Komatsu 830E Dump Truck Shop Manual (A30710 and up) – CEBM013500

This complete service repair workshop manual PDF download for the Komatsu 830E Dump Truck (SN: A30710 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 :

Komatsu Dump Truck 830E 
Serial Numbers : A30710 and up
With Full Time Axle Blower

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 : CEBM013500
Total Pages : 808

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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GENERAL INFORMATION
Truck Component Description and Specifications
General Safety and Truck Operation
Precautions During Operation
Battery
Precautions For Maintenance
During Maintenance
Tires
Additional Job Site Rules
When Repairs Are Necessary
Operating Instructions
Warnings and Cautions
Charts and Tables
Storage Procedures
Short Term Idle Periods
Preparation for Storage
Removal from Storage
Reconditioning an Idle Vehicle
Engine Operation
After Engine Has Started
Engine Storage-Cummins
Engine Storage (Short Term)
Engine Storage (Long Term)
Electric Drive Trucks
Preservation and Storage- Allison Transmission

STRUCTURES
Structural Components
Ladders
Right Hand Deck
Removal
Installation
Center and Left Hand Deck Components
Fuel Tank
Removal
Installation
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

ENGINE
Power Module
Preparation
Removal
Installation
Cooling System
Cooling System Description
Radiator
Removal
Installation
Radiator Filling Procedure
Power Train
Alternator Removal Procedure
Engine Alternator Mating
Measuring Procedure
Joining Alternator and Engine
Engine
Removal
Installation
Air Filtration System
Air Cleaner
Operation
General Service Information
Main Filter Element
Safety Filter Element
Air Intake Troubleshooting
Air Cleaner Assembly Cleaning
Main Filter Cleaning
Precleaner Section Cleaning

ELECTRICAL SYSTEM (24VDC NON-PROPULSION)
24VDC Electric Supply System
Electrical System Description
Battery- Maintenance and Service
Troubleshooting
Battery Charging System (Niehoff)
General Description
Troubleshooting Procedures
On Vehicle Troubleshooting Guide- Self Energized Alternator
Advanced System Troubleshooting
24VDC Electric Starter System (with Prelube)
Operation
Maintenance
Troubleshooting
24VDC Electrical System Components
Passenger Seat Base Compartment
Components
Alarm Indicating Device
Battery Equalizer
Body-Up Switch
Hoist Limit Switch
24Volt Relay and Diode Boards
Circuit Breaker Chart

ELECTRICAL PROPULSION COMPONENTS
Electrical Propulsion Components
General System Description
Control System
FL275 Panel
Card Replacement
Card Repair
Computer Description
Software
2-Digit Display Panel
Events
Frames
Windows
2 Digit Display Panel Codes (Table I)
Subcode Descriptions (Table II)
Portable Test Unit (PTU)
Description
Software Installation Preparation
The Main Menu
PTU Software Menu Tree
Configuration (CFG) File Conversion
Statex Configuration Files
Programming The Truck
PTU Hookup
Download Configuration Files
Event Data
Statistical Data
Statistical Data Codes- Counters (Table III)
Statistical Data Codes- Profiles (Table IV)
Truck Specific Information
Temporary Truck Settings
Miscellaneous Software Features
Saving Data
PTU Abbreviations
Other Menu Selections
Miscellaneous Electrical Propulsion Components
Alternator
Electric Wheel Motors
Electronic Accelerator and Retard Control
Cooling Blower Warning System
Electrical Control Cabinet
Statex III Electric Drive Components Abbreviations
Statex III Electrical System Checkout Procedure
General Information
Communications Port Check
PTU Hookup
1.0 Sequence Tests
Throttle System Check and Adjustment
Electronic Throttle System
Electronic Throttle System fuel Enhancement (“Fuel Saver”)
Retard System Check and Adjustment- Electronic Pedal System
Williams Electronic Retard Pedal and ACC/RET or RET Interface
Electronic Retard Pedal, Current Production Trucks
Reverser and Propulsion Contractors Check
Propulsion Lockout Test (DDEC&MTU Engine Trucks Only)
Retard Contractors Operation Check
Ground Fault Sensing Check
Ground Fault in Retard Operation Check
Override Operation Check
Anti-Reversal Function (AR) Check
Overspeed Retard Operation Check
Hoist Interlock Operation Check
Motor Blower Fault Light Operation Check
Digital Input/Output Signals Tests- FL275 Card Panel
Setup Manual Digital Input/Output Test on PTU
Digital Input Checks
Digital Output Checks
Analog Input Signals Test- FL275 Card Panel
Setup Analog Input Monitor Screen on PTU
Analog Input Checks
Frequency Input Checks
Speed Event Checks
Single Speed Overspeed-Overspeed Settings Check
Empty Truck- 2 Speed Overspeed Settings Check
Loaded Truck- 2 Speed Overspeed Settings Check
Other Speed Events Checks
Retard Speed Control System Check
Overspeed Pickup and Dropout Check
Retard Pot Maximum Setting Check
Retard Pot Minimum Setting Check
Accelerator Pedal Override of Retard Speed Control
Load Test Using Truck Retard Grids
Load Test
Motor Field current Check in Retarding
Retard Check
Miscellaneous Component Test and Adjustment
Brake System Interlocks Check
Blower Loss Pressure Switch Adjustment
SYNC Transformer Checkout
Power Contactor Position Sensor Adjustment
Battery Boost Adjustment
Isolation Amplifier& Voltage Module Test
Voltage Measuring Module Test (VMM1&VMM2)
ISO-AMP Test
Motor Rotation Test
Ground Fault Checks
Miscellaneous Charts
Wheel Motor Gear Ratios
Maximum Allowable Truck Speeds
Engine Options

DRIVE AXLE, SPINDLE AND WHEELS
Tires and Rims
Front Tires and Rims
Removal
Installation
Rear Tires and Rims
Removal
Installation
Rim
Tire Removal
Rim and Tire Preparation
Lubricants
Tire Installation
Front Wheel Hub and Spindle
Wheel Hub and Spindle Assembly
Removal
Spindle Pusher Tool Usage
Installation
Disassembly
Cleaning and Inspection
Assembly
Wheel Bearing Adjustment
Wheel Bearing Adjustment (Tire Mounted)
Steering Cylinders and Tie Rod
Spherical Bearing Wear Limits
Removal
Installation
Bearing Replacement
Toe-In Adjustment
Rear Axle Housing Attachment
Pivot Pin
Removal
Installation
Pivot Eye Bearing
Disassembly
Assembly
Pivot Eye Repair
Removal
Disassembly
Assembly
Installation
Anti-Sway Bar
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Rear Axle Housing
Rear Axle Housing
Removal
Installation
Wheel Motor
Removal
Cleaning and Inspection
Installation

HYDRAIR II SUSPENSIONS
Front Suspension
Removal
Installation
“Turn of the Nut” Tightening Procedure
Minor Repair
Bearing Structure Removal
Bearing Structure Installation
Major Suspension Rebuild
Disassembly
Assembly
Pressure Test
Rear Suspension
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Pressure Test
Oiling and Charging Procedure
General
Equipment List
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
Service Brake Circuit Operation
Secondary Braking and Automatic Apply
Parking Brake Circuit
Brake Lock Circuit
Warning Circuit
Brake Circuit Component Service
Brake Valve
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Differential Pressure Switch
Disassembly
Cleaning and Inspection
Assembly
Valve Bench Test and Adjustment
Test Set Up Procedure
Differential Pressure Switch Test
Final Test and Adjustment
Installation of Brake Pedal Actuator Assembly to Brake Valve
Brake Valves with Integral Mounted Electronic Retard Pedal
Hydraulic Brake Accumulators
Removal
Installation
Disassembly
Cleaning and Inspection
Assembly
Brake Circuit Check-Out Procedure
Equipment Required
Initial System Set-Up
Parking Brake
Brake System Check-Out
Failure Modes Check-Out
Brake Circuit and Brake Valve Troubleshooting
Hydraulic Brake System Check-Out Procedure Data Sheet
Rockwell Wheel Speed Front Disc Brakes
Brake Caliper
Brake Lining
Front Service Brake Conditioning (Burnishing) Procedure
Brake Bleeding Procedures
Rockwell Armature Speed Rear Disc Brakes
Rear Brakes
Caliper, Disc and Parking Brake
Caliper Piston
Bench Test
Brake Lining
Service Brake Conditioning (Burnishing) Procedure
Brake Bleeding Procedure
Rockwell Disc Parking Brake
Park Brake Caliper
Removal
Installation
Parking Brake Adjustment
Park Brake Caliper Disassembly
Cleaning and Inspection
Park Brake Caliper Assembly
Park Brake Lining Replacement
Park Brake Burnish Procedure
Brake Bleeding Procedure

HYDRAULIC SYSTEM
Hydraulic System
Hydraulic System Operation
Component Description
Axle Blower System
Hydraulic System Component Repair
Hoist Pump
Brake / Steering Pump
Axle Blower Pump
Hand Wheel Control
Hydraulic Tank
Hydraulic Tank Strainers
Steering Circuit
Steering Circuit Operation
Component Description
Steering Pump Compensator Vent
Steering Depressurization Valve
Pilot To Open Check Valve
Pilot To Open Check Valve Control Solenoid
Steering Control Unit
Flow Amplifier
Bleed Down Manifold
Accumulators
High Pressure Filter
Brake/Steering Pump
Operation
Steering Circuit Component Repair
Bleed Down Manifold
Accumulator
Steering Accumulator Charging Procedure
Flow Amplifier
Steering Control Unit
Steering Cylinder
Steering Circuit Filter
Steering and Brake Pump
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
Electronic Hoist Controller
Counterbalance Valve Manifold
Hoist System Operation Modes
Hoist Circuit Component Repair
Hoist Valve
Inlet Section
Spool Section
Hoist Pilot Valve
Body Up Limit Solenoid
Pilot Operated Check Valve
Hoist Controller
Hoist Cylinders
Counterbalance Manifold
Disabled Truck Dumping Procedure
Hydraulic Checkout Procedure
Initial Start Up and Flushing
Component Checkout and Adjustment
Brake/Steering Pump Pressure Procedure
Steering Circuit Pressure Adjustment
Remote Pressure Compensator Adjustment
Axle Box Blower Circuit Adjustment
Adjustment Procedure for Hoist Counterbalance Cartridge Valve
Counterbalance Valve Adjustment
Manifold Reassembly
Hoist Controller Troubleshooting Procedure
Troubleshooting Charts
Steering Circuit
Brake/Steering Pump
Hoist Pump
Flow Amplifier

OPTIONS AND SPECIAL TOOLS
Ansulfire Control System Manual
Operation
Inspection and Maintenance
Recharging Procedures
Alternator and Wheelmotor Cooling Air Filter System
System Adjustment
Pump
Blower Drive Motor
Blower Bearing Repair
Air Cleaner
Wiggins Quick Fill Fuel System
Fuel Receiver
Tank Breather Valve
Buckeye Quick Fill Fuel System
Tank Breather Valve
Fuel Receiver
Engine Coolant Heater
Heating Element
Thermostat
Special Tools
Air Conditioning System
Environmental Impact
Operator Cab Air Conditioning
Principles of Refrigeration
Air Conditioner System Components
Electrical Circuit
System Servicing
Service Tools and Equipment
Manifold Gauge Set
System Performance Test
System Leak Testing
System Repair
Evacuating the System
Troubleshooting
Preventive Maintenance Schedule for A/C Systems
Radiator Shutters
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
Keyswitch 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
States or Stages of a Typical Haul Cycle
Haul Cycle Description
Load Calculation
Carry Back
Measurement Accuracy
Sources for Payload Error
Payload Error
Loading Conditions
Pressure Sensors
Swing Loads
Speed and Distance
Haul Cycle Data
Haul Cycle Data
Haul Cycle Warning Flags
Alarm Records
Frame Torque Data
Sprung Weight Data
Maximum Speed Data
PC Software Overview
PC Overview
System Configuration
Installing the PLM III 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 Customer
Clean Truck Tare
Inclinometer Calibration
Data Analysis
Creating a Query
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 Communication 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
Troubleshooting Wiring to Right Front Suspension
Alarm 5-Left Rear Pressure High
Alarm 6-Left Rear Pressure Low
Troubleshooting 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 15-Memory Write Failure
Alarm 16 – Memory Read Failure
Alarm 24 – System Key-On Status
Operator Switch Doesn’t Work
Alarm 26 – User Switch Fault – Select
Alarm 27 – User Switch Fault – Set
Connector Map
Connectors
PLM III Check Out Procedure
General Description
Tools Required
Check Out Procedure
PLM III Check Out Procedure Confirmation
Flashburn Programming
Confirmation Checklist
PLM III Components
Pressure Sensor
Controller
Speedometer
Reserve Engine Oil System

OPERATOR’S CAB
Truck Cab
Description
Removal
Installation
Cab Door
Removal
Installation
Door Adjustment
Door Jam 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
Glass Replacement
Adhesive Bonded Windows
Windshield and Rear Glass
Cab Components
Windshield Wiper
Windshield Washer
Operator Comfort
Operator Seat
Adjustment
Heater/ Air Conditioner Controls
Heater Components
Filter
Operator Controls and Equipment
Steering Wheel and Controls
Steering Column
Pedal Controls
Overhead Controls, Gauges, Etc.
Center Console
Hoist Control Lever
Instrument Panel and Indicator Lights
Control Symbols
Instrument Panel
Panel Gauges, Indicators and Controls
Overhead Status / Warning Indicator Lights

LUBRICATION AND SERVICE
Lubrication and Service
Lubrication Specifications Charts
Service Capacities
Hydraulic Tank Service and Filling Instructions
Radiator Filling Procedure
Anti-Freeze Specifications
Reserve Engine Oil System
Lubrication Chart- Oil and Grease Specifications
10 Hour (Daily) Lubrication and Maintenance Checks
50 Hour Lubrication and Maintenance Checks
100 Hour Lubrication and Maintenance Checks
250 Lubrication and Maintenance Checks
500 Hour Lubrication and Maintenance Checks
1000 Hour Lubrication and Maintenance Checks
2500 Hour Lubrication and Maintenance Checks
5000 Hour Lubrication and Maintenance Checks
10,000 Hour Lubrication and Maintenance Checks
Automatic Lubrication System
General Description
System Components
System Operation
Injector Operation
General Instructions
System Checkout
Pump Rebuild
System Troubleshooting Chart
Preventative Maintenance Procedures
Motorized Wheel Maintenance Schedule

ALPHABETICAL INDEX

SYSTEM SCHEMATICS
HYDRAULIC BRAKE SCHEMATIC EG4934
HYDRAULIC SCHEMATIC EK4841
HE481 PLM III ELECTRICAL SCHEMATIC
ELECTRICAL SCHEMATIC XS2100
XS2101 INDEX AND SYMBOLS
XS2102 CIRCUIT NUMBER LOCATION
XS2103 COMPONENT LOCATOR
XS2104 COMPONENT LOCATOR
XS2105 POWER DISTRIBUTION – 24V
XS2106 POWER 18 ELEMENT 3 STEP RETARDING
XS2107 POWER 18 ELEMENT 7 STEP RETARDING
XS2108 POWER 20 ELEMENT 7 STEP RETARDING
XS2109 DRIVE SYSTEM CONTROL CIRCUITS
XS2110 TWO DIGIT DISPLAY
XS2111 G.E. DIGITAL INPUTS, AUTO LUBE CONTROL
XS2112 REAR TAIL LIGHTS, DIMMER CONTROL
XS2113 5 MINUTE IDLE, SPARE WIRES
XS2114 WINDOWS, RADIO, GAUGES
XS2115 CONTACTOR FEEDBACK
XS2116 CONTACTOR COILS
XS2117 MACHINE CONTROL CIRCUITS
XS2118 ACCELERATOR, RETARD PEDALS
XS2119 HYDRAULIC CONTROLS, ALARMS
XS2120 HEATER/AC, WINDSHIELD WIPER CONTROLS
XS2121 LIGHT CONTROL CIRCUITS
XS2122 INSTRUMENT LIGHTS, DIAGNOSTIC PORTS
XS2123 MOD. MINING DISPATCH
XS2124 CUMMINS QSK60 ENGINE
XS2125 CUMMINS QSK60 ENGINE
XS2126 ELECTRONIC HOIST CONTROLLER

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