 156 Radiator Filling Procedure.......................................................... 157 REPAIRING THE RADIATOR...................................................................... 158 Internal Inspection..................................................................... 158 External Cleaning....................................................................... 158 Disassembly............................................................................. 158 Cleaning and Inspection................................................................. 159 Assembly................................................................................ 159 Pressure Testing........................................................................ 161 COOLANT SYSTEM TROUBLESHOOTING.............................................................. 161 POWER TRAIN..................................................................................... 163 ALTERNATOR REMOVAL PROCEDURE................................................................ 165 Removal (Komatsu SSDA16V160 or SDA16V160 Engine)........................................ 165 ENGINE/ALTERNATOR MATING.................................................................... 167 General Instructions.................................................................... 167 Measuring Procedure..................................................................... 167 Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine........................... 169 ENGINE...................................................................................... 170 Removal................................................................................. 170 Service................................................................................. 171 Installation............................................................................ 171 AIR CLEANERS.................................................................................... 173 AIR CLEANERS................................................................................ 175 OPERATION............................................................................... 175 SERVICING THE AIR CLEANERS.............................................................. 175 Replacing The Filter Element........................................................ 176 AIR CLEANER ASSEMBLY CLEANING........................................................... 177 Main Filter Cleaning................................................................ 177 Precleaner Section Cleaning......................................................... 179 AIR INTAKE TROUBLESHOOTING.............................................................. 180 FAN CLUTCH ..................................................................................... 181 FAN CLUTCH.................................................................................. 183 REMOVAL & INSTALLATION TOOLING.......................................................... 183 DISASSEMBLY............................................................................. 186 CLEANING AND INSPECTION................................................................. 196 ASSEMBLY................................................................................ 200 TEST PROCEDURE.......................................................................... 214 SECTION D ELECTRICAL SYSTEM (24VDC) ................................................................ 215 24VDC ELECTRIC SUPPLY SYSTEM.................................................................... 217 24VDC ELECTRIC SUPPLY SYSTEM................................................................ 219 ELECTRICAL SYSTEM DESCRIPTION........................................................... 219 BATTERIES............................................................................... 219 Maintenance and Service............................................................. 219 Troubleshooting..................................................................... 219 BATTERY SUPPLY SYSTEM................................................................... 221 24VDC Battery Charging Alternator................................................... 221 Battery Box......................................................................... 221 Battery Control Box................................................................. 222 Battery Disconnect Switches......................................................... 222 24VDC Auxiliary Battery Receptacles................................................. 222 Isolator Diode...................................................................... 222 Engine Start Relay.................................................................. 222 24VDC to 12VDC Converter............................................................ 222 24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE).................................... 223 Operation........................................................................... 223 Pressure Switch..................................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 MAINTENANCE............................................................................. 224 Prelube System Operation Checks..................................................... 224 Check Valve......................................................................... 224 Timer Solenoid...................................................................... 224 TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT.............................................. 225 24 VDC ELECTRIC START SYSTEM................................................................ 227 CRANKING MOTORS......................................................................... 227 Operation........................................................................... 227 Removal............................................................................. 227 Installation........................................................................ 227 CRANKING MOTOR TROUBLESHOOTING.......................................................... 228 Preliminary Inspection.............................................................. 228 No-Load Test........................................................................ 228 Interpreting Results of Tests....................................................... 229 Disassembly......................................................................... 229 Cleaning and Inspection............................................................. 230 Armature Servicing.................................................................. 232 Field Coil Checks................................................................... 232 Field Coil Removal.................................................................. 232 SOLENOID CHECKS......................................................................... 233 Test................................................................................ 233 Assembly............................................................................ 234 Bearing Replacement:................................................................ 234 Motor Assembly:..................................................................... 234 Pinion Clearance.................................................................... 235 MAGNETIC SWITCH......................................................................... 235 Removal............................................................................. 235 Installation........................................................................ 235 Coil Test........................................................................... 236 24VDC ELECTRICAL SYSTEM COMPONENTS.............................................................. 237 24 VDC ELECTRICAL SYSTEM COMPONENTS......................................................... 239 TRUCK SHUTDOWN PROCEDURE................................................................ 239 BRAKE WARNING BUZZER.................................................................... 239 AUXILIARY CONTROL CABINET COMPONENTS.................................................... 239 Power Distribution Terminals........................................................ 239 Engine Starter Failure Delay Timer.................................................. 239 5 Minute Idle Timer................................................................. 240 Pulse Voltage Modulator (PMV)....................................................... 240 Control Power Relay................................................................. 240 Auto Lube Timer..................................................................... 240 Diode Board - DB1................................................................... 242 Fuse Blocks......................................................................... 243 Alarm Indicating Device (AID) System................................................ 243 Diode Matrix (With Sound)........................................................... 244 Diode Matrix (Without Sound)........................................................ 244 Hot Switch Inverter................................................................. 244 Hot Switch Inverter (Not Used)...................................................... 245 Temperature and Latch............................................................... 245 RELAY BOARDS............................................................................ 246 Relay Boards RB1, RB3, RB4, RB5..................................................... 246 Relay Board RB6, RB7, RB8, RB9...................................................... 247 Service............................................................................. 247 Relay Board Functions............................................................... 249 BODY-UP SWITCH.......................................................................... 251 Operation........................................................................... 251 Adjustment.......................................................................... 251 Service............................................................................. 251 HOIST LIMIT SWITCH...................................................................... 252 Operation........................................................................... 252 Adjustment.......................................................................... 252 Service............................................................................. 252 FUSE BLOCK CHARTS....................................................................... 253 CIRCUIT BREAKER CHART................................................................... 255 CIRCUIT BREAKERS........................................................................ 255 CHARGING SYSTEM ................................................................................ 257 CHARGING SYSTEM DESCRIPTION................................................................. 259 PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION............................................... 259 Excessive heat.......................................................................... 259 Dirt and dust........................................................................... 259 Vibration............................................................................... 259 PREVENTIVE MAINTENANCE PROCEDURES........................................................... 260 Alternator Cleanliness.................................................................. 260 Alternator Mounting..................................................................... 260 Belt Tension And Condition.............................................................. 260 TROUBLESHOOTING PROCEDURES.................................................................. 260 ALTERNATOR PERFORMANCE TEST................................................................. 260 ALTERNATOR PERFORMANCE TEST - LOAD APPLIED.................................................. 261 ALTERNATOR CABLE TEST....................................................................... 261 VOLTAGE REGULATOR ADJUSTMENT................................................................ 262 ALTERNATOR.................................................................................. 263 Removal................................................................................. 263 Installation............................................................................ 264 KOMTRAX Plus COMPONENTS......................................................................... 267 KOMTRAX Plus COMPONENTS..................................................................... 269 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 ORBCOMM CONTROLLER...................................................................... 282 Removal............................................................................. 282 Installation........................................................................ 282 INTERFACE MODULE........................................................................ 283 Removal............................................................................. 283 Installation........................................................................ 283 SENSORS................................................................................. 284 Temperature Sensors................................................................. 284 Pressure Sensors.................................................................... 284 KOMTRAX Plus SOFTWARE........................................................................... 285 KOMTRAX Plus SOFTWARE....................................................................... 287 NECESSARY SOFTWARE...................................................................... 287 NECESSARY TOOLS......................................................................... 287 KOMTRAX Plus SYSTEM SET UP.............................................................. 288 INTERFACE MODULE.................................................................... 288 KOMTRAX Plus CONTROLLER............................................................. 288 INTERFACE MODULE........................................................................ 288 FLASHBURN PROGRAM................................................................... 288 Installation.................................................................... 288 INTERFACE MODULE APPLICATION CODE................................................... 288 Installation.................................................................... 288 INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM............................. 289 Installation.................................................................... 289 Using The Program............................................................... 289 KOMTRAX Plus CONTROLLER................................................................. 289 KOMTRAX Plus TOOL BOX............................................................... 289 Installation.................................................................... 289 KOMTRAX Plus SETTING TOOL........................................................... 289 Installation.................................................................... 289 KOMTRAX Plus INITIALIZATION PROCEDURE................................................... 290 1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE.......................................... 290 VHMS Setting Tool software program.............................................. 290 Select Operation................................................................ 290 VHMS Setting Function........................................................... 291 Machine Information Setting(1).................................................. 291 Machine Information Setting(2).................................................. 291 Date & Time Setting............................................................. 291 GCC Setting..................................................................... 292 Setting Summary................................................................. 292 2. KOMTRAX Plus SNAPSHOT PROCEDURE.................................................. 293 3. KOMTRAX Plus DOWNLOAD PROCEDURE.................................................. 294 4. LOCATION OF DOWNLOAD FILES....................................................... 294 5. KOMTRAX Plus FTP UPLOAD PROCEDURE................................................ 295 6. KOMTRAX Plus INITIALIZATION FORMS................................................ 296 WHEN REPLACING A KOMTRAX Plus CONTROLLER................................................ 297 To Set: Date & Time; Satellite; Payload Meter....................................... 299 Review Setting Information.......................................................... 301 KOMTRAX Plus CHECKOUT AND TROUBLESHOOTING....................................................... 303 INTERFACE MODULE AND KOMTRAX Plus CHECKOUT & TROUBLESHOOTING................................ 305 GENERAL................................................................................. 305 Structure and Purpose............................................................... 305 INTERFACE MODULE CHECKOUT............................................................... 306 Interface Module.................................................................... 306 Necessary Equipment:................................................................ 306 Preliminary......................................................................... 307 Checking Inputs And Outputs From The Interface Module............................... 307 Check Analog Inputs To The Interface Module......................................... 310 Check CAN RPC & J1939 Interfaces To The IM.......................................... 311 Check Outputs From The Interface Module............................................. 311 KOMTRAX Plus CONTROLLER CHECKOUT........................................................ 312 KOMTRAX Plus Controller............................................................. 312 Necessary Equipment:................................................................ 312 Preliminary......................................................................... 313 KOMTRAX Plus Controller Checkout Procedure.......................................... 314 ORBCOMM CONTROLLER...................................................................... 316 TROUBLESHOOTING......................................................................... 316 Communications Networks............................................................. 316 Coaxial Cable....................................................................... 316 FAULT CODES............................................................................. 317 Fault History....................................................................... 317 KOMTRAX Plus LED Display Fault Codes................................................ 318 Chassis Fault Codes................................................................. 319 Engine Fault Codes.................................................................. 322 FAULT TREE ANALYSIS..................................................................... 328 Unable to connect to KOMTRAX Plus from laptop PC.................................... 328 Flashing Error Code N4-23 (PLM III Communications Fault)............................ 329 Flashing Error Code N4-22 (Engine Communications Fault)............................. 330 No Data Received By WebCARE......................................................... 331 Coaxial Cable Troubleshooting....................................................... 332 KOMTRAX PLUS FORMS ............................................................................. 333 KOMTRAX PLUS FORMS.......................................................................... 335 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 335 KOMTRAX PLUS DATA DOWNLOAD.............................................................. 336 KOMTRAX PLUS INITIALIZATION CHECK LIST.................................................. 337 KOMTRAX PLUS INITIALIZATION FORM........................................................ 339 SECTION E ELECTRIC PROPULSION SYSTEM ............................................................... 341 ELECTRIC PROPULSION SYSTEM COMPONENTS .......................................................... 343 ELECTRICAL PROPULSION SYSTEM COMPONENTS..................................................... 345 GENERAL SYSTEM DESCRIPTION.............................................................. 345 SYSTEM COMPONENTS....................................................................... 347 Propulsion System Controller (PSC).................................................. 347 Truck Control Interface (TCI)....................................................... 348 Diagnostic Information Display (DID) Panel.......................................... 349 DID Panel Event Codes............................................................... 349 PSC SOFTWARE FUNCTIONS.................................................................. 368 Input Processing.................................................................... 368 State Machine....................................................................... 368 DC Link State....................................................................... 371 Engine Control...................................................................... 372 ALTERNATOR FIELD CONTROL................................................................ 372 Desired Three-Phase Voltage......................................................... 372 Desired DC Link Voltage............................................................. 372 Self-Load........................................................................... 373 Propel Torque Control............................................................... 373 Retard Torque Control............................................................... 373 Wheel Slide Control................................................................. 374 Resistor Grid Control............................................................... 374 Chopper Voltage Control............................................................. 374 EVENT DETECTION AND PROCESSING.......................................................... 374 Power-On Tests...................................................................... 374 Initiated Tests..................................................................... 375 Periodic Tests...................................................................... 375 EVENT RESTRICTIONS...................................................................... 375 EVENT LOGGING AND STORAGE............................................................... 375 Event History Buffer................................................................ 376 Data Packs.......................................................................... 376 To Record and Save a Data Pack to a Disk............................................ 376 Event Reset......................................................................... 377 SERIAL DATA COMMUNICATIONS.............................................................. 377 PSC - TCI Communications Processing................................................. 377 PSC - PTU Communications Processing................................................. 377 Inverter Communications Processing.................................................. 378 OUTPUT PROCESSING....................................................................... 378 ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS................................................ 378 Fast Start.......................................................................... 378 Engine Shutdown/Engine Not Running.................................................. 378 Limp Home Mode...................................................................... 379 PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS................................... 380 ELECTRONIC ACCELERATOR AND RETARD PEDALS................................................ 388 Removal............................................................................. 388 Installation........................................................................ 388 Disassembly......................................................................... 388 Assembly............................................................................ 388 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE .................................................. 389 AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE............................................... 391 AC DRIVE SYSTEM MAINTENANCE............................................................. 391 NORMAL TRUCK SHUTDOWN PROCEDURE......................................................... 392 SHUTDOWN AFTER SYSTEM FAILURE........................................................... 392 SYSTEM CHECKOUT......................................................................... 393 Battery and Control Circuit Checks - Battery Power OFF.............................. 393 Battery and Control Circuit Checks - Battery Power ON............................... 396 Checks with Key Switch OFF.......................................................... 397 Checks with Key Switch ON........................................................... 397 CPU Battery Checks.................................................................. 397 MEMORY BACKUP BATTERY REPLACEMENT....................................................... 398 TCI PROGRAMMING......................................................................... 398 PSC PROGRAMMING......................................................................... 399 INVERTER PROGRAMMING.................................................................... 399 CPU RESET............................................................................... 399 PSC CHECKOUT............................................................................ 400 PSC Digital Input Checks............................................................ 400 PSC Digital Output Checks........................................................... 404 TCI CHECKOUT............................................................................ 405 Modular Mining Communication Port Check............................................. 405 TCI Digital Input Checks............................................................ 405 TCI Digital Output Tests............................................................ 411 CALIBRATIONS............................................................................ 413 Speedometer......................................................................... 413 Accelerator Pedal, Retarder Pedal/Lever and RSC Dial................................ 413 ERASING EVENTS.......................................................................... 413 PSC................................................................................. 413 TCI................................................................................. 414 GATE DRIVER POWER CONVERTER TEST........................................................ 414 LOAD TESTING............................................................................ 415 Preparation......................................................................... 415 Alternator Speed Sensor Checks...................................................... 415 Battery Boost Check................................................................. 415 Brake Circuit Switch Checks......................................................... 416 Hoist & Steering Circuit Switch Checks.............................................. 416 Link Energized Checks............................................................... 416 Loadbox Test........................................................................ 418 TROUBLESHOOTING......................................................................... 422 PVM Optimum Load Curve Handshaking Troubleshooting.................................. 422 Phase Module and Chopper Module Troubleshooting..................................... 422 PHASE MODULE REPLACEMENT................................................................ 423 Phase Module Removal................................................................ 423 Phase Module Installation........................................................... 423 SECTION G DRIVE AXLE, SPINDLE, AND WHEELS .......................................................... 425 TIRES AND RIMS.................................................................................. 427 TIRES AND RIMS.............................................................................. 429 FRONT TIRES AND RIMS.................................................................... 429 Removal............................................................................. 429 Installation........................................................................ 431 REAR TIRES AND RIMS..................................................................... 431 Removal............................................................................. 431 Installation........................................................................ 432 RIM AND TIRE............................................................................ 434 Tire Removal........................................................................ 434 Rim And Tire Preparation............................................................ 434 Lubricants.......................................................................... 435 Tire Installation................................................................... 435 FRONT WHEEL HUB AND SPINDLES.................................................................... 437 FRONT WHEEL HUB AND SPINDLE................................................................. 439 WHEEL HUB AND SPINDLE ASSEMBLY.......................................................... 439 Removal............................................................................. 439 Spindle Removal Procedure (Optional) (off of the truck)............................. 442 Installation........................................................................ 444 Disassembly......................................................................... 447 Cleaning and Inspection............................................................. 447 Assembly............................................................................ 448 Wheel Bearing Adjustment (Tire Removed)............................................. 450 Wheel Bearing Adjustment (Tire mounted)............................................. 451 OIL SAMPLING PROCEDURE.................................................................. 452 Oil Sampling Guidelines............................................................. 453 Procedure........................................................................... 453 OIL DRAIN AND REFILL PROCEDURE.......................................................... 453 STEERING CYLINDERS AND TIE ROD.......................................................... 454 Spherical Bearing Wear Limits....................................................... 454 Installation........................................................................ 455 Bearing Replacement (Steering cylinder and tie rod)................................. 455 TIE ROD................................................................................. 457 Removal............................................................................. 457 Installation........................................................................ 457 Assembly............................................................................ 458 TOE-IN ADJUSTMENT....................................................................... 459 REAR AXLE HOUSING ATTACHMENT.................................................................... 461 REAR AXLE HOUSING ATTACHMENT................................................................ 463 PIVOT PIN............................................................................... 463 Removal............................................................................. 463 Installation........................................................................ 463 PIVOT EYE BEARING....................................................................... 464 Disassembly......................................................................... 464 Assembly............................................................................ 464 PIVOT EYE REPAIR........................................................................ 465 Removal............................................................................. 465 Installation........................................................................ 465 Disassembly......................................................................... 465 Assembly............................................................................ 465 ANTI-SWAY BAR........................................................................... 466 Removal............................................................................. 466 Installation........................................................................ 466 Disassembly......................................................................... 466 Cleaning and Inspection............................................................. 466 Assembly............................................................................ 466 REAR AXLE HOUSING............................................................................... 467 REAR AXLE HOUSING........................................................................... 469 REAR AXLE HOUSING....................................................................... 469 Removal............................................................................. 469 Installation........................................................................ 469 WHEEL MOTOR............................................................................. 470 Removal............................................................................. 470 Cleaning and Inspection............................................................. 470 Installation........................................................................ 471 WHEEL MOTOR GEAR OIL.................................................................... 474 Change/Filter The Gear case Oil..................................................... 474 Oil................................................................................. 474 Remove And Clean Magnetic Plugs..................................................... 474 Flushing The Gearbox................................................................ 474 Check Gear Case Oil Level........................................................... 474 SECTION H SUSPENSIONS .............................................................................. 475 FRONT SUSPENSION................................................................................ 477 FRONT SUSPENSION............................................................................ 479 Removal................................................................................. 479 Installation............................................................................ 480 TURN-OF-THE-NUT Tightening Procedure.................................................... 482 Upper Mounting Joint - 60° Advance.................................................. 482 Lower Mounting Joint - 90° Advance.................................................. 484 Inspection.......................................................................... 484 MINOR REPAIR ONLY (Lower Bearing Structure & Seals)..................................... 485 Bearing Structure Removal........................................................... 485 Bearing Structure Installation...................................................... 485 MAJOR SUSPENSION REBUILD................................................................ 486 Disassembly......................................................................... 486 Assembly............................................................................ 487 PRESSURE TEST........................................................................... 489 REAR SUSPENSIONS ............................................................................... 491 REAR SUSPENSIONS............................................................................ 493 Removal................................................................................. 493 Installation............................................................................ 496 ROD UP SUSPENSION....................................................................... 498 Disassembly......................................................................... 498 Cleaning and Inspection............................................................. 498 Assembly............................................................................ 498 ROD DOWN SUSPENSION..................................................................... 500 Disassembly......................................................................... 500 Cleaning and Inspection............................................................. 500 Assembly............................................................................ 502 PRESSURE TEST........................................................................... 504 Suspension pressure test............................................................ 504 OILING AND CHARGING PROCEDURE................................................................... 505 OILING AND CHARGING PROCEDURE............................................................... 507 GENERAL................................................................................. 507 EQUIPMENT LIST.......................................................................... 507 HYDRAIR® CHARGING KIT................................................................... 508 Installation of Charging Kit........................................................ 508 Removal of Charging Kit............................................................. 508 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................... 509 FRONT SUSPENSION........................................................................ 509 Front Suspension Oiling............................................................. 509 Front Suspension Nitrogen Charging.................................................. 511 REAR SUSPENSION - ROD UP................................................................ 513 Rear Suspension Oiling (Rod Up Only)................................................ 513 Rear Suspension Nitrogen Charging (Rod Up Only)..................................... 514 REAR SUSPENSION - ROD DOWN.............................................................. 516 Rear Suspension Oiling (Rod Down Only).............................................. 516 Rear Suspension Nitrogen Charging (Rod Down Only)................................... 518 OIL AND NITROGEN SPECIFICATIONS CHART................................................... 520 SECTION J BRAKE CIRCUIT ............................................................................ 521 BRAKE CIRCUIT................................................................................... 523 BRAKE CIRCUIT............................................................................... 525 OPERATION............................................................................... 525 SERVICE BRAKE CIRCUIT OPERATION......................................................... 525 SECONDARY BRAKING AND AUTOMATIC APPLY................................................... 527 PARKING BRAKE CIRCUIT................................................................... 527 Normal Operation (key switch on, engine running).................................... 527 BRAKE LOCK CIRCUIT...................................................................... 528 WARNING CIRCUIT......................................................................... 528 BRAKE CIRCUIT COMPONENT SERVICE................................................................. 531 BRAKE CIRCUIT COMPONENT SERVICE............................................................. 533 BRAKE VALVE............................................................................. 533 Rebuild Criteria.................................................................... 533 Removal............................................................................. 533 Installation........................................................................ 535 DISASSEMBLY............................................................................. 537 Cleaning and Inspection............................................................. 539 ASSEMBLY................................................................................ 539 Actuator Base Threaded Inserts...................................................... 539 Boot and Cap........................................................................ 539 Valve Body Seal Installation........................................................ 540 Regulator Sleeve O-Ring Installation................................................ 540 Actuator Plunger O-ring Installation................................................ 541 Assembly of Valve................................................................... 541 VALVE BENCH TEST AND ADJUSTMENT......................................................... 543 Test Set Up Procedure............................................................... 544 Brake Valve Output Pressure Adjustment.............................................. 544 Final Test and Adjustment........................................................... 545 Installation Of Brake Pedal Actuator Assembly to Brake Valve........................ 546 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal).... 548 Installation of Retard Pedal To Brake Pedal......................................... 548 HYDRAULIC BRAKE ACCUMULATORS............................................................ 549 Brake Accumulator Bleed Down Procedure.............................................. 549 Removal............................................................................. 549 Installation........................................................................ 549 Disassembly......................................................................... 549 Cleaning and Inspection............................................................. 551 Assembly............................................................................ 551 Charging Procedure.................................................................. 553 BRAKE MANIFOLD.......................................................................... 554 Removal............................................................................. 554 Removal............................................................................. 554 Installation........................................................................ 555 Disassembly......................................................................... 555 Cleaning and Inspection............................................................. 556 Assembly............................................................................ 556 BRAKE CIRCUIT CHECK-OUT PROCEDURE............................................................... 557 BRAKE CIRCUIT CHECK-OUT PROCEDURE........................................................... 559 EQUIPMENT REQUIRED...................................................................... 560 INITIAL SYSTEM SET-UP................................................................... 562 PARKING BRAKE........................................................................... 562 BRAKE SYSTEM CHECK-OUT.................................................................. 563 BRAKE LOCK.............................................................................. 563 FAILURE MODES CHECK-OUT................................................................. 564 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................... 565 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 568 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET............................... 569 FRONT BRAKES.................................................................................... 571 WHEEL SPEED FRONT DISC BRAKES............................................................... 573 BRAKE CALIPER........................................................................... 573 Caliper Removal..................................................................... 573 Installation........................................................................ 574 Disassembly......................................................................... 575 Assembly............................................................................ 575 Cleaning and Inspection............................................................. 576 BRAKE LINING............................................................................ 577 Replacement......................................................................... 577 FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................. 579 GENERAL............................................................................. 579 Safety Precautions.............................................................. 579 Front Brake Conditioning........................................................ 579 BRAKE BLEEDING PROCEDURES............................................................... 580 ARMATURE SPEED REAR DISC BRAKES................................................................. 581 ARMATURE SPEED REAR DISC BRAKES............................................................. 583 REAR BRAKES............................................................................. 583 CALIPER AND DISC.................................................................... 583 Removal......................................................................... 583 Installation.................................................................... 585 PARK BRAKE ADJUSTMENT PROCEDURE..................................................... 587 BRAKE BLEEDING PROCEDURE............................................................ 588 Service Brake................................................................... 588 Park Brake...................................................................... 588 CALIPER............................................................................. 589 Disassembly..................................................................... 589 PISTON SUBASSEMBLY.................................................................. 592 Disassembly..................................................................... 592 PREPARATION FOR ASSEMBLY............................................................ 593 Clean Parts..................................................................... 593 For Rough Metal Parts........................................................... 594 Dry and Inspect Parts........................................................... 594 Corrosion Protection............................................................ 594 INSPECTION.......................................................................... 594 Caliper Parts................................................................... 594 Shoes, Linings and End Plates................................................... 595 Inspect linings................................................................. 595 PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC).................... 595 Piston Assembly Adjuster Grip Force............................................. 596 Adjuster Force.................................................................. 598 Piston Return Spring............................................................ 600 ASSEMBLY............................................................................ 601 Adjuster and Pin Assembly....................................................... 601 Piston Subassembly.............................................................. 602 Brake Caliper................................................................... 603 PERIODIC INSPECTIONS................................................................ 609 Shoes, Linings and End Plates................................................... 609 Inspect the following areas for fluid leaks..................................... 609 Dust Boots...................................................................... 609 Brake Disc...................................................................... 609 BRAKE LINING........................................................................ 610 Replacement..................................................................... 610 BRAKE DISC.......................................................................... 610 Inspection...................................................................... 610 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE................................... 611 GENERAL......................................................................... 611 SAFETY PRECAUTIONS.............................................................. 611 Rear Brake Conditioning..................................................... 612 SECTION L HYDRAULIC SYSTEM......................................................................... 615 HYDRAULIC SYSTEM................................................................................ 617 HYDRAULIC SYSTEM............................................................................ 619 HYDRAULIC SYSTEM OPERATION.............................................................. 619 COMPONENT DESCRIPTION................................................................... 620 Hoist Pump.......................................................................... 620 Steering/Brake Pump................................................................. 620 Tank................................................................................ 620 High Pressure Hydraulic Filters..................................................... 620 Bleeddown Manifold.................................................................. 620 Steering System Accumulators........................................................ 620 DISABLED TRUCK CONNECTORS............................................................... 622 GENERAL............................................................................. 622 STEERING AND BRAKE SYSTEM........................................................... 622 Hookup.......................................................................... 622 HOIST SYSTEM........................................................................ 623 Hookup.......................................................................... 623 Dumping Procedure............................................................... 623 HYDRAULIC SYSTEM COMPONENT REPAIR............................................................... 625 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................... 627 HOIST PUMP.............................................................................. 627 Removal............................................................................. 627 Installation........................................................................ 628 Disassembly......................................................................... 630 Inspection Of Parts................................................................. 633 Assembly............................................................................ 634 HYDRAULIC TANK.......................................................................... 640 Filling Instructions................................................................ 640 Removal............................................................................. 640 Installation........................................................................ 641 HYDRAULIC TANK STRAINERS................................................................ 642 Removal............................................................................. 642 Inspect and Clean................................................................... 642 Installation........................................................................ 643 HYDRAULIC TANK BREATHERS................................................................ 643 HOIST CIRCUIT FILTERS................................................................... 644 FILTER ELEMENT REPLACEMENT.............................................................. 645 Removal............................................................................. 645 Installation........................................................................ 645 INDICATOR SWITCH........................................................................ 645 STEERING CIRCUIT................................................................................ 647 STEERING CIRCUIT............................................................................ 649 STEERING CIRCUIT OPERATION.............................................................. 649 COMPONENT DESCRIPTION................................................................... 650 STEERING CONTROL UNIT............................................................... 650 FLOW AMPLIFIER...................................................................... 650 No Steer........................................................................ 652 Steering Left................................................................... 654 Steering Right.................................................................. 656 No Steer, External Shock Load................................................... 658 BLEED DOWN MANIFOLD................................................................. 660 ACCUMULATORS........................................................................ 661 Low Precharge Warning Switch.................................................... 661 HIGH PRESSURE FILTER................................................................ 661 STEERING/BRAKE PUMP................................................................. 661 Operation....................................................................... 662 PRINCIPLE OF OPERATION.............................................................. 664 Full Pump Volume:............................................................... 664 Half Pump Volume:............................................................... 664 Neutral Position:............................................................... 665 STEERING CIRCUIT COMPONENT REPAIR............................................................... 667 STEERING CIRCUIT COMPONENT REPAIR........................................................... 669 BLEED DOWN MANIFOLD..................................................................... 669 Removal............................................................................. 669 Installation........................................................................ 669 ACCUMULATOR............................................................................. 670 Removal............................................................................. 670 Installation........................................................................ 671 Disassembly......................................................................... 671 Cleaning and Inspection............................................................. 672 Assembly............................................................................ 672 LEAK TESTING............................................................................ 674 STEERING ACCUMULATOR CHARGING PROCEDURE................................................. 675 Temperature During Precharge........................................................ 678 ACCUMULATOR STORAGE PROCEDURES.......................................................... 678 Instructions For Storing Bladder Accumulators....................................... 678 Installation........................................................................ 679 Bladder Storage Procedures.......................................................... 679 FLOW AMPLIFIER.......................................................................... 680 Removal............................................................................. 680 Installation........................................................................ 680 Disassembly......................................................................... 682 Reassembly.......................................................................... 683 STEERING CONTROL UNIT................................................................... 684 Removal............................................................................. 684 Spline Inspection................................................................... 684 Installation........................................................................ 685 Disassembly......................................................................... 685 Cleaning and Inspection............................................................. 686 Assembly............................................................................ 687 STEERING CYLINDER....................................................................... 691 Disassembly......................................................................... 691 Inspection and Cleaning............................................................. 691 Assembly............................................................................ 691 STEERING CIRCUIT FILTER................................................................. 692 Filter Element Replacement.......................................................... 692 Removal............................................................................. 693 Installation........................................................................ 693 Indicator Switch.................................................................... 693 STEERING AND BRAKE PUMP................................................................. 694 Removal............................................................................. 694 Installation........................................................................ 695 Disassembly......................................................................... 696 Control Piston Group................................................................ 696 Valve Plate Group................................................................... 697 Rotating Group...................................................................... 697 Swashblock Group.................................................................... 698 Driveshaft Group.................................................................... 698 INSPECTION.............................................................................. 698 Control Piston Group................................................................ 698 Valve Plate Group................................................................... 698 Rotating Group...................................................................... 698 Swashblock Group.................................................................... 702 Driveshaft Group.................................................................... 702 Compensator Block and Unloader Module............................................... 702 Stroke Adjuster Assembly............................................................ 702 ASSEMBLY................................................................................ 702 Swashblock Group.................................................................... 702 Control Piston Group................................................................ 704 Valve Plate Group................................................................... 705 HOIST CIRCUIT................................................................................... 707 HOIST CIRCUIT............................................................................... 709 HOIST CIRCUIT OPERATION................................................................. 709 COMPONENT DESCRIPTION................................................................... 710 Hydraulic Tank...................................................................... 710 Hoist Pump.......................................................................... 710 High Pressure Filters............................................................... 710 Hoist Valve......................................................................... 711 Hoist Pilot Valve................................................................... 712 Hoist-up Limit Solenoid............................................................. 712 Pilot Operated Check Valve.......................................................... 712 Counterbalance Valve Manifold....................................................... 713 HOIST SYSTEM OPERATION MODES............................................................ 714 Float Position Of Pilot Valve And Body On Frame (Figure 7-6)........................ 714 Power Up Operation (Figure 7-7)..................................................... 716 Hold Operation (Figure 7-8)......................................................... 718 Power Down Operation (Figure 7-9)................................................... 720 Float Operation (Figure 7-10)....................................................... 722 HOIST CIRCUIT COMPONENT REPAIR.................................................................. 725 HOIST CIRCUIT COMPONENT REPAIR.............................................................. 727 HOIST VALVE............................................................................. 727 Removal............................................................................. 727 Installation........................................................................ 727 O-Ring Replacement.................................................................. 728 INLET SECTION........................................................................... 729 Disassembly......................................................................... 729 Cleaning and Inspection............................................................. 730 Assembly............................................................................ 730 SPOOL SECTION........................................................................... 730 Disassembly......................................................................... 730 Cleaning and Inspection............................................................. 733 Assembly............................................................................ 733 HOIST PILOT VALVE....................................................................... 734 Removal............................................................................. 734 Installation........................................................................ 734 Disassembly......................................................................... 735 Cleaning and Inspection............................................................. 736 Assembly............................................................................ 737 BODY UP LIMIT SOLENOID.................................................................. 738 PILOT OPERATED CHECK VALVE.............................................................. 738 HOIST CYLINDERS......................................................................... 738 Removal............................................................................. 738 Installation........................................................................ 739 Disassembly......................................................................... 740 Cleaning and Inspection............................................................. 742 ASSEMBLY OF QUILL AND CYLINDER.......................................................... 743 Quill Installation.................................................................. 743 Installation of Check Balls and Plugs in Quill...................................... 744 Assembly of Cylinder................................................................ 745 Assembly of Cylinder................................................................ 745 Pressure Testing.................................................................... 746 OVERCENTER MANIFOLD..................................................................... 747 HYDRAULIC CHECKOUT PROCEDURE.................................................................... 749 HYDRAULIC CHECKOUT PROCEDURE................................................................ 751 STEERING AND BRAKE PUMP................................................................. 751 Pressure Check And Adjustment Procedure............................................. 751 BLEEDDOWN MANIFOLD...................................................................... 753 SHOCK & SUCTION VALVES.................................................................. 753 Shock & Suction Valve Settings...................................................... 753 LEAKAGE TESTS........................................................................... 755 Steering Control Unit & Flow Amplifier.............................................. 755 Bleeddown Manifold.................................................................. 755 ACCUMULATOR BLEED DOWN PROCEDURE........................................................ 757 LOW STEERING PRESSURE SWITCH............................................................ 757 CHECKING HOIST SYSTEM PRESSURES......................................................... 764 Hoist System Relief Pressure Adjustment............................................. 764 Power Down Relief Pressure Adjustment............................................... 765 HOIST COUNTERBALANCE VALVE.......................................................... 766 Preparation:.................................................................... 766 Counterbalance Valve Pressure Check Only:....................................... 766 Counterbalance Valve Adjustment................................................. 767 HYDRAULIC SYSTEM FLUSHING PROCEDURE..................................................... 770 Hydraulic System Flushing Procedure................................................. 770 OIL CLEANLINESS CHECK............................................................... 775 SECTION M SPECIAL TOOLS ............................................................................ 777 HEATER OPTIONS ................................................................................. 779 GENERAL INFORMATION......................................................................... 781 TROUBLESHOOTING............................................................................. 781 HEATER ELEMENT.............................................................................. 781 Removal................................................................................. 781 Installation............................................................................ 782 GENERAL..................................................................................... 783 Maintenance............................................................................. 783 HEATING ELEMENT............................................................................. 783 Removal................................................................................. 783 Installation............................................................................ 784 THERMOSTAT.................................................................................. 784 Removal................................................................................. 784 Installation............................................................................ 784 GENERAL INFORMATION......................................................................... 785 TROUBLESHOOTING............................................................................. 785 HEATER ELEMENT.............................................................................. 785 Removal................................................................................. 785 Installation............................................................................ 786 SPECIAL TOOLS................................................................................... 787 NITROGEN CHARGING VALVE..................................................................... 787 ROLL-OUT ASSEMBLY........................................................................... 787 EYE BOLT.................................................................................... 787 OFFSET WRENCH............................................................................... 788 TORQUE ADAPTER.............................................................................. 788 HANDLE...................................................................................... 788 SEAL INSTALLER.............................................................................. 788 SLEEVE ALIGNMENT TOOLS...................................................................... 789 QUICK DISCONNECT COUPLING................................................................... 789 HARNESS..................................................................................... 789 SEAL INSTALLATION RING...................................................................... 789 BELT TENSION TESTER......................................................................... 790 BELT ALIGNMENT TOOL......................................................................... 790 SOCKETS AND ADAPTERS........................................................................ 790 DUST CAPS................................................................................... 790 HYDRAULIC SYSTEM FLUSHING TOOLS............................................................. 791 PAYLOAD DATA MANAGER........................................................................ 791 HYDRAULIC SYSTEM VACUUM PUMP................................................................ 791 MISCELLANEOUS SERVICE TOOLS................................................................. 792 BRAKE PISTON TOOL........................................................................... 793 HIGH VOLTAGE TOOLS.......................................................................... 796 2000 VDC METER.............................................................................. 796 GROUNDING STICKS............................................................................ 796 BODY PAD SPACER TOOL........................................................................ 797 RADIATOR SHUTTERS .............................................................................. 799 RADIATOR SHUTTERS........................................................................... 801 OPERATION............................................................................... 801 Hydraulic Circuit................................................................... 801 Electrical Circuit:................................................................. 802 MAINTENANCE AND REPAIR.................................................................. 802 TROUBLESHOOTING......................................................................... 803 Hydraulic Troubleshooting........................................................... 806 Electrical Troubleshooting.......................................................... 808 PAYLOAD METER III ™ ........................................................................... 809 OPERATION SECTION........................................................................... 813 Introduction............................................................................ 813 Data Summary........................................................................ 813 Data Gathering...................................................................... 813 COMPONENT DESCRIPTION................................................................... 814 System Diagram...................................................................... 814 Suspension Pressure Sensors......................................................... 814 Inclinometer........................................................................ 814 Operator Display.................................................................... 814 Operator Switch..................................................................... 815 Speed Input......................................................................... 815 Body-Up Switch...................................................................... 815 Brake Lock Switch................................................................... 815 Payload Meter....................................................................... 815 Communications Ports................................................................ 815 Key Switch Input.................................................................... 816 Payload Meter Power................................................................. 816 Load Lights......................................................................... 816 Wiring and Termination.............................................................. 817 TCI Outputs......................................................................... 817 OPERATOR’S DISPLAY AND SWITCH........................................................... 818 Reading the Speedometer............................................................. 818 Reading the Load Display............................................................ 818 Using the Operator ID............................................................... 818 Using the Load and Ton Counter...................................................... 818 Total Ton Counter................................................................... 818 Total Load Counter.................................................................. 819 Clearing the Counters............................................................... 819 Viewing Live Sensor Data............................................................ 819 Other Display Messages.............................................................. 819 PAYLOAD OPERATION & CALCULATION......................................................... 820 Description of Haul Cycle States.................................................... 820 Haul Cycle Description.............................................................. 820 Load Calculation.................................................................... 821 Carry Back.......................................................................... 821 Measurement Accuracy................................................................ 821 SOURCES FOR PAYLOAD ERROR............................................................... 821 Payload Error....................................................................... 821 Loading Conditions.................................................................. 822 Pressure Sensors.................................................................... 822 Swingloads.......................................................................... 822 Speed and Distance.................................................................. 822 HAUL CYCLE DATA......................................................................... 822 Haul Cycle Warning Flags............................................................ 824 Frame Torque Data................................................................... 825 Sprung Weight Data.................................................................. 825 Maximum Speed Data.................................................................. 825 Alarm Records....................................................................... 825 Fault Code Data..................................................................... 826 PC SOFTWARE OVERVIEW.................................................................... 827 System Configuration................................................................ 827 Installing the PLMIII Software...................................................... 827 DOWNLOADING DATA........................................................................ 828 PLM III SYSTEM CONFIGURATION............................................................ 829 Starting Communications............................................................. 829 Displayed Payload Units............................................................. 829 Time Units.......................................................................... 829 Connection Menu..................................................................... 829 Connecting to the Payload Meter..................................................... 830 Configure the Payload Meter......................................................... 830 Setting the Date and Time........................................................... 830 Setting the Truck Type.............................................................. 831 Setting the Gauge Display Units..................................................... 831 Setting the Frame Serial Number..................................................... 831 Setting the Truck Number............................................................ 831 Setting the Komatsu Distributor..................................................... 831 Setting the Komatsu Customer........................................................ 831 Clean Truck Tare.................................................................... 832 Inclinometer Calibration............................................................ 832 DATA ANALYSIS........................................................................... 833 Creating a Query.................................................................... 833 Sorting on Truck Unit Number........................................................ 833 Sorting on Truck Type............................................................... 833 Sorting on Date Range............................................................... 834 Sorting on Time Range............................................................... 834 Payload Detail Screen............................................................... 835 Creating Reports.................................................................... 835 Summary - one page report........................................................... 836 Detailed - multi-page report........................................................ 836 Creating Graphs..................................................................... 837 Exporting Data...................................................................... 837 CSV Export.......................................................................... 837 Compressed.......................................................................... 838 Importing Data...................................................................... 839 Deleting Haul Cycle Records......................................................... 839 Viewing Alarms...................................................................... 840 Deleting Alarm Records.............................................................. 840 TROUBLESHOOTING SECTION..................................................................... 841 TROUBLESHOOTING......................................................................... 841 Viewing Active Alarms............................................................... 841 Real-Time Data Display.............................................................. 841 Testing the Payload Lights.......................................................... 841 Creating Log Files of Inputs........................................................ 842 Daily Inspections................................................................... 842 Periodic Maintenance................................................................ 842 Abnormal Displays at Power-Up....................................................... 843 No Payload Display When Key Switch is Turned ON..................................... 844 No Display on Speedometer........................................................... 845 No Display on Operator Display...................................................... 845 No Communications With PC........................................................... 846 Load Lights Don’t Light During Loading.............................................. 847 Load Lights Remain ON............................................................... 848 Load Lights Remain ON During Dumping................................................ 848 Display Doesn't Clear When The Load Is Dumped....................................... 848 Calibration Problems................................................................ 849 Alarm 1 - Left Front Pressure High.................................................. 850 Alarm 2 - Left Front Pressure Low................................................... 850 Troubleshoot Wiring to Left Front Suspension........................................ 850 Alarm 3 - Right Front Pressure High................................................. 851 Alarm 4 - Right Front Pressure Low.................................................. 851 Troubleshoot Wiring to Right Front Suspension....................................... 851 Alarm 5 -Left Rear Pressure High.................................................... 852 Alarm 6 - Left Rear Pressure Low.................................................... 852 Troubleshoot Wiring to Left Rear Suspension......................................... 852 Alarm 7 - Right Rear Pressure High.................................................. 853 Alarm 8 - Right Rear Pressure Low................................................... 853 Troubleshoot Wiring to Right Rear Suspension........................................ 853 Alarm 9 - Inclinometer High......................................................... 854 Alarm 10 - Inclinometer Low......................................................... 854 Troubleshoot Inclinometer Wiring.................................................... 854 Alarm 13 - Body Up Input Failure.................................................... 855 Alarm 16 - Memory Write Failure..................................................... 856 Alarm 17 - Memory Read Failure...................................................... 856 Alarm 18............................................................................ 857 Alarm 19............................................................................ 857 Alarm 22............................................................................ 857 Operator Switch Doesn't Work........................................................ 858 Alarm 26 - User Switch Fault - SELECT............................................... 858 Alarm 27 - User Switch Fault - SET.................................................. 858 Connector Map....................................................................... 859 Connectors.......................................................................... 860 PLMIII CHECK OUT PROCEDURE.................................................................. 861 General Description..................................................................... 861 Tools Required.......................................................................... 861 Checkout Procedure...................................................................... 861 PLMIII CHECKOUT PROCEDURE CONFIRMATION.................................................. 865 Flashburn Programming............................................................... 865 Confirmation Checklist.............................................................. 867 RESERVE ENGINE OIL SYSTEM ...................................................................... 869 RESERVE ENGINE OIL SYSTEM................................................................... 871 Operation............................................................................... 872 LED Monitor Light....................................................................... 872 Tank Fill Control (Optional)............................................................ 873 Filling Procedure (Remote Fill Feature)................................................. 873 SERVICE................................................................................. 874 Every 10 Hours, or once each shift:................................................. 874 Every 500 Hours..................................................................... 874 Changing Oil........................................................................ 874 TROUBLESHOOTING......................................................................... 875 Circuit Fuse........................................................................ 875 SYSTEM ELECTRICAL SCHEMATICS............................................................ 876 SECTION N OPERATOR CAB ............................................................................. 877 TRUCK CAB AND COMPONENTS........................................................................ 879 TRUCK CAB AND COMPONENTS.................................................................... 881 TRUCK CAB............................................................................... 881 Description......................................................................... 881 Removal............................................................................. 882 Installation........................................................................ 883 CAB DOOR................................................................................ 884 Removal............................................................................. 884 Installation........................................................................ 884 Door Adjustment..................................................................... 884 Door Jamb Bolt Adjustment........................................................... 885 Door Handle Plunger Adjustment...................................................... 886 Replace Door Glass.................................................................. 887 Replace Door Window Regulator....................................................... 891 Replacing the Door Handle or Latch Assembly......................................... 892 Replacing the Door and Door Hinge Seal.............................................. 892 Removing the Door Opening Seal...................................................... 893 Installation........................................................................ 893 GLASS REPLACEMENT....................................................................... 894 Adhesive-bonded Windows............................................................. 894 Replacement Procedure............................................................... 894 WINDSHIELD & REAR GLASS................................................................. 896 Removal............................................................................. 896 Installation........................................................................ 896 CAB COMPONENTS ................................................................................. 899 CAB COMPONENTS.............................................................................. 901 WINDSHIELD WIPERS....................................................................... 901 WIPER MOTOR......................................................................... 901 Removal......................................................................... 901 Installation.................................................................... 901 WIPER ARM........................................................................... 901 Removal......................................................................... 901 Installation.................................................................... 902 WIPER LINKAGE....................................................................... 902 Removal......................................................................... 902 Installation.................................................................... 902 WINDSHIELD WASHER....................................................................... 903 Operation........................................................................... 903 Service............................................................................. 903 OPERATOR SEAT........................................................................... 904 Seat Belts.......................................................................... 904 Adjustment.......................................................................... 904 Inspection.......................................................................... 905 Removal............................................................................. 905 Installation........................................................................ 905 PASSENGER SEAT.......................................................................... 906 Inspection.......................................................................... 906 Removal............................................................................. 906 Installation........................................................................ 906 OPERATOR COMFORT................................................................................ 907 OPERATOR COMFORT............................................................................ 909 HEATER / AIR CONDITIONER................................................................ 909 Operation........................................................................... 909 Fan Control Knob.................................................................... 909 Temperature Control Knob............................................................ 909 Directional Control Knob............................................................ 909 Heater Vents........................................................................ 909 COMPONENTS.............................................................................. 910 Circuit Breakers.................................................................... 910 Relays.............................................................................. 910 Heater Core......................................................................... 910 Fan Motor And Speed Control......................................................... 911 Actuators........................................................................... 911 Cab Air Filter...................................................................... 911 ENVIRONMENTAL IMPACT OF AIR CONDITIONING................................................ 914 AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES............................................... 914 PRINCIPLES OF REFRIGERATION............................................................. 914 Air Conditioning.................................................................... 914 Refrigeration - The Act Of Cooling.................................................. 915 The Refrigeration Cycle............................................................. 915 AIR CONDITIONER SYSTEM COMPONENTS....................................................... 916 Compressor (Refrigerant Pump)....................................................... 916 Service Valves...................................................................... 916 Condenser........................................................................... 916 Receiver-Drier...................................................................... 916 Expansion Block Valve............................................................... 917 Accumulator......................................................................... 917 Evaporator.......................................................................... 917 ELECTRICAL CIRCUIT...................................................................... 918 Thermostat.......................................................................... 918 Compressor Clutch................................................................... 918 Trinary™ Switch..................................................................... 919 SYSTEM SERVICING........................................................................ 920 SERVICE TOOLS AND EQUIPMENT............................................................. 921 Recovery/Recycle Station............................................................ 921 Leak Detector....................................................................... 921 Service Valves...................................................................... 922 Vacuum Pump......................................................................... 922 Manifold Gauge Set.................................................................. 923 Installing Manifold Gauge Set....................................................... 924 Purging Air From Service Hoses...................................................... 924 SYSTEM PERFORMANCE TEST................................................................. 925 SYSTEM OIL.............................................................................. 926 Handling and Reusing PAG Oil........................................................ 926 Oil Quantity........................................................................ 926 Checking System Oil................................................................. 926 REFRIGERANT............................................................................. 927 Recycled Refrigerant................................................................ 927 Reclaimed Refrigerant............................................................... 927 Refrigerant Quantity................................................................ 927 R-134a Refrigerant Containers....................................................... 928 SYSTEM LEAK TESTING..................................................................... 928 Electronic Leak Detector............................................................ 929 Tracer Dyes......................................................................... 929 Soap and Water...................................................................... 929 RECOVERING AND RECYCLING THE REFRIGERANT................................................ 929 Performing the Recovery Cycle....................................................... 929 Performing the Recycling Procedure.................................................. 930 Evacuating and Charging the A/C System.............................................. 930 SYSTEM REPAIR........................................................................... 930 System Flushing..................................................................... 931 A/C DRIVE BELT CHECKOUT PROCEDURE....................................................... 932 Pulley Alignment.................................................................... 932 Belt Tension Check.................................................................. 932 COMPONENT REPLACEMENT................................................................... 934 Hoses and Fittings.................................................................. 934 Lines............................................................................... 934 Expansion Valve..................................................................... 934 Receiver-Drier...................................................................... 934 Thermostat.......................................................................... 934 Compressor.......................................................................... 935 Accumulator......................................................................... 935 Clutch.............................................................................. 935 Servicing the Compressor Clutch..................................................... 936 Pulley Removal...................................................................... 938 Clutch Coil Check................................................................... 939 Pulley Installation................................................................. 939 Clutch Assembly Installation........................................................ 939 EVACUATING THE SYSTEM................................................................... 941 CHARGING THE A/C SYSTEM................................................................. 943 TROUBLESHOOTING......................................................................... 944 Preliminary Checks.................................................................. 944 Diagnosis Of Gauge Readings And System Performance.................................. 944 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS.......................................... 945 PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM.......................................... 951 OPERATOR CAB CONTROLS........................................................................... 953 OPERATOR CAB AND CONTROLS................................................................... 955 STEERING WHEEL AND CONTROLS............................................................. 956 Horn Button......................................................................... 956 Tilt / Telescope Lever.............................................................. 956 Multi-Function Turn Signal Switch................................................... 956 STEERING COLUMN......................................................................... 957 Removal............................................................................. 957 Steering Column Inspection.......................................................... 957 Installation........................................................................ 957 STEERING WHEEL.......................................................................... 958 Removal............................................................................. 958 Installation........................................................................ 958 PEDALS.................................................................................. 960 Service Brake Pedal................................................................. 960 Dynamic Retarding................................................................... 960 Dynamic Retard Pedal................................................................ 960 Throttle/Accelerator Pedal.......................................................... 960 GRADE/SPEED RETARD CHART................................................................ 961 OVERHEAD PANEL AND DISPLAYS............................................................. 962 CENTER CONSOLE.......................................................................... 963 Directional Control Lever........................................................... 963 Override/Fault Reset Switch......................................................... 964 Engine Stop Switch.................................................................. 964 L.H. Window Control Switch.......................................................... 964 R.H. Window Control Switch.......................................................... 964 Hoist Control Lever................................................................. 964 Raising The Dump Body............................................................... 964 Lowering The Dump Body.............................................................. 964 Retard Speed Control (RSC) Adjust Dial.............................................. 965 Retard Speed Control (RSC) Switch................................................... 965 Data Store Button................................................................... 966 KOMTRAX Plus Snapshot In Progress Light............................................. 966 Link Energized Light................................................................ 966 Service Engine Light................................................................ 966 DIAGNOSTIC PORTS.................................................................... 966 KOMTRAX Plus Diagnostic Port........................................................ 966 Interface Module (IM) Diagnostic Port............................................... 966 Payload Meter Diagnostic Port....................................................... 966 Truck Control Interface (TCI) Diagnostic Port....................................... 966 Propulsion System Controller (PSC) Diagnostic Port.................................. 966 Engine Diagnostic Port (CENSE)...................................................... 966 Engine Diagnostic Port (QUANTUM).................................................... 966 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 967 Fan Control Knob.................................................................... 967 Temperature Control Knob............................................................ 967 Directional Control Knob............................................................ 967 Heater Vents........................................................................ 967 INSTRUMENT PANEL........................................................................ 968 Key Switch.......................................................................... 970 Starting............................................................................ 970 Engine Stop Switch with Five Minute Idle Timer Delay................................ 970 Rotating Beacon Light Switch (Optional)............................................. 971 Heated Mirror Switch (Optional)..................................................... 971 Rest Switch......................................................................... 971 Wheel Brake Lock Control............................................................ 971 Hazard Warning Lights............................................................... 971 Cab/Air Conditioner Vents........................................................... 971 Engine Oil Pressure Gauge........................................................... 972 Right Turn Signal Indicator......................................................... 972 Tachometer.......................................................................... 972 High Beam Indicator................................................................. 972 Speedometer/Payload Meter Display................................................... 972 Left Turn Signal Indicator.......................................................... 972 Water Temperature Gauge............................................................. 972 Lamp Test Switch.................................................................... 972 Light Switch........................................................................ 972 Ladder Light Switch................................................................. 973 Manual Backup Switch................................................................ 973 Fog Lights (Optional)............................................................... 973 Payload Meter Switch................................................................ 973 Panel Light Dimmer.................................................................. 973 Hydraulic Oil Temperature Gauge..................................................... 974 Hourmeter........................................................................... 974 Fuel Level Gauge.................................................................... 974 OVERHEAD STATUS / WARNING INDICATORS.................................................... 975 Status / Warning Indicator Light Symbols............................................ 976 KOMTRAX Plus MONITORING SYSTEM.......................................................... 982 Operation........................................................................... 982 Interface Module.................................................................... 983 Basic Precautions................................................................... 983 SECTION P LUBRICATION AND SERVICE .................................................................. 985 LUBRICATION AND SERVICE......................................................................... 987 LUBRICATION AND SERVICE..................................................................... 989 830E SERVICE CAPACITIES................................................................. 989 HYDRAULIC TANK SERVICE.................................................................. 989 Adding Oil.......................................................................... 989 COOLING SYSTEM SERVICE.................................................................. 990 Radiator Filling Procedure.......................................................... 990 Coolant Specifications.............................................................. 990 Unacceptable Practices.............................................................. 990 WHEEL MOTOR SERVICE..................................................................... 990 RESERVE ENGINE OIL SYSTEM (Optional).................................................... 991 Reserve Oil Tank Filling Procedure (Remote fill).................................... 991 Inline Screen....................................................................... 991 QUICK FILL SERVICE CENTER............................................................... 992 LUBRICATION CHART....................................................................... 993 10 HOUR (DAILY) INSPECTION.............................................................. 994 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................. 997 100 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 998 250 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................. 999 500 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................1003 1000 HOURS LUBRICATION AND MAINTENANCE CHECKS...........................................1005 2500 HOUR MAINTENANCE CHECKS............................................................1006 5000 HOUR MAINTENANCE CHECKS............................................................1006 AUTOMATIC LUBRICATION SYSTEM ...................................................................1007 AUTOMATIC LUBRICATION SYSTEM................................................................1009 GENERAL DESCRIPTION.....................................................................1009 SYSTEM COMPONENTS.......................................................................1011 Filter..............................................................................1011 Hydraulic Motor and Pump............................................................1011 Grease Reservoir....................................................................1011 Pressure Reducing Valve.............................................................1011 Flow Control Valve..................................................................1011 Solenoid Valve......................................................................1011 Vent Valve..........................................................................1011 Lubrication Cycle Timer.............................................................1011 Over Pressure Cut Off Switch........................................................1011 Grease Pressure Failure Switch......................................................1011 Injectors...........................................................................1011 Relief Valve........................................................................1011 SYSTEM OPERATION........................................................................1012 GENERAL INSTRUCTIONS....................................................................1013 Required Lubricant..................................................................1013 System Priming......................................................................1013 Filter Assembly.....................................................................1013 LUBRICANT PUMP..........................................................................1014 Pump Housing Oil Level..............................................................1014 Pump Pressure Control...............................................................1014 INJECTORS (SL-1 Series “H”).............................................................1014 Injector Specifications.............................................................1014 Injector Adjustment.................................................................1014 INJECTOR OPERATION......................................................................1016 PREVENTIVE MAINTENANCE PROCEDURES.......................................................1017 Daily Lubrication System Inspection.................................................1017 250 Hour Inspection.................................................................1017 1,000 Hour Inspection...............................................................1017 SYSTEM CHECKOUT.........................................................................1018 Lubrication Controller Check........................................................1018 Lubrication Controller Operation....................................................1018 Lubrication Controller Components...................................................1018 Lubrication Controller Adjustment...................................................1018 SYSTEM TROUBLESHOOTING CHART............................................................1020 SECTION Q ALPHABETICAL INDEX .......................................................................1023 SECTION R SYSTEM SCHEMATICS ........................................................................1027 HH360 HYDRAULIC SCHEMATIC ......................................................................1029 HH366 HYDRAULIC SCHEMATIC .....................................................................1030 HE484 ELECTRICAL SCHEMATIC HEATER/AC CONTROLS ..................................................1032 XS3800 ELECTRICAL SCHEMATIC ....................................................................1033
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
2 reviews for KOMATSU 830E-1AC DUMP TRUCK Shop Repair Manual SERIAL NUMBERS A30072 – A30078 – PDF DOWNLOAD
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Kameron Langston –
Trenton Chandler –
ya great easy