Komatsu 830E-AC Dump Truck Shop Manual – CEBM019200

This complete service repair workshop manual PDF download for the Komatsu Dump Truck 830E-AC has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Machine Model :
Komatsu 830E-AC

Serial Numbers :
A30036 – A30071
A30079 and up

TABLE OF CONTENTS :

– GENERAL INFORMATION
– STRUCTURES
– ENGINE, FUEL, COOLING AND AIR CLEANER
– ELECTRIC SYSTEM (24 VDC. NON-PROPULSION)
– ELECTRIC PROPULSION AND CONTROL
– DRIVE AXLE, SPINDLES AND WHEELS
– HYDRAIR® II SUSPENSIONS
– BRAKE CIRCUIT
– HYDRAULIC SYSTEM
– OPTIONS AND SPECIAL TOOLS
– OPERATOR’S CAB
– LUBRICATION AND SERVICE
– ALPHABETICAL INDEX
– SYSTEM SCHEMATICS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM019200
Total Pages : 1089

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GENERAL INFORMATION
MAJOR COMPONENT DESCRIPTION
SPECIFICATIONS
GENERAL SAFETY AND OPERATING INSTRUCTIONS
GENERAL SAFETY
Safety Rules
Truck Safety Features
Clothing And Personal Items
Unauthorized Modification
Leaving The Operator’s Seat
Mounting And Dismounting
Fire Extinguishers And First Aid Kits
Precautions For High Temperature Fluids
Asbestos Dust Hazard Prevention
Fire Prevention For Fuel And Oil
ROPS Precautions
Preventing Injury From Work Equipment
Precautions For Optional Attachments
Precautions When Starting The Machine
PRECAUTIONS FOR TRUCK OPERATION
Safety Is Thinking Ahead
Safety At The Worksite
Fire Prevention
Preparing For Operation
Ventilation For Enclosed Areas
Mirrors, Windows, And Lights
In The Operator’s Cab – Before Starting The Engine
OPERATING THE MACHINE
Starting The Engine
Truck Operation – General
Traveling In The Truck
Precautions When Traveling In Reverse
Traveling On Slopes
Ensuring Good Visibility
Operating On Snow
Avoid Damage To The Dump Body
Driving Near High Voltage Cables
When Loading The Truck
When Dumping
Working On Loose Ground
Parking The Machine
TOWING
WORKING NEAR BATTERIES
Jump Starting With Booster Cables
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
Stopping The Engine Before Service
Warning Tag
Proper Tools
Securing The Dump Body
DURING MAINTENANCE
Personnel
Attachments
Working Under The Machine
Keeping The Machine Clean
Rules To Follow When Adding Fuel Or Oil
Radiator Coolant Level
Use Of Lighting
Precautions With The Battery
Handling High Pressure Hoses
Precautions With High Pressure Oil
Maintenance Near High Temperatures And High Pressures
Rotating Fan And Belts
Waste Materials
TIRES
Handling Tires
Tire Maintenance
Storing Tires After Removal
ADDITIONAL JOB SITE RULES
WHEN REPAIRS ARE NECESSARY
SPECIAL PRECAUTIONS FOR WORKING ON A 830E-AC TRUCK
Preliminary Procedures before Welding or Performing Maintenance
Engine Shutdown Procedure before Welding or Performing Maintenance
TRUCK OPERATION
PREPARING FOR OPERATION
Safety Is Thinking Ahead
WALK AROUND INSPECTION
ENGINE START-UP SAFETY PRACTICES
AFTER ENGINE HAS STARTED
EMERGENCY STEERING SYSTEM
Operation
Pre-Operation Testing
Additional Guidelines
MACHINE OPERATION SAFETY PRECAUTIONS
MACHINE OPERATION ON THE HAUL ROAD
STARTING ON A GRADE WITH A LOADED TRUCK
PASSING
LOADING
DUMPING
Raising The Dump Body
Lowering The Dump Body
SUDDEN LOSS OF ENGINE POWER
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DELAYED ENGINE SHUTDOWN PROCEDURE
DISABLED TRUCK DUMPING PROCEDURE
Hookup
Raising the Body
Lowering the Body
TOWING
RESERVE ENGINE OIL SYSTEM (Optional)
WARNINGS AND CAUTIONS
STANDARD TORQUE CHARTS AND CONVERSION TABLES
STORAGE PROCEDURES
STORAGE AND IDLE MACHINE PREPARATION
SHORT TERM IDLE PERIODS
PREPARATION FOR STORAGE
REMOVAL FROM STORAGE
RECONDITIONING AN IDLE VEHICLE
ENGINE OPERATION
AFTER ENGINE HAS STARTED
ENGINE STORAGE
Engine Storage-(Short Term)
Engine Storage- (Long Term)
ELECTRIC DRIVE TRUCKS
TRANSMISSION PRESERVATION AND STORAGE
Restoring Transmission to Service

STRUCTURES
STRUCTURAL COMPONENTS
STRUCTURAL COMPONENTS
Preparation
LADDERS
Removal
Installation
RIGHT DECK
Removal
Installation
LEFT DECK
Removal
Installation
CENTER DECK
DUMP BODY
DUMP BODY
Removal
Installation
BODY PADS
Adjustment
BODY GUIDE
BODY-UP RETENTION CABLE
BODY POSITION INDICATOR
ROCK EJECTORS
Inspection
HOIST LIMIT SWITCH
BODY UP SWITCH
FUEL TANK
FUEL TANK
Removal
Installation
Repair
Cleaning
FUEL GAUGE SENDER
Removal
Installation
FUEL TANK BREATHER VALVE
Disassembly
Assembly
FUEL RECEIVERS (WIGGINS QUICK FILL)
LOW FUEL SWITCH

ENGINE
POWER MODULE
POWER MODULE
PREPARATION
Removal
Installation
COOLING SYSTEM
COOLING SYSTEM DESCRIPTION
RADIATOR
Removal
Installation
Radiator Filling Procedure
REPAIRING THE RADIATOR
Internal Inspection
External Cleaning
Disassembly
Cleaning and Inspection
Assembly
Pressure Testing
COOLANT SYSTEM TROUBLESHOOTING
POWER TRAIN
ALTERNATOR REMOVAL PROCEDURE
Removal (Komatsu SSDA16V160 or SDA16V160 Engine)
ENGINE/ALTERNATOR MATING
General Instructions
Measuring Procedure
Joining Alternator and Komatsu SSDA16V160 or SDA16V160 Engine
ENGINE
Removal
Service
Installation
AIR CLEANERS
AIR CLEANERS
OPERATION
SERVICING THE AIR CLEANERS
Replacing The Filter Element
AIR CLEANER ASSEMBLY CLEANING
Main Filter Cleaning
Precleaner Section Cleaning
AIR INTAKE TROUBLESHOOTING
FAN CLUTCH
FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
TEST PROCEDURE

ELECTRICAL SYSTEM (24VDC NON-PROPULSION)
24VDC ELECTRIC SUPPLY SYSTEM
24VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERIES
Maintenance and Service
Troubleshooting
BATTERY SUPPLY SYSTEM
24VDC Battery Charging Alternator
Battery Box
Battery Control Box
Battery Disconnect Switches
24VDC Auxiliary Battery Receptacles
Isolator Diode
Engine Start Relay
24VDC to 12VDC Converter
24 VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)
Operation
Pressure Switch
Check Valve
Timer Solenoid
MAINTENANCE
Prelube System Operation Checks
Check Valve
Timer Solenoid
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT
24 VDC ELECTRIC START SYSTEM
CRANKING MOTORS
Operation
Removal
Installation
CRANKING MOTOR TROUBLESHOOTING
Preliminary Inspection
No-Load Test
Interpreting Results of Tests
Disassembly
Cleaning and Inspection
Armature Servicing
Field Coil Checks
Field Coil Removal
SOLENOID CHECKS
Test
Assembly
Bearing Replacement:
Motor Assembly:
Pinion Clearance
MAGNETIC SWITCH
Removal
Installation
Coil Test
24VDC ELECTRICAL SYSTEM COMPONENTS
24 VDC ELECTRICAL SYSTEM COMPONENTS
TRUCK SHUTDOWN PROCEDURE
BRAKE WARNING BUZZER
AUXILIARY CONTROL CABINET COMPONENTS
Power Distribution Terminals
Engine Starter Failure Delay Timer
5 Minute Idle Timer
Pulse Voltage Modulator (PMV)
Control Power Relay
Auto Lube Timer
Diode Board – DB1
Fuse Blocks
Alarm Indicating Device (AID) System
Diode Matrix (With Sound)
Diode Matrix (Without Sound)
Hot Switch Inverter
Hot Switch Inverter (Not Used)
Temperature and Latch
RELAY BOARDS
Relay Boards RB1, RB3, RB4, RB5
Relay Board RB6, RB7, RB8, RB9
Service
Relay Board Functions
BODY-UP SWITCH
Operation
Adjustment
Service
HOIST LIMIT SWITCH
Operation
Adjustment
Service
FUSE BLOCK CHARTS
CIRCUIT BREAKER CHART
BATTERY CHARGING ALTERNATOR
BATTERY CHARGING SYSTEM
BATTERY CHARGING SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
CHARGE VOLT AND AMP VALUES
BATTERY
Maintenance and Service
Troubleshooting
Undercharging
Overcharging
Corrosion
Acid Levels
Non-Use or Storage
Freezing
BATTERY CHARGING ALTERNATOR
GENERAL INFORMATION
General Description
Terminal Identification and Location
Battery Positive (B+)
Battery Negative (B-)
DC Output (D+)
AC Output (R)
Regulator Harness Plug Identification
Alternator Specifications
Performance Curve
Battery/Alternator Terminology
WIRING DIAGRAM
DIMENSIONS AND TORQUE VALUES
PERIODIC MAINTENANCE
TESTING
GENERAL INFORMATION
Troubleshooting Alternator (On-Truck)
Equipment Required
Preliminary Checks
Test Set-up
Test Procedure
REGULATOR TESTING
Regulator Bypass Test (No Output)
Regulator Bypass Test (Amp Rating)
BENCH TESTING
Equipment
Identification Record
Advanced Troubleshooting
Bench Test 1: No-Load Test
Bench Test 2: Full Load Test
Bench Test 3: Regulator Bypass Test
STATIC TESTING
Equipment
Identification Record
Regulator Tester
Check For Shorted Power Transistor
Circuit Tests
FIELD COIL TESTS
Field Coil Test 1: Check for Open or Shorted Field Coil
Field Coil Test 2: Check For Grounded Field Coil
STATOR TESTS
Stator Test 1: Check For Stator-To-Stator Continuity
Stator Test 2: Check For Grounded Stators
THERMAL SWITCH TEST
Initial Test
Verifying a Faulty Thermal Switch
TROUBLESHOOTING TIPS
ALTERNATOR
ALTERNATOR REPAIR
Removal
Installation
Special Tools and Lubricants
Epoxy Adhesive
Liquid Threadlockers
Elastoplastic Silicone Resin
ALTERNATOR EXPLODED VIEW
ALTERNATOR DISASSEMBLY
Regulator Removal
Fan Removal
Pulley Removal
Anti-Drive End Housing Removal
Anti-Drive End Rotor Removal
Drive End Housing Removal
Drive End Rotor Removal
Field Coil Removal
Drive End and/or Anti-Drive End Stator Removal
CLEANING AND INSPECTION
ALTERNATOR ASSEMBLY
Anti-Drive End Stator Installation
Drive End Stator Installation
Field Coil Installation
Drive End Bearing Installation
Drive End Rotor Installation
Rotor and Rotor Shaft Installation
Drive End Housing Installation
Anti-Drive End Rotor Installation
Anti-Drive End Housing Installation
Regulator Installation
THERMAL SWITCH
Removal
Installation
SUPPORT STAND
VHMS COMPONENTS
VHMS COMPONENTS
VHMS BASIC FEATURES
Gather Data
Convert and Record Data
Communicate Data to Off-Board Systems
USING THE VHMS SYSTEM
Turning the VHMS System ON
Normal VHMS Operation
Turning the VHMS System OFF
Downloading from the VHMS Controller
VHMS DATA ITEMS
Fault Codes
Machine History
VHMS History
Snapshots
Manual Snapshots
Trends
Histogram (Load Map) Data
Haul Cycle Data
Alarm and Snapshot Triggers
Satellite Features
VHMS DIAGNOSTIC FEATURES
Fault History
VHMS LED Digits
VHMS CONTROLLER
Removal
Installation
ORBCOMM CONTROLLER
Removal
Installation
INTERFACE MODULE
Removal
Installation
SENSORS
Temperature Sensors
Pressure Sensors
VHMS SOFTWARE
VHMS SOFTWARE
NECESSARY SOFTWARE
NECESSARY TOOLS
VHMS SYSTEM SET UP
INTERFACE MODULE
VHMS CONTROLLER
INTERFACE MODULE
FLASHBURN PROGRAM
Installation
INTERFACE MODULE APPLICATION CODE
Installation
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM
Installation
Using The Program
VHMS CONTROLLER
VHMS TOOL BOX
Installation
VHMS SETTING TOOL
Installation
VHMS INITIALIZATION PROCEDURE
1. VHMS CONTROLLER SETUP PROCEDURE
VHMS Setting Tool software program
Select Operation
VHMS Setting Function
Machine Information Setting(1)
Machine Information Setting(2)
Date & Time Setting
GCC Setting
Setting Summary
2. VHMS SNAPSHOT PROCEDURE
3. VHMS DOWNLOAD PROCEDURE
4. LOCATION OF DOWNLOAD FILES
5. VHMS FTP UPLOAD PROCEDURE
6. VHMS INITIALIZATION FORMS
WHEN REPLACING A VHMS CONTROLLER
To Set: Date & Time; Satellite; Payload Meter
Review Setting Information
VHMS CHECKOUT AND TROUBLESHOOTING
INTERFACE MODULE AND VHMS CHECKOUT & TROUBLESHOOTING
GENERAL
Structure and Purpose
INTERFACE MODULE CHECKOUT
Interface Module
Necessary Equipment:
Preliminary
Checking Inputs And Outputs From The Interface Module
Check Analog Inputs To The Interface Module
Check CAN RPC & J1939 Interfaces To The IM
Check Outputs From The Interface Module
VHMS CONTROLLER CHECKOUT
VHMS Controller
Necessary Equipment:
Preliminary
VHMS Controller Checkout Procedure
ORBCOMM CONTROLLER
TROUBLESHOOTING
Communications Networks
Coaxial Cable
FAULT CODES
Fault History
VHMS LED Display Fault Codes
Chassis Fault Codes
Engine Fault Codes
FAULT TREE ANALYSIS
Unable to connect to VHMS from laptop PC
Flashing Error Code N4-23 (PLM III Communications Fault)
Flashing Error Code N4-22 (Engine Communications Fault)
No Data Received By WebCARE
Coaxial Cable Troubleshooting
VHMS FORMS
VHMS FORMS
VHMS INITIALIZATION CHECK LIST
VHMS DATA DOWNLOAD
VHMS INITIALIZATION FORM
VHMS INITIALIZATION CHECK LIST
VHMS INITIALIZATION FORM

ELECTRIC PROPULSION SYSTEM
ELECTRICAL PROPULSION SYSTEM COMPONENTS
ELECTRICAL PROPULSION SYSTEM COMPONENTS
GENERAL SYSTEM DESCRIPTION
SYSTEM COMPONENTS
Propulsion System Controller (PSC)
Truck Control Interface (TCI)
Diagnostic Information Display (DID) Panel
DID Panel Event Codes
PSC SOFTWARE FUNCTIONS
Input Processing
State Machine
DC Link State
Engine Control
ALTERNATOR FIELD CONTROL
Desired Three-Phase Voltage
Desired DC Link Voltage
Self-Load
Propel Torque Control
Retard Torque Control
Wheel Slide Control
Resistor Grid Control
Chopper Voltage Control
EVENT DETECTION AND PROCESSING
Power-On Tests
Initiated Tests
Periodic Tests
EVENT RESTRICTIONS
EVENT LOGGING AND STORAGE
Event History Buffer
Data Packs
To Record and Save a Data Pack to a Disk
Event Reset
SERIAL DATA COMMUNICATIONS
PSC – TCI Communications Processing
PSC – PTU Communications Processing
Inverter Communications Processing
OUTPUT PROCESSING
ABNORMAL CONDITIONS/OVERRIDING FUNCTIONS
Fast Start
Engine Shutdown/Engine Not Running
Limp Home Mode
PROPULSION SYSTEM COMPONENT ABBREVIATIONS & LOCATIONS
ELECTRONIC ACCELERATOR AND RETARD PEDALS
Removal
Installation
Disassembly
Assembly
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
AC DRIVE SYSTEM ELECTRICAL CHECKOUT PROCEDURE
AC DRIVE SYSTEM MAINTENANCE
NORMAL TRUCK SHUTDOWN PROCEDURE
SHUTDOWN AFTER SYSTEM FAILURE
SYSTEM CHECKOUT
Battery and Control Circuit Checks – Battery Power OFF
Battery and Control Circuit Checks – Battery Power ON
Checks with Key Switch OFF
Checks with Key Switch ON
CPU Battery Checks
MEMORY BACKUP BATTERY REPLACEMENT
TCI PROGRAMMING
PSC PROGRAMMING
INVERTER PROGRAMMING
CPU RESET
PSC CHECKOUT
PSC Digital Input Checks
PSC Digital Output Checks
TCI CHECKOUT
Modular Mining Communication Port Check
TCI Digital Input Checks
TCI Digital Output Tests
CALIBRATIONS
Speedometer
Accelerator Pedal, Retarder Pedal/Lever and RSC Dial
ERASING EVENTS
PSC
TCI
GATE DRIVER POWER CONVERTER TEST
LOAD TESTING
Preparation
Alternator Speed Sensor Checks
Battery Boost Check
Brake Circuit Switch Checks
Hoist & Steering Circuit Switch Checks
Link Energized Checks
Loadbox Test
TROUBLESHOOTING
PVM Optimum Load Curve Handshaking Troubleshooting
Phase Module and Chopper Module Troubleshooting
PHASE MODULE REPLACEMENT
Phase Module Removal
Phase Module Installation

DRIVE AXLE, SPINDLE, AND WHEELS
TIRES AND RIMS
TIRES AND RIMS
FRONT TIRES AND RIMS
Removal
Installation
REAR TIRES AND RIMS
Removal
Installation
RIM AND TIRE
Tire Removal
Rim And Tire Preparation
Lubricants
Tire Installation
FRONT WHEEL HUB AND SPINDLES
FRONT WHEEL HUB AND SPINDLE
WHEEL HUB AND SPINDLE ASSEMBLY
Removal
Spindle Pusher Tool Usage
Installation
Disassembly
Cleaning and Inspection
Assembly
Wheel Bearing Adjustment (Tire Removed)
Wheel Bearing Adjustment (Tire mounted)
OIL SAMPLING PROCEDURE
Oil Sampling Guidelines
Procedure
OIL DRAIN AND REFILL PROCEDURE
STEERING CYLINDERS AND TIE ROD
Spherical Bearing Wear Limits
Removal
Installation
Bearing Replacement
TOE-IN ADJUSTMENT
REAR AXLE HOUSING ATTACHMENT
REAR AXLE HOUSING ATTACHMENT
PIVOT PIN
Removal
Installation
PIVOT EYE BEARING
Disassembly
Assembly
PIVOT EYE REPAIR
Removal
Installation
Disassembly
Assembly
ANTI-SWAY BAR
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
REAR AXLE HOUSING
REAR AXLE HOUSING
REAR AXLE HOUSING
Removal
Installation
WHEEL MOTOR
Removal
Cleaning and Inspection
Installation

SUSPENSIONS
FRONT SUSPENSION
FRONT SUSPENSION
Removal
Installation
TURN-OF-THE-NUT Tightening Procedure
MINOR REPAIR ONLY (Lower Bearing Structure & Seals)
Bearing Structure Removal
Bearing Structure Installation
MAJOR SUSPENSION REBUILD
Disassembly
Assembly
PRESSURE TEST
REAR SUSPENSIONS
REAR SUSPENSIONS
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
PRESSURE TEST
OILING AND CHARGING PROCEDURE
OILING AND CHARGING PROCEDURE
GENERAL
EQUIPMENT LIST
HYDRAIR® CHARGING KIT
Installation of Charging Kit
Removal of Charging Kit
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
FRONT SUSPENSION
Front Suspension Oiling
Front Suspension Nitrogen Charging
REAR SUSPENSION
Rear Suspension Oiling
Rear Suspension Nitrogen Charging
OIL AND NITROGEN SPECIFICATIONS CHART

BRAKE CIRCUIT
BRAKE CIRCUIT
BRAKE CIRCUIT
OPERATION
SERVICE BRAKE CIRCUIT OPERATION
SECONDARY BRAKING AND AUTOMATIC APPLY
PARKING BRAKE CIRCUIT
Normal Operation (key switch on, engine running)
BRAKE LOCK CIRCUIT
WARNING CIRCUIT
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE CIRCUIT COMPONENT SERVICE
BRAKE VALVE
Rebuild Criteria
Removal
Installation
DISASSEMBLY
Cleaning and Inspection
ASSEMBLY
Actuator Base Threaded Inserts
Boot and Cap
Valve Body Seal Installation
Regulator Sleeve O-Ring Installation
Actuator Plunger O-ring Installation
Assembly of Valve
VALVE BENCH TEST AND ADJUSTMENT
Test Set Up Procedure
Brake Valve Output Pressure Adjustment
Final Test and Adjustment
Installation Of Brake Pedal Actuator Assembly to Brake Valve
BRAKE ASSEMBLIES WITH INTEGRAL MOUNTED ELECTRONIC RETARD PEDAL (Dual Function Pedal)
Installation of Retard Pedal To Brake Pedal
HYDRAULIC BRAKE ACCUMULATORS
Brake Accumulator Bleed Down Procedure
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Charging Procedure
BRAKE MANIFOLD
Removal
Removal
Installation
Disassembly
Cleaning and Inspection.
Assembly
BRAKE CIRCUIT CHECK-OUT PROCEDURE
BRAKE CIRCUIT CHECK-OUT PROCEDURE
EQUIPMENT REQUIRED
INITIAL SYSTEM SET-UP
PARKING BRAKE
BRAKE SYSTEM CHECK-OUT
BRAKE LOCK
FAILURE MODES CHECK-OUT
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET
KOMATSU CHECK-OUT PROCEDURE HYDRAULIC BRAKE SYSTEM DATA SHEET
FRONT BRAKES
ROCKWELL WHEEL SPEED FRONT DISC BRAKES
BRAKE CALIPER
Caliper Removal
Installation
Disassembly
Assembly
Cleaning and Inspection
BRAKE LINING
Replacement
FRONT SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE
GENERAL
Safety Precautions
Front Brake Conditioning
BRAKE BLEEDING PROCEDURES
ARMATURE SPEED REAR DISC BRAKES
ARMATURE SPEED REAR DISC BRAKES
REAR BRAKES
CALIPER AND DISC
Removal
Installation
Adjustment
CALIPER
Disassembly
PISTON SUBASSEMBLY
Disassembly
PREPARATION FOR ASSEMBLY
Clean Parts
For Rough Metal Parts
Dry and Inspect Parts
Corrosion Protection
INSPECTION
Caliper Parts
Shoes, Linings and End Plates
Inspect linings
PISTON ASSEMBLY RETURN SPRING FORCE AND BUILT-IN CLEARANCE (BIC)
Piston Assembly Adjuster Grip Force
Adjuster Force
Piston Return Spring
ASSEMBLY
Adjuster and Pin Assembly
Piston Subassembly
Brake Caliper
PERIODIC INSPECTIONS
Shoes, Linings and End Plates
Inspect the following areas for fluid leaks.
Dust Boots
Brake Disc
BRAKE LINING
Replacement
BRAKE DISC
Inspection
SERVICE BRAKE CONDITIONING (BURNISHING) PROCEDURE
GENERAL
SAFETY PRECAUTIONS
Rear Brake Conditioning
BRAKE BLEEDING PROCEDURE

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
COMPONENT DESCRIPTION
HYDRAULIC SYSTEM COMPONENT REPAIR
HYDRAULIC SYSTEM COMPONENT REPAIR
HOIST PUMP
Removal
Installation
Disassembly
Inspection Of Parts
Assembly
HYDRAULIC TANK
Filling Instructions
Removal
Installation
HYDRAULIC TANK STRAINERS
Removal
Inspect and Clean
Installation
HYDRAULIC TANK BREATHERS
HOIST CIRCUIT FILTERS
FILTER ELEMENT REPLACEMENT
Removal
Installation
INDICATOR SWITCH
STEERING CIRCUIT
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
COMPONENT DESCRIPTION
STEERING CONTROL UNIT
FLOW AMPLIFIER
No Steer
Steering Left
Steering Right
No Steer, External Shock Load
BLEED DOWN MANIFOLD
ACCUMULATORS
Low Precharge Warning Switch
HIGH PRESSURE FILTER
STEERING/BRAKE PUMP
Operation
PRINCIPLE OF OPERATION
Full Pump Volume:
Half Pump Volume:
Neutral Position:
STEERING CIRCUIT COMPONENT REPAIR
STEERING CIRCUIT COMPONENT REPAIR
BLEED DOWN MANIFOLD
Removal
Installation
ACCUMULATOR
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
LEAK TESTING
STEERING ACCUMULATOR CHARGING PROCEDURE
Temperature During Precharge
ACCUMULATOR STORAGE PROCEDURES
Instructions For Storing Bladder Accumulators
Installation
Bladder Storage Procedures
FLOW AMPLIFIER
Removal
Installation
Disassembly
Reassembly
STEERING CONTROL UNIT
Removal
Spline Inspection
Installation
Disassembly
Cleaning and Inspection
Assembly
STEERING CYLINDER
Disassembly
Inspection and Cleaning
Assembly
STEERING CIRCUIT FILTER
Filter Element Replacement
Removal
Installation
Indicator Switch
STEERING AND BRAKE PUMP
Removal
Installation
Disassembly
Control Piston Group
Valve Plate Group
Rotating Group
Swashblock Group
Driveshaft Group
INSPECTION
Control Piston Group
Valve Plate Group
Rotating Group
Swashblock Group
Driveshaft Group
Compensator Block and Unloader Module
Stroke Adjuster Assembly
ASSEMBLY
Swashblock Group
Control Piston Group
Valve Plate Group
HOIST CIRCUIT
HOIST CIRCUIT
HOIST CIRCUIT OPERATION
COMPONENT DESCRIPTION
Hydraulic Tank
Hoist Pump
High Pressure Filters
Hoist Valve
Hoist Pilot Valve
Hoist-up Limit Solenoid
Pilot Operated Check Valve
Counterbalance Valve Manifold
HOIST SYSTEM OPERATION MODES
Float Position Of Pilot Valve And Body On Frame (Figure 7-6)
Power Up Operation (Figure 7-7)
Hold Operation (Figure 7-8)
Power Down Operation (Figure 7-9)
Float Operation (Figure 7-10)
HOIST CIRCUIT COMPONENT REPAIR
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
Removal
Installation
O-Ring Replacement
INLET SECTION
Disassembly
Cleaning and Inspection
Assembly
SPOOL SECTION
Disassembly
Cleaning and Inspection
Assembly
HOIST PILOT VALVE
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
BODY UP LIMIT SOLENOID
PILOT OPERATED CHECK VALVE
HOIST CYLINDERS
Removal
Installation
Disassembly
Cleaning and Inspection
ASSEMBLY OF QUILL AND CYLINDER
Quill Installation
Installation of Check Balls and Plugs in Quill
Assembly of Cylinder
COUNTERBALANCE MANIFOLD
DISABLED TRUCK DUMPING PROCEDURE
Hookup
Dumping Procedure
HYDRAULIC CHECKOUT PROCEDURE
HYDRAULIC CHECKOUT PROCEDURE
STEERING AND BRAKE PUMP
Pressure Check And Adjustment Procedure
BLEEDDOWN MANIFOLD
SHOCK & SUCTION VALVES
Shock & Suction Valve Settings
LEAKAGE TESTS
Steering Control Unit & Flow Amplifier
Bleeddown Manifold
ACCUMULATOR BLEED DOWN PROCEDURE
LOW STEERING PRESSURE SWITCH
CHECKING HOIST SYSTEM PRESSURES
Hoist System Relief Pressure Adjustment
Power Down Relief Pressure Adjustment
HOIST COUNTERBALANCE VALVE
Preparation:
Counterbalance Valve Pressure Check Only:
Counterbalance Valve Adjustment
HYDRAULIC SYSTEM FLUSHING PROCEDURE
OIL CLEANLINESS CHECK

OPTIONS AND SPECAIL TOOLS
FIRE CONTROL SYSTEMS
FIRE CONTROL SYSTEM (MANUAL)
Operation
Inspection and Maintenance
Recharging Procedures
CHECKFIRE ELECTRIC DETECTION AND ACTUATION SYSTEM – SERIES 1
Control Module
Actuator
Linear Detection Wire
Power Wire
Test Kit
Squib
Securing the Detection Wire
Preliminary Test Before Final Hook-Up
Installation Procedure for Squib
Placing the Electric Detection & Actuation System Into Service
INSPECTION AND MAINTENANCE SCHEDULES
Daily
Normal Maintenance Based On Actual Operating Hours
IN CASE OF FIRE
TROUBLESHOOTING THE ELECTRIC DETECTION SYSTEM
TROUBLE: Detonated Squib
ENGINE COOLANT HEATER
ENGINE COOLANT HEATER
GENERAL
Maintenance
HEATING ELEMENT
Removal
Installation
THERMOSTAT
Removal
Installation
SPECIAL TOOLS
NITROGEN CHARGING VALVE
ROLL-OUT ASSEMBLY
EYE BOLT
OFFSET WRENCH
TORQUE ADAPTER
HANDLE
SEAL INSTALLER
SLEEVE ALIGNMENT TOOLS
QUICK DISCONNECT COUPLING
HARNESS
TUBE
BELT TENSION TESTER
BELT ALIGNMENT TOOL
SOCKETS AND ADAPTERS
PAYLOAD DATA MANAGER
MISCELLANEOUS SERVICE TOOLS
RADIATOR SHUTTERS
RADIATOR SHUTTERS
OPERATION
Hydraulic Circuit
Electrical Circuit:
MAINTENANCE AND REPAIR
TROUBLESHOOTING
Hydraulic Troubleshooting
Electrical Troubleshooting
PAYLOAD METER III ™
OPERATION SECTION
Introduction
Data Summary
Data Gathering
COMPONENT DESCRIPTION
System Diagram
Suspension Pressure Sensors
Inclinometer
Operator Display
Operator Switch
Speed Input
Body-Up Switch
Brake Lock Switch
Payload Meter
Communications Ports
Key Switch Input
Payload Meter Power
Load Lights
Wiring and Termination
TCI Outputs
OPERATOR’S DISPLAY AND SWITCH
Reading the Speedometer
Reading the Load Display
Using the Operator ID
Using the Load and Ton Counter
Total Ton Counter
Total Load Counter
Clearing the Counters
Viewing Live Sensor Data
Other Display Messages
PAYLOAD OPERATION & CALCULATION
Description of Haul Cycle States
Haul Cycle Description
Load Calculation
Carry Back
Measurement Accuracy
SOURCES FOR PAYLOAD ERROR
Payload Error
Loading Conditions
Pressure Sensors
Swingloads
Speed and Distance
HAUL CYCLE DATA
Haul Cycle Warning Flags
Frame Torque Data
Sprung Weight Data
Maximum Speed Data
Alarm Records
Fault Code Data
PC SOFTWARE OVERVIEW
System Configuration
Installing the PLMIII Software
DOWNLOADING DATA
PLM III SYSTEM CONFIGURATION
Starting Communications
Displayed Payload Units
Time Units
Connection Menu
Connecting to the Payload Meter
Configure the Payload Meter
Setting the Date and Time
Setting the Truck Type
Setting the Gauge Display Units
Setting the Frame Serial Number
Setting the Truck Number
Setting the Komatsu Distributor
Setting the Komatsu Customer
Clean Truck Tare
Inclinometer Calibration
DATA ANALYSIS
Creating a Query
Sorting on Truck Unit Number
Sorting on Truck Type
Sorting on Date Range
Sorting on Time Range
Payload Detail Screen
Creating Reports
Summary – one page report
Detailed – multi-page report
Creating Graphs
Exporting Data
CSV Export
Compressed
Importing Data
Deleting Haul Cycle Records
Viewing Alarms
Deleting Alarm Records
TROUBLESHOOTING SECTION
TROUBLESHOOTING
Viewing Active Alarms
Real-Time Data Display
Testing the Payload Lights
Creating Log Files of Inputs
Daily Inspections
Periodic Maintenance
Abnormal Displays at Power-Up
No Payload Display When Key Switch is Turned ON
No Display on Speedometer
No Display on Operator Display
No Communications With PC
Load Lights Don’t Light During Loading
Load Lights Remain ON
Load Lights Remain ON During Dumping
Display Doesn’t Clear When The Load Is Dumped
Calibration Problems
Alarm 1 – Left Front Pressure High
Alarm 2 – Left Front Pressure Low
Troubleshoot Wiring to Left Front Suspension
Alarm 3 – Right Front Pressure High
Alarm 4 – Right Front Pressure Low
Troubleshoot Wiring to Right Front Suspension
Alarm 5 -Left Rear Pressure High
Alarm 6 – Left Rear Pressure Low
Troubleshoot Wiring to Left Rear Suspension
Alarm 7 – Right Rear Pressure High
Alarm 8 – Right Rear Pressure Low
Troubleshoot Wiring to Right Rear Suspension
Alarm 9 – Inclinometer High
Alarm 10 – Inclinometer Low
Troubleshoot Inclinometer Wiring
Alarm 13 – Body Up Input Failure
Alarm 16 – Memory Write Failure
Alarm 17 – Memory Read Failure
Alarm 18
Alarm 19
Alarm 22
Operator Switch Doesn’t Work
Alarm 26 – User Switch Fault – SELECT
Alarm 27 – User Switch Fault – SET
Connector Map
Connectors
PLMIII CHECK OUT PROCEDURE
General Description
Tools Required
Checkout Procedure
PLMIII CHECKOUT PROCEDURE CONFIRMATION
Flashburn Programming
Confirmation Checklist
RESERVE ENGINE OIL SYSTEM 1
RESERVE ENGINE OIL SYSTEM
Operation
LED Monitor Light
Tank Fill Control (Optional)
Filling Procedure (Remote fill feature)
SERVICE
Every 10 Hours, or once each shift:
Every 500 Hours:
Changing Oil
TROUBLESHOOTING
Circuit Fuse
SYSTEM ELECTRICAL SCHEMATICS

OPERATOR CAB
TRUCK CAB
TRUCK CAB
TRUCK CAB AND COMPONENTS
DESCRIPTION
Removal
Installation
CAB DOOR
Removal
Installation
Door Adjustment
Door Jamb Bolt Adjustment
Door Handle Plunger Adjustment
Replace Door Glass
Replace Door Window Regulator
Replace Door Handle or Latch Assembly
Door and Door Hinge Seal Replacement
Door Opening Seal Removal
Installation
GLASS REPLACEMENT
Adhesive-bonded Windows
Replacement Procedure
WINDSHIELD & REAR GLASS
Removal
Installation
CAB COMPONENTS
CAB COMPONENTS
WINDSHIELD WIPERS
WIPER MOTOR
Removal
Installation
WIPER ARM
Removal
Installation
WIPER LINKAGE
Removal
Installation
WINDSHIELD WASHER
Operation
Service
OPERATOR SEAT
Adjustment
Seat Removal
Seat Installation
OPERATOR COMFORT
OPERATOR COMFORT
HEATER / AIR CONDITIONER
Operation
Fan Control Knob
Temperature Control Knob
Directional Control Knob
Heater Vents
COMPONENTS
Circuit Breakers
Relays
Heater Core
Fan Motor And Speed Control
Actuators
Cab Air Filter
ENVIRONMENTAL IMPACT OF AIR CONDITIONING
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES
PRINCIPLES OF REFRIGERATION
Air Conditioning
Refrigeration – The Act Of Cooling
The Refrigeration Cycle
AIR CONDITIONER SYSTEM COMPONENTS
Compressor (Refrigerant Pump)
Service Valves
Condenser
Receiver-Drier
Expansion Block Valve
Accumulator
Evaporator
ELECTRICAL CIRCUIT
Thermostat
Compressor Clutch
Trinary™ Switch
SYSTEM SERVICING
SERVICE TOOLS AND EQUIPMENT
Recovery/Recycle Station
Leak Detector
Service Valves
Vacuum Pump
Manifold Gauge Set
Installing Manifold Gauge Set
Purging Air From Service Hoses
SYSTEM PERFORMANCE TEST
SYSTEM OIL
Handling and Reusing PAG Oil
Oil Quantity
Checking System Oil
REFRIGERANT
Recycled Refrigerant
Reclaimed Refrigerant
Refrigerant Quantity
R-134a Refrigerant Containers
SYSTEM LEAK TESTING
Electronic Leak Detector
Tracer Dyes
Soap and Water
RECOVERING AND RECYCLING THE REFRIGERANT
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the A/C System
SYSTEM REPAIR
System Flushing
A/C DRIVE BELT CHECKOUT PROCEDURE
Pulley Alignment
Belt Tension Check
COMPONENT REPLACEMENT
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Accumulator
Clutch
Servicing the Compressor Clutch
Pulley Removal
Clutch Coil Check
Pulley Installation
Clutch Assembly Installation
EVACUATING THE SYSTEM
CHARGING THE A/C SYSTEM
TROUBLESHOOTING
Preliminary Checks
Diagnosis Of Gauge Readings And System Performance
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM
OPERATOR CAB CONTROLS
OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
Horn Button
Tilt / Telescope Lever
Multi-Function Turn Signal Switch
STEERING COLUMN
Removal
Steering Column Inspection
Installation
PEDALS
Service Brake Pedal
Dynamic Retarding
Dynamic Retard Pedal
Throttle/Accelerator Pedal
GRADE/SPEED RETARD CHART
OVERHEAD PANEL AND DISPLAYS
CENTER CONSOLE
Directional Control Lever
Override/Fault Reset Switch
Engine Stop Switch
L.H. Window Control Switch
R.H. Window Control Switch
Hoist Control Lever
Raising The Dump Body
Lowering The Dump Body
Retard Speed Control (RSC) Adjust Dial
Retard Speed Control (RSC) Switch
Data Store Button
VHMS Snapshot In Progress Light
Link Energized Light
Service Engine Light
DIAGNOSTIC PORTS
VHMS Diagnostic Port
Interface Module (IM) Diagnostic Port
Payload Meter Diagnostic Port
Truck Control Interface (TCI) Diagnostic Port
Propulsion System Controller (PSC) Diagnostic Port
Engine Diagnostic Port (CENSE)
Engine Diagnostic Port (QUANTUM)
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS
Fan Control Knob
Temperature Control Knob
Directional Control Knob
Heater Vents
INSTRUMENT PANEL
Key Switch
Starting
Engine Stop Switch with Five Minute Idle Timer Delay
Rotating Beacon Light Switch (Optional)
Heated Mirror Switch (Optional)
Rest Switch
Wheel Brake Lock Control
Hazard Warning Lights
Cab/Air Conditioner Vents
Engine Oil Pressure Gauge
Right Turn Signal Indicator
Tachometer
High Beam Indicator
Speedometer/Payload Meter Display
Left Turn Signal Indicator
Water Temperature Gauge
Lamp Test Switch
Light Switch
Ladder Light Switch
Manual Backup Switch
Fog Lights (Optional)
Payload Meter Switch
Panel Light Dimmer
Hydraulic Oil Temperature Gauge
Hourmeter
Fuel Level Gauge
OVERHEAD STATUS / WARNING INDICATORS
Status / Warning Indicator Light Symbols
VEHICLE HEALTH MONITORING SYSTEM (VHMS)
Operation
Interface Module
Basic Precautions
FUSE BLOCKS
CIRCUIT BREAKERS

LUBRICATION AND SERVICE
LUBRICATION AND SERVICE
LUBRICATION AND SERVICE
830E SERVICE CAPACITIES
HYDRAULIC TANK SERVICE
Adding Oil
WHEEL MOTOR SERVICE
COOLANT LEVEL CHECK
RADIATOR FILLING PROCEDURE
RESERVE ENGINE OIL SYSTEM (Optional)
Reserve Oil Tank Filling Procedure (Remote fill)
LUBRICATION CHART
10 HOUR (DAILY) INSPECTION
50 HOUR LUBRICATION AND MAINTENANCE CHECKS
100 HOUR LUBRICATION AND MAINTENANCE CHECKS
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
2500 HOUR MAINTENANCE CHECKS
5000 HOUR MAINTENANCE CHECKS
10,000 HOUR MAINTENANCE CHECKS
AUTOMATIC LUBRICATION SYSTEM
AUTOMATIC LUBRICATION SYSTEM
GENERAL DESCRIPTION
SYSTEM COMPONENTS
Filter
Hydraulic Motor and Pump
Grease Reservoir
Pressure Reducing Valve
Flow Control Valve
Solenoid Valve
Vent Valve
Lubrication Cycle Timer
Pump Cutoff Pressure Switch
Grease Pressure Failure Switch
Pressure Gauge
Injectors
SYSTEM OPERATION
Normal Operation
System Priming
Filter Assembly
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
Pressure Control Valve Adjustment
INJECTORS (SL-1 Series “H”))
Injector Specifications
Injector Adjustment
INJECTOR OPERATION
PREVENTIVE MAINTENANCE PROCEDURES
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection
SYSTEM CHECKOUT
Lubrication Controller Check
Lubrication Controller Operation
Lubrication Controller Components
Lubrication Controller Adjustment
SYSTEM TROUBLESHOOTING CHART

ALPHABETICAL INDEX

SYSTEM SCHEMATICS
HH360 HYDRAULIC SCHEMATIC (BRAKE SYSTEM)
HH361 HYDTRULIC SCHEMATIC (HYDRAULIC SYSTEM)
XS4700 ELECTRICAL SCHEMATIC
SHEET 1 INDEX AND SYMBOLS
SHEET 2 GE SYSTEM BLOCK DIAGRAM
SHEET 3 MAIN PROPULSION SCHEMATIC
SHEET 4 24V/15V POWER DISTRIBUTION
SHEET 5 GE INVERTER FIRING
SHEET 6 GE INVERTER FIRING
SHEET 7 ENGINE I/O
SHEET 8 FE/24V DIGITAL I/O
SHEET 9 GE TRUCK ANALOG I/O
SHEET 10 POWER DISTRIBUTION/CIRCUIT PROTECTION
SHEET 11 OPERATOR CAB OVERHEAD WARNING LIGHTS
SHEET 12 OPERATOR CAB OVERHEAD WARNING LIGHTS
SHEET 13 OPERATOR CAB OVERHEAD WARNING LIGHTS
SHEET 14 OPERATOR CAB OVERHEAD WARNING LIGHTS
SHEET 15 AUTO LUBE SYSTEM WITH WARNING
SHEET 16 OPERATOR CAB GAUGES & OPTION SWITCHES
SHEET 17 HEATER, AIR CONDITIONER CONTROLS
SHEET 18 WORK LIGHTS AND HORN
SHEET 19 RETARD LIGHTS, BCKUP LIGHTS AND HORNS
SHEET 20 OPERATOR DRIVE SYSTEM CONTROLS
SHEET 21 RADIO, WINDOWS AND WIPER CONTROL
SHEET 22 TURN SIGNAL AND CLEARANCE LIGHTS
SHEET 23 FOG LIGHTS AND HEAD LIGHTS
SHEET 24 OPERATOR CAB INSTRUMENT LIGHTS
SHEET 25 KEY SWITCH AND 5-MINUTE IDLE SHUTDOWN
SHEET 26 QSK-60 START CIRCUIT
SHEET 27 ENGINE CIRCUITS
SHEET 28 PAYLOAD METER III CIRCUITS
SHEET 29 DIAGNOSTIC PORTS/DISPATCH SYSTEM
SHEET 30 PARK BRAKE AND GE I/O
SHEET 31 WINDSHIELD WIPER & TURN SIGNAL CONTROLS
SHEET 32 VHMS, INTERFACE ORBCOM MODULES
SHEET 33 BATTERY BOX
SHEET 34 CIRCUIT LOCATOR SHEET
SHEET 35 COMPONENT LOCATOR SHEET

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