KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual CEAW006402 – PDF DOWNLOAD

Description

KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual

FILE DETAILS:

KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual

Size : 46.5 MB
Format : PDF
Language : English
Brand: Komatsu
Type of machine: Dump Truck
Type of document: Field Assembly Manual
Model: Komatsu Dump Trucks 830E-1AC

KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL CEAW006402 – PDF DOWNLOAD:

DESCRIPTION:

KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual

FOREWORD:

• This manual is provided to aid assemblers during field assembly of the standard Komatsu 830E-AC dump truck. Variations of design required for specific truck orders may require some modification of the general procedures outlined in this manual.
• Follow all safety notices, warnings, and cautions provided in this book when assembling the truck. General assembly pictures and illustrations are used in this manual. At times the illustrations may not reflect the current production truck model.
• This manual lists metric (SI) and U.S. standard dimensions throughout. All location references to “front”, “rear”, “right”, or “left”, are given in respect to the operator’s normal seated position. It is recommended that all maintenance personnel read and understand the materials in the service manual before performing maintenance and/or operational checks on the assembled truck.

TABLE OF CONTENTS:

KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual

COVER..................................................................  1
FOREWORD...............................................................  3
TABLE OF CONTENTS......................................................  5
SAFETY RULES, TOOLS & EQUIPMENT........................................  7
	SAFETY RULES.......................................................  7
		BODY-UP RETENTION CABLE........................................  7
	HYDRAULIC SYSTEM FLUSHING TOOLS.................................... 15
	HYDRAULIC SYSTEM VACUUM PUMP....................................... 15
TRUCK COMPONENTS AND SPECIFICATIONS.................................... 19
	Truck And Engine................................................... 19
	AC Induction Traction Motorized Wheels............................. 19
	Suspension......................................................... 19
	Operator's Cab..................................................... 19
	Power Steering..................................................... 19
	Dynamic Retarding.................................................. 19
	Brake System....................................................... 19
	SPECIFICATIONS..................................................... 21
		REAR AXLE COMPONENTS........................................... 24
MAJOR COMPONENT WEIGHTS................................................ 23
FIELD WELDING FOR ASSEMBLY OR REPAIR................................... 25
	WELDER QUALIFICATION AND TRAINING.................................. 25
	WELD PROCEDURES.................................................... 25
	APPROVED CONSUMABLES............................................... 25
	WELD QUALITY REQUIREMENTS.......................................... 25
	MATERIALS, CONTROLS, AND PRECAUTIONS............................... 26
	WELD INSPECTION.................................................... 26
	RECORDS............................................................ 27
	ANNEX A............................................................ 27
	ANNEX B............................................................ 29
		1.0 TOE HAMMER PEENING......................................... 29
			Procedure.................................................. 29
		2.0 TOE GRINDING WITH A ROTARY BURR............................ 29
			Procedure.................................................. 29
	BIBLIOGRAPHY....................................................... 32
		SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK.... 32
			General Welding Guidelines................................. 33
RECEIVING & ASSEMBLY PREPARATION....................................... 35
	ASSEMBLY LAYOUT.................................................... 36
CHASSIS ASSEMBLY....................................................... 37
	RECOMMENDED ASSEMBLY DATA.......................................... 37
	BASIC ASSEMBLY PROCEDURE........................................... 37
		ORDER OF ASSEMBLY.............................................. 38
		LEVEL 1........................................................ 38
		LEVEL 2........................................................ 38
		LEVEL 7........................................................ 38
	GENERAL PRECAUTIONS AND INSTRUCTION................................ 40
DUMP BODY ASSEMBLY.....................................................127
	GENERAL INFORMATION................................................127
	BODY ASSEMBLY......................................................128
	BODY WELDING.......................................................130
FINAL ASSEMBLY.........................................................135
FINAL CHECKOUT.........................................................163
APPENDIX...............................................................165
	LUBRICATION CHART..................................................167
	OILING AND CHARGING PROCEDURE......................................169
		GENERAL........................................................169
		EQUIPMENT LIST.................................................169
		HYDRAIR® CHARGING KIT..........................................170
			Installation of Charging Kit...............................170
			Removal of Charging Kit....................................170
		SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS..............171
		FRONT SUSPENSION...............................................171
			Front Suspension Oiling....................................171
			Front Suspension Nitrogen Charging.........................173
		REAR SUSPENSION................................................174
			Rear Suspension Oiling.....................................175
			Rear Suspension Nitrogen Charging..........................176
		OIL AND NITROGEN SPECIFICATIONS CHART..........................178
	TOE-IN ADJUSTMENT..................................................179
	AUTOMATIC LUBRICATION SYSTEM.......................................181
		GENERAL DESCRIPTION............................................181
		SYSTEM COMPONENTS..............................................183
			Filter.....................................................183
			Hydraulic Motor and Pump...................................183
			Grease Reservoir...........................................183
			Pressure Reducing Valve....................................183
			Flow Control Valve.........................................183
			Solenoid Valve.............................................183
			Vent Valve.................................................183
			Lubrication Cycle Timer....................................183
			Over Pressure Cut Off Switch...............................183
			Grease Pressure Failure Switch.............................183
			Injectors..................................................183
			Relief Valve (unloader valve)..............................183
		SYSTEM OPERATION...............................................184
			Normal Operation...........................................184
			Lubricant Required For System..............................185
			System Priming.............................................185
			Filter Assembly............................................185
		LUBRICANT PUMP.................................................186
			Pump Housing Oil Level.....................................186
			Pump Pressure Control......................................186
		SYSTEM CHECKOUT................................................187
			Lubrication Controller Check...............................187
			Lubrication Controller Components..........................187
			Lubrication Controller Adjustment..........................187
		SYSTEM TROUBLESHOOTING CHART...................................189
	A/C CHECKOUT PROCEDURE.............................................191
	AIR CONDITIONING DRIVE BELT ADJUSTMENT PROCEDURE...................193
	HYDRAULIC CHECKOUT PROCEDURE.......................................195
	BRAKE CHECKOUT PROCEDURE...........................................207
	VHMS CHECKOUT PROCEDURE............................................217
	INTERFACE MODULE CHECKOUT PROCEDURE................................221
	ADDITIONAL INTERFACE MODULE CHECKOUT PROCEDURE.....................229
	PAYLOAD METER III CHECKOUT PROCEDURE...............................237
	ELECTRICAL CHECKOUT PROCEDURE......................................251
	AMENDMENTS TO ELECTRICAL CHECKOUT PROCEDURE........................339
	STANDARD TORQUE CHARTS AND CONVERSION TABLES.......................343
	HYDRAULIC SYSTEM FLUSHING PROCEDURE................................349
		SYSTEM FLUSHING................................................349
			Hydraulic System Flushing Procedure........................349
	STATIC BRAKE SYSTEM CHECKOUT.......................................355
		STATIC BRAKE SYSTEM CHECKOUT...................................355
			Events.....................................................355
			OPERATION..................................................355
				Description............................................355
				Brake Test Exit Criteria...............................356
			PERFORMING THE BRAKE TESTS.................................356
				Setup..................................................356
				Service Brake Test.....................................357
				Parking Brake Test.....................................358
				Retard System Test:....................................358
	FIELD ASSEMBLY INSPECTION REPORT...................................359
	50 HOUR POST-COMMISSIONING CHECKSHEET..............................365

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.