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Komatsu 830E Dump Truck Shop Manual SN A30607-A30624 – PDF DOWNLOAD
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Komatsu 830E Dump Truck Shop Manual
SERIAL NUMBERS A30607 – A30624
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Description
Komatsu 830E Dump Truck Shop Manual
FILE DETAILS:
Komatsu 830E Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 830E
Serial Number: A30607-A30624
Book Code: DG753
Language: English
Pages: 782
File Format: Portable Document Format (PDF)
TABLE OF CONTENTS:
Komatsu 830E Dump Truck Shop Manual
COVER............................................................................................................. 1 FOREWORD.......................................................................................................... 3 TABLE OF CONTENTS................................................................................................. 5 SECTION A - GENERAL INFORMATION................................................................................... 7 GENERAL INFORMATION INDEX..................................................................................... 7 STANDARD TORQUE CHARTS AND CONVERSION TABLES.............................................................. 41 STORAGE AND IDLE MACHINE PREPARATION...................................................................... 47 SHORT TERM IDLE PERIODS............................................................................... 47 PREPARATION FOR STORAGE................................................................................... 48 REMOVAL FROM STORAGE.................................................................................. 49 RECONDITIONING AN IDLE VEHICLE........................................................................ 51 ENGINE OPERATION...................................................................................... 54 AFTER ENGINE HAS STARTED.............................................................................. 55 ENGINE STORAGE-CUMMINS................................................................................ 56 Engine Storage-(Short Term)....................................................................... 56 Prepare the Engine for Short Term Storage......................................................... 56 Remove the Engine from Short Term Storage......................................................... 56 Engine Storage- (Long Term)....................................................................... 57 6 Months to 24 Months............................................................................. 57 Prepare the Engine for Long Term Storage.......................................................... 57 Remove the Engine from Long Term Storage.......................................................... 57 ENGINE STORAGE - DETROIT DIESEL....................................................................... 58 Preparing Engine For Storage...................................................................... 58 Temporary Storage (30 Days Or Less)............................................................... 58 Extended Storage (more Than 30 Days).............................................................. 58 PROCEDURE FOR RESTORING AN ENGINE TO SERVICE WHICH HAS BEEN IN EXTENDED STORAGE....................... 60 ELECTRIC DRIVE TRUCKS................................................................................. 61 Storage Instructions and Procedures............................................................... 61 Placing Equipment Into Storage.................................................................... 61 When Storing A Truck That Is Operational.......................................................... 61 When Storing A Truck That Is Not Operational...................................................... 62 When Storing A Major Component.................................................................... 62 Periodic Inspections.............................................................................. 63 Placing Equipment Into Service After Storage...................................................... 63 When A Truck Is Operational....................................................................... 63 When A Truck Is Not Operational................................................................... 63 For The First Hour................................................................................ 64 PRESERVATION AND STORAGE ALLISON TRANSMISSION......................................................... 65 Storage, New Transmission......................................................................... 65 Storage, One Year -- Without Oil.................................................................. 65 Storage, One Year With Oil (normally in a vehicle chassis)........................................ 65 Restoring Transmission to Service................................................................. 65 STRUCTURAL COMPONENTS..................................................................................... 69 LADDERS............................................................................................... 69 Removal........................................................................................... 69 Installation...................................................................................... 69 RIGHT HAND DECK....................................................................................... 70 Removal........................................................................................... 70 Installation...................................................................................... 70 CENTER AND LEFT HAND DECK COMPONENTS.................................................................. 71 FUEL TANK............................................................................................. 72 Removal........................................................................................... 72 Installation...................................................................................... 72 SECTION B - STRUCTURES............................................................................................ 67 STRUCTURES INDEX.............................................................................................. 67 STRUCTURAL COMPONENTS..................................................................................... 67 DUMP BODY................................................................................................. 73 SECTION C - ENGINE................................................................................................ 79 ENGINE INDEX.................................................................................................. 79 ENGINE, FUEL, COOLING AND AIR CLEANER INDEX................................................................... 93 POWER TRAIN............................................................................................... 95 ALTERNATOR REMOVAL PROCEDURE.......................................................................... 95 Removal (MTU/DDC 4000 Engine)..................................................................... 95 ENGINE/ALTERNATOR MATING.............................................................................. 97 General Instructions.............................................................................. 97 MEASURING PROCEDURE................................................................................... 97 Joining Alternator and MTU/DDC Engine............................................................. 99 ENGINE................................................................................................100 Removal...........................................................................................100 Service...........................................................................................100 Installation......................................................................................100 AIR FILTRATION SYSTEM.....................................................................................101 AIR CLEANER...........................................................................................101 Operation.........................................................................................101 General Service Information.......................................................................101 MAIN FILTER ELEMENT...................................................................................101 Removal...........................................................................................101 Installation......................................................................................102 SAFETY FILTER ELEMENT.................................................................................103 Removal...........................................................................................103 Installation......................................................................................103 AIR INTAKE TROUBLESHOOTING............................................................................103 AIR CLEANER ASSEMBLY CLEANING.........................................................................103 Main Filter Cleaning..............................................................................103 Precleaner Section Cleaning.......................................................................104 SECTION D - ELECTRIC SYSTEM.......................................................................................119 ELECTRIC SYSTEM (24 VDV NON-PROPULSION) INDEX.................................................................131 DDEC ELECTRONIC ENGINE CONTROL For MTU/DDC 4000 SERIES ENGINE.............................................133 COMPONENT DESCRIPTION.................................................................................134 Electronic Control Module.........................................................................134 Electronic Unit Nozzles...........................................................................136 System Sensors and Operator Inputs................................................................136 ENGINE PROTECTION SYSTEM..............................................................................137 DIAGNOSTICS...........................................................................................138 SECTION E - ELECTRICAL PROPULSION.................................................................................139 ELECTRIC PROPULSION AND CONTROL INDEX.........................................................................141 ELECTRICAL PROPULSION COMPONENTS..........................................................................145 GENERAL SYSTEM DESCRIPTION............................................................................145 CONTROL SYSTEM........................................................................................145 System Operation..................................................................................146 FL275 Panel.......................................................................................147 CARD REPLACEMENT......................................................................................148 Removal...........................................................................................148 Installation......................................................................................148 Card Repair.......................................................................................148 Panel Wiring......................................................................................148 COMPUTER DESCRIPTION..................................................................................149 Microprocessor....................................................................................149 Download Capability...............................................................................149 SOFTWARE..............................................................................................149 Base Monitor Program..............................................................................149 Runtime Monitor Program - OBJ Running Code........................................................149 Configuration Software - CFG......................................................................150 PTU - Portable Test Unit Code.....................................................................150 System Regulation.................................................................................150 Propulsion........................................................................................151 Retarding.........................................................................................151 TWO-DIGIT DISPLAY PANEL...............................................................................152 The Coded Number..................................................................................152 Events............................................................................................152 Frames............................................................................................153 Windows...........................................................................................153 System Categories.................................................................................153 Limits On Resetting Faults........................................................................153 NA Faults.........................................................................................154 Event Sequence....................................................................................154 Resetting Events..................................................................................154 Event Descriptions................................................................................154 Subcode Descriptions..............................................................................154 2-DIGIT DISPLAY PANEL SUBCODES........................................................................162 PORTABLE TEST UNIT (PTU)..................................................................................165 DESCRIPTION...........................................................................................165 Operational Hints.................................................................................165 SOFTWARE INSTALLATION PREPARATION.....................................................................166 HARD DISK SPACE REQUIREMENTS..........................................................................166 SOFTWARE INSTALLATION ON PTU..........................................................................166 PTU/Truck Communication Problems..................................................................167 THE MAIN MENU.........................................................................................168 Quit Menu.........................................................................................168 PTU Talk To Truck.................................................................................168 View PTU Saved Files..............................................................................168 List Stat Data Files..............................................................................168 Truck Setup (CFG).................................................................................168 Select Truck Setup................................................................................168 Update CFG Version................................................................................168 Change PTU Password...............................................................................168 CONFIGURATION (CFG) FILE CONVERSION...................................................................170 Conversion Procedure..............................................................................170 Convert Old CFG files for New software............................................................171 STATEX CONFIGURATION FILES............................................................................174 0) Source Directory: . . .........................................................................174 1) Select A Truck Configuration . . ..............................................................175 2) View Truck Configuration: Data Curves . . .....................................................176 3) Change/View Serial and Model Numbers . . ......................................................177 4) View Options . . ..............................................................................177 5) Change/View Truck Specifics . . ...............................................................179 6) Change/View Overspeeds . . ....................................................................181 7) Save a Truck Configuration, filename: . . .....................................................182 8) Save Directory: . . ...........................................................................183 CHANGE PTU PASSWORD...................................................................................184 PROGRAMMING THE TRUCK.................................................................................185 Connect PTU to the Truck..........................................................................185 Select Configuration File.........................................................................185 Activate The PTU Mode.............................................................................185 Check Object Code Version.........................................................................186 Download Configuration Files......................................................................187 Date And Time.....................................................................................188 Event Data........................................................................................189 Statistical Data..................................................................................191 View Counters.....................................................................................191 View Profiles.....................................................................................191 Upload Statistical Data To A File.................................................................191 Statistical Data Codes - Counters.................................................................192 STATISTICAL DATA CODES - COUNTERS.....................................................................193 STATISTICAL DATA CODES - PROFILES.....................................................................198 TRUCK SPECIFIC INFORMATION............................................................................202 Temporary Truck Settings..........................................................................203 MISCELLANEOUS FEATURES................................................................................204 Saving Data.......................................................................................204 PTU Abbreviations.................................................................................205 Other Menu Selections.............................................................................205 MISCELLANEOUS ELECTRICAL PROPULSION COMPONENTS............................................................206 ALTERNATOR............................................................................................206 ELECTRIC WHEEL MOTORS.................................................................................206 RETARDING GRIDS.......................................................................................206 ELECTRONIC ACCELERATOR AND RETARD PEDALS..............................................................206 Removal...........................................................................................206 Installation......................................................................................206 Disassembly.......................................................................................207 Reassembly........................................................................................207 COOLING BLOWER WARNING SYSTEM.........................................................................207 Operation.........................................................................................207 Test..............................................................................................207 Removal...........................................................................................208 Installation......................................................................................208 ELECTRICAL CONTROL CABINET................................................................................209 ABBREVIATIONS FOR STATEX III ELECTRIC DRIVE COMPONENTS....................................................214 CARD IDENTIFICATION LIST 17FL275 PANEL, STATEX III........................................................215 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE...........................................................217 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE.......................................................221 GENERAL INFORMATION...................................................................................221 COMMUNICATIONS PORT CHECK.............................................................................222 PTU Hookup........................................................................................222 4.0 SEQUENCE TESTS - (ENGINE NOT ON)..................................................................223 Preparation and Setup.............................................................................223 CONTROL SYSTEM SELF-TEST..............................................................................224 4.1 THROTTLE SYSTEM CHECK AND ADJUSTMENT..........................................................224 4.2 RETARD SYSTEM CHECK AND ADJUSTMENT............................................................225 PTU Setup.....................................................................................225 4.3 REVERSER AND PROPULSION CONTACTORS CHECK..................................................226 4.4 NOT USED......................................................................................227 4.5 RETARD CONTACTORS OPERATION CHECK.............................................................227 4.6 GROUND FAULT SENSING CHECK....................................................................227 4.7 GROUND FAULT IN RETARD OPERATION CHECK........................................................228 4.8 OVERRIDE OPERATION CHECK......................................................................228 4.9 ANTI-REVERSAL FUNCTION (AR) CHECK.............................................................229 4.10 OVERSPEED RETARD OPERATION CHECK.............................................................229 4.11 HOIST INTERLOCK OPERATION CHECK..............................................................230 4.12 MOTOR BLOWER FAULT LIGHT OPERATION CHECK.....................................................230 Return to Main Menu...........................................................................230 5.0 DIGITAL INPUT/OUTPUT SIGNALS TEST - FL275 CARD PANEL..........................................231 5.1 SETUP MANUAL DIGITAL INPUT/OUTPUT TEST ON PTU.................................................231 5.2 DIGITAL INPUT CHECKS..........................................................................232 5.3 DIGITAL OUTPUT CHECKS.........................................................................233 6.0 ANALOG INPUT SIGNALS TEST - FL275 CARD PANEL..................................................237 6.1 SETUP ANALOG INPUT MONITOR SCREEN ON PTU......................................................237 6.2 ANALOG INPUT CHECKS...........................................................................238 6.3 FREQUENCY INPUT CHECKS........................................................................242 Return to Main Menu...........................................................................243 7.0 SPEED EVENT CHECKS............................................................................243 Preparation and Setup.........................................................................243 Setup PTU.....................................................................................243 7.1 SINGLE SPEED OVERSPEED TRUCK - OVERSPEED SETTINGS CHECK.......................................244 7.2 TWO SPEED OVERSPEED TRUCK (EMPTY TRUCK) - OVERSPEED SETTINGS CHECK............................244 7.3 TWO SPEED OVERSPEED TRUCK (LOADED TRUCK) - OVERSPEED SETTINGS CHECK...........................244 7.4 OTHER SPEED EVENTS CHECKS.....................................................................244 Return to Main Menu...........................................................................244 8.0 RETARD SPEED CONTROL SYSTEM CHECK.............................................................245 Preparation and Setup.........................................................................245 Setup PTU.....................................................................................245 8.1 OVERSPEED PICKUP AND DROPOUT CHECK............................................................245 8.2 RETARD POT MAXIMUM SETTING CHECK..............................................................245 8.3 RETARD POT MINIMUM SETTING CHECK..............................................................245 8.4 ACCELERATOR PEDAL OVERRIDE OF RETARD SPEED CONTROL............................................246 Return to Main Menu...........................................................................246 9.0 LOAD TEST USING TRUCK RETARD GRIDS............................................................246 Setup and Preparation.........................................................................246 PTU Setup.....................................................................................246 9.1 LOAD TEST.....................................................................................247 10.0 MOTOR FIELD CURRENT CHECK IN RETARDING.......................................................247 Setup PTU.....................................................................................247 10.1 RETARD CHECK.................................................................................248 11.0 MISCELLANEOUS COMPONENT TEST AND ADJUSTMENT..................................................249 11.1 BRAKE SYSTEM INTERLOCKS CHECK................................................................249 Preparation...................................................................................249 11.2 BLOWER LOSS PRESSURE SWITCH ADJUSTMENT.......................................................249 11.3 SYNC TRANSFORMER CHECKOUT....................................................................250 11.4 POWER CONTACTOR POSITION SENSOR ADJUSTMENT...................................................250 11.5 BATTERY BOOST ADJUSTMENT.....................................................................250 11.6 ISOLATION AMPLIFIER AND VOLTAGE MODULE TEST..................................................250 11.7 MOTOR ROTATION TEST..........................................................................251 11.8 GROUND FAULT CHECKS..........................................................................251 12.0 MISCELLANEOUS CHARTS.........................................................................252 12.1 WHEEL MOTOR GEAR RATIOS......................................................................252 12.2 MAXIMUM ALLOWABLE TRUCK SPEEDS...............................................................253 12.3 ENGINE OPTIONS...............................................................................254 STATEX III ELECTRICAL SYSTEM CHECKOUT PROCEDURE TABLE OF CONTENTS.........................................255 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS.......................................................................257 DRIVE AXLE, SPINDLES AND WHEELS INDEX.........................................................................257 TIRES AND RIMS............................................................................................259 FRONT TIRES AND RIMS..................................................................................259 Removal...........................................................................................259 Installation......................................................................................260 REAR TIRES AND RIMS...................................................................................261 Removal...........................................................................................261 Installation......................................................................................262 RIM...................................................................................................263 Tire Removal......................................................................................263 RIM AND TIRE PREPARATION..............................................................................263 LUBRICANTS............................................................................................264 TIRE INSTALLATION.....................................................................................264 FRONT WHEEL HUB AND SPINDLE...............................................................................267 WHEEL HUB AND SPINDLE ASSEMBLY........................................................................267 Removal...........................................................................................267 Spindle Pusher Tool Usage.........................................................................268 Installation......................................................................................269 Disassembly.......................................................................................271 Cleaning and Inspection...........................................................................271 Assembly..........................................................................................272 Wheel Bearing Adjustment (Tire Removed)...........................................................274 Wheel Bearing Adjustment (Tire mounted)...........................................................274 STEERING CYLINDERS AND TIE ROD........................................................................276 Spherical Bearing Wear Limits.....................................................................276 Removal...........................................................................................277 Installation......................................................................................277 Bearing Replacement...............................................................................277 TOE-IN ADJUSTMENT.....................................................................................279 REAR AXLE HOUSING ATTACHMENT..............................................................................281 PIVOT PIN.............................................................................................281 Removal...........................................................................................281 Installation......................................................................................281 PIVOT EYE BEARING.....................................................................................282 Disassembly.......................................................................................282 Assembly..........................................................................................282 PIVOT EYE REPAIR......................................................................................283 Removal...........................................................................................283 Disassembly.......................................................................................283 Assembly..........................................................................................283 Installation......................................................................................283 ANTI-SWAY BAR.........................................................................................284 Removal...........................................................................................284 Installation......................................................................................284 Disassembly.......................................................................................284 Cleaning and Inspection...........................................................................284 Assembly..........................................................................................284 REAR AXLE HOUSING.........................................................................................285 REAR AXLE HOUSING.....................................................................................285 Removal...........................................................................................285 Installation......................................................................................285 WHEEL MOTOR...........................................................................................285 Removal...........................................................................................285 Cleaning and Inspection...........................................................................286 Installation......................................................................................286 Maximum Cap Screw Usage...........................................................................286 SECTION H - HYDRAIR II SUSPENSIONS................................................................................287 HYDRAIL II SUSPENSIONS INDEX..................................................................................287 OILING AND CHARGING PROCEDURE.............................................................................301 GENERAL...............................................................................................301 EQUIPMENT LIST........................................................................................301 HYDRAIR® CHARGING KIT.................................................................................301 Installation of Charging Kit......................................................................301 Removal of Charging Kit...........................................................................302 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.....................................................302 FRONT SUSPENSION......................................................................................303 Front Suspension Oiling...........................................................................303 Front Suspension Nitrogen Charging................................................................304 REAR SUSPENSION.......................................................................................305 Rear Suspension Oiling............................................................................305 Rear Suspension Nitrogen Charging.................................................................306 OIL AND NITROGEN SPECIFICATIONS CHART.....................................................................308 SECTION J - BRAKE CIRCUIT.........................................................................................309 BRAKE CIRCUIT INDEX...........................................................................................309 BRAKE CIRCUIT COMPONENT SERVICE...........................................................................317 BRAKE VALVE...........................................................................................317 Rebuild Criteria..................................................................................317 Removal...........................................................................................317 DISASSEMBLY...........................................................................................320 Cleaning and Inspection...........................................................................322 ASSEMBLY..............................................................................................322 Actuator Base Threaded Inserts....................................................................322 Boot and Cap......................................................................................322 Valve Body Seal Installation......................................................................323 Regulator Sleeve O-Ring Installation..............................................................323 Actuator Plunger O-ring Installation..............................................................323 Assembly of Valve.................................................................................324 DIFFERENTIAL PRESSURE SWITCH..........................................................................325 Disassembly.......................................................................................325 Cleaning and Inspection...........................................................................325 Assembly..........................................................................................325 VALVE BENCH TEST AND ADJUSTMENT.......................................................................326 Test Set Up Procedure.............................................................................327 Brake Valve Output Pressure Adjustment............................................................327 Differential Pressure Switch Test.................................................................327 Final Test and Adjustment.........................................................................328 Installation Of Brake Pedal Actuator Assembly to Brake Valve......................................329 BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)..................330 Installation of Retard Pedal To Brake Pedal.......................................................330 HYDRAULIC BRAKE ACCUMULATORS..........................................................................331 Brake Accumulator Bleed Down Procedure............................................................331 Removal...........................................................................................331 Installation......................................................................................331 Disassembly.......................................................................................331 Cleaning and Inspection...........................................................................332 Assembly..........................................................................................333 Charging Procedure................................................................................334 BRAKE MANIFOLD........................................................................................335 Removal...........................................................................................335 Removal...........................................................................................335 Installation......................................................................................336 Disassembly.......................................................................................336 Cleaning and Inspection...........................................................................336 Assembly..........................................................................................336 BRAKE CIRCUIT CHECK-OUT PROCEDURE.........................................................................337 EQUIPMENT REQUIRED....................................................................................339 INITIAL SYSTEM SET-UP.................................................................................340 PARKING BRAKE.........................................................................................340 BRAKE SYSTEM CHECK-OUT................................................................................340 Failure Modes Check-Out...........................................................................341 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING.............................................................343 KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET.............................................347 KOMATSU CHECK-OUT PROCEDURE HYDRAULICBRAKESYSTEMDATASHEET.................................................348 ROCKWELL WHEEL SPEED FRONT DISC BRAKES....................................................................349 BRAKE CALIPER.........................................................................................349 Removal...........................................................................................349 Installation......................................................................................350 Piston Removal....................................................................................351 Installation......................................................................................351 Caliper Cleaning and Inspection...................................................................351 BRAKE LINING..........................................................................................353 Replacement.......................................................................................353 SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE.....................................................354 Front Brake Conditioning..........................................................................354 Temporary Disconnect Procedures For Rear Brakes...................................................354 BRAKE BLEEDING PROCEDURES.............................................................................356 ROCKWELL ARMATURE SPEED REAR DISC BRAKES..................................................................357 REAR BRAKES...........................................................................................357 CALIPER, DISC, AND PARKING BRAKE......................................................................357 Caliper, Disc, And Parking Brake Removal..........................................................357 Caliper, Disc, And Parking Brake Installation.....................................................358 CALIPER, DISC, AND PARKING BRAKE REMOVAL..............................................................360 Caliper, Disc, And Parking Brake Installation.....................................................361 CALIPER PISTON ASSEMBLY...............................................................................362 Piston Assembly Removal...........................................................................362 Piston Assembly Inspection........................................................................362 Piston Assembly Installation......................................................................362 FUNCTIONAL TEST OF PISTON ASSEMBLY....................................................................363 Return Spring Force...............................................................................363 Built-In Clearance................................................................................363 Grip Force........................................................................................364 Grip Force Measurement............................................................................365 Spring Force Measurement..........................................................................366 Disassembly of Piston Assembly....................................................................367 Assembly of Piston Assembly.......................................................................368 BENCH TEST............................................................................................368 BRAKE LINING..........................................................................................369 Replacement.......................................................................................369 Brake Pad Conditioning (Burnishing) Procedure.....................................................371 General...........................................................................................371 Conditioning (Burnishing) Rear Brakes.............................................................371 BLEEDING PROCEDURE....................................................................................372 Temporary Disconnect Procedures for Disabling Front Brakes........................................372 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Models 630E and 685E Komatsu Trucks....373 TEMPORARY DISCONNECT PROCEDURES for Disabling Front Brakes For Model 830E Komatsu Trucks..............373 ROCKWELL DISC PARKING BRAKE...........................................................................375 CALIPER STYLE IDENTIFICATION......................................................................375 PARK BRAKE CALIPER................................................................................376 Park Brake Caliper Removal....................................................................376 Park Brake Caliper Installation...............................................................376 Parking Brake Adjustment (SCL70)..............................................................376 Parking Brake Adjustment (SCL15)..............................................................378 Park Brake Caliper Disassembly................................................................379 Cleaning and Inspection.......................................................................380 Park Brake Caliper Assembly...................................................................381 PARK BRAKE LINING REPLACEMENT.....................................................................381 PARK BRAKE BURNISH PROCEDURE......................................................................381 Lining Conditioning...........................................................................381 BRAKE BLEEDING PROCEDURE..........................................................................381 SECTION L - HYDRAULIC SYSTEM......................................................................................383 HYDRAULIC SYSTEM INDEX........................................................................................383 HYDRAULIC CHECK-OUT PROCEDURE.............................................................................483 STEERING AND BRAKE PUMP...............................................................................483 Pressure Check And Adjustment Procedure...........................................................483 BLEEDDOWN MANIFOLD....................................................................................484 SHOCK & SUCTION VALVES................................................................................485 Shock & Suction Valve Settings....................................................................485 LEAKAGE TESTS.........................................................................................485 Steering Control Unit & Flow Amplifier............................................................486 Bleed Down Manifold...............................................................................487 TROUBLESHOOTING CHART.................................................................................488 TROUBLESHOOTING CHART.................................................................................491 TROUBLESHOOTING CHART.................................................................................494 CHECKING HOIST SYSTEM RELIEF VALVE PRESSURE...........................................................496 HYDRAULIC SYSTEM FLUSHING PROCEDURE...................................................................499 SECTION M - OPTIONS AND SPECIAL TOOLS.............................................................................501 OPTIONS AND SPECIAL TOOLS INDEX...............................................................................501 FIRE CONTROL SYSTEM (MANUAL)..............................................................................503 Operation.............................................................................................503 Inspection and Maintenance............................................................................503 Recharging Procedures.................................................................................504 ALTERNATOR AND WHEELMOTOR COOLING AIR FILTER SYSTEM.......................................................505 SYSTEM ADJUSTMENT.....................................................................................505 PUMP..............................................................................................505 Removal.......................................................................................505 Disassembly...................................................................................505 Inspection....................................................................................507 Assembly......................................................................................507 Installation..................................................................................508 BLOWER DRIVE MOTOR................................................................................508 Removal.......................................................................................509 Disassembly...................................................................................509 Inspection Of Parts...........................................................................510 Assembly......................................................................................510 Installation..................................................................................511 BLOWER BEARING REPAIR.............................................................................511 Removal.......................................................................................511 Replacement...................................................................................511 Assembly......................................................................................512 AIR CLEANER.......................................................................................512 Assembly......................................................................................512 Removal.......................................................................................512 Washing Air Cleaner...........................................................................512 Assembly......................................................................................512 WIGGINS QUICK FILL FUEL SYSTEM............................................................................513 FUEL RECEIVER.........................................................................................513 TANK BREATHER VALVE...................................................................................514 Removal...........................................................................................514 Installation......................................................................................514 Disassembly.......................................................................................514 Assembly..........................................................................................514 LEFT SIDE FILL........................................................................................515 BUCKEYE QUICK FUEL SYSTEM.................................................................................517 FUEL TANK BREATHER VALVE..............................................................................517 Maintenance.......................................................................................517 Filter Service....................................................................................517 Disassembly.......................................................................................517 Inspection........................................................................................517 Assembly..........................................................................................517 FUEL RECEIVER.........................................................................................518 ENGINE COOLANT HEATER.....................................................................................519 Maintenance...........................................................................................519 HEATING ELEMENT.......................................................................................519 Removal...........................................................................................519 Installation......................................................................................519 THERMOSTAT............................................................................................520 Removal...........................................................................................520 Installation......................................................................................520 SPECIAL TOOLS.............................................................................................521 AIR CONDITIONING SYSTEM...................................................................................527 Environmental Impact..................................................................................527 OPERATOR CAB AIR CONDITIONING.........................................................................528 PRINCIPLES OF REFRIGERATION...........................................................................528 Air Conditioning..................................................................................528 Refrigeration - The Act Of Cooling................................................................529 The Refrigeration Cycle...........................................................................529 AIR CONDITIONER SYSTEM COMPONENTS.....................................................................530 Compressor (Refrigerant Pump).....................................................................530 Service Valves....................................................................................530 Condenser.........................................................................................530 Expansion Block Valve.............................................................................531 Evaporator........................................................................................531 ELECTRICAL CIRCUIT....................................................................................532 Thermostat........................................................................................532 Compressor Clutch.................................................................................532 Trinary™ Switch...................................................................................533 SYSTEM SERVICING......................................................................................534 SYSTEM OIL............................................................................................535 Handling and Reusing PAG Oil......................................................................535 Oil Quantity......................................................................................535 Replacing Oil After Servicing the System..........................................................535 Setting Up a New Compressor.......................................................................535 REFRIGERANT...........................................................................................536 Recycled Refrigerant..............................................................................536 Reclaimed Refrigerant.............................................................................536 Refrigerant Quantity..............................................................................536 R-134a Refrigerant Containers.....................................................................536 SERVICE TOOLS AND EQUIPMENT...........................................................................537 Recovery/Recycle Station..........................................................................537 Leak Detector.....................................................................................537 Service Valves....................................................................................538 Vacuum Pump.......................................................................................538 Manifold Gauge Set................................................................................539 Installing Manifold Gauge Set.....................................................................540 Purging Air From Service Hoses....................................................................541 Stabilizing the AC System.........................................................................542 SYSTEM PERFORMANCE TEST...............................................................................542 SYSTEM LEAK TESTING...................................................................................543 Electronic leak detector..........................................................................543 Tracer dyes.......................................................................................543 Soap and water....................................................................................543 SYSTEM REPAIR.........................................................................................544 System Cleaning...................................................................................544 Hoses and Fittings................................................................................544 Lines.............................................................................................544 Expansion Valve...................................................................................544 Receiver-Drier....................................................................................545 Thermostat........................................................................................545 Compressor........................................................................................545 Clutch............................................................................................545 Servicing the Compressor Clutch...................................................................546 Pulley Removal....................................................................................548 Clutch Coil Check.................................................................................548 Pulley Installation...............................................................................548 Clutch Assembly Installation......................................................................549 RECOVERING AND RECYCLING THE REFRIGERANT..............................................................550 Performing the Recovery Cycle.....................................................................550 Performing the Recycling Procedure................................................................550 Evacuating and Charging the AC System.............................................................550 EVACUATING THE SYSTEM.................................................................................551 CHARGING THE AC SYSTEM................................................................................552 TROUBLESHOOTING.......................................................................................553 Pre-Diagnosis Checks..............................................................................553 Preparing For Diagnosis...........................................................................553 Preliminary Steps.................................................................................553 System Performance Test...........................................................................553 Diagnosis Of Gauge Readings And System Performance................................................554 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM.......................................................561 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...............................................................563 PAYLOAD METER II - ON BOARD WEIGHING SYSTEM...........................................................565 GENERAL INFORMATION...............................................................................565 Haul Cycles...................................................................................565 LIGHTS, SWITCHES AND COMPONENTS...................................................................566 TIPS FOR OPERATION................................................................................567 EXTERNAL DISPLAY LIGHTS...........................................................................567 THEORY OF OPERATION...............................................................................568 Basic Description.............................................................................568 Inclinometer..................................................................................568 Linkage Factor................................................................................568 Gain Factor...................................................................................569 Brake Lock....................................................................................569 Sources of Error..............................................................................569 Typical Data From Service Check Mode..........................................................569 Example Calculation of Payload................................................................570 Viewing Payload Calculation Inputs............................................................570 Checking the Gain.............................................................................571 Adjusting the Gain............................................................................571 TYPES OF DATA STORED..........................................................................572 Cycle Data....................................................................................572 Fault Codes and Warning Data..................................................................573 Engine ON/OFF Data............................................................................573 Engine Operation..............................................................................574 Total Payload and Total Number of Cycles......................................................574 Other Data....................................................................................574 OPERATOR FUNCTIONS................................................................................575 Using the Operator Load Counter...............................................................575 Viewing the Operator Load Counter.............................................................575 Clearing the Operator Load Counter............................................................575 Dimming the Lights on the Display.............................................................575 INITIAL SETUP OF PAYLOAD METER....................................................................576 Switch Settings...............................................................................576 Checking the Operator Check Mode..............................................................577 Checking the Service Check Mode...............................................................577 Checking the Gt setting:......................................................................578 Checking the Inclinometer Settings............................................................578 Calibrating a Truck...........................................................................578 DISPLAYS AT START-UP..............................................................................579 Normal Operation..............................................................................579 SETUP AND MAINTENANCE.............................................................................580 Setting The Speed Limit.......................................................................580 Setting the Option Code.......................................................................580 Setting The Machine I.D. Code.................................................................581 Setting The Operator I.D. Code................................................................581 Setting The Time and Date.....................................................................581 DOWNLOAD OF INFORMATION...........................................................................582 DISPLAY OF FAULT CODES............................................................................582 Monitoring Input Signals......................................................................586 Service Check Mode............................................................................586 UP FACTOR - PAYLOAD CALCULATION GAIN..............................................................587 PL MODE -LOAD CALCULATION TIMING..................................................................587 FINAL GEAR RATIO SELECTION........................................................................588 BATTERY REPLACEMENT PROCEDURE.....................................................................589 Replacing the Battery.........................................................................589 After Replacing the Battery...................................................................590 SUSPENSION PRESSURE SENSOR........................................................................590 Removal.......................................................................................590 Installation..................................................................................591 INCLINOMETER......................................................................................591 Removal.......................................................................................591 Installation..................................................................................591 Adjustment....................................................................................591 PAYLOAD METER BACK PANEL..........................................................................592 CONNECTIONS.......................................................................................593 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE.........................................................594 PAYLOAD CIRCUIT NUMBERS...........................................................................595 TROUBLESHOOTING...................................................................................596 COMMON PROBLEMS...................................................................................596 Suspension Charging...........................................................................596 Symptom Table.................................................................................597 Missing Body-Up Signal........................................................................597 Missing Speed Signal..........................................................................598 F-18: Alternator R-Terminal, Oil Pressure Signals.............................................598 Shorted 18v Sensor Power Supply (930E)........................................................598 FAULT TREE DIAGNOSIS..............................................................................599 Payload Lights Won't Illuminate...............................................................599 Red, Amber or Green Payload Light Does Not Illuminate.........................................600 Cannot Download - PC Communications...........................................................601 PC Communications Configuration...............................................................602 F.CAL: Payload Meter Won't Calibrate..........................................................603 F-20: Sensor Power Fault......................................................................604 F-21, F-25: Left Front Pressure Sensor........................................................606 F-22, F-26: Right Front Pressure Sensor.......................................................606 F-23, F-27: Left Rear Pressure Sensor.........................................................606 F-24, F-28: Right Rear Pressure Sensor........................................................606 F-31, F-32: Inclinometer......................................................................608 Body Up Input.................................................................................610 Brake Lock Input..............................................................................611 Speed Signal..................................................................................612 Adjusting the Speed Sensor....................................................................612 CONNECTORS AND PRESSURE SENSORS...................................................................614 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM...........................................................617 Menu Functions....................................................................................620 Using Scope.......................................................................................620 Log File Information..............................................................................620 Connections to Payload Meter II™..................................................................621 USING SCOPE...........................................................................................622 Monitoring Inputs Using Scope.....................................................................622 Monitoring Suspension Charging Using Scope........................................................622 Pressure Sensor Dummy Loads.......................................................................625 GAIN ADJUSTMENT WORKSHEET.............................................................................626 SECTION N - OPERATOR'S CAB........................................................................................627 OPERATOR'S CAB INDEX..........................................................................................627 TRUCK CAB.................................................................................................629 Description...........................................................................................629 Removal...............................................................................................630 Installation..........................................................................................631 CAB DOOR..............................................................................................632 Removal...........................................................................................632 Installation......................................................................................632 Door Adjustment...................................................................................632 Door Jamb Bolt Adjustment.........................................................................632 Door Handle Plunger Adjustment....................................................................634 Replace Door Glass................................................................................635 Replace Door Window Regulator.....................................................................639 Replace Door Handle or Latch Assembly.............................................................639 Door and Door Hinge Seal Replacement..............................................................640 Door Opening Seal Removal.........................................................................640 Installation......................................................................................640 GLASS REPLACEMENT.....................................................................................641 ADHESIVE-BONDED WINDOWS...........................................................................641 Replacement Procedure.........................................................................641 WINDSHIELD & REAR GLASS...........................................................................642 Removal.......................................................................................642 Installation..................................................................................643 CAB COMPONENTS............................................................................................645 WINDSHIELD WIPER......................................................................................645 Removal...........................................................................................645 Installation......................................................................................645 WINDSHIELD WASHER.....................................................................................646 Operation.........................................................................................646 Service...........................................................................................646 OPERATOR COMFORT......................................................................................647 ELECTRICAL CIRCUITS...................................................................................650 SECTION P - LUBRICATION AND SERVICE...............................................................................679 LUBRICATION AND SERVICE INDEX.................................................................................679 MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................707 AXLE BOX..............................................................................................707 MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................708 ARMATURE AREA.........................................................................................708 AT TIRE CHANGE - FOR ALL MOTORIZED WHEELS.............................................................708 MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................709 GENERATOR / ALTERNATOR................................................................................709 GRID BLOWER MOTOR.....................................................................................709 CONTROL EQUIPMENT CHECKS..............................................................................709 MOTORIZED WHEEL MAINTENANCE SCHEDULE......................................................................710 AUXILIARY EQUIPMENT AND AIR VENTILATION SYSTEM........................................................710 VEHICLE OPERATIONS TESTS..............................................................................710 SECTION Q - ALPHABETICAL INDEX....................................................................................711 SECTION R - SYSTEM SCHEMATICS.....................................................................................715 SYSTEM SCHEMATICS INDEX.......................................................................................715
KOMATSU 830E DUMP TRUCK SHOP MANUAL SN A30607-A30624 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu 830E Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of 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 æ10% tolerance unless otherwise specified.
- A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “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.
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
