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KOMATSU 830E-5 DUMP TRUCK SHOP MANUAL CEBM035504 – PDF DOWNLOAD
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Description
KOMATSU 830E-5 DUMP TRUCK SHOP MANUAL CEBM035504 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU 830E-5 DUMP TRUCK SHOP MANUAL CEBM035504 – PDF DOWNLOAD
Language : English
Pages : 1357
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU 830E-5 DUMP TRUCK SHOP MANUAL CEBM035504 – PDF DOWNLOAD
COVER....................................................................................................... 1 00 Index and foreword....................................................................................... 3 Index................................................................................................... 3 Table of contents................................................................................... 6 Foreword, safety and general information................................................................ 21 Foreword............................................................................................ 24 How to read the shop manual......................................................................... 25 Composition of shop manual...................................................................... 25 Revision and distribution....................................................................... 25 Symbols......................................................................................... 26 General safety...................................................................................... 27 Safety rules.................................................................................... 27 Safety features................................................................................. 27 Fire extinguisher and first aid kit............................................................. 27 Clothing and personal items..................................................................... 27 Leaving the operator seat....................................................................... 28 Mounting and dismounting........................................................................ 28 Fire prevention for fuel and oil................................................................ 28 Precautions with high temperature fluids........................................................ 29 Asbestos dust hazard prevention................................................................. 29 Prevention of injury by work equipment.......................................................... 29 Unauthorized modification....................................................................... 29 Precautions when using ROPS..................................................................... 29 Precautions for attachments..................................................................... 30 Precautions for starting the truck.............................................................. 30 Precautions before operating the truck.............................................................. 30 Safety at the worksite.......................................................................... 30 Fire prevention................................................................................. 31 Ventilation in enclosed areas................................................................... 31 Preparing for operation......................................................................... 31 Mirrors, windows and lights..................................................................... 31 In operator cab (before starting the engine).................................................... 31 Seat Belts...................................................................................... 31 Precautions while operating the truck............................................................... 32 When starting the engine........................................................................ 32 General truck operation......................................................................... 32 Ensuring good visibility........................................................................ 32 Traveling....................................................................................... 33 Traveling in reverse............................................................................ 33 Traveling on slopes............................................................................. 33 Operating on snow or ice........................................................................ 33 Avoid damage to dump body....................................................................... 33 Driving near high voltage cables................................................................ 34 When dumping.................................................................................... 34 When loading.................................................................................... 34 Working on loose ground......................................................................... 34 Parking the truck............................................................................... 35 Towing.......................................................................................... 35 Working near batteries.............................................................................. 36 Battery hazard prevention....................................................................... 36 Starting with jumper cables..................................................................... 37 Jump starting with receptacles.................................................................. 37 Precautions before performing service............................................................... 38 Warning tag..................................................................................... 38 Stopping the engine............................................................................. 38 Proper tools.................................................................................... 38 Use of tie-off anchor during maintenance and repair............................................. 39 Tie-off anchor installation..................................................................... 39 Securing the dump body.......................................................................... 40 Jack point locations............................................................................ 41 Precautions while performing service................................................................ 42 Keep the truck clean............................................................................ 42 Attachments..................................................................................... 42 Working under the truck......................................................................... 42 Rotating fan and belts.......................................................................... 42 Adding fuel or oil.............................................................................. 42 Use of lighting................................................................................. 42 Radiator coolant level.......................................................................... 43 Precautions with the battery.................................................................... 43 Precautions with high pressure oil.............................................................. 43 Handling high pressure hoses.................................................................... 43 Precautions when performing maintenance near high temperature or high pressure.................. 43 Waste materials................................................................................. 43 Tires............................................................................................... 44 Inspection...................................................................................... 44 Maintenance..................................................................................... 44 Storage......................................................................................... 45 Handling........................................................................................ 46 Precautions for performing repairs.................................................................. 47 Engine shutdown procedure after AC drive system failure......................................... 47 Precautions for welding on the truck................................................................ 48 Control cabinet capacitor discharge system.......................................................... 49 Handling electrical equipment and hydraulic components.............................................. 51 Points to remember when handling electrical equipment........................................... 51 Points to remember when handling hydraulic equipment............................................ 57 Actions taken to meet exhaust gas regulations....................................................... 59 About DEF....................................................................................... 59 Precautions for diesel exhaust fluid (DEF).......................................................... 60 About DEF....................................................................................... 60 Precautions for handling DEF.................................................................... 60 Precautions for storing DEF..................................................................... 60 Precautions for disposing of DEF................................................................ 61 Crystallization management...................................................................... 61 Precautions for cold weather operation.......................................................... 61 Standard tightening torques......................................................................... 62 Effect of special lubricants on fasteners and standard torque values............................ 62 Suggested sources for rust preventive grease.................................................... 62 SAE grade 5 and grade 8 hex head capscrew and nut assemblies.................................... 63 SAE grade 9 capscrews........................................................................... 64 Class 10.9 capscrews and class 10 nuts.......................................................... 65 Standard tightening torques for fittings........................................................ 65 Standard tightening torques for clamps.......................................................... 67 Conversion tables................................................................................... 68 Common conversion multipliers................................................................... 68 01 Specification............................................................................................ 73 Specification and technical data........................................................................ 73 Specification drawing............................................................................... 75 Specifications...................................................................................... 76 Weight table........................................................................................ 78 Fuel, coolant and lubricants........................................................................ 79 Suspension cylinder oil and nitrogen specifications............................................. 80 Wheel motor oil specifications.................................................................. 80 10 Structure and functions.................................................................................. 83 Steering circuit........................................................................................ 83 Steering circuit operation.......................................................................... 85 Steering circuit components......................................................................... 89 Steering control unit........................................................................... 89 High pressure filter............................................................................ 89 Steering accumulators........................................................................... 89 Bleeddown manifold.............................................................................. 90 Steering accumulator bleeddown solenoid......................................................... 90 Quick disconnect ports.......................................................................... 90 Flow amplifier.................................................................................. 90 Steering/brake pump operation....................................................................... 91 High altitude operation......................................................................... 91 Neutral position................................................................................ 92 Full pump volume................................................................................ 93 Half pump volume................................................................................ 93 Flow amplifier operation............................................................................ 94 No steer........................................................................................ 94 Steering left................................................................................... 96 Steering right.................................................................................. 98 No steer, external shock load................................................................... 100 Hoist circuit........................................................................................... 103 Hoist circuit operation............................................................................. 104 Hydraulic circuit components........................................................................ 104 Hydraulic tank.................................................................................. 104 Hoist pump...................................................................................... 104 High pressure filters........................................................................... 104 Hoist valve..................................................................................... 107 Inlet sections.................................................................................. 107 Tank ports (front) spool section................................................................ 107 Work ports (rear) spool section................................................................. 108 Hoist pilot valve............................................................................... 108 Hoist limit solenoid............................................................................ 109 Pilot operated check valve...................................................................... 109 Overcenter manifold............................................................................. 109 Hoist pilot valve operation......................................................................... 110 Float position with body down................................................................... 110 Power up operation.............................................................................. 112 Hold operation.................................................................................. 114 Power down operation............................................................................ 116 Float operation with body up.................................................................... 118 Brake circuits.......................................................................................... 121 General information................................................................................. 123 Service brake circuit operation..................................................................... 123 Secondary braking and auto apply.................................................................... 125 Parking brake circuit operation..................................................................... 125 Normal operation (key switch ON, engine on)..................................................... 125 Wheel brake lock circuit operation.................................................................. 126 Brake warning circuit operation..................................................................... 126 Electrical system, 24 volt.............................................................................. 129 Battery supply system............................................................................... 131 Batteries....................................................................................... 131 24VDC auxiliary battery receptacles............................................................. 131 Isolation box....................................................................................... 132 Ground level shutdown switch.................................................................... 132 Battery disconnect switches..................................................................... 132 Propel lockout lever............................................................................ 132 System busy light............................................................................... 132 LED lights...................................................................................... 132 Engine starting system with prelube................................................................. 133 Prelube operation............................................................................... 133 Auxiliary control cabinet components................................................................ 134 VEC blocks...................................................................................... 135 24VDC to 12VDC converter........................................................................ 135 Circuit breakers................................................................................ 135 Engine service light timer...................................................................... 135 Ground terminals................................................................................ 135 24VDC power terminals........................................................................... 135 Relays.......................................................................................... 136 Body-up switch...................................................................................... 137 Hoist limit switch.................................................................................. 138 Heating/air conditioning (HVAC) system.................................................................. 141 Basic air conditioning system operation............................................................. 143 HVAC components..................................................................................... 145 Control panel................................................................................... 145 Water valve..................................................................................... 145 Expansion valve................................................................................. 145 Actuators....................................................................................... 145 Blower.......................................................................................... 145 Heater core..................................................................................... 145 Evaporator core................................................................................. 145 Cab air temperature sensor...................................................................... 145 ECU module...................................................................................... 145 Air filters..................................................................................... 147 Compressor (refrigerant pump)................................................................... 147 Compressor clutch............................................................................... 147 Trinary™ switch................................................................................. 148 Receiver-drier.................................................................................. 148 Condenser....................................................................................... 148 Accumulator..................................................................................... 148 Automatic lubrication (auto lube) system................................................................ 151 General information................................................................................. 153 System operation.................................................................................... 154 Engine emissions aftertreatment system.................................................................. 157 About emissions aftertreatment...................................................................... 160 DEF injection system................................................................................ 160 DEF heating system.................................................................................. 160 Sensors............................................................................................. 160 Exhaust system cleaning............................................................................. 161 Propel lockout precaution....................................................................... 161 Inducement strategy................................................................................. 161 20 Standard value table..................................................................................... 163 Standard value table.................................................................................... 163 Standard value table for truck...................................................................... 165 30 Testing and adjusting.................................................................................... 171 Steering, hoist and auxiliary hydraulic systems......................................................... 171 Hydraulic system bleeddown procedure................................................................ 173 Hydraulic system vacuum procedure................................................................... 175 General information on system checkout.............................................................. 176 Hydraulic system checkout procedures................................................................ 176 Required equipment.............................................................................. 176 Preliminary steps............................................................................... 176 Hydraulic system flushing procedure............................................................. 177 Flow amplifier adjustment....................................................................... 180 Steering pump unloader valve adjustment......................................................... 181 Auxiliary accumulator pressure verification..................................................... 181 System diagnostics.............................................................................. 182 Hoist pilot relief valve adjustment............................................................. 185 Hoist counterbalance valve adjustment........................................................... 185 Final steps..................................................................................... 186 Oil cleanliness check........................................................................... 186 Hydraulic system checkout data sheet................................................................ 188 Toe-in adjustment................................................................................... 191 Hoist cylinder leakage test......................................................................... 192 Steering cylinder leakage test...................................................................... 192 Brake system............................................................................................ 195 General information on system checkout.............................................................. 197 Brake system checkout procedures.................................................................... 197 Required equipment.............................................................................. 197 Pre-Checkout Items.............................................................................. 197 Checkout Procedure Set-up....................................................................... 199 Brake System Checkout Procedure................................................................. 199 Brake Lock System check......................................................................... 201 Parking Brake System............................................................................ 202 Park Brake Hydraulic Circuit Troubleshooting Guide:............................................. 203 Low Brake Pressure and Auto Apply............................................................... 203 Brake Reapplications (Stored Energy Check)...................................................... 205 Park Brake Control Logic Check.................................................................. 205 Brake Lock Control Logic Check.................................................................. 206 Brake system checkout data sheet.................................................................... 209 Service brake conditioning (burnishing)............................................................. 216 Brake burnishing procedure...................................................................... 217 Front brake conditioning........................................................................ 218 Rear brake conditioning......................................................................... 220 Parking brake adjustment procedure.................................................................. 223 Brake bleeding procedure............................................................................ 224 Service brake................................................................................... 224 Parking brake (rear brake calipers only)........................................................ 224 Piston assembly return spring force and built-in clearance (BIC).................................... 225 Piston assembly adjuster grip force............................................................. 226 Adjuster force.................................................................................. 228 Piston return spring............................................................................ 230 Accumulators and suspensions............................................................................ 233 Accumulator charging and storage.................................................................... 235 Temperature during precharge.................................................................... 235 Bladder accumulator charging procedure.............................................................. 236 Precharge maintenance........................................................................... 238 Bladder accumulator storage procedure........................................................... 238 Bladder storage................................................................................. 238 Installing a bladder accumulator from storage................................................... 239 Bladder accumulator leak testing................................................................ 239 Piston accumulator charging procedure............................................................... 240 Piston accumulator storage.......................................................................... 243 Piston accumulator leak testing..................................................................... 244 Checking for improper suspension charge on operating trucks......................................... 245 Suspension oil change recommendations............................................................... 246 Suspension oiling and charging procedures........................................................... 247 Required equipment.............................................................................. 247 Installing the charging kit..................................................................... 248 Removing the charging kit....................................................................... 248 Support blocks for oiling and charging dimensions............................................... 249 Front suspensions............................................................................... 252 TOP FILL METHOD................................................................................. 253 PRESSURE FILL METHOD............................................................................ 253 Rear suspensions................................................................................ 255 TOP FILL METHOD................................................................................. 257 PRESSURE FILL METHOD............................................................................ 257 Suspension pressure test............................................................................ 259 Electrical systems...................................................................................... 261 General information on system checkout.............................................................. 263 Truck shutdown procedure............................................................................ 264 Required software and tools......................................................................... 264 Electrical system checkout procedures............................................................... 266 Visual inspection............................................................................... 266 Resistance checks............................................................................... 266 Voltage checks.................................................................................. 266 Truck function checks........................................................................... 267 Interface module (IM) checks.................................................................... 268 KOMTRAX Plus II checks.......................................................................... 268 Payload meter (PLM) checks...................................................................... 268 Drive system checks............................................................................. 269 Engine delayed shutdown Smart Timer check....................................................... 269 Body hoist limit switch check................................................................... 269 Electrical checkout sheet........................................................................... 270 Interface module 2 (IM2)................................................................................ 275 Required tools...................................................................................... 277 Programming the IM2................................................................................. 277 Updating the software........................................................................... 277 Configuring the IM2............................................................................. 278 Viewing IM2 real-time data...................................................................... 278 Interface module checkout procedures................................................................ 279 Checking for IM fault codes..................................................................... 279 Checking digital inputs to the IM............................................................... 279 Checking analog inputs to the IM................................................................ 282 Checking serial communication to the IM......................................................... 282 Checking outputs from the IM.................................................................... 283 IM checkout sheet................................................................................... 284 KOMTRAX Plus II......................................................................................... 289 Required software and tools......................................................................... 291 Ethernet connection to KOMTRAX Plus II controller................................................... 291 KOMTRAX Plus II configuration....................................................................... 293 GPS connection test................................................................................. 295 Iridium satellite system opening.................................................................... 297 Data download over ethernet connection for KOMTRAX Plus II initialization........................... 300 Payload meter IV........................................................................................ 303 Payload meter IV software and tools................................................................. 305 Payload meter IV system configuration............................................................... 305 Connecting to the payload meter IV web server................................................... 305 Configuring a static IP address................................................................. 305 Payload meter IV software installation.............................................................. 307 Inclinometer calibration and clean truck tare....................................................... 308 Payload meter IV checkout procedure................................................................. 308 PLM IV system checkout data sheet................................................................... 314 Downloading PLM IV data and possible errors......................................................... 315 Komatsu wireless bridge (KWB)........................................................................... 319 General information................................................................................. 321 Required software and tools......................................................................... 321 Configuring the Bullet wireless radio............................................................... 322 Installing the Bullet wireless radio................................................................ 325 Configuring the NanoStation access point............................................................ 326 Testing the connection.............................................................................. 329 Changing a service computer’s IP address............................................................ 330 Cab air conditioning.................................................................................... 333 General information................................................................................. 335 Service tools and equipment......................................................................... 336 Recovery/recycle station........................................................................ 336 Leak detector................................................................................... 336 Manifold gauge set.............................................................................. 337 Service valves.................................................................................. 338 Vacuum pump..................................................................................... 338 Detecting leaks..................................................................................... 339 System performance test............................................................................. 340 Checking system oil................................................................................. 341 System flushing..................................................................................... 342 Installing the manifold gauge set................................................................... 343 Purging air from the service hoses.............................................................. 344 Recovering and recycling refrigerant................................................................ 345 Draining oil from previous recovery cycle....................................................... 346 Recovery cycle.................................................................................. 346 Recycling procedure............................................................................. 346 Evacuating the air conditioning system.............................................................. 347 Charging the air conditioning system................................................................ 348 Automatic lubrication (auto lube) system................................................................ 351 Priming the system.................................................................................. 353 Checkout procedure.................................................................................. 355 Adjusting the lubrication cycle timing.............................................................. 356 Trucks with Interface Module 1.................................................................. 356 Trucks with Interface Module 2.................................................................. 356 KomVision............................................................................................... 359 Requirements........................................................................................ 361 Initial setup....................................................................................... 362 Checkout data sheet................................................................................. 371 Calibration sheets.................................................................................. 376 Layout and assemblage........................................................................... 376 Unfolding a calibration sheet................................................................... 379 Folding a calibration sheet..................................................................... 380 Placement of calibration sheets................................................................. 381 Camera calibration procedures....................................................................... 383 Automatic 6 camera calibration.................................................................. 383 Manual 6 camera calibration..................................................................... 387 1 camera calibration............................................................................ 390 Radar setting procedure............................................................................. 393 Tire monitoring system.................................................................................. 397 Tire monitoring system software and tools........................................................... 399 Tire monitoring system configuration................................................................ 399 Connecting to the tire monitoring system web server............................................. 399 Configuring a static IP address................................................................. 399 Tire monitoring system software installation........................................................ 401 Tire monitoring system checkout procedure........................................................... 402 Field Troubleshooting........................................................................... 402 Ethernet troubleshooting........................................................................ 402 Tire monitoring system configuration............................................................ 403 CAN RPC Troubleshooting......................................................................... 403 Resetting the tire monitoring system................................................................ 403 Tire monitoring system checkout data sheet.......................................................... 404 40 Troubleshooting.......................................................................................... 407 Fuse, diode and relay locations......................................................................... 407 Vehicle Electrical Center (VEC-89).................................................................. 409 Vehicle Electrical Center (VEC-90).................................................................. 411 Vehicle Electrical Center (VEC-91).................................................................. 413 Vehicle Electrical Center (VEC-92).................................................................. 415 Rear Terminal Mini-fuse and Relay (RTMR3)........................................................... 416 Rear Terminal Mini-fuse and Relay (RTMR4)........................................................... 417 Circuit breakers.................................................................................... 417 Troubleshooting by fault code, Part 1................................................................... 419 Fault Code A001..................................................................................... 422 Fault Code A002..................................................................................... 423 Fault Code A003..................................................................................... 424 Fault Code A004..................................................................................... 425 Fault Code A005..................................................................................... 426 Fault Code A006..................................................................................... 427 Fault Code A007..................................................................................... 428 Fault Code A008..................................................................................... 429 Fault Code A009..................................................................................... 430 Related circuit diagram......................................................................... 430 Fault Code A010..................................................................................... 431 Related circuit diagram......................................................................... 431 Fault Code A011..................................................................................... 432 Fault Code A013..................................................................................... 433 Fault Code A014..................................................................................... 434 Fault Code A016..................................................................................... 435 Fault Code A017..................................................................................... 436 Fault Code A018..................................................................................... 437 Fault Code A019..................................................................................... 438 Fault Code A022..................................................................................... 439 Fault Code A100..................................................................................... 440 Related circuit diagram......................................................................... 440 Fault Code A101..................................................................................... 441 Fault Code A103..................................................................................... 442 Fault Code A104..................................................................................... 443 Fault Code A105..................................................................................... 444 Fault Code A109..................................................................................... 445 Fault Code A111..................................................................................... 446 Fault Code A115..................................................................................... 447 Fault Code A117..................................................................................... 448 Fault Code A118..................................................................................... 449 Fault Code A123..................................................................................... 450 Fault Code A124..................................................................................... 451 Fault Code A125..................................................................................... 452 Fault Code A126..................................................................................... 453 Fault Code A127..................................................................................... 454 Fault Code A128..................................................................................... 455 Fault Code A139..................................................................................... 456 Troubleshooting by fault code, Part 2................................................................... 459 Fault Code A145..................................................................................... 462 Fault Code A146..................................................................................... 463 Fault Code A152..................................................................................... 464 Fault Code A153..................................................................................... 465 Fault Code A154..................................................................................... 466 Fault Code A155..................................................................................... 467 Fault Code A158..................................................................................... 468 Fault Code A166..................................................................................... 469 Fault Code A167..................................................................................... 470 Fault Code A168..................................................................................... 471 Fault Code A169..................................................................................... 472 Fault Code A170..................................................................................... 473 Fault Code A171..................................................................................... 474 Fault Code A172..................................................................................... 475 Fault Code A173..................................................................................... 476 Fault Code A184..................................................................................... 477 Fault Code A190..................................................................................... 478 Fault Code A193..................................................................................... 479 Fault Code A194..................................................................................... 480 Fault Code A195..................................................................................... 481 Fault Code A196..................................................................................... 482 Fault Code A197..................................................................................... 483 Fault Code A198..................................................................................... 484 Fault Code A199..................................................................................... 485 Fault Code A200..................................................................................... 486 Fault Code A201..................................................................................... 487 Fault Code A202..................................................................................... 488 Fault Code A203..................................................................................... 489 Fault Code A204..................................................................................... 490 Fault Code A205..................................................................................... 491 Fault Code A206..................................................................................... 492 Fault Code A207..................................................................................... 493 Fault Code A213..................................................................................... 494 Fault Code A214..................................................................................... 495 Fault Code A215..................................................................................... 496 Fault Code A216..................................................................................... 497 Fault Code A223..................................................................................... 498 Fault Code A230..................................................................................... 499 Fault Code A231..................................................................................... 500 Fault Code A233..................................................................................... 501 Fault Code A235..................................................................................... 502 Fault Code A236..................................................................................... 503 Fault Code A237..................................................................................... 504 Fault Code A238..................................................................................... 505 Fault Code A239..................................................................................... 507 Related circuit diagram......................................................................... 508 Fault Code A240..................................................................................... 509 Fault Code A242..................................................................................... 510 Fault Code A243..................................................................................... 511 Fault Code A244..................................................................................... 512 Fault Code A245..................................................................................... 513 Fault Code A246..................................................................................... 514 Troubleshooting by fault code, Part 3................................................................... 517 Fault Code A248..................................................................................... 521 Fault Code A249..................................................................................... 522 Fault Code A250..................................................................................... 523 Fault Code A251..................................................................................... 524 Fault Code A252..................................................................................... 525 Fault Code A253..................................................................................... 526 Fault Code A256..................................................................................... 527 Fault Code A257..................................................................................... 528 Fault Code A258..................................................................................... 529 Fault Code A260..................................................................................... 530 Fault Code A261..................................................................................... 531 Fault Code A262..................................................................................... 532 Fault Code A264..................................................................................... 533 Fault Code A265..................................................................................... 534 Fault Code A266..................................................................................... 535 Fault Code A267..................................................................................... 536 Fault Code A268..................................................................................... 537 Fault Code A270..................................................................................... 538 Fault Code A271..................................................................................... 539 Related circuit diagram......................................................................... 540 Fault Code A272..................................................................................... 541 Fault Code A273..................................................................................... 542 Fault Code A274..................................................................................... 543 Fault Code A275..................................................................................... 544 Fault Code A277..................................................................................... 545 Fault Code A278..................................................................................... 546 Fault Code A279..................................................................................... 547 Fault Code A280..................................................................................... 548 Fault Code A281..................................................................................... 549 Fault Code A282..................................................................................... 550 Fault Code A283..................................................................................... 551 Fault Code A284..................................................................................... 552 Fault Code A285..................................................................................... 553 Fault Code A286..................................................................................... 554 Fault Code A292..................................................................................... 555 Troubleshooting by fault code, Part 4................................................................... 557 Fault Code A303..................................................................................... 560 Fault Code A304..................................................................................... 561 Fault Code A305..................................................................................... 562 Fault Code A307..................................................................................... 563 Fault Code A309..................................................................................... 564 Fault Code A310..................................................................................... 565 Fault Code A311..................................................................................... 566 Fault Code A312..................................................................................... 567 Fault Code A313..................................................................................... 568 Fault Code A315..................................................................................... 569 Fault Code A316..................................................................................... 570 Fault Code A317..................................................................................... 571 Fault Code A318..................................................................................... 572 Fault Code A328..................................................................................... 573 Fault Code A332..................................................................................... 574 Fault Code A333..................................................................................... 575 Fault Code A334..................................................................................... 576 Fault Code A335..................................................................................... 577 Fault Code A337..................................................................................... 578 Fault Code A338..................................................................................... 579 Fault Code A339..................................................................................... 580 Fault Code A340..................................................................................... 581 Fault Code A341..................................................................................... 582 Fault Code A342..................................................................................... 583 Fault Code A343..................................................................................... 584 Fault Code A344..................................................................................... 585 Fault Code A345..................................................................................... 586 Fault Code A346..................................................................................... 587 Fault Code A347..................................................................................... 588 Fault Code A348..................................................................................... 589 Fault Code A349..................................................................................... 590 Fault Code A350..................................................................................... 591 Fault Code A351..................................................................................... 592 Fault Code A352..................................................................................... 593 Fault Code A353..................................................................................... 594 Fault Code A354..................................................................................... 595 Fault Code A355..................................................................................... 596 Fault Code A356..................................................................................... 597 Fault Code A357..................................................................................... 598 Fault Code A358..................................................................................... 599 Fault Code A359..................................................................................... 600 Fault Code A360..................................................................................... 601 Fault Code A361..................................................................................... 602 Fault Code A362..................................................................................... 603 Fault Code A363..................................................................................... 604 Fault Code A364..................................................................................... 605 Fault Code A365..................................................................................... 606 Fault Code A366..................................................................................... 607 Troubleshooting by fault code, Part 5................................................................... 609 Fault Code A400..................................................................................... 612 Fault Code A401..................................................................................... 613 Fault Code A402..................................................................................... 614 Fault Code A403..................................................................................... 615 Fault Code A404..................................................................................... 616 Fault Code A405..................................................................................... 617 Fault Code A406..................................................................................... 618 Fault Code A407..................................................................................... 619 Fault Code A408..................................................................................... 620 Fault Code A409..................................................................................... 621 Fault Code A410..................................................................................... 622 Fault Code A411..................................................................................... 623 Fault Code A412..................................................................................... 624 Fault Code A413..................................................................................... 625 Fault Code A414..................................................................................... 626 Fault Code A415..................................................................................... 627 Fault Code A416..................................................................................... 628 Fault Code A417..................................................................................... 629 Fault Code A418..................................................................................... 630 Fault Code A419..................................................................................... 631 Fault Code A420..................................................................................... 632 Fault Code A421..................................................................................... 633 Fault Code A422..................................................................................... 634 Fault Code A423..................................................................................... 635 Fault Code A424..................................................................................... 636 Fault Code A425..................................................................................... 637 Fault Code A426..................................................................................... 638 Fault Code A427..................................................................................... 639 Fault Code A428..................................................................................... 640 Fault Code A429..................................................................................... 641 Fault Code A430..................................................................................... 642 Fault Code A431..................................................................................... 643 Fault Code A432..................................................................................... 644 Fault Code A433..................................................................................... 645 Fault Code A434..................................................................................... 646 Fault Code A435..................................................................................... 647 Fault Code A436..................................................................................... 648 Fault Code A437..................................................................................... 649 Fault Code A438..................................................................................... 650 Fault Code A439..................................................................................... 651 Fault Code A440..................................................................................... 652 Fault Code A441..................................................................................... 653 Fault Code A442..................................................................................... 654 Fault Code A443..................................................................................... 655 Fault Code A444..................................................................................... 656 Fault Code A445..................................................................................... 657 Fault Code A446..................................................................................... 658 Fault Code A447..................................................................................... 659 Aftertreatment system fault codes....................................................................... 661 Fault Code CA256.................................................................................... 665 Fault Code CA1677................................................................................... 667 Fault Code CA1678................................................................................... 669 Fault Code CA1682................................................................................... 672 Fault Code CA1683................................................................................... 679 Fault Code CA1684................................................................................... 681 Fault Code CA1685................................................................................... 683 Fault Code CA1686................................................................................... 685 Fault Code CA1712................................................................................... 687 Fault Code CA1713................................................................................... 689 Fault Code CA1714................................................................................... 691 Fault Code CA1715................................................................................... 692 Fault Code CA1887................................................................................... 694 Fault Code CA2771................................................................................... 695 Fault Code CA3142................................................................................... 699 Fault Code CA3143................................................................................... 701 Fault Code CA3146................................................................................... 703 Fault Code CA3147................................................................................... 705 Fault Code CA3232................................................................................... 707 Fault Code CA3497................................................................................... 710 Fault Code CA3498................................................................................... 711 Fault Code CA3547................................................................................... 712 Fault Code CA3558................................................................................... 713 Fault Code CA3559................................................................................... 715 Fault Code CA3562................................................................................... 717 Fault Code CA3563................................................................................... 719 Fault Code CA3567................................................................................... 721 Fault Code CA3571................................................................................... 723 Fault Code CA3572................................................................................... 725 Fault Code CA3573................................................................................... 728 Fault Code CA3574................................................................................... 730 Fault Code CA3575................................................................................... 732 Fault Code CA3712................................................................................... 734 Fault Code CA3713................................................................................... 735 Fault Code CA3714................................................................................... 738 Fault Code CA3867................................................................................... 739 Fault Code CA3868................................................................................... 741 Fault Code CA3878................................................................................... 744 Fault Code CA3988................................................................................... 745 Fault Code CA3995................................................................................... 749 Fault Code CA4113................................................................................... 751 Fault Code CA4114................................................................................... 753 Fault Code CA4119................................................................................... 755 Fault Code CA4121................................................................................... 757 Fault Code CA4152................................................................................... 759 Fault Code CA4164................................................................................... 763 Fault Code CA4165................................................................................... 765 Fault Code CA4166................................................................................... 768 Fault Code CA4168................................................................................... 770 Fault Code CA4169................................................................................... 772 Fault Code CA4174................................................................................... 774 Fault Code CA4175................................................................................... 776 Fault Code CA4233................................................................................... 779 Fault Code CA4234................................................................................... 780 Fault Code CA4243................................................................................... 781 Fault Code CA4277................................................................................... 782 Fault Code CA4457................................................................................... 784 Fault Code CA4458................................................................................... 786 Fault Code CA4459................................................................................... 789 Fault Code CA4461................................................................................... 791 Fault Code CA4462................................................................................... 793 Fault Code CA4464................................................................................... 795 Fault Code CA4465................................................................................... 797 Fault Code CA4466................................................................................... 800 Fault Code CA4467................................................................................... 807 Fault Code CA4474................................................................................... 809 Fault Code CA4475................................................................................... 811 Fault Code CA4572................................................................................... 814 Fault Code CA4677................................................................................... 818 Fault Code CA4679................................................................................... 822 Fault Code CA4682................................................................................... 823 Fault Code CA4731................................................................................... 824 Fault Code CA4732................................................................................... 825 Fault Code CA4736................................................................................... 826 Fault Code CA4737................................................................................... 827 Fault Code CA4738................................................................................... 828 Fault Code CA4739................................................................................... 829 Fault Code CA4745................................................................................... 830 Fault Code CA4768................................................................................... 831 Fault Code CA4769................................................................................... 833 Fault Code CA4842................................................................................... 835 Fault Code CA4863................................................................................... 836 Fault Code CA4947................................................................................... 837 Fault Code CA5115................................................................................... 838 Fault Code CA5116................................................................................... 841 Fault Code CA5117................................................................................... 844 Fault Code CA5247................................................................................... 847 Fault Code CA5653................................................................................... 849 Fault Code CA5654................................................................................... 852 Fault Code CA5725................................................................................... 854 Fault Code CA5727................................................................................... 859 Fault Code CA5728................................................................................... 862 Fault Code CA5729................................................................................... 865 Fault Code CA5748................................................................................... 867 Fault Code CA5749................................................................................... 869 Fault Code CA5751................................................................................... 871 Fault Code CA5753................................................................................... 873 Fault Code CA5755................................................................................... 876 Fault Code CA5756................................................................................... 881 Fault Code CA5758................................................................................... 883 Fault Code CA5768................................................................................... 885 Fault Code CA5769................................................................................... 887 Fault Code CA5771................................................................................... 890 Fault Code CA5772................................................................................... 892 Fault Code CA5773................................................................................... 895 Fault Code CA5774................................................................................... 898 Fault Code CA5775................................................................................... 900 Fault Code CA5776................................................................................... 905 Fault Code CA5778................................................................................... 907 Fault Code CA5779................................................................................... 909 Fault Code CA5887................................................................................... 911 Fault Code CA5888................................................................................... 912 Fault Code CA5889................................................................................... 913 Fault Code CA5891................................................................................... 914 Fault Code CA5892................................................................................... 915 Fault Code CA5893................................................................................... 916 Fault Code CA6692................................................................................... 917 Fault Code CA6693................................................................................... 919 Fault Code CA6694................................................................................... 921 Fault Code CA6695................................................................................... 923 Fault Code CA6696................................................................................... 925 Fault Code CA6697................................................................................... 927 Fault Code CA6855................................................................................... 929 Fault Code CA6856................................................................................... 932 Steering system......................................................................................... 935 Steering circuit troubleshooting chart.............................................................. 937 Steering circuit troubleshooting guidelines......................................................... 941 Basic hydraulic system checks....................................................................... 942 System leakage check................................................................................ 943 Steering pump troubleshooting guide................................................................. 945 Pump pressure control checks........................................................................ 948 Pump fails to unload............................................................................ 949 Pump fails to develop pressure.................................................................. 949 Pump slow in developing pressure................................................................ 950 Pump control valve inspection and troubleshooting............................................... 950 Pump case drain check........................................................................... 952 KomVision............................................................................................... 955 KomVision fault codes............................................................................... 957 Automatic lubrication (auto lube) system................................................................ 967 Autolube troubleshooting chart...................................................................... 969 Heating/air conditioning (HVAC) system.................................................................. 973 Control panel configurations........................................................................ 975 Diagnostics mode.................................................................................... 976 Error codes..................................................................................... 976 Advanced diagnostics............................................................................ 976 Firmware version................................................................................ 977 Additional HVAC troubleshooting chart............................................................... 977 Voltage levels...................................................................................... 979 Electronic fan clutch................................................................................... 981 Electronic fan clutch troubleshooting............................................................... 983 Electronic fan clutch fault codes................................................................... 985 50 Disassembly and assembly................................................................................. 987 Service tools........................................................................................... 987 Special tool group.................................................................................. 989 Additional service tools............................................................................ 990 KomVision calibration tools......................................................................... 990 Locally made tools.................................................................................. 990 Wheels, spindles and rear axle.......................................................................... 993 General precautions for tires and rims.............................................................. 995 Wheel stud maintenance.............................................................................. 996 Rear outer wheel stud installation.................................................................. 997 Removal and installation of front wheel............................................................. 998 Removal......................................................................................... 998 Installation.................................................................................... 999 Removal and installation of rear wheel..............................................................1000 Removal.........................................................................................1000 Installation....................................................................................1001 Rim Components......................................................................................1003 Rim and tire service................................................................................1004 Lubricants......................................................................................1004 Tire inflation..................................................................................1004 Lock ring retainer installation.................................................................1004 Remove Smart Lock Ring from Inside Position of Outer Dual and Outside Position of Inner Dual....1005 Install Smart Lock Ring to Inside Position of Outer Dual and Outside Position of Inner Dual.....1006 Removal (5-piece standard rim)..................................................................1007 Removal (7-piece Smart rim).....................................................................1010 Removal (5-piece Smart rim).....................................................................1012 Preparation before assembly.....................................................................1014 Installation (5-piece standard rim).............................................................1014 Installation - horizontal mount (Smart rim).....................................................1016 Installation - vertical mount (5-piece Smart rim)...............................................1018 Installation - vertical mount (7-piece Smart rim)...............................................1020 Removal and installation of front wheel hub and spindle.............................................1021 Removal.........................................................................................1021 Spindle removal (off the truck).................................................................1025 Installation....................................................................................1027 Disassembly and assembly of front wheel hub and spindle.............................................1028 Cross Section View..............................................................................1028 Disassembly.....................................................................................1029 Cleaning and inspection.........................................................................1033 Assembly........................................................................................1034 Wheel bearing adjustment........................................................................1035 Speed sensor installation and adjustment........................................................1037 Floating seal assembly and installation.............................................................1038 Removal and installation of rear axle...............................................................1044 Removal.........................................................................................1044 Cleaning and inspection.........................................................................1046 Installation....................................................................................1046 Removal and installation of anti-sway bar...........................................................1047 Removal.........................................................................................1047 Installation....................................................................................1049 Removal and installation of pivot pin...............................................................1050 Removal.........................................................................................1050 Installation....................................................................................1051 Pivot eye and bearing service.......................................................................1052 Bearing replacement.............................................................................1052 Pivot eye repair................................................................................1053 Removal of wheel motor..............................................................................1054 Preparation.....................................................................................1054 Removal.........................................................................................1054 Installation of wheel motor.........................................................................1057 Cleaning and inspection.........................................................................1057 Installation....................................................................................1058 Brake system............................................................................................1063 Removal and installation of brake valve.............................................................1065 Removal.........................................................................................1065 Installation....................................................................................1067 Disassembly and assembly of brake valve/pedal assembly..............................................1068 Disassembly.....................................................................................1068 Assembly........................................................................................1069 Removal and installation of brake manifold..........................................................1071 Removal.........................................................................................1071 Installation....................................................................................1072 Disassembly and assembly of brake manifold..........................................................1073 Disassembly.....................................................................................1073 Assembly........................................................................................1073 Disassembly and assembly of brake accumulator.......................................................1074 Cleaning and inspection.........................................................................1075 Assembly........................................................................................1076 Removal and installation of front brake caliper.....................................................1078 Removal.........................................................................................1078 Inspection......................................................................................1079 Installation....................................................................................1079 Disassembly and assembly of front brake caliper.....................................................1080 Disassembly.....................................................................................1080 Cleaning and inspection.........................................................................1080 Brake lining replacement........................................................................1083 Assembly........................................................................................1083 Removal and installation of rear brake caliper......................................................1083 Removal.........................................................................................1083 Inspection......................................................................................1086 Installation....................................................................................1086 Disassembly and assembly of rear brake caliper......................................................1090 Disassembly.....................................................................................1090 Piston subassembly..............................................................................1093 Cleaning and inspection.........................................................................1094 Assembly........................................................................................1095 Piston subassembly..............................................................................1095 Brake caliper...................................................................................1096 Steering system.........................................................................................1103 Removal and installation of steering control unit...................................................1105 Removal.........................................................................................1105 Installation....................................................................................1107 Disassembly and assembly of steering control unit...................................................1108 Disassembly.....................................................................................1108 Assembly........................................................................................1110 Removal and installation of steering column.........................................................1113 Removal.........................................................................................1113 Installation....................................................................................1114 Removal and installation of steering wheel..........................................................1115 Removal.........................................................................................1115 Installation....................................................................................1115 Removal and installation of bleeddown manifold......................................................1116 Removal.........................................................................................1116 Installation....................................................................................1117 Removal and installation of flow amplifier..........................................................1117 Removal.........................................................................................1117 Installation....................................................................................1118 Removal and installation of steering cylinders and tie rod..........................................1119 Removal.........................................................................................1119 Installation....................................................................................1119 Disassembly and assembly of steering cylinders......................................................1121 Disassembly.....................................................................................1121 Cleaning and inspection.........................................................................1123 Assembly........................................................................................1124 Removal and installation of steering/brake pump.....................................................1125 Removal.........................................................................................1125 Installation....................................................................................1126 Removal and installation of piston steering accumulator.............................................1127 Removal.........................................................................................1127 Installation....................................................................................1129 Disassembly and assembly of piston steering accumulator.............................................1131 Disassembly.....................................................................................1131 Cleaning and inspection.........................................................................1133 Piston seal replacement.........................................................................1133 Assembly........................................................................................1134 Suspensions.............................................................................................1137 General information.................................................................................1139 Removal and installation of front suspension........................................................1139 Preparation.....................................................................................1139 Removal.........................................................................................1139 Cleaning and Inspection.........................................................................1141 Installation....................................................................................1142 Disassembly and assembly of front suspension........................................................1148 Disassembly.....................................................................................1148 Cleaning and inspection.........................................................................1150 Assembly........................................................................................1151 Removal and installation of rear suspension.........................................................1153 Removal.........................................................................................1153 Installation....................................................................................1156 Disassembly and assembly of rear suspension.........................................................1159 Disassembly.....................................................................................1159 Cleaning and inspection.........................................................................1161 Assembly........................................................................................1162 Hoist circuit...........................................................................................1165 Removal and installation of hoist pump..............................................................1167 Removal.........................................................................................1167 Installation....................................................................................1171 Disassembly and assembly of hoist pump..............................................................1172 Disassembly.....................................................................................1172 Inspection......................................................................................1177 Assembly........................................................................................1178 Removal and installation of hoist valve.............................................................1181 Removal.........................................................................................1181 Installation....................................................................................1183 Disassembly and assembly of hoist valve.............................................................1183 O-ring replacement..............................................................................1183 Disassembly of inlet section....................................................................1185 Assembly of inlet section.......................................................................1186 Disassembly of spool section....................................................................1187 Assembly of spool section.......................................................................1189 Overcenter manifold service.........................................................................1190 Removal and installation of hoist pilot valve.......................................................1191 Removal.........................................................................................1191 Installation....................................................................................1191 Disassembly and assembly of hoist pilot valve.......................................................1192 Disassembly.....................................................................................1192 Cleaning and Inspection.........................................................................1194 Assembly........................................................................................1195 Removal and installation of hoist cylinders.........................................................1196 Removal.........................................................................................1196 Installation....................................................................................1199 Disassembly and assembly of hoist cylinders.........................................................1202 Disassembly.....................................................................................1202 Cleaning and inspection.........................................................................1206 Installation of the quill.......................................................................1207 Installation of check balls and plugs in quill..................................................1208 Assembly........................................................................................1209 Body and structures.....................................................................................1215 Removal and installation of dump body...............................................................1217 Removal.........................................................................................1217 Inspection......................................................................................1218 Installation....................................................................................1219 Removal and installation of body pads...............................................................1220 Removal.........................................................................................1220 Installation....................................................................................1220 Body pad shimming procedure.....................................................................1221 Removal and installation of diagonal ladder/ hood and grille assembly...............................1222 Removal.........................................................................................1222 Installation....................................................................................1222 Removal and installation of RH deck.................................................................1224 Removal.........................................................................................1224 Installation....................................................................................1224 Removal and installation of LH deck.................................................................1226 Removal.........................................................................................1226 Installation....................................................................................1226 Removal and installation of fuel tank...............................................................1228 Removal.........................................................................................1228 Cleaning and inspection.........................................................................1228 Installation....................................................................................1230 Removal and installation of fuel gauge sender.......................................................1230 Removal.........................................................................................1230 Installation....................................................................................1230 Removal and installation of hydraulic tank..........................................................1231 Removal.........................................................................................1231 Installation....................................................................................1232 Removal and installation of hydraulic tank strainers................................................1233 Removal.........................................................................................1233 Cleaning and inspection.........................................................................1234 Installation....................................................................................1234 Operator cab............................................................................................1237 Removal and installation of operator cab............................................................1239 Removal.........................................................................................1239 Installation....................................................................................1242 Removal and installation of cab door................................................................1242 Removal.........................................................................................1242 Installation....................................................................................1243 Disassembly and assembly of cab door................................................................1244 Removing the window regulator...................................................................1244 Installing the window regulator.................................................................1245 Removing the door glass.........................................................................1246 Installing the door glass.......................................................................1247 Replacing the inner door seal...................................................................1248 Replacing the outer door seal...................................................................1248 Removing the interior door handle and door latch (earlier models)...............................1249 Installation and removal of interior door handle and door latch (later models)..................1252 Adjustment of cab door..............................................................................1254 Door jamb bolt adjustment.......................................................................1254 Exterior door handle release button adjustment..................................................1256 Removal and installation of side window glass.......................................................1257 Recommended tools and supplies..................................................................1257 Removal.........................................................................................1257 Installation....................................................................................1258 Removal and installation of windshield and rear window glass........................................1259 Removal.........................................................................................1259 Installation....................................................................................1259 Removal and installation of windshield wiper components.............................................1260 Removing the windshield wiper motor.............................................................1260 Installing the windshield wiper motor...........................................................1260 Removing the windshield wiper arm and linkage...................................................1261 Installing the windshield wiper arm and linkage.................................................1262 Removal and installation of cab seats...............................................................1262 Removal.........................................................................................1262 Servicing the seat..............................................................................1263 Installation....................................................................................1263 Removal and installation of seat belts..............................................................1264 Removal.........................................................................................1264 Installation....................................................................................1265 Power module............................................................................................1267 Removal and installation of power module............................................................1269 General.........................................................................................1269 Removal.........................................................................................1270 Installation....................................................................................1279 Exhaust tube installation...........................................................................1289 Exhaust blanket installation........................................................................1289 Removal and installation of alternator..............................................................1290 Removal.........................................................................................1290 Installation....................................................................................1293 Engine / alternator attachment checkout data sheet..................................................1303 Removal and installation of radiator................................................................1308 Removal.........................................................................................1308 Installation....................................................................................1312 Repairing the radiator..............................................................................1313 Internal inspection.............................................................................1313 External cleaning...............................................................................1313 Disassembly.....................................................................................1314 Cleaning and inspection.........................................................................1315 Assembly........................................................................................1315 Pressure testing................................................................................1316 Removal and installation of engine..................................................................1317 Removal.........................................................................................1317 Service.........................................................................................1317 Installation....................................................................................1318 Removal and installation of electronic fan clutch...................................................1319 Removal.........................................................................................1319 Installation....................................................................................1320 Removal and installation of electronic fan clutch speed sensor......................................1320 Removal.........................................................................................1320 Installation....................................................................................1320 90 Diagrams and drawings....................................................................................1323 Hydraulic circuit diagrams..............................................................................1323 Steering and hoist hydraulic circuit diagram - 58E-60-02431.......................................1325 Brake hydraulic circuit diagram - 58E-60-50030....................................................1326 Auxiliary system hydraulic circuit schematic - 58E-60-01680.......................................1327 Electrical circuit diagrams.............................................................................1330 Electrical circuit diagram - 58E-06-02317.........................................................1332 HVAC electrical circuit diagram - 58B-06-06830....................................................1355
DESCRIPTION:
KOMATSU 830E-5 DUMP TRUCK SHOP MANUAL CEBM035504 – PDF DOWNLOAD
Foreword
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing 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 typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of US. standard and metric (SI) units throughout. All references to “right,” ‘left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
- When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 Mm (100 ft lb). All torque specifications have 110% tolerance unless otherwise specified.
S.S 28/12/24
