Komatsu 830E Manuals

Manuals and User Guides for Komatsu 830E. We have 2 Komatsu 830E manuals available for free PDF download: Shop Manual, Brochure

KOMATSU 830E Shop Manual (783 pages)

DUMP TRUCK

Brand: KOMATSU | Category: Trucks | Size: 13.21 MB

Standard Charts and Tables

55
- A00032 Introduction a
  5
- Table of Contents
  55
- Table V
  58
- Table VI
  58
- Table IX
  58
- Table X
  58
- Table XI
  59
Section B Structures Index

81
- Structural Components
  83
  - Ladders
    83
  - Right Hand Deck
    84
    
    Installation
    84
    
    Removal
    84
  - Center and Left Hand Deck Components
    85
  - Fuel Tank
    86
    
    Installation
    86
    
    Removal
    86
- Dump Body
  87
  - Removal
    87
  - Installation
    88
  - Body Pads
    89
    
    Adjustment
    90
  - Body Guide
    90
  - Body-Up Retention Cable
    90
  - Body Position Indicator
    91
  - Rock Ejectors
    91
    
    Inspection
    91
  - Hoist Limit Switch
    91
  - Body up Switch
    91
Section C Engine Index

93
- Power Module
  95
  - Preparation
    95
    
    Removal
    95
    
    Installation
    99
- Cooling System
  101
  - Cooling System Description
    101
  - Radiator
    102
    
    Removal
    102
    
    Installation
    104
  - Radiator Filling Procedure
    104
- Power Train
  105
  - Alternator Removal Procedure
    105
    
    Engine/Alternator Mating
    107
    
    Measuring Procedure
    107
  - Engine
    110
    
    Installation
    110
    
    Removal
    110
- Air Filtration System
  111
  - Air Cleaner
    111
    
    General Service Information
    111
    
    Operation
    111
  - Main Filter Element
    111
  - Safety Filter Element
    112
    
    Air Intake Troubleshooting
    113
  - Air Cleaner Assembly Cleaning
    113
    
    Main Filter Element Cleaning
    113
    
    Precleaner Section Cleaning
    114
Section D Electrical System (24Vdc Non-Propulsion) Index

117
- 24Vdc Electric Supply System
  119
- Electrical System Description
  119
  - Troubleshooting
    119
- Battery Charging System (Niehoff)
  121
  - General Description
    121
  - Troubleshooting Procedures
    121
  - Advanced System Troubleshooting
    126
  - Operation
    128
  - Maintenance
    129
  - Troubleshooting
    133
- 24Vdc Electrical System Components
  141
  - Passenger Seat Base Compartment
    141
  - Components
    141
  - Alarm Indicating Device (Aid) System
    144
  - Battery Equalizer Box
    146
  - Body up Switch
    147
  - Hoist Limit Switch
    147
  - Volt Relay and Diode Boards
    148
  - Circuit Breaker Chart
    149
Section E Electrical Propulsion Components Index

155
- Electrical Propulsion Components
  157
  - General System Description
    157
  - Control System
    157
    
    Computer Description
    161
    
    Software
    161
  - 2-Digit Display Panel
    164
    
    Events
    164
    
    Frames
    165
    
    Windows
    165
    
    Subcode Descriptions (Table II)
    166
- Table I
  171
  - Portable Test Unit (PTU)
    177
    
    Description
    177
    
    Software Installation Preparation
    178
    
    The Main Menu
    180
    
    Configuration (CFG) File Conversion
    182
    
    Statex Configuration Files
    186
    
    Programming the Truck
    197
    
    Download Configuration Files
    199
    
    Event Data
    201
- Table IV
  203
  - Statistical Data
    203
    
    Statistical Data Codes - Counters (Table III)
    204
- Table III
  205
  - Truck Specific Information
    214
    
    Temporary Truck Settings
    215
    
    Saving Data
    216
    
    PTU Abbreviations
    217
  - Miscellaneous Electrical Propulsion Components
    218
    
    Alternator
    218
    
    Electric Wheel Motors
    218
    
    Retarding Grids
    218
    
    Cooling Blower Warning System
    220
    
    Electrical Control Cabinet
    221
Statex III Electrical System Checkout Procedure

229
- General Information
  231
- Communications Port Check
  232
  - PTU Hookup
    232
- 1 SEQUENCE TESTS - (Engine Not Running)
  
  234
  - Throttle System Check and Adjustment
    235
    
    Electronic Throttle System
    235
  - Reverser and Propulsion Contactors Check
    241
  - Retard Contactors Operation Check
    243
  - Ground Fault Sensing Check
    243
  - Ground Fault in Retard Operation Check
    243
  - Override Operation Check
    244
  - Anti-Reversal Function (AR) Check
    245
  - Overspeed Retard Operation Check
    245
  - Hoist Interlock Operation Check
    246
  - Motor Blower Fault Light Operation Check
    247
- 2 Digital Input/Output Signals Tests - Fl275 Card Panel
  
  248
  - Setup Manual Digital Input/Output Test on PTU
    248
  - Digital Input Checks
    249
  - Digital Output Checks
    251
- 3 Analog Input Signals Tests - Fl275 Card Panel
  
  254
  - Setup Analog Input Monitor Screen on PTU
    254
  - Analog Input Checks
    255
  - Frequency Input Checks
    262
- 4 Speed Event Checks
  
  264
  - Other Speed Events Checks
    265
- 5 Retard Speed Control System Check
  
  267
- 6 Load Test Using Truck Retard Grids
  
  269
- 7 Motor Field Current Check in Retarding
  
  271
- 8 Miscellaneous Component Test and Adjustment
  
  272
  - Brake System Interlocks Check
    272
  - Blower Loss Pressure Switch Adjustment
    273
  - SYNC Transformer Checkout
    273
  - Power Contactor Position Sensor Adjustment
    273
  - Battery Boost Adjustment
    274
  - Isolation Amplifier & Voltage Module Test
    274
    
    Voltage Measuring Module Test (VMM1 & VMM2)
    274
  - Motor Rotation Test
    275
  - Ground Fault Checks
    276
- 9 Optional Payload Meter (Plm II) Check-Out Procedure
  
  277
- 10 Miscellaneous Charts
  
  278
  - Wheel Motor Gear Ratios
    278
  - Maximum Allowable Truck Speeds
    279
  - Engine Options
    280
Section G Drive Axle, Spindle and Wheels Index

281
- Tires and Rims
  283
  - Front Tires and Rims
    283
    
    Removal
    283
    
    Installation
    284
  - Rear Tires and Rims
    285
    
    Removal
    285
    
    Installation
    286
  - Rim
    287
    
    Rim and Tire Preperation
    287
    
    Tire Removal
    287
    
    Lubricants
    288
    
    Tire Installation
    288
  - Wheel Hub and Spindle Assembly
    291
    
    Removal
    291
    
    Spindle Pusher Tool Usage
    292
    
    Installation
    293
    
    Cleaning and Inspection
    295
    
    Disassembly
    295
    
    Assembly
    296
    
    Wheel Bearing Adjustment
    298
    
    Wheel Bearing Adjustment (Tire Mounted)
    298
  - Steering Cylinders and Tie Rod
    300
    
    Spherical Bearing Wear Limits
    300
    
    Bearing Replacement
    301
    
    Installation
    301
    
    Removal
    301
    
    Toe-In Adjustment
    303
- Rear Axle Housing Attachment
  305
  - Pivot Pin
    305
    
    Installation
    305
    
    Removal
    305
  - Pivot Eye Bearing
    306
    
    Assembly
    306
    
    Disassembly
    306
  - Anti-Sway Bar
    308
    
    Assembly
    308
    
    Cleaning and Inspection
    308
    
    Disassembly
    308
    
    Installation
    308
    
    Removal
    308
- Rear Axle Housing
  309
  - Removal
    309
  - Installation
    309
  - Wheel Motor
    309
    
    Cleaning and Inspection
    310
    
    Installation
    310
Section H ® Hydrair II Suspensions Index

311
- Front Suspension
  313
  - Removal
    313
  - Installation
    314
  - Turn-Of-The-Nut" Tightening Procedure
    316
  - Bearing Structure Removal
    317
  - Bearing Structure Installation
    317
  - Major Suspension Rebuild
    318
    
    Disassembly
    318
    
    Assembly
    319
    
    Pressure Test
    320
- Rear Suspension
  321
  - Removal
    321
  - Installation
    323
  - Disassembly
    325
  - Assembly
    325
  - Pressure Test
    326
Section J Brake Circuit Index

335
- Brake Circuit
  337
  - Service Brake Circuit Operation
    337
  - Secondary Braking and Automatic Apply
    339
  - Parking Brake Circuit
    339
  - Brake Lock Circuit
    340
  - Warning Circuit
    340
- Brake Circuit Component Service
  343
  - Brake Valve
    343
    
    Removal
    343
    
    Installation
    345
    
    Disassembly
    346
    
    Assembly
    348
    
    Cleaning and Inspection
    348
    
    Differential Pressure Switch
    351
    
    Valve Bench Test and Adjustment
    352
    
    Installation of Brake Pedal Actuator to Brake Valve
    354
  - Hydraulic Brake Accumulators
    357
  - Parking Brake
    364
- Brake Circuit Checkout Procedure
  372
- Rockwell Wheel Speed Front Disc Brakes
  373
  - Brake Caliper
    373
  - Brake Lining
    377
  - Brake Bleeding Procedure
    379
- Rockwell Armature Speed Rear Disc Brakes
  381
  - Rear Brakes
    381
  - Caliper, Disc and Parking Brake
    381
  - Bench Test
    392
  - Brake Lining
    393
  - Brake Bleeding Procedure
    398
- Rockwell Disc Parking Brake
  399
  - Park Brake Caliper
    399
    
    Removal
    399
    
    Installation
    400
    
    Parking Brake Adjustment
    400
    
    Cleaning and Inspection
    402
    
    Park Brake Caliper Disassembly
    402
    
    Park Brake Caliper Assembly
    403
  - Park Brake Lining
    404
    
    Park Brake Burnish Procedure
    404
  - Brake Bleeding Procedure
    404
Section L Hydraulic System Index

405
- Hydraulic System
  407
  - Component Description
    408
- Hydraulic System Component Repair
  411
  - Hoist Pump
    411
  - Hydraulic Tank
    411
    
    Hydraulic Tank Strainers
    423
    
    Hoist Circuit Filters
    424
- Steering Circuit
  427
  - Steering Circuit Operation
    427
  - Component Description
    428
    
    Flow Amplifier
    428
    
    Steering Control Unit
    428
    
    Bleed down Manifold
    438
    
    Accumulators
    439
    
    Steering/Brake Pump
    439
- Steering Circuit Component Repair
  445
  - Bleed down Manifold
    445
  - Accumulator
    446
    
    Steering Accumulator Charging Procedure
    450
  - Flow Amplifier
    451
  - Steering Control Unit
    456
  - Steering Cylinder
    462
  - Steering Circuit Filter
    463
  - Steering and Brake Pump
    465
- Hoist Circuit
  477
  - Hoist Circuit Operation
    477
  - Component Description
    478
    
    High Pressure Filters
    478
    
    Hoist Pump
    478
    
    Hoist Valve
    493
    
    Hoist Pilot Valve
    499
    
    Pilot Operated Check Valve
    502
  - Disabled Truck Dumping Procedure
    511
- Hydraulic Checkout Procedure
  513
  - Steering and Brake Pump
    513
  - Bleeddown Manifold
    514
  - Shock & Suction Valves
    515
  - Leakage Tests
    516
  - Troubleshooting Chart
    518
    
    Steering Circuit
    518
    
    Steering Pump
    520
  - Counterbalance Valve
    527
  - Hydraulic System Flushing Procedure
    530
    
    Inspection and Maintenance
    533
    
    Operation
    533
    
    Recharging Procedures
    534
  - Alternator and Wheelmotor Cooling Air Filter System (M04002)
    535
    
    Pump
    535
    
    System Adjustment
    535
    
    Blower Drive Motor
    538
    
    Blower Bearing Repair
    541
    
    Air Cleaner
    542
  - Wiggins Quick Fill Fuel System (M05002)
    543
    
    Fuel Receiver
    543
    
    Tank Breather Valve
    544
  - Buckeye Quick Fill Fuel System (M05003)
    547
    
    Tank Breather Valve
    547
    
    Fuel Receiver
    548
  - Engine Coolant Heater (M07001)
    549
    
    Heating Element
    549
    
    Thermostat
    550
    
    Special Tools
    551
    
    Environmental Impact
    557
    
    Principles of Refrigeration
    558
    
    Air Conditioner System Components
    560
    
    Electrical Circuit
    562
    
    System Servicing
    564
    
    Service Tools and Equipment
    567
    
    Manifold Gauge Set
    569
    
    System Performance Test
    572
    
    System Leak Testing
    573
    
    System Repair
    574
    
    Evacuating the System
    581
    
    Troubleshooting
    583
    
    Preventive Maintenance Schedule for AC System
    591
  - Radiator Shutters
    593
Section N Operator's Cab Index

661
- Truck Cab
  663
  - Description
    663
  - Removal
    664
  - Installation
    665
  - Cab Door
    666
    
    Door Adjustment
    666
    
    Installation
    666
    
    Removal
    666
    
    Door Handle Plunger Adjustment
    668
    
    Replace Door Glass
    669
    
    Replace Door Window Regulator
    673
    
    Adhesive-Bonded Windows
    675
    
    Glass Replacement
    675
- Cab Components
  679
  - Windshield Wiper
    679
  - Windshield Washer
    681
- Operator Comfort
  683
  - Operator Seat
    683
    
    Adjustment
    683
    
    Heater Components
    685
    
    Filter
    686
- Operator Controls and Equipment
  689
  - Steering Wheel and Controls
    690
    
    Steering Column
    690
  - Pedal Controls
    692
  - Overhead Controls, Gauges, Etc
    693
  - Center Console Controls
    694
    
    Hoist Control Lever
    694
    
    Instrument Panel
    699
Section P Lubrication and Service Index

711
- Service Capacities
  713
- Radiator Filling Procedure
  714
- HOUR (Daily) Lubrication and Maintenance Checks
  716
- HOUR Lubrication and Maintenance Checks
  716
- HOUR Lubrication and Maintenance Checks
  719
- HOUR Lubrication and Maintenance Checks
  720
- 1000 HOUR Lubrication and Maintenance Checks
  723
- HOUR Lubrication and Maintenance Checks
  725
- Automatic Lubrication System
  727
- General Description
  727
- System Components
  729
- System Operation
  730
  - Injector Operation
    732
- General Instructions
  733
- System Checkout
  736
  - Pump Rebuild
    737
  - System Troubleshooting Chart
    740
  - Alphabetical Index
    749

Komatsu 830E Brochure (4 pages)

ELECTRIC DRIVE TRUCK

Brand: Komatsu | Category: Trucks | Size: 0.57 MB

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Komatsu 830E Manuals

KOMATSU 830E Shop Manual (783 pages)

Table of Contents

Standard Charts and Tables

Section B Structures Index

Section C Engine Index

Section D Electrical System (24Vdc Non-Propulsion) Index

Section E Electrical Propulsion Components Index

Statex III Electrical System Checkout Procedure

1 SEQUENCE TESTS - (Engine Not Running)

2 Digital Input/Output Signals Tests - Fl275 Card Panel

3 Analog Input Signals Tests - Fl275 Card Panel

4 Speed Event Checks

5 Retard Speed Control System Check

6 Load Test Using Truck Retard Grids

7 Motor Field Current Check in Retarding

8 Miscellaneous Component Test and Adjustment

9 Optional Payload Meter (Plm II) Check-Out Procedure

10 Miscellaneous Charts

Section G Drive Axle, Spindle and Wheels Index

Section H ® Hydrair II Suspensions Index

Section J Brake Circuit Index

Section L Hydraulic System Index

Section N Operator's Cab Index

Section P Lubrication and Service Index

Komatsu 830E Brochure (4 pages)

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