Komatsu 830E Dump Truck Shop Manual DG681 – PDF DOWNLOAD

Description

Komatsu 830E Dump Truck Shop Manual DG681 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E Dump Truck Shop Manual DG681 – PDF DOWNLOAD

Language : English
Pages : 918
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 830E Dump Truck Shop Manual DG681 – PDF DOWNLOAD

SERIAL SUFFIX
AFE32-AS – AFE32-DH
AFE32-DN – AFE32-DR

COVER 1
FOREWARD 3
TABLE OF CONTENTS 5
GENERAL INFORMATION 7
GENERAL INFORMATION INDEX 7
GENERAL SAFETY AND OPERATION 13
SAFETY IS THINKING AHEAD 13
Safe practices start before the operator gets to the equipment! 13
PREPARING FOR OPERATION 13
ENGINE START-UP SAFETY PRACTICES 14
AFTER ENGINE HAS STARTED 15
SAFETY PRECAUTIONS DURING TRUCK OPERATION 15
LOADING 16
HAULING 17
PASSING 17
DUMPING 17
To Raise dump body: 18
To Lower Body: 18
TOWING 18
WHEN REPAIRS ARE NECESSARY 19
SAFE PARKING PROCEDURES 20
SHUTDOWN PROCEDURE 20
STORAGE AND IDLE MACHINE PREPARATION 33
SHORT TERM IDLE PERIODS 33
PREPARATION FOR STORAGE 34
REMOVAL FROM STORAGE 35
RECONDITIONING AN IDLE VEHICLE 37
ENGINE OPERATION 40
AFTER ENGINE HAS STARTED 41
ENGINE STORAGE-CUMMINS 42
Engine Storage-(Short Term) 42
Prepare the Engine for Short Term Storage 42
Remove the Engine from Short Term Storage 42
Engine Storage- (Long Term) 43
6 Months to 24 Months 43
Prepare the Engine for Long Term Storage 43
Remove the Engine from Long Term Storage 43
ENGINE STORAGE – DETROIT DIESEL 44
Preparing Engine For Storage 44
Temporary Storage (30 Days Or Less) 44
Extended Storage (more Than 30 Days) 44
PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE 46
ELECTRIC DRIVE TRUCKS 47
Storage Instructions and Procedures 47
Placing Equipment Into Storage 47
When Storing A Truck That Is Operational 47
When Storing A Truck That Is Not Operational 48
When Storing A Major Component 48
Periodic Inspections 49
Placing Equipment Into Service After Storage 49
When A Truck Is Operational 49
When A Truck Is Not Operational 49
For The First Hour 50
PRESERVATION AND STORAGE ALLISON TRANSMISSION 51
Storage, New Transmission 51
Storage, One Year — Without Oil 51
Storage, One Year With Oil (normally in a vehicle chassis) 51
Restoring Transmission to Service 51
STRUCTURES 53
DUMP BODY 59
Removal 59
Installation 60
BODY PADS 60
Adjustment 61
BODY GUIDE 61
BODY LOCK PIN 61
BODY POSITION INDICATOR 61
ROCK EJECTORS 62
Inspection 62
ENGINE, FUEL, COOLING AND AIR COOLER 63
AIR FILTRATION SYSTEM 87
AIR CLEANER 87
Operation 87
General Service Information 87
MAIN FILTER ELEMENT 87
Removal 87
Installation 88
SAFETY FILTER ELEMENT 89
Removal 89
Installation 89
AIR INTAKE TROUBLESHOOTING 89
AIR CLEANER ASSEMBLY CLEANING 89
Main Filter Cleaning 89
Precleaner Section Cleaning 90
ELECTRICAL SYSTEM (24VDC NON-PROPULSION) 93
24 VDC ELECTRIC SUPPLY SYSTEM 95
ELECTRICAL SYSTEM DESCRIPTION 95
BATTERY 95
Maintenance and Service 95
Troubleshooting 95
BATTERY CHARGING SYSTEM (Used with DDC and Cummins Engines) 96
General Description 96
Operating Principles 97
Energizing Speed 98
Rated Voltage 98
Magnetizing The Rotor 98
INTEGRAL CHARGING SYSTEM (Battery Charging Alternator) 99
Troubleshooting Procedures 99
Integral Charging System Repair 99
Regulator Check100
Rectifier Bridge Check (Omit for Overcharged Battery)100
Field Coil Checks100
Diode Trio Check101
Stator Checks (Omit for Overcharged Battery)101
Disassembly (Refer to Figure 2-10)101
Reassembly102
DDEC II ELECTRONIC ENGINE CONTROL111
GENERAL DESCRIPTION111
COMPONENT DESCRIPTION112
Electronic Control Module112
Electronic Unit Injectors112
System Sensors and Operator inputs113
ENGINE PROTECTION SYSTEM114
DIAGNOSTICS114
BATTERY EQUALIZER116
Troubleshooting116
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE195
STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE199
GENERAL INFORMATION199
COMMUNICATIONS PORT CHECK200
PTU Hookup200
40 SEQUENCE TESTS – (ENGINE NOT ON)201
Preparation and Setup201
CONTROL SYSTEM SELF-TEST202
41 THROTTLE SYSTEM CHECK AND ADJUSTMENT202
42 RETARD SYSTEM CHECK AND ADJUSTMENT203
PTU Setup203
43 REVERSER AND PROPULSION CONTACTORS CHECK204
44 NOT USED205
45 RETARD CONTACTORS OPERATION CHECK205
46 GROUND FAULT SENSING CHECK205
47 GROUND FAULT IN RETARD OPERATION CHECK206
48 OVERRIDE OPERATION CHECK206
49 ANTI-REVERSAL FUNCTION (AR) CHECK207
410 OVERSPEED RETARD OPERATION CHECK207
411 HOIST INTERLOCK OPERATION CHECK208
412 MOTOR BLOWER FAULT LIGHT OPERATION CHECK208
Return to Main Menu208
50 DIGITAL INPUT/OUTPUT SIGNALS TEST – FL275 CARD PANEL209
51 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU209
52 DIGITAL INPUT CHECKS210
53 DIGITAL OUTPUT CHECKS211
60 ANALOG INPUT SIGNALS TEST – FL275 CARD PANEL215
61 SETUP ANALOG INPUT MONITOR SCREEN ON PTU215
62 ANALOG INPUT CHECKS216
63 FREQUENCY INPUT CHECKS220
Return to Main Menu221
70 SPEED EVENT CHECKS221
Preparation and Setup221
Setup PTU221
71 SINGLE SPEED OVERSPEED TRUCK – OVERSPEED SETTINGS CHECK222
72 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) – OVERSPEED SETTINGS CHECK222
73 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) – OVERSPEED SETTINGS CHECK222
74 OTHER SPEED EVENTS CHECKS222
Return to Main Menu222
80 RETARD SPEED CONTROL SYSTEM CHECK223
Preparation and Setup223
Setup PTU223
81 OVERSPEED PICKUP AND DROPOUT CHECK223
82 RETARD POT MAXIMUM SETTING CHECK223
83 RETARD POT MINIMUM SETTING CHECK223
84 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL224
Return to Main Menu224
90 LOAD TEST USING TRUCK RETARD GRIDS224
Setup and Preparation224
PTU Setup224
91 LOAD TEST225
100 MOTOR FIELD CURRENT CHECK IN RETARDING225
Setup PTU225
101 RETARD CHECK226
110 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT227
111 BRAKE SYSTEM INTERLOCKS CHECK227
Preparation227
112 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT227
113 SYNC TRANSFORMER CHECKOUT228
114 POWER CONTACTOR POSITION SENSOR ADJUSTMENT228
115 BATTERY BOOST ADJUSTMENT228
116 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST228
117 MOTOR ROTATION TEST229
118 GROUND FAULT CHECKS229
120 MISCELLANEOUS CHARTS230
121 WHEEL MOTOR GEAR RATIOS230
122 MAXIMUM ALLOWABLE TRUCK SPEEDS231
123 ENGINE OPTIONS232
DRIVE AXLE, SPINDLE AND WHEELS235
TIRES AND RIMS237
FRONT TIRES AND RIMS237
Removal237
Installation238
REAR TIRES AND RIMS239
Removal239
Installation240
RIM241
Tire Removal241
RIM AND TIRE PREPARATION241
LUBRICANTS242
TIRE INSTALLATION242
REAR AXLE HOUSING263
REAR AXLE HOUSING263
Removal263
Installation263
WHEEL MOTOR263
Removal263
Cleaning and Inspection264
Installation264
Maximum Cap Screw Usage264
HYDRAIR II SUSPENSIONS265
OILING AND CHARGING PROCEDURE279
GENERAL279
EQUIPMENT LIST279
HYDRAIR® CHARGING KIT279
Installation of Charging Kit279
Removal of Charging Kit280
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS280
FRONT SUSPENSION281
Front Suspension Oiling281
Front Suspension Nitrogen Charging282
REAR SUSPENSION283
Rear Suspension Oiling283
Rear Suspension Nitrogen Charging284
OIL AND NITROGEN SPECIFICATIONS CHART286
BRAKE CIRCUIT287
CARLISLE WHEEL SPEED DISC BRAKES327
BRAKE CALIPERS327
Lining Replacement327
Brake Caliper Removal328
Brake Caliper Installation329
Brake Caliper Disassembly329
Inspection329
Brake Caliper Assembly330
BRAKE CALIPER BENCH TEST331
BRAKE BLEEDING PROCEDURE331
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE332
Front Brake Conditioning332
Temporary Disconnect Procedures For Rear Brakes332
Temporary Disconnect Procedures for Disabling Rear Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks333
Temporary Disconnect Procedures for Disabling Rear Brakes For Model 830E HAULPAK® Trucks333
SPECIAL TOOLS334
ROCKWELL WHEEL SPEED FRONT DISC BRAKES335
BRAKE CALIPER335
Removal335
Installation336
Piston Removal337
Installation337
Caliper Cleaning and Inspection337
BRAKE LINING339
Replacement339
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE340
Front Brake Conditioning340
Temporary Disconnect Procedures For Rear Brakes340
BRAKE BLEEDING PROCEDURES342
CARLISLE ARMATURE SPEED REAR DISC BRAKES343
BRAKE CALIPERS343
Lining Replacement343
Caliper Removal344
Inspection346
Installation347
Disassembly of Brake Calipers348
Inspection350
Caliper Assembly350
BRAKE CALIPER BENCH TEST351
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE352
BRAKE PAD CONDITIONING (BURNISHING) PROCEDURE352
General352
Carlisle Armature Speed Disc Brakes Conditioning (Burnishing) Rear Brakes352
BLEEDING PROCEDURE353
TEMPORARY DISCONNECT PROCEDURES FOR DISABLING FRONT BRAKES353
Temporary Disconnect Procedures for Disabling Front Brakes For Models 445E, 510E, 630E, and 685E HAULPAK® Trucks354
Temporary Disconnect Procedures for Disabling Front Brakes For Model 830E HAULPAK® Trucks354
ROCKWELL ARMATURE SPEED REAR DISC BRAKES355
REAR BRAKES355
CALIPER, DISC, AND PARKING BRAKE355
Caliper, Disc, And Parking Brake Removal355
Caliper, Disc, And Parking Brake Installation356
CALIPER, DISC, AND PARKING BRAKE REMOVAL358
Caliper, Disc, And Parking Brake Installation359
CALIPER PISTON ASSEMBLY360
Piston Assembly Removal360
Piston Assembly Inspection360
Piston Assembly Installation360
FUNCTIONAL TEST OF PISTON ASSEMBLY361
Return Spring Force361
Built-In Clearance361
Grip Force362
Grip Force Measurement363
Spring Force Measurement364
Disassembly of Piston Assembly365
Assembly of Piston Assembly366
BENCH TEST366
BRAKE LINING367
Replacement367
Brake Pad Conditioning (Burnishing) Procedure369
General369
Conditioning (Burnishing) Rear Brakes369
BLEEDING PROCEDURE370
Temporary Disconnect Procedures for Disabling Front Brakes370
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks371
TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks371
ROCKWELL DISC PARKING BRAKE373
CALIPER STYLE IDENTIFICATION373
PARK BRAKE CALIPER374
Park Brake Caliper Removal374
Park Brake Caliper Installation374
Parking Brake Adjustment (SCL70)374
Parking Brake Adjustment (SCL15)376
Park Brake Caliper Disassembly377
Cleaning and Inspection378
Park Brake Caliper Assembly379
PARK BRAKE LINING REPLACEMENT379
PARK BRAKE BURNISH PROCEDURE379
Lining Conditioning379
BRAKE BLEEDING PROCEDURE379
CARLISLE DISC PARKING BRAKE381
PARKING BRAKE OPERATION381
TRUCKS WITH ROCKWELL SERVICE BRAKES381
Caliper Removal381
Caliper Installation382
TRUCKS WITH CARLISLE SERVICE BRAKES383
Caliper Removal383
Caliper Installation383
Lining Replacement384
Caliper Disassembly384
Inspection384
Caliper Assembly385
BRAKE CALIPER BENCH TEST386
PARKING BRAKE BLEEDING386
CONDITIONING PROCEDURE FOR DISC PARKING BRAKE386
500 HOUR SERVICE GUIDE FOR DISC PARKING BRAKE387
AIR SYSTEM389
AIR SYSTEM OPERATION391
HYDRAUILIC SYSTEM407
HYDRAULIC CHECK-OUT PROCEDURE509
STEERING AND BRAKE PUMP509
Pressure Check And Adjustment Procedure509
BLEEDDOWN MANIFOLD510
SHOCK & SUCTION VALVES511
Shock & Suction Valve Settings511
LEAKAGE TESTS511
Steering Control Unit & Flow Amplifier512
Bleed Down Manifold513
TROUBLESHOOTING CHART514
CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE522
HYDRAULIC SYSTEM FLUSHING PROCEDURE525
OPTIONS AND SPECIAL TOOLS527
FIRE CONTROL SYSTEM (MANUAL)531
Operation531
Inspection and Maintenance531
Recharging Procedures532
ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM533
SYSTEM ADJUSTMENT533
PUMP533
Removal533
Disassembly533
Inspection535
Assembly535
Installation536
BLOWER DRIVE MOTOR536
Removal537
Disassembly537
Inspection Of Parts538
Assembly538
Installation539
BLOWER BEARING REPAIR539
Removal539
Replacement539
Assembly540
AIR CLEANER540
Assembly540
Removal540
Washing Air Cleaner540
Assembly540
WIGGINS QUICK FILL FUEL SYSTEM541
FUEL RECEIVER541
TANK BREATHER VALVE542
Removal542
Installation542
Disassembly542
Assembly542
LEFT SIDE FILL543
BUCKEYE QUICK FUEL SYSTEM545
FUEL TANK BREATHER VALVE545
Maintenance545
Filter Service545
Disassembly545
Inspection545
Assembly545
FUEL RECEIVER546
INSPECTION OF PARTS547
REBUILD TOOLS552
FAN CLUTCH DISASSEMBLY INSTRUCTIONS553
REASSEMBLY OF THE FAN CLUTCH560
FAN DRIVE CLUTCH571
GENERAL DESCRIPTION571
COMPONENTS571
Input571
Output572
Stationary Components572
OPERATION MODES572
Fully Engaged572
Modulated Variable Speed573
Fully Released573
Remember:573
Lubricating & Cooling Oil573
MAINTENANCE574
Maintenance Checks To Be Made574
TROUBLE SHOOTING576
Basic Preliminary Checks576
FIELD CHECK DIAGNOSIS577
Preliminary Checks With Engine Off577
Check Clutch Release577
Check Clutch Lock-up577
Overheating Complaint578
Thermal Sensor And Solenoid Valve578
On Truck Test578
Off Truck Test579
Test Conditions and Requirements:579
TEST:579
TROUBLESHOOTING CHART581
PROBABLE CAUSES581
SUGGESTED CORRECTIVE ACTIONS581
PROBABLE CAUSES582
SUGGESTED CORRECTIVE ACTIONS582
PROBABLE CAUSES583
SUGGESTED CORRECTIVE ACTIONS583
ENGINE COOLANT HEATER585
Maintenance585
HEATING ELEMENT585
Removal585
Installation585
THERMOSTAT586
Removal586
Installation586
SPECIAL TOOLS589
AIR CONDITIONING SYSTEM595
Environmental Impact595
OPERATOR CAB AIR CONDITIONING596
PRINCIPLES OF REFRIGERATION596
Air Conditioning596
Refrigeration – The Act Of Cooling597
The Refrigeration Cycle597
AIR CONDITIONER SYSTEM COMPONENTS598
Compressor (Refrigerant Pump)598
Service Valves598
Condenser598
Expansion Block Valve599
Evaporator599
ELECTRICAL CIRCUIT600
Thermostat600
Compressor Clutch600
Trinary™ Switch601
SYSTEM SERVICING602
SYSTEM OIL603
Handling and Reusing PAG Oil603
Oil Quantity603
Replacing Oil After Servicing the System603
Setting Up a New Compressor603
REFRIGERANT604
Recycled Refrigerant604
Reclaimed Refrigerant604
Refrigerant Quantity604
R-134a Refrigerant Containers604
SERVICE TOOLS AND EQUIPMENT605
Recovery/Recycle Station605
Leak Detector605
Service Valves606
Vacuum Pump606
Manifold Gauge Set607
Installing Manifold Gauge Set608
Purging Air From Service Hoses609
Stabilizing the AC System610
SYSTEM PERFORMANCE TEST610
SYSTEM LEAK TESTING611
Electronic leak detector611
Tracer dyes611
Soap and water611
SYSTEM REPAIR612
System Cleaning612
Hoses and Fittings612
Lines612
Expansion Valve612
Receiver-Drier613
Thermostat613
Compressor613
Clutch613
Servicing the Compressor Clutch614
Pulley Removal616
Clutch Coil Check616
Pulley Installation616
Clutch Assembly Installation617
RECOVERING AND RECYCLING THE REFRIGERANT618
Performing the Recovery Cycle618
Performing the Recycling Procedure618
Evacuating and Charging the AC System618
EVACUATING THE SYSTEM619
CHARGING THE AC SYSTEM620
TROUBLESHOOTING621
Pre-Diagnosis Checks621
Preparing For Diagnosis621
Preliminary Steps621
System Performance Test621
Diagnosis Of Gauge Readings And System Performance622
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM629
AFTERCOOLER OPERATION AND REPAIR635
OPERATION635
MAINTENANCE635
Removal635
Installation635
Disassembly636
Cleaning and Inspection637
Assembly637
AIR DRYER (AEROFINER III)639
AIR DRYER639
Service639
Indications To Change Desiccant639
Removal640
Installation640
Disassembly640
Assembly641
CHECK VALVE641
Removal641
Installation641
PURGE VALVE & HEATER642
Removal642
Inspection642
Installation642
24VDC ELECTRIC SUPPLY SYSTEM655
ELECTRICAL SYSTEM DESCRIPTION655
BATTERY655
Maintenance and Service655
Troubleshooting655
BATTERY CHARGING SYSTEM (Niehoff)657
General Description657
TROUBLESHOOTING PROCEDURES (On- Truck)657
Equipment Required:657
Preliminary Checks658
Test Setup658
Test Procedure658
Regulator Bypass Test659
ON VEHICLE TROUBLESHOOTING GUIDE661
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage661
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS:661
CHARGE VOLT AND AMP VALUES662
DEFINITIONS662
ADVANCED SYSTEM TROUBLESHOOTING663
Static Test – Engine OFF, Key ON, Battery Switch ON663
Go To Alternator663
Go To Regulator (If Required)664
Go To Regulator Connector On The Alternator664
NIEHOFF Alternator Overhaul Manual665
TABLE OF CONTENTS665
ALTERNATOR SPECIFICATIONS667
ON-VEHICLE TEST670
Equipment:670
Preliminary Checks:670
Test Set-up670
Test Procedure670
ON-VEHICLE TEST671
Bypass Test:671
BENCH TEST672
Equipment:672
TEST 1 – NO-LOAD TEST672
TEST 2 – FULL LOAD TEST672
TEST 3 – REGULATOR BYPASS TEST672
STATIC TESTS673
EQUIPMENT:673
REGULATOR TESTS673
TEST 1 – Check For Shorted Output Transistor673
TEST 2 – Check Function Of Clamping Diode673
FIELD COIL TESTS673
TEST 3 – Check For Open Field Coil673
TEST 4 – Check For Grounded Field Coil674
CONTROL BOX TESTS674
TEST 5 – Check Continuity Of Terminal Strip Connections674
TEST 6 – Diode Heat Sink Tests674
TEST 7 – Check Positive Diodes675
TEST 8 – Check Negative Diodes675
TEST 9 – Check Front & Rear Stator675
ALTERNATOR DISASSEMBLY676
FAN REMOVAL676
PULLEY REMOVAL676
REGULATOR REMOVAL676
END HOUSING REMOVAL677
REAR ROTOR REMOVAL677
Alternate Method677
REAR BEARING REMOVAL677
FRONT HOUSING REMOVAL678
CONTROL UNIT ASSEMBLY REMOVAL679
FRONT BEARING REMOVAL680
FRONT ROTOR REMOVAL680
Alternate Method680
FIELD COIL REMOVAL680
ALTERNATOR ASSEMBLY681
FIELD COIL ASSEMBLY681
FRONT BEARING ASSEMBLY682
FRONT ROTOR ASSEMBLY683
FRONT HOUSING – STATOR, FIELD COIL & SHELL ASSEMBLY684
CONTROL UNIT ASSEMBLY REPLACEMENT685
REAR ROTOR ASSEMBLY686
END HOUSING ASSEMBLY686
REAR BEARING ASSEMBLY688
PRESS FIT REAR BEARINGS688
LOOSE FIT REAR BEARINGS688
REGULATOR ASSEMBLY688
FAN ASSEMBLY689
PULLEY ASSEMBLY689
BF4822 STATOR SERVICE TOOL INSTRUCTIONS690
Function of Service Tool690
STATOR REMOVAL AND REPLACEMENT690
Pressure Plate Set-up (Refer to Figure 13-42)690
STATOR INSTALLATION (Refer to Figure 13-41)691
PRESSURE PLATE SET UP (Refer to Figure 13- 42)692
OPTIONAL OPERATOR SEAT693
SEAT693
Removal693
Installation693
Disassembly694
Assembly696
Air Suspension Cam Adjustment697
SEAT MAINTENANCE AND REPAIR698
Headrest698
Backrest698
Armrests698
Seat Cushion698
Seat Frame698
Slides699
Suspension699
TDI SINGLE STAGE AIR STARTER701
STARTER701
Removal701
Installation701
Disassembly701
Cleaning705
Parts Inspection705
PARTS INSPECTION (Refer to Figure 15-2 for reference to parts)706
Assembly708
AUTOMATIC TRIP VALVE712
Disassembly712
Reassembly712
Operation Check713
TDI TWO-STAGE AIR STARTER715
AIR STARTER715
Removal715
Installation715
Description of Basic Groups715
Disassembly718
Cleaning and Inspection720
Assembly722
TDI TWO-STAGE AIR STARTER TROUBLESHOOTING GUIDE728
INGERSOLL-RAND TURBINE POWERED STARTER731
MAINTENANCE731
Removal731
Installation731
Disassembly Tips731
Disassembly – Housing Exhaust Cover, Motor Assembly, and Motor Housing734
Disassembly – Drive Housing736
Assembly Tips738
Lubrication738
Assembly – Gear Case and Drive Housing739
Assembly – Intermediate Gear Case, Motor Housing, Motor Assembly, and Housing Exhaust Cover740
TEST AND INSPECTION PROCEDURE745
TROUBLESHOOTING CHART746
24 VDC ELECTRIC START SYSTEM759
OPERATION759
CRANKING MOTOR759
Removal759
Installation759
CRANKING MOTOR TROUBLESHOOTING760
Preliminary Inspection760
No-Load Test760
Interpreting Results of Tests760
Disassembly761
Cleaning and Inspection761
Armature Servicing761
Field Coil Checks762
Field Coil Removal762
Solenoid Checks764
Test764
Assembly765
Pinion Clearance765
Magnetic Switch766
Removal766
Installation766
Coil Test766
ELECTRIC START SYSTEM WIRING DIAGRAMS767
HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)769
GENERAL INFORMATION769
TIPS FOR OPERATION769
DECK MOUNTED LIGHTS770
OPERATION AND FUNCTIONS770
DISPLAY LOGIC770
METRIC/SHORT TON SELECTION770
DATA STORAGE LOGIC770
DATA PRINT OUT771
CLEAR MEMORY771
SETTING THE TIME OF DAY771
CALIBRATING THE PAYLOAD METER772
To perform calibration:772
DIMMING THE PAYLOAD METER DISPLAY772
ERROR CODES772
SERVICING THE PAYLOAD METER772
Payload Meter Removal772
Payload Meter Installation772
REPLACING PRINTER PAPER772
Replacing Paper773
Troubleshooting Paper Printer773
REPLACEMENT OF PRINTER MODULE773
Printer Module Removal773
Printer Module Installation775
BATTERY (P/N EC2453)775
Removal775
Installation775
PRESSURE SENSOR775
To Perform A Sensor Check:776
Removal776
Installation776
INCLINOMETER776
Removal776
Installation776
RELAYS AND DATA STORAGE TRIGGER MODULE (DSTM)777
CHECK OUT PROCEDURE778
Deck Mounted Lights778
Pressure Sensor Location778
Error Codes778
Data storage trigger module779
Inclinometer779
Body Up Switch779
TROUBLESHOOTING THE HAULPAK® ON-BOARD WEIGHING SYSTEM (OBWS)781
ERROR CODES781
ON-BOARD WEIGHING SYSTEM EXPANDED MEMORY BOX785
DOWNLOAD785
ANALYSIS785
Tips For Operation785
GETTING STARTED786
Installing The Software786
INITIAL START UP OF THE EXPANDED MEMORY BOX786
COMMON PROCEDURES787
DOWNLOAD PROGRAM788
Payload Box788
SPECIAL791
ANALYSIS PROGRAM795
PRINTER CHART798
HELP MENU799
PAYLOAD DATA800
SERVICE802
Removal802
Installation802
Disassembly802
Battery Replacement803
Assembly803
Wire Connections803
TROUBLESHOOTING EXPANDED MEMORY BOX804
MOTORIZED WHEEL MAINTENANCE SCHEDULE867
AXLE BOX867
MOTORIZED WHEEL MAINTENANCE SCHEDULE868
ARMATURE AREA868
AT TIRE CHANGE – FOR ALL MOTORIZED WHEELS868
MOTORIZED WHEEL MAINTENANCE SCHEDULE869
GENERATOR / ALTERNATOR869
GRID BLOWER MOTOR869
CONTROL EQUIPMENT CHECKS869
MOTORIZED WHEEL MAINTENANCE SCHEDULE870
AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM870
VEHICLE OPERATIONS TESTS870
OPERATOR’S CAB807
TRUCK CAB809
LUBRICATION AND SERVICE841
LUBRICATION AND SERVICE843
INDEX871
SYSTEM SCHEMATICS875

DESCRIPTION:

Komatsu 830E Dump Truck Shop Manual DG681 – PDF DOWNLOAD

SERIAL SUFFIX
AFE32-AS – AFE32-DH
AFE32-DN – AFE32-DR

FORWARD:

• This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck.
• All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example:
• The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of 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 designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating. The HAULPAK® Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model.
• The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload. To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck.
• Record this value and subtract from the GVW rating. The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc. become a part of the GVW and reduces allowable payload. To maximize payload and to keep from exceeding the GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce expected life of truck components.

G.B 13/12/24