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Komatsu 830E-1AC DUMP TRUCK Field Assembly Manual – PDF Download
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- Komatsu 830E-1AC DUMP TRUCK Field Assembly Manual
- SERIAL NUMBERS A30561 – A30565
- PUBLICATION NUMBER:CEAW006700
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Description
Komatsu 830E-1AC DUMP TRUCK Field Assembly Manual
Screenshot of the Manual:
KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL – PDF DOWNLOAD:
Description:
Komatsu 830E-1AC DUMP TRUCK Field Assembly Manual
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 MAJOR COMPONENT WEIGHTS ............................................... 23 FIELD WELDING FOR ASSEMBLY OR REPAIR .................................. 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 "Turn-Of-The-Nut" Tightening Procedure......................... 66 Upper Mounting Joint - 60° Advance............................. 66 Lower Mounting Joint - 90° Advance............................. 67 Inspection..................................................... 68 DUMP BODY ASSEMBLY ....................................................125 BODY ASSEMBLY......................................................126 BODY WELDING.......................................................128 FINAL ASSEMBLY.........................................................133 FINAL CHECKOUT ........................................................161 APPENDIX...............................................................163 LUBRICATION CHART..................................................165 OILING AND CHARGING PROCEDURE......................................167 GENERAL........................................................167 EQUIPMENT LIST.................................................167 HYDRAIR® CHARGING KIT..........................................168 Installation of Charging Kit...............................168 Removal of Charging Kit....................................168 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS..............169 FRONT SUSPENSION...............................................169 Front Suspension Oiling....................................169 Front Suspension Nitrogen Charging.........................171 REAR SUSPENSION................................................172 Rear Suspension Oiling.....................................173 Rear Suspension Nitrogen Charging..........................174 OIL AND NITROGEN SPECIFICATIONS CHART..........................176 TOE-IN ADJUSTMENT..................................................177 AUTOMATIC LUBRICATION SYSTEM.......................................179 GENERAL DESCRIPTION............................................179 SYSTEM COMPONENTS..............................................181 Filter.....................................................181 Hydraulic Motor and Pump...................................181 Grease Reservoir...........................................181 Pressure Reducing Valve....................................181 Flow Control Valve.........................................181 Solenoid Valve.............................................181 Vent Valve.................................................181 Lubrication Cycle Timer....................................181 Over Pressure Cut Off Switch...............................181 Grease Pressure Failure Switch.............................181 Injectors..................................................181 Relief Valve (unloader valve)..............................181 SYSTEM OPERATION...............................................182 Normal Operation...........................................182 Lubricant Required For System..............................183 System Priming.............................................183 Filter Assembly............................................183 LUBRICANT PUMP.................................................184 Pump Housing Oil Level.....................................184 Pump Pressure Control......................................184 SYSTEM CHECKOUT................................................185 Lubrication Controller Check...............................185 Lubrication Controller Components..........................185 Lubrication Controller Adjustment..........................185 SYSTEM TROUBLESHOOTING CHART...................................187 STANDARD TORQUE CHARTS AND CONVERSION TABLES...................343 A/C CHECKOUT PROCEDURE ............................................189 A/C DRIVE BELT ....................................................191 HYDRAULIC SYSTEM CHECKOUT PROCEDURE ...............................193 BRAKE SYSTEM CHECKOUT .............................................205 VHMS CHECKOUT PROCEDURE ...........................................215 INTERFACE MODULE CHECKOUT PROCEDURE ...............................219 ADDITIONAL INTERFACE MODULE CHECKOUT PROCEDURES ...................227 PAYLOAD METER CHECKOUT PROCEDURE ..................................235 ELECTRIC DRIVE SYSTEM CHECKOUT PROCEDURE ..........................249 AMENDMENTS TO ELECTRIC DRIVE SYSTEM CHECKOUT PROCEDURE ............338 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 .............................364
Please Note:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
