Komatsu 830E Dump Truck Shop Manual CEBM006301 PDF

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Komatsu 830E Dump Truck Shop Manual CEBM006301 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E Dump Truck Shop Manual CEBM006301 – PDF DOWNLOAD 

Language : English
Pages : 785
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual CEBM006301 – PDF DOWNLOAD 

SERIAL NUMBERS A30625 – A30649

FOREWORD:

This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance per- sonnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accom- plishing repairs on the truck.

• The first section covers component descriptions, truck specifications and safe work practices, as well as other gen- eral information. The major portion of the manual pertains to disassembly, service and reassembly. Each major ser- viceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs
• .The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ±10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and desig- nates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “E” designates an Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original man- ufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other compo- nents. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual CEBM006301 – PDF DOWNLOAD 

SERIAL NUMBERS A30625 – A30649

COVER 1
FOREWARD 7
CONTENTS 9
GENERAL INFORMATION 11
TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS 13
GENERAL SAFETY AND TRUCK OPERATION 17
WARNINGS AND CAUTIONS 45
CHARTS AND TABLES 51
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 51
Standard Assembly Torques For 12-Point, Grade 9, Cap Screws (SAE) 52
Standard Metric Assembly Torque For Class 10 9 Cap Screws & Class 10 Nuts 52
Suggested* Sources for Rust Preventive Grease: 52
STORAGE AND IDLE MACHINE PREPARATION 57
SHORT TERM IDLE PERIODS 57
REMOVAL FROM STORAGE 59
RECONDITIONING AN IDLE VEHICLE 61
ENGINE OPERATION 64
AFTER ENGINE HAS STARTED 65
ENGINE STORAGE-CUMMINS 66
Engine Storage-(Short Term) 66
Prepare the Engine for Short Term Storage 66
Remove the Engine from Short Term Storage 66
Engine Storage- (Long Term) 67
6 Months to 24 Months 67
Prepare the Engine for Long Term Storage 67
Remove the Engine from Long Term Storage 67
PREPARATION FOR STORAGE 58
ENGINE STORAGE – DETROIT DIESEL 68
Preparing Engine For Storage 68
Temporary Storage (30 Days Or Less) 68
Extended Storage (more Than 30 Days) 68
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 70
ELECTRIC DRIVE TRUCKS 71
Storage Instructions and Procedures 71
Placing Equipment Into Storage 71
When Storing A Truck That Is Operational 71
When Storing A Truck That Is Not Operational 72
When Storing A Major Component 72
Periodic Inspections 73
Placing Equipment Into Service After Storage 73
When A Truck Is Operational 73
When A Truck Is Not Operational 73
For The First Hour 74
PRESERVATION AND STORAGE ALLISON TRANSMISSION 75
Storage, New Transmission 75
Storage, One Year — Without Oil 75
Storage, One Year With Oil (normally in a vehicle chassis) 75
Restoring Transmission to Service 75
STRUCTURES 77
STRUCTURAL COMPONENTS 79
LADDERS 79
Removal 79
Installation 79
RIGHT HAND DECK 80
Removal 80
Installation 80
CENTER AND LEFT HAND DECK COMPONENTS 81
FUEL TANK 82
Removal 82
Installation 82
DUMP BODY 83
Removal 83
Installation 84
BODY PADS 85
Adjustment 86
BODY GUIDE 86
BODY-UP RETENTION CABLE 86
BODY POSITION INDICATOR 87
ROCK EJECTORS (Type I) 87
Inspection 87
HOIST LIMIT SWITCHES 87
ROCK EJECTORS (Type II) 88
ENGINE, FUEL, COOLING AND AIR CLEANER 89
POWER MODULE 91
PREPARATION 91
Removal 91
Installation 95
COOLING SYSTEM 97
COOLING SYSTEM DESCRIPTION 97
RADIATOR 98
Removal 98
Installation 100
RADIATOR FILLING PROCEDURE 100
POWER TRAIN 101
ALTERNATOR REMOVAL PROCEDURE 101
Removal (Komatsu SSDA16V160 or SDA16V160 Engine) 101
ENGINE/ALTERNATOR MATING 103
General Instructions 103
MEASURING PROCEDURE 103
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine 105
ENGINE 106
Removal 106
Service 106
Installation 106
AIR FILTRATION SYSTEM 107
AIR CLEANER 107
Operation 107
General Service Information 107
MAIN FILTER ELEMENT 107
Removal 107
Installation 108
SAFETY FILTER ELEMENT 109
Removal 109
Installation 109
AIR INTAKE TROUBLESHOOTING 109
AIR CLEANER ASSEMBLY CLEANING 109
Main Filter Cleaning 109
Precleaner Section Cleaning 110
ELECTRICAL SYSTEM (24 VDC NON-PROPULSION 113
24VDC ELECTRIC SUPPLY SYSTEM 115
ELECTRICAL SYSTEM DESCRIPTION 115
BATTERY 115
Maintenance and Service 115
Troubleshooting 115
BATTERY CHARGING SYSTEM (Niehoff) 117
General Description 117
TROUBLESHOOTING PROCEDURES (On-Truck) 117
Preliminary Checks 118
Test Setup 118
Test Procedure 118
Regulator Bypass Test 119
ON VEHICLE TROUBLESHOOTING GUIDE – SELF ENERGIZED ALTERNATOR 120
ALTERNATOR ELECTRICAL CONDITION – Low Voltage – High Voltage – No Voltage 120
PRELIMINARY PROCEDURES 120
LOW VOLTAGE OUTPUT 120
HIGH VOLTAGE OUTPUT 120
NO VOLTAGE OUTPUT 120
TOOLS AND EQUIPMENT: 120
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 120
Low Maintenance Types: 120
Maintenance Free types: 121
High-Cycle Maintenance Free Types: 121
DEFINITIONS 121
ADVANCED SYSTEM TROUBLESHOOTING 24V/240A Self Energized 122
NO ALTERNATOR OUTPUT 122
STATIC TEST – ENGINE OFF, KEY ON, BATTERY SWITCH ON 122
GO TO ALTERNATOR” 122
GO TO “R” TERMINAL ON ALTERNATOR 122
RE-TEST CHARGING CIRCUIT FOR OPERATION with ENGINE RUNNING 122
GO TO REGULATOR (IF REQUIRED) 123
GO TO REGULATOR CONNECTOR ON ALTERNATOR 123
24 VDC ELECTRIC STARTER SYSTEM (WITH PRELUBE) 124
OPERATION 124
Pressure Switch 125
Check Valve 125
Timer Solenoid 125
MAINTENANCE 125
Prelube System Operation Checks 125
Check Valve 125
Timer Solenoid 125
Troubleshooting Prelube Starter Circuit 126
24 VDC ELECTRIC START SYSTEM 128
CRANKING MOTORS 128
OPERATION 128
Removal 128
Installation 128
CRANKING MOTOR TROUBLESHOOTING 129
Preliminary Inspection 129
No-Load Test 129
Interpreting Results of Tests 129
Disassembly 130
Cleaning and Inspection 132
Armature Servicing 132
Field Coil Checks 132
Field Coil Removal 132
Solenoid Checks 133
Test 133
Assembly 134
Bearing Replacement: 134
Motor Assembly: 134
Pinion Clearance 135
Removal 135
Installation 135
Coil Test 136
24VDC ELECTRICAL SYSTEM COMPONENTS 137
ALARM INDICATING DEVICE (AID) 137
Coolant Level/Flasher Card 137
Temperature/Latch Card 137
Oil Level Card 138
Temperature Card 138
Hot Switch Inverter Card (Slot 4) 138
Hot Switch Inverter Card (Slot 3) 138
Diode Matrix Without Sound Card 138
Diode Matrix With Sound Card 138
BODY-UP SWITCH 138
Adjustment 139
Service 139
HOIST LIMIT SWITCH 139
Adjustment 139
Service 139
BATTERY EQUALIZER 140
Troubleshooting 140
GROUND LEVEL SHUTDOWN 140
24 VOLT RELAY AND DIODE BOARDS 141
RELAY BOARDS 141
Description 141
SERVICE 142
RELAY BOARD COMPONENTS 143
Relay Board 1 Turn Signal 143
Relay Board 2 Payload Meter (Optional) 143
Relay Board 3 Stop Lights 144
Relay Board 4 Parking Brake 144
Relay Board 5 Head Lights 144
Relay Board 6 Auxiliary Panel 145
DIODE BOARD 1 146
Diode Testing 146
CIRCUIT BREAKERS 146
ELECTRICAL PROPULSION COMPONENTS 149
ELECTRICAL PROPULSION COMPONENTS 155
GENERAL SYSTEM DESCRIPTION 155
CONTROL SYSTEM 155
System Operation 156
FL275 Panel 157
CARD REPLACEMENT 158
Removal 158
Installation 158
Card Repair 158
Panel Wiring 158
COMPUTER DESCRIPTION 159
Microprocessor 159
Download Capability 159
SOFTWARE 159
Base Monitor Program 159
Runtime Monitor Program – OBJ Running Code 159
Configuration Software – CFG 160
PTU – Portable Test Unit Code 160
System Regulation 160
Propulsion 161
Retarding 161
TWO-DIGIT DISPLAY PANEL 162
The Coded Number 162
Events 162
Frames 163
Windows 163
System Categories 163
Limits On Resetting Faults 163
NA Faults 164
Event Sequence 164
Resetting Events 164
Event Descriptions 164
Subcode Descriptions 164
2-DIGIT DISPLAY PANEL SUBCODES 172
PORTABLE TEST UNIT (PTU) 175
DESCRIPTION 175
Operational Hints 175
SOFTWARE INSTALLATION PREPARATION 176
HARD DISK SPACE REQUIREMENTS 176
SOFTWARE INSTALLATION ON PTU 176
PTU/Truck Communication Problems 177
THE MAIN MENU 178
Quit Menu 178
PTU Talk To Truck 178
View PTU Saved Files 178
List Stat Data Files 178
Truck Setup (CFG) 178
Select Truck Setup 178
Change PTU Password 178
Update CFG Version 178
CONFIGURATION (CFG) FILE CONVERSION 180
Conversion Procedure 180
Convert Old CFG files for New software 181
STATEX CONFIGURATION FILES 184
0) Source Directory: 184
1) Select A Truck Configuration 185
2) View Truck Configuration: Data Curves 186
3) Change/View Serial and Model Numbers 187
4) View Options 187
5) Change/View Truck Specifics 189
6) Change/View Overspeeds 191
7) Save a Truck Configuration, filename: 192
8) Save Directory: 193
CHANGE PTU PASSWORD 194
PROGRAMMING THE TRUCK 195
Connect PTU to the Truck 195
Select Configuration File 195
Activate The PTU Mode 195
Check Object Code Version 196
Download Configuration Files 197
Date And Time 198
Event Data 199
Statistical Data 201
View Counters 201
View Profiles 201
Upload Statistical Data To A File 201
Statistical Data Codes – Counters 202
STATISTICAL DATA CODES – COUNTERS 203
STATISTICAL DATA CODES – PROFILES 208
TRUCK SPECIFIC INFORMATION 212
Temporary Truck Settings 213
MISCELLANEOUS FEATURES 214
Saving Data 214
PTU Abbreviations 215
Other Menu Selections 215
MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS 216
ALTERNATOR 216
ELECTRIC WHEEL MOTORS 216
RETARDING GRIDS 216
ELECTRONIC ACCELERATOR AND RETARD PEDALS 216
Removal 216
Installation 216
Disassembly 217
Reassembly 217
COOLING BLOWER WARNING SYSTEM 217
Operation 217
Test 217
Removal 218
Installation 218
ELECTRICAL CONTROL CABINET 219
ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS 224
CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III 225
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 227
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE 231
GENERAL INFORMATION 231
COMMUNICATIONS PORT CHECK 232
PTU Hookup 232
4 0 SEQUENCE TESTS – (ENGINE NOT ON) 233
Preparation and Setup 233
CONTROL SYSTEM SELF-TEST 234
4 1 THROTTLE SYSTEM CHECK AND ADJUSTMENT 234
4 2 RETARD SYSTEM CHECK AND ADJUSTMENT 235
PTU Setup 235
4 3 REVERSER AND PROPULSION CONTACTORS CHECK 236
4 4 NOT USED 237
4 5 RETARD CONTACTORS OPERATION CHECK 237
4 6 GROUND FAULT SENSING CHECK 237
4 7 GROUND FAULT IN RETARD OPERATION CHECK 238
4 8 OVERRIDE OPERATION CHECK 238
4 9 ANTI-REVERSAL FUNCTION (AR) CHECK 239
4 10 OVERSPEED RETARD OPERATION CHECK 239
4 11 HOIST INTERLOCK OPERATION CHECK 240
4 12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK 240
Return to Main Menu 240
5 0 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL 241
5 1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU 241
5 2 DIGITAL INPUT CHECKS 242
5 3 DIGITAL OUTPUT CHECKS 243
6 0 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL 247
6 1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU 247
6 2 ANALOG INPUT CHECKS 248
6 3 FREQUENCY INPUT CHECKS 252
Return to Main Menu 253
7 0 SPEED EVENT CHECKS 253
Preparation and Setup 253
Setup PTU 253
7 1 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK 254
7 2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK 254
7 3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK 254
7 4 OTHER SPEED EVENTS CHECKS 254
Return to Main Menu 254
8 0 RETARD SPEED CONTROL SYSTEM CHECK 255
Preparation and Setup 255
Setup PTU 255
8 1 OVERSPEED PICKUP AND DROPOUT CHECK 255
8 2 RETARD POT MAXIMUM SETTING CHECK 255
8 3 RETARD POT MINIMUM SETTING CHECK 255
8 4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL 256
Return to Main Menu 256
9 0 LOAD TEST USING TRUCK RETARD GRIDS 256
Setup and Preparation 256
PTU Setup 256
9 1 LOAD TEST 257
10 0 MOTOR FIELD CURRENT CHECK IN RETARDING 257
Setup PTU 257
10 1 RETARD CHECK 258
11 0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT 259
11 1 BRAKE SYSTEM INTERLOCKS CHECK 259
Preparation 259
11 2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT 259
11 3 SYNC TRANSFORMER CHECKOUT 260
11 4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT 260
11 5 BATTERY BOOST ADJUSTMENT 260
11 6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST 260
11 7 MOTOR ROTATION TEST 261
11 8 GROUND FAULT CHECKS 261
12 0 MISCELLANEOUS CHARTS 262
12 1 WHEEL MOTOR GEAR RATIOS 262
12 2 MAXIMUM ALLOWABLE TRUCK SPEEDS 263
12 3 ENGINE OPTIONS 264
DRIVE AXLE, SPINDLES AND WHEELS 267
TIRES AND RIMS 269
FRONT TIRES AND RIMS 269
Removal 269
Installation 270
REAR TIRES AND RIMS 271
Removal 271
Installation 272
RIM 273
Tire Removal 273
RIM AND TIRE PREPARATION 273
LUBRICANTS 274
TIRE INSTALLATION 274
FRONT WHEEL HUB AND SPINDLE 277
WHEEL HUB AND SPINDLE ASSEMBLY 277
Removal 277
Spindle Pusher Tool Usage 278
Installation 279
Disassembly 281
Cleaning and Inspection 281
Assembly 282
Wheel Bearing Adjustment (Tire Removed) 284
Wheel Bearing Adjustment (Tire mounted) 284
STEERING CYLINDERS AND TIE ROD 286
Spherical Bearing Wear Limits 286
Removal 287
Installation 287
Bearing Replacement 287
TOE-IN ADJUSTMENT 289
REAR AXLE HOUSING ATTACHMENT 291
PIVOT PIN 291
Removal 291
Installation 291
PIVOT EYE BEARING 292
Disassembly 292
Assembly 292
PIVOT EYE REPAIR 293
Removal 293
Disassembly 293
Assembly 293
Installation 293
ANTI-SWAY BAR 294
Removal 294
Installation 294
Disassembly 294
Cleaning and Inspection 294
Assembly 294
REAR AXLE HOUSING 295
REAR AXLE HOUSING 295
Removal 295
Installation 295
WHEEL MOTOR 295
Removal 295
Cleaning and Inspection 296
Installation 296
Maximum Cap Screw Usage 296
FRONT SUSPENSION 299
Removal 299
MAXIMUM CAPSCREW USAGE 301
MINOR REPAIR ONLY (Lower Bearing Structure & Seals) 303
Bearing Structure Removal 303
Bearing Structure Installation 303
MAJOR SUSPENSION REBUILD 304
Disassembly 304
Assembly 305
PRESSURE TEST 306
REAR SUSPENSIONS 307
Removal 307
Installation 309
Disassembly 311
Cleaning and Inspection 311
Assembly 311
PRESSURE TEST 312
OILING AND CHARGING PROCEDURE 313
GENERAL 313
EQUIPMENT LIST 313
HYDRAIR® CHARGING KIT 313
Installation of Charging Kit 313
Removal of Charging Kit 314
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS 314
FRONT SUSPENSION 315
Front Suspension Oiling 315
Front Suspension Nitrogen Charging 316
REAR SUSPENSION 317
Rear Suspension Oiling 317
Rear Suspension Nitrogen Charging 318
OIL AND NITROGEN SPECIFICATIONS CHART 320
HYDRAIR II SUSPENSIONS 297
FRONT SUSPENSION 299
FRONT SUSPENSION 299
REMOVAL 299
INSTALLATION 300
TURN-OF-THE-NUT” 302
MINOR REPAIR (LOWER BEARING STRUCTURE AND SALES) 303
BEARING STRUCTURE REMOVAL 303
BEARING STRUCTURE INSTALLATION 303
MAJOR ASSEMBLY REBUILD 304
DISASSEMBLY 304
ASSEMBLY 305
PRESSURE TEST 306
REAR SUSPENSION 307
REMOVAL 307
INSTALLATION 309
DISASSEMBLY 311
ASSEMBLY 311
PRESSURE TEST 312
OILING AND CHARGING PROCEDURES 313
GENERAL 313
EQUIPMENT LIST 313
FRONT SUSPENSION 315
FRONT SUSPENSION OILING 315
FRONT SUSPENSION NITROGEN CHARGING 316
REAR SUSPENSION 317
REAR SUSPENSION OILING 317
REAR SUSPENSION NITROGEN CHARGING 318
OIL AND NITROGEN SPECIFICATIONS 320
BRAKE CIRCUIT 321
BRAKE CIRCUIT 323
SERVICE BRAKE CIRCUIT OPERATION 323
SECONDARY BRAKING AND AUTOMATIC APPLY 325
PARKING BRAKE CIRCUIT 325
BRAKE LOCK CIRCUIT 326
WARNING CIRCUIT 326
BRAKE CIRCUIT COMPONENT SERVICE 329
BRAKE VALVE 329
Rebuild Criteria 329
Removal 329
DISASSEMBLY 332
Cleaning and Inspection 334
ASSEMBLY 334
Actuator Base Threaded Inserts 334
Boot and Cap 334
Valve Body Seal Installation 335
Regulator Sleeve O-Ring Installation 335
Actuator Plunger O-ring Installation 335
Assembly of Valve 336
DIFFERENTIAL PRESSURE SWITCH 337
Disassembly 337
Cleaning and Inspection 337
Assembly 337
VALVE BENCH TEST AND ADJUSTMENT 338
Test Set Up Procedure 339
Brake Valve Output Pressure Adjustment 339
Differential Pressure Switch Test 339
Final Test and Adjustment 340
Installation Of Brake Pedal Actuator Assembly to Brake Valve 341
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal) 342
Installation of Retard Pedal To Brake Pedal 342
HYDRAULIC BRAKE ACCUMULATORS 343
Brake Accumulator Bleed Down Procedure 343
Removal 343
Installation 343
Disassembly 343
Cleaning and Inspection 344
Assembly 345
Charging Procedure 346
BRAKE MANIFOLD 347
Removal 347
Removal 347
Installation 348
Disassembly 348
Cleaning and Inspection 348
Assembly 348
BRAKE CIRCUIT CHECK-OUT PROCEDURE 349
EQUIPMENT REQUIRED 351
INITIAL SYSTEM SET-UP 352
PARKING BRAKE 352
BRAKE SYSTEM CHECK-OUT 352
Failure Modes Check-Out 353
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 355
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET 359
KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET 360
ROCKWELL WHEEL SPEED FRONT DISC BRAKES 361
BRAKE CALIPER 361
Removal 361
Installation 362
Piston Removal 363
Installation 363
Caliper Cleaning and Inspection 363
BRAKE LINING 365
Replacement 365
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE 366
Front Brake Conditioning 366
Temporary Disconnect Procedures For Rear Brakes 366
BRAKE BLEEDING PROCEDURES 368
ROCKWELL ARMATURE SPEED REAR DISC BRAKES 369
REAR BRAKES 369
CALIPER, DISC, AND PARKING BRAKE 369
Caliper, Disc, And Parking Brake Removal 369
Caliper, Disc, And Parking Brake Installation 370
CALIPER, DISC, AND PARKING BRAKE REMOVAL 372
Caliper, Disc, And Parking Brake Installation 373
CALIPER PISTON ASSEMBLY 374
Piston Assembly Removal 374
Piston Assembly Inspection 374
Piston Assembly Installation 374
FUNCTIONAL TEST OF PISTON ASSEMBLY 375
Return Spring Force 375
Built-In Clearance 375
Grip Force 376
Grip Force Measurement 377
Spring Force Measurement 378
Disassembly of Piston Assembly 379
Assembly of Piston Assembly 380
BENCH TEST 380
BRAKE LINING 381
Replacement 381
Brake Pad Conditioning (Burnishing) Procedure 383
Conditioning (Burnishing) Rear Brakes 383
General 383
BLEEDING PROCEDURE 384
Temporary Disconnect Procedures for Disabling Front Brakes 384
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks 385
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks 385
ROCKWELL DISC PARKING BRAKE 387
CALIPER STYLE IDENTIFICATION 387
PARK BRAKE CALIPER 388
Park Brake Caliper Removal 388
Park Brake Caliper Installation 388
Parking Brake Adjustment (SCL70) 388
Parking Brake Adjustment (SCL15) 390
Park Brake Caliper Disassembly 391
Cleaning and Inspection 392
Park Brake Caliper Assembly 393
PARK BRAKE LINING REPLACEMENT 393
PARK BRAKE BURNISH PROCEDURE 393
Lining Conditioning 393
BRAKE BLEEDING PROCEDURE 393
HYDRAULIC SYSTEM 395
HYDRAULIC SYSTEM 397
HYDRAULIC SYSTEM OPERATION 397
COMPONENT DESCRIPTION 398
HYDRAULIC SYSTEM COMPONENT REPAIR 401
HOIST PUMP 401
Removal 401
Installation 402
Disassembly 403
INSPECTION OF PARTS 406
Assembly 407
HYDRAULIC TANK 412
Filling Instructions 412
Removal 412
Installation 413
HYDRAULIC TANK STRAINERS 413
Removal 413
Inspect and Clean 413
Installation 413
HYDRAULIC TANK BREATHERS 414
HOIST CIRCUIT FILTERS 414
FILTER ELEMENT REPLACEMENT 415
Removal 415
INDICATOR SWITCH 415
STEERING CIRCUIT 417
STEERING CIRCUIT OPERATION 417
COMPONENT DESCRIPTION 418
STEERING CONTROL UNIT 418
FLOW AMPLIFIER 418
No Steer 420
Steering Left 422
Steering Right 424
No Steer, External Shock Load 426
BLEED DOWN MANIFOLD 428
ACCUMULATORS 429
Low Precharge Warning Switch 429
HIGH PRESSURE FILTER 429
STEERING/BRAKE PUMP 429
Operation 430
PRINCIPLE OF OPERATION 432
Full Pump Volume: 432
Half Pump Volume: 432
STEERING CIRCUIT COMPONENT REPAIR 435
BLEED DOWN MANIFOLD 435
Removal 435
Installation 435
ACCUMULATOR 436
Removal 436
Installation 437
Disassembly 438
Cleaning and Inspection 438
Assembly 439
TESTING 439
FLOW AMPLIFIER 441
Removal 441
Installation 441
Disassembly 442
Reassembly 445
STEERING CONTROL UNIT 446
Removal 446
Spline Inspection 446
Installation 446
Disassembly 447
Cleaning and Inspection 448
Assembly 448
STEERING CYLINDER 452
Disassembly 452
Inspection and Cleaning 452
Assembly 452
STEERING CIRCUIT FILTER 453
FILTER ELEMENT REPLACEMENT 453
Removal 454
Installation 454
INDICATOR SWITCH 454
STEERING AND BRAKE PUMP 455
Removal 455
Installation 455
Disassembly 457
Control Piston Group 457
Valve Plate Group 457
Rotating Group 458
Swashblock Group 458
Driveshaft Group 458
INSPECTION 458
Control Piston Group 458
Valve Plate Group 458
Rotating Group 458
Swashblock Group 462
Driveshaft Group 462
Compensator Block and Unloader Module 462
Stroke Adjuster Assembly 462
ASSEMBLY 462
Swashblock Group 462
Control Piston Group 464
Valve Plate Group 464
HOIST CIRCUIT 467
HOIST CIRCUIT OPERATION 467
COMPONENT DESCRIPTION 468
HOIST PUMP 468
HIGH PRESSURE FILTERS 468
HOIST VALVE 469
HOIST PILOT VALVE 470
HOIST-UP LIMIT SOLENOID 470
PILOT OPERATED CHECK VALVE 470
COUNTERBALANCE VALVE MANIFOLD 470
FLOAT POSITION OF PILOT VALVE AND BODY ON FRAME 472
POWER UP OPERATION (Figure 7-6) 474
HOLD OPERATION (Figure 7-7) 476
POWER DOWN OPERATION (Figure 7-8) 478
FLOAT OPERATION (Figure 7-9) 480
HOIST CIRCUIT COMPONENT REPAIR 483
HOIST VALVE 483
Relieve pressure before disconnecting hydraulic lines Tighten all connections securely before applying pressure 483
Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause ser 483
Removal 483
Installation 483
O-Ring Replacement 484
INLET SECTION 484
Disassembly 484
Cleaning and Inspection 485
Assembly 486
SPOOL SECTION 486
Disassembly 486
Cleaning and Inspection 488
Assembly 488
HOIST PILOT VALVE 489
Removal 489
Installation 489
Disassembly 489
Cleaning and Inspection 491
Assembly 491
BODY UP LIMIT SOLENOID 492
PILOT OPERATED CHECK VALVE 492
COUNTERBALANCE VALVE MANIFOLD 492
HOIST CYLINDERS 492
Removal 492
Installation 493
Disassembly 495
Cleaning and Inspection 496
ASSEMBLY OF QUILL AND CYLINDER 497
Quill Installation 497
Installation Of Check Balls And Plugs In Quill 498
Assembly of Cylinder 499
DISABLED TRUCK DUMPING PROCEDURE 500
HOOKUP 500
DUMPING PROCEDURE 500
HYDRAULIC CHECK-OUT PROCEDURE 501
STEERING AND BRAKE PUMP 501
Pressure Check And Adjustment Procedure 501
BLEEDDOWN MANIFOLD 502
SHOCK & SUCTION VALVES 503
Shock & Suction Valve Settings 503
LEAKAGE TESTS 503
Steering Control Unit & Flow Amplifier 504
Bleed Down Manifold 505
TROUBLESHOOTING CHART (Steering Circuit) 506
TROUBLESHOOTING CHART (Steering Pump) 509
TROUBLESHOOTING CHART (Flow Amplifier) 512
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE 514
HYDRAULIC SYSTEM FLUSHING PROCEDURE 517
OPTIONS AND SPECIAL TOOLS 519
FIRE CONTROL SYSTEM (MANUAL) 521
Operation 521
Inspection and Maintenance 521
Recharging Procedures 522
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM 523
SYSTEM ADJUSTMENT 523
PUMP 523
Removal 523
Disassembly 523
Inspection 525
Assembly 525
Installation 526
BLOWER DRIVE MOTOR 526
Removal 527
Disassembly 527
Inspection Of Parts 528
Assembly 528
Installation 529
BLOWER BEARING REPAIR 529
Removal 529
Replacement 529
Assembly 530
AIR CLEANER 530
Assembly 530
Removal 530
Washing Air Cleaner 530
Assembly 530
WIGGINS QUICK FILL FUEL SYSTEM 531
FUEL RECEIVER 531
TANK BREATHER VALVE 532
Removal 532
Installation 532
Disassembly 532
Assembly 532
LEFT SIDE FILL 533
BUCKEYE QUICK FUEL SYSTEM 535
FUEL TANK BREATHER VALVE 535
Maintenance 535
Filter Service 535
Disassembly 535
Inspection 535
Assembly 535
FUEL RECEIVER 536
ENGINE COOLANT HEATER 537
Maintenance 537
HEATING ELEMENT 537
Removal 537
Installation 537
THERMOSTAT 538
Removal 538
Installation 538
SPECIAL TOOLS 539
AIR CONDITIONING SYSTEM 545
Environmental Impact 545
OPERATOR CAB AIR CONDITIONING 546
PRINCIPLES OF REFRIGERATION 546
Air Conditioning 546
Refrigeration – The Act Of Cooling 547
The Refrigeration Cycle 547
AIR CONDITIONER SYSTEM COMPONENTS 548
Compressor (Refrigerant Pump) 548
Service Valves 548
Condenser 548
Expansion Block Valve 549
Evaporator 549
ELECTRICAL CIRCUIT 550
Thermostat 550
Compressor Clutch 550
Trinary™ Switch 551
SYSTEM SERVICING 552
SYSTEM OIL 553
Handling and Reusing PAG Oil 553
Oil Quantity 553
Replacing Oil After Servicing the System 553
Setting Up a New Compressor 553
REFRIGERANT 554
Recycled Refrigerant 554
Reclaimed Refrigerant 554
Refrigerant Quantity 554
R-134a Refrigerant Containers 554
SERVICE TOOLS AND EQUIPMENT 555
Recovery/Recycle Station 555
Leak Detector 555
Service Valves 556
Vacuum Pump 556
Manifold Gauge Set 557
Installing Manifold Gauge Set 558
Purging Air From Service Hoses 559
Stabilizing the AC System 560
SYSTEM PERFORMANCE TEST 560
SYSTEM LEAK TESTING 561
Electronic leak detector 561
Tracer dyes 561
Soap and water 561
SYSTEM REPAIR 562
System Cleaning 562
Hoses and Fittings 562
Lines 562
Expansion Valve 562
Receiver-Drier 563
Thermostat 563
Compressor 563
Clutch 563
Servicing the Compressor Clutch 564
Pulley Removal 566
Clutch Coil Check 566
Pulley Installation 566
Clutch Assembly Installation 567
RECOVERING AND RECYCLING THE REFRIGERANT 568
Performing the Recovery Cycle 568
Performing the Recycling Procedure 568
Evacuating and Charging the AC System 568
EVACUATING THE SYSTEM 569
CHARGING THE AC SYSTEM 570
TROUBLESHOOTING 571
Pre-Diagnosis Checks 571
Preparing For Diagnosis 571
Preliminary Steps 571
System Performance Test 571
Diagnosis Of Gauge Readings And System Performance 572
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 579
RADIATOR SHUTTERS 581
OPERATION 581
Hydraulic Circuit 581
Electrical Circuit: 582
MAINTENANCE AND REPAIR 582
TROUBLESHOOTING 584
Hydraulic Troubleshooting 587
Electrical Troubleshooting 589
Electrical troubleshooting 590
PAYLOAD METER II – ON BOARD WEIGHING SYSTEM 593
GENERAL INFORMATION 595
Haul Cycles 595
LIGHTS, SWITCHES AND COMPONENTS 596
TIPS FOR OPERATION 597
EXTERNAL DISPLAY LIGHTS 597
THEORY OF OPERATION 598
Basic Description 598
Inclinometer 598
Linkage Factor 598
Gain Factor 599
Brake Lock 599
Sources of Error 599
Typical Data From Service Check Mode 599
Example Calculation of Payload 600
Viewing Payload Calculation Inputs 600
Checking the Gain 601
Adjusting the Gain 601
TYPES OF DATA STORED 602
Cycle Data 602
Engine ON/OFF Data 603
Fault Codes and Warning Data 603
Engine Operation 604
Total Payload and Total Number of Cycles 604
Other Data 604
OPERATOR FUNCTIONS 605
Using the Operator Load Counter 605
Viewing the Operator Load Counter 605
Clearing the Operator Load Counter 605
Dimming the Lights on the Display 605
INITIAL SETUP OF PAYLOAD METER 606
Switch Settings 606
Checking the Operator Check Mode 607
Checking the Service Check Mode 607
Checking the Gt setting: 608
Checking the Inclinometer Settings 608
Calibrating a Truck 608
DISPLAYS AT START-UP 609
Normal Operation 609
SETUP AND MAINTENANCE 610
Setting The Speed Limit 610
Setting the Option Code 610
Setting The Machine I D Code 611
Setting The Operator I D Code 611
Setting The Time and Date 611
DOWNLOAD OF INFORMATION 612
DISPLAY OF FAULT CODES 612
Monitoring Input Signals 616
Service Check Mode 616
UP FACTOR – PAYLOAD CALCULATION GAIN 617
PL MODE -LOAD CALCULATION TIMING 617
FINAL GEAR RATIO SELECTION 618
BATTERY REPLACEMENT PROCEDURE 619
Replacing the Battery 619
After Replacing the Battery 620
SUSPENSION PRESSURE SENSOR 620
Removal 620
Installation 621
INCLINOMETER 621
Removal 621
Installation 621
Adjustment 621
PAYLOAD METER BACK PANEL 622
CONNECTIONS 623
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 624
PAYLOAD CIRCUIT NUMBERS 625
TROUBLESHOOTING 626
COMMON PROBLEMS 626
Suspension Charging 626
Symptom Table 627
Missing Body-Up Signal 627
Missing Speed Signal 628
F-18: Alternator R-Terminal, Oil Pressure Signals 628
Shorted 18v Sensor Power Supply (930E) 628
FAULT TREE DIAGNOSIS 629
Payload Lights Won’t Illuminate 629
Red, Amber or Green Payload Light Does Not Illuminate 630
Cannot Download – PC Communications 631
PC Communications Configuration 632
F CAL: Payload Meter Won’t Calibrate 633
F-20: Sensor Power Fault 634
F-21, F-25: Left Front Pressure Sensor 636
F-22, F-26: Right Front Pressure Sensor 636
F-23, F-27: Left Rear Pressure Sensor 636
F-24, F-28: Right Rear Pressure Sensor 636
F-31, F-32: Inclinometer 638
Body Up Input 640
Brake Lock Input 641
Speed Signal 642
Adjusting the Speed Sensor 642
CONNECTORS AND PRESSURE SENSORS 644
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 647
Menu Functions 650
Using Scope 650
Log File Information 650
Connections to Payload Meter II™ 651
USING SCOPE 652
Monitoring Inputs Using Scope 652
Monitoring Suspension Charging Using Scope 652
Pressure Sensor Dummy Loads 655
GAIN ADJUSTMENT WORKSHEET 656
OPERATOR’S CAB 657
TRUCK CAB 659
Description 659
Removal 660
Installation 661
CAB DOOR 662
Removal 662
Installation 662
Door Adjustment 662
Door Jamb Bolt Adjustment 662
Door Handle Plunger Adjustment 664
Replace Door Glass 665
Replace Door Window Regulator 669
Replace Door Handle or Latch Assembly 669
Door and Door Hinge Seal Replacement 670
Door Opening Seal Removal 670
Installation 670
GLASS REPLACEMENT 671
ADHESIVE-BONDED WINDOWS 671
Replacement Procedure 671
WINDSHIELD & REAR GLASS 672
Removal 672
Installation 673
CAB COMPONENTS 675
WINDSHIELD WIPER 675
Removal 675
Installation 675
WINDSHIELD WASHER 676
Operation 676
Service 676
OPERATOR COMFORT 677
ELECTRICAL CIRCUITS 680
OPERATOR CONTROLS AND EQUIPMENT 683
STEERING WHEEL AND CONTROLS 684
HORN BUTTON 684
TILT / TELESCOPE LEVER 684
TURN SIGNAL / HEADLIGHT DIMMER 684
STEERING COLUMN 684
Removal 684
Installation 685
SERVICE BRAKE PEDAL 686
DYNAMIC RETARDER PEDAL 686
OPTIONAL – DUAL FUNCTION / SINGLE PEDAL 686
THROTTLE PEDAL 686
HEATER / AIR CONDITIONER VENTS 686
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 687
DEFROSTER VENT CONTROL SWITCH 687
OUTSIDE/INSIDE AIR CONTROL SWITCH 687
HEAT VENT CONTROL SWITCH 687
TEMPERATURE CONTROL KNOB 687
FAN CONTROL KNOB 687
HEATER/AIR CONDITIONER SELECTOR SWITCH 687
HEATER/AIR CONDITIONER VENTS 687
INSTRUMENT PANEL 688
GRADE/SPEED WARNING CHART 688
HOIST CONTROL LEVER 690
INSTRUMENT PANEL AND INDICATOR LIGHTS 693
CONTROL SYMBOLS 693
INSTRUMENT PANEL 694
PANEL GAUGES, INDICATORS, AND CONTROLS (Figure 3-6) 695
INDICATOR LIGHT SYMBOLS 700
LUBRICATION AND SERVICE 705
LUBRICATION AND SERVICE 707
LUBRICATION SPECIFICATIONS CHARTS 707
SERVICE CAPACITIES 707
HYDRAULIC TANK SERVICE AND FILING INSTRUCTIONS 707
RADIATOR FILING PROCEDURE 708
ANTI-FREEZE SPECIFICATIONS 708
LUBRICATION CHART – OIL GREASE SPECIFICATIONS 709
10 HOUR (DAILY) LUBRICATION AND MAINTENANCE CHECKS 710
50 HOUR LUBRICATION AND MAINTENANCE CHECKS 712
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 713
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 714
500 HOUR LUBRICATION AND MAINTENANCE CHECKS 716
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 717
2500 HOUR LUBRICATION AND MAINTENANCE CHECKS 718
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 719
10,000 HOUR LUBRICATION AND MAINTENANCE CHECKS 719
AUTOMATIC LUBRICATION SYSTEM 721
GENERAL DESCRIPTION 721
SYSTEM COMPONENTS 723
SYSTEM OPERATION 724
INJECTOR OPERATION 726
GENERAL INSTRUCTIONS 727
SYSTEM CHECKOUT 729
PUMP REBUILD 730
SYSTEM TROUBLESHOOTING CHART 733
PREVENTATIVE MAINTENANCE PROCEDURES 736
MOTORIZED WHEEL MAINTENANCE SCHEDULE 737
AXLE BOX 737
ARMATURE AREA 738
AT TIRE CHANGE – FOR ALL MOTORIZED WHEELS 738
GENERATOR / ALTERNATOR 739
GRID BLOWER MOTOR 739
CONTROL EQUIPMENT CHECKS 739
AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM 740
VEHICLE OPERATIONS TESTS 740
ALPHABETICAL INDEX 741
SYSTEM SCHEMATICS 745
HYDRAULIC HOIST/STEERING SCHEMATIC 747
HYDRAULIC BRAKE SCHEMATIC (STATEX III; LAPS) 748
STATEX III FL-275 PANEL 749
STATEX III POWER & EXCITATION SCHEMATIC 779
STATEX III ELECTRICAL CONTROL CABINET COMPONENT LOCATION 782

S.V 15/12/24