Komatsu 830E-1AC Dump Truck Shop Manual (A40851 and up) – CEBM027400

This complete service repair workshop manual PDF download for the Komatsu Dump Truck 830E-1AC (SN: A40851 and up) 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 : 830E-1AC
Serial Numbers : A40851 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 : CEBM027400
Total Pages : 1053

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SECTION A – GENERAL INFORMATION
MAJOR COMPONENT DESCRIPTION
Truck And Engine
Main Control Cabinet
AC Induction Traction Motorized Wheels
Suspension
Operator’s Cab
Power Steering
Dynamic Retarding
Brake System
SPECIFICATIONS
GENERAL SAFETY AND
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
Seat Belts
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
Jump Starting With Receptacles
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE
Stopping The Engine Before Service
Electrical Systems Isolation
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 AN 830E-1AC TRUCK
Preliminary Procedures before Welding or Performing Maintenance
Engine Shutdown Procedure before Welding or Performing Maintenance
CAPACITOR DISCHARGE SYSTEM
Necessary Tools
Warnings And Cautions
MANUAL DC LINK CAPACITOR DISCHARGE PROCEDURE
Preparation
CAPACITOR CHARGE LIGHTS
FAILURE OF DISCHARGE SYSTEM
Measuring Dc Voltage On Capacitors
MANUAL DISCHARGE OF CAPACITORS
SHORT ISOLATED CAPACITOR TERMINALS
TRUCK OPERATION
PREPARING FOR OPERATION
Safety Is Thinking Ahead
WALK AROUND INSPECTION
RETRACTABLE LADDER SYSTEM (If equipped)
LADDER SYSTEM DESCRIPTION
LADDER SYSTEM OPERATION
Normal Operation
GENERAL SAFETY
IN-CAB CONTROL PANEL
IN-CAB CONTROL PANEL FEATURES
Digital Display Screen
Command Buttons
USING THE IN-CAB CONTROL PANEL
Raising the Ladder
Lowering the Ladder
USING THE GROUND LEVEL CONTROL BOX
Raising the Ladder
Lowering the Ladder
Emergency Operation
ENGINE START-UP SAFETY PRACTICES
AFTER ENGINE HAS STARTED
PRE-SHIFT BRAKE CHECK (if equipped)
Events
OPERATION
Description
Brake Test Exit Criteria
PERFORMING THE BRAKE TESTS
Setup
Service Brake Test
Parking Brake Test
Retard System Test:
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
FUEL DEPLETION
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DISABLED TRUCK CONNECTORS
GENERAL
STEERING AND BRAKE SYSTEM
Hookup
HOIST SYSTEM
Hookup
Dumping Procedure
TOWING
Special Wiring Harness
Towing Procedure
RESERVE ENGINE OIL SYSTEM (Optional)
WARNINGS AND CAUTIONS
TORQUE TABLES AND CONVERSION CHARTS
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)
TRANSMISSION PRESERVATION AND STORAGE
Restoring Transmission to Service
ELECTRIC DRIVE TRUCKS

SECTION B – 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
Removal
Installation
Adjustment
BODY GUIDE
BODY-UP RETENTION CABLE
BODY POSITION INDICATOR
HOIST LIMIT SWITCH
BODY UP SWITCH
ROCK EJECTORS
Inspection
FUEL TANK
FUEL TANK
Removal
Installation
Repair
Cleaning
FUEL TANK BREATHER VALVE
Disassembly
Assembly
FUEL GAUGE SENDER
Removal
Operation
Specifications:
QUICK FILL FUEL RECEIVERS

SECTION C – 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 Elements
AIR CLEANER ASSEMBLY CLEANING
Primary Element Cleaning
Precleaner Section Cleaning
AIR INTAKE TROUBLESHOOTING
FAN CLUTCH

FAN CLUTCH
REMOVAL & INSTALLATION TOOLING
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
TEST PROCEDURE

SECTION D – 24VDC ELECTRICAL SYSTEM
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
Removal
Installation
Battery Control Box
24VDC Auxiliary Battery Receptacles
Engine Start Relay
ISOLATION BOX ASSEMBLY
Engine Shutdown Switch
Access Ladder Light Switch
Battery Disconnect Switches
Propel Lockout Lever
LED Lights
AUXILIARY CONTROL CABINET
24VDC to 12VDC Converter
24VDC ELECTRIC CRANKING MOTOR SYSTEM (WITH PRELUBE)
Operation
Engine Oil Pressure Switch
Check Valve
MAINTENANCE
Prelube System Operation Checks
Check Valve
TROUBLESHOOTING PRELUBE CRANKING MOTOR CIRCUIT
24VDC 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
Interface Module
Payload Meter
24VDC to 12VDC Converter
Circuit Breaker (CB60)
Inclinometer
Vehicle Electrical Center (VEC)
Pump Module Service Light Timer
Power Distribution Terminals
Ground Terminal
Relays
Engine Service Light Timer
RTMR1 – VEC Block
VEC-89
VEC-90
VEC-91
MAGNETIC SWITCHES
Body position switches (With proximity switch and magnet)
Proximity switch operation
Service
BODY-UP SWITCH
Adjust the body up switch.
HOIST LIMIT SWITCH
Operation
Adjust the hoist limit switch
KOMTRAX Plus SYSTEM

KOMTRAX Plus COMPONENTS
KOMTRAX Plus BASIC FEATURES
Gather Data
Convert and Record Data
Communicate Data to Off-Board Systems
USING THE KOMTRAX Plus SYSTEM
Turning the KOMTRAX Plus System ON
Normal KOMTRAX Plus Operation
Turning the KOMTRAX Plus System OFF
Downloading from the KOMTRAX Plus Controller
KOMTRAX Plus DATA ITEMS
Fault Codes
Machine History
KOMTRAX Plus History
Snapshots
Manual Snapshots
Trends
Histogram (Load Map) Data
Haul Cycle Data
Alarm and Snapshot Triggers
Satellite Features
KOMTRAX Plus DIAGNOSTIC FEATURES
Fault History
KOMTRAX Plus LED Digits
KOMTRAX Plus CONTROLLER
Removal
Installation
KOMTRAX Plus SOFTWARE
NECESSARY SOFTWARE
NECESSARY TOOLS
KOMTRAX Plus SYSTEM SET UP
KOMTRAX Plus Controller
KOMTRAX Plus CONTROLLER
KOMTRAX Plus TOOL BOX
Installation
KOMTRAX Plus SETTING TOOL
Installation
KOMTRAX Plus INITIALIZATION PROCEDURE
1. KOMTRAX Plus CONTROLLER SETUP PROCEDURE
KOMTRAX Plus Setting Tool software program
Select Operation
KOMTRAX Plus Setting Function
Machine Information Setting(1)
Machine Information Setting(2)
Date & Time Setting
GCC Setting
Setting Summary
2. KOMTRAX Plus SNAPSHOT PROCEDURE
3. KOMTRAX Plus DOWNLOAD PROCEDURE
4. LOCATION OF DOWNLOAD FILES
5. KOMTRAX Plus FTP UPLOAD PROCEDURE
6. KOMTRAX Plus INITIALIZATION FORMS
WHEN REPLACING A KOMTRAX Plus CONTROLLER
To Set: Date & Time; Satellite; Payload Meter
Review Setting Information
KOMTRAX Plus CONTROLLER CHECKOUT
KOMTRAX Plus Controller
Necessary Equipment:
Preliminary
KOMTRAX Plus Controller Checkout Procedure
ORBCOMM CONTROLLER
Removal
Installation
INTERFACE MODULE

INTERFACE MODULE
Removal
Installation
SENSORS
Temperature Sensors
Pressure Sensors
INTERFACE MODULE SOFTWARE
NECESSARY SOFTWARE
NECESSARY TOOLS
FLASHBURN PROGRAM
Installation
INTERFACE MODULE APPLICATION CODE
Installation
INTERFACE MODULE REALTIME DATA MONITOR SOFTWARE PROGRAM
Installation
Using The Program
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
KOMTRAX Plus & INTERFACE MODULE TROUBLESHOOTING AND ERROR CODES

KOMTRAX Plus AND INTERFACE MODULE ERROR CODES AND TROUBLESHOOTING
TROUBLESHOOTING
GENERAL
Structure and Purpose
TROUBLESHOOTING
Communications Networks
Coaxial Cable
FAULT CODES
Fault History
KOMTRAX Plus LED Display Fault Codes
Chassis Fault Codes
Engine Fault Codes
FAULT TREE ANALYSIS
Unable to connect to KOMTRAX Plus 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
KOMTRAX PLUS FORMS

KOMTRAX PLUS FORMS
KOMTRAX PLUS INITIALIZATION CHECK LIST
KOMTRAX PLUS DATA DOWNLOAD
KOMTRAX PLUS INITIALIZATION CHECK LIST
KOMTRAX PLUS INITIALIZATION FORM

SECTION E – ELECTRIC PROPULSION SYSTEM INDEX

SECTION G – 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 Removal Procedure (Optional) (off of the truck)
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
Spherical Bearing Wear Limits
Removal
Installation
Bearing Replacement (Steering cylinder and tie rod)
TIE ROD
Removal
Installation
Disassembly
Assembly
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
WHEEL MOTOR GEAR OIL
Change/Filter The Gear case Oil
Oil
Remove And Clean Magnetic Plugs
Flushing The Gearbox
Check Gear Case Oil Level

SECTION H SUSPENSIONS INDEX
FRONT SUSPENSION
FRONT SUSPENSION
Removal
Installation
TURN-OF-THE-NUT Tightening Procedure
Upper Mounting Joint – 60° Advance
Lower Mounting Joint – 90° Advance
Inspection
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
ROD DOWN SUSPENSION
Disassembly
Cleaning and Inspection
Assembly
PRESSURE TEST
Suspension pressure test
OIL 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 – ROD DOWN
Rear Suspension Oiling (Rod Down Only)
Rear Suspension Nitrogen Charging (Rod Down Only)
OIL AND NITROGEN SPECIFICATIONS CHART

SECTION J – 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
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
PARK BRAKE ADJUSTMENT PROCEDURE
BRAKE BLEEDING PROCEDURE
Service Brake
Park Brake
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

SECTION L – HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM OPERATION
COMPONENT DESCRIPTION
Hoist Pump
Steering/Brake Pump
Tank
High Pressure Hydraulic Filters
Bleeddown Manifold
Steering System Accumulators
DISABLED TRUCK CONNECTORS
GENERAL
STEERING AND BRAKE SYSTEM
Hookup
HOIST SYSTEM
Hookup
Dumping Procedure
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
Testing
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
Driveshaft Group
Rotating 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
Pressure Testing
OVERCENTER MANIFOLD
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
OIL CLEANLINESS CHECK

SECTION M – OPTIONS AND SPECIAL TOOLS

SECTION M7 HEATER OPTIONS INDEX
GENERAL INFORMATION
TROUBLESHOOTING
HEATER ELEMENT
Removal
Installation
GENERAL
Maintenance
HEATING ELEMENT
Removal
Installation
THERMOSTAT
Removal
Installation
GENERAL INFORMATION
TROUBLESHOOTING
HEATER ELEMENT
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
SEAL INSTALLATION RING
SOCKETS AND ADAPTERS
DUST CAPS
HYDRAULIC SYSTEM FLUSHING TOOLS
MISCELLANEOUS SERVICE TOOLS
PAYLOAD DATA MANAGER
HYDRAULIC SYSTEM VACUUM PUMP
BRAKE PISTON TOOL
HIGH VOLTAGE TOOLS
0-2000 VDC CUSTOM METER KIT (58B-06-00800)
BODY PAD SPACER TOOL
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 Calibration
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

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
RETRACTABLE LADDER SYSTEM
RETRACTABLE LADDER SYSTEM
GENERAL SAFETY
LADDER SYSTEM DESCRIPTION
LADDER SYSTEM OPERATION
Normal Operation
Emergency Operation
Limit Switch Operation
IN-CAB CONTROL PANEL
IN-CAB CONTROL PANEL FEATURES
Digital Display Screen
Command Buttons
IN-CAB CONTROL PANEL FUNCTIONS
Timing Control
Ladder System Status
Fault Code Identification
Ladder System Configuration
In-Cab Control Panel Lockout
Automatic Raising
Diagnostics
Maintenance
USING THE IN-CAB CONTROL PANEL
Raising the Ladder
Lowering the Ladder
USING THE GROUND LEVEL CONTROL BOX
Raising the Ladder
Lowering the Ladder
POWER PACK OPERATION
MAINTENANCE
Safety During Maintenance
Unplanned Ladder Movements
Automatic Ladder Raising
Automatic Accumulator Recharging (Ladder in UP position)
PREVENTIVE MAINTENANCE PROCEDURES
Daily Inspection
250 Hour Inspection
5000 Hour Inspection
SERVICING
Check Reservoir Oil Level
Changing RLS Fluid
Cleaning the RLS
RLS DIAGNOSTICS
Description of Diagnostics Features
Continuous System Monitoring
Historic System Data Review
Comms Integrity Monitoring
Log and Service Information
System Event Logs
SECURITY ACCESS LEVELS
Access Level 1 – NONE
Access Level 2 – RESTRICTED
Access Level 3 – COMPLETE
User Access Privileges
USER ID – PASSWORD
Sequential Field Value Selection Options
Password Character Table
USER ID – NEW USER SETUP
SYSTEM FAULTS
Fault Type 1: Communications error
Fault Type 2: 10A/15A fuse blown
Fault Types 3, 4, 5, 6, 7: Up/Down/In/Out pump coil short or disconnected
Fault Type 8: Power pack recharge too long
Fault Type 9: Inhibit relay fail
Fault Types 10, 11: Light/Siren relay failure
Fault Type 12: Ladder came off upper limit
Fault Type 13: Ladder did not reach limit
Fault Type 14: Ladder stayed on limit
Fault Type 15: Low oil level
Fault Type 16: System voltage over 18V during movement
Fault Type 17: System voltage under 18V
Fault Type 18: System voltage over 31V
Fault Types 19, 20: Remote UP and/or DOWN toggle held too long (when equipped)
Fault Type 21: Accumulator recharge > than once/hour
Fault Type 22: System raised by park brake
Fault Types 23, 24: Levels 1 and 2 service overdue
Fault Type 25: Levels 1 and 2 service complete
DATA MANAGEMENT
Log Files
Generating Reports
MENU DIAGRAMS
Controller Config
Contact Information
Show Recent Logs
System Settings
Upload Logs to USB
Diagnostics
SECTION M33 CAMERA SYSTEM INDEX
CAMERA SYSTEM
CAMERA SYSTEM
General
Operation
Camera Switch
CAMERA MONITOR
General
CAMERA CONTROLLER
General
Removal
Installation
Camera Controller Connector Pins
CAMERA SWITCHER
General
Removal
Installation
SETUP AND CHECKOUT PROCEDURE
General
STEP 1 – Switch Function
STEP 2 – Monitor System Settings to Default
STEP 4 – Monitor Settings – System Settings Unique
STEP 4 – Monitor Settings – System Settings Unique – Cameras
STEP 5 – Monitor Settings – System Settings Unique – On Screen Delay
STEP 6 – Monitor Settings – System Settings Unique – Standby Mode
STEP 7 – Integrated Functions Check

SECTION N – OPERATOR CAB

TRUCK CAB AND COMPONENTS
TRUCK CAB AND COMPONENTS
TRUCK CAB
Description
Removal
Installation
CAB DOOR
Removal
Installation
Door Adjustment
Door Jamb Bolt Adjustment
Door Handle Plunger Adjustment
Replace Door Glass
Replace Door Window Regulator
Replacing the Door Handle or Latch Assembly
Replacing the Door and Door Hinge Seal
Removing the Door Opening Seal
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 (STANDARD SEAT)
Adjustment
Inspection
Removal
Installation
Replacing the Seat Compressor
PASSENGER SEAT (STANDARD SEAT)
Inspection
Removal
Installation
SEAT BELT REPLACEMENT (STANDARD SEATS – PC3230)
Removal
Installation
SEAT BELT REPLACEMENT (STANDARD SEATS – 58E-57-00500)
Removal
Installation
OPERATOR SEAT (OPTIONAL SEAT)
Seat Belts
Adjustment
PASSENGER SEAT (OPTIONAL SEAT)
Seat Belts
Adjustment
SEAT BELT REPLACEMENT (OPTIONAL SEATS)
General
Removal
OPERATOR COMFORT
OPERATOR COMFORT
HEATER / AIR CONDITIONER
Fan Speed Control Knob
Temperature Control Knob
Air Flow Directional Knob
Heater/Air Conditioner Vents
COMPONENTS
Fuse and Circuit Breaker
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
Draining Oil from the Previous Recovery Cycle
Performing the Recovery Cycle
Performing the Recycling Procedure
Evacuating and Charging the A/C System
SYSTEM REPAIR
System Flushing
COMPONENT REPLACEMENT
Hoses and Fittings
Lines
Expansion Valve
Receiver-Drier
Thermostat
Compressor
Accumulator
Clutch
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
STEERING WHEEL
Removal
Installation
PEDALS
Service Brake Pedal
Dynamic Retarding
Dynamic Retard Pedal
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
12V Auxiliary Power Outlets
Fire Suppression Control Outlet
Communication Radio Outlet
DIAGNOSTIC PORTS
KOMTRAX Plus Diagnostic Port
Interface Module (IM) Diagnostic Port
Payload Meter Diagnostic Port
Drive System Or Modular Mining
Drive System Controller (DSC) Diagnostic Port
Engine Diagnostic Port (CENSE)
Engine Diagnostic Port (QUANTUM)
HEATER / AIR CONDITIONER
Fan Speed Control Knob
Temperature Control Knob
Air Flow Directional Knob
Heater/Air Conditioner Vents
INSTRUMENT PANEL
Control Symbols
Cab/Air Conditioner Vents
Status Indicator Light Panel
Hydraulic Oil Temperature Gauge
Coolant Temperature Gauge
Speedometer/Digital Display
Fuel Level Gauge
Drive System Temperature Gauge
Hazard Warning Light Switch
Pre-Shift Brake Test Switch
Wheel Brake Lock Control
Rest Switch
Engine Warm Up Switch (Optional)
Heated Mirror Switch (Optional)
Rotating Beacon Light Switch (Optional)
Camera System Switch (Optional)
Key Switch
Starting
Warning Light
Digital Display Contrast Buttons
Turn Signal Indicators
Panel Light Dimmer
Mode Switches
Fog Light Switch (Optional)
Manual Backup Switch
Headlight/Panel Illumination Light Switch
STATUS INDICATOR LIGHT PANEL
Status Indicator Light Panel
DIGIT DISPLAY OPERATION
Toggling Through Main Level Screens
Toggling Through Warning Screens
Entering Payload Meter Data
KOMTRAX PLUS
Operation
Interface Module
Basic Precautions
KOMATSU WIRELESS BRIDGE (Optional)
General Information
Communication Setup
Switching to the KWB_SETUP Network
Setting the Computer Subnet Mask and IP Address
Properties
Setting Up the KWB
Adding Encryption
Final Computer Settings
Data Downloading
Resetting the KWB
KWB Lights

SECTION P – LUBRICATION AND SERVICE

LUBRICATION AND SERVICE

LUBRICATION AND SERVICE
830E SERVICE CAPACITIES
HYDRAULIC TANK SERVICE
Adding Oil
COOLANT LEVEL CHECK
Radiator Filling Procedure
Coolant Specifications
Unacceptable Practices
WHEEL MOTOR SERVICE
RESERVE ENGINE OIL SYSTEM (Optional)
Reserve Oil Tank Filling Procedure (Remote fill)
Inline Screen
QUICK FILL SERVICE CENTER
LUBRICATION CHART
10 HOUR (DAILY) INSPECTION
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS
500 HOUR LUBRICATION AND MAINTENANCE CHECKS (Continued)
1000 HOURS LUBRICATION AND MAINTENANCE CHECKS
2500 HOUR MAINTENANCE CHECKS
5000 HOUR MAINTENANCE CHECKS
INJECTOR OPERATION
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
Over Pressure Cut Off Switch
Grease Pressure Failure Switch
Injectors
Interface Module
Relief Valve (unloader valve)
SYSTEM OPERATION
Normal Operation
Lubricant Required For System
Filter Assembly
LUBRICANT PUMP
Pump Housing Oil Level
Pump Pressure Control
INJECTORS (SL-1 Series “H”)
Injector Specifications
Injector Adjustment
PREVENTIVE MAINTENANCE PROCEDURES
Daily Lubrication System Inspection
250 Hour Inspection
1000 Hour Inspection
SYSTEM CHECKOUT
Lubrication Cycle Operation
SYSTEM TROUBLESHOOTING CHART

SECTION R – SYSTEM SCHEMATICS

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