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KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual SERIAL NUMBERS (SN:A30566 & UP) – PDF DOWNLOAD
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- KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual
- SERIAL NUMBER:A30566 & UP
- PUBLICATION NUMBER:CEAW006802
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Description
KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual SERIAL NUMBERS (SN:A30566 & UP)
KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL SERIAL NUMBERS (SN:A30566 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 830E-1AC DUMP TRUCK Field Assembly Manual SERIAL NUMBERS (SN:A30566 & UP)
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 SERIAL NUMBERS (SN:A30566 & UP)
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 ........................................................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 STANDARD TORQUE CHARTS AND CONVERSION TABLES...................343 A/C CHECKOUT PROCEDURE ............................................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 CAMERA SYSTEM CHECKOUT PROCEDURE ..................................359 FIELD ASSEMBLY INSPECTION REPORT ..................................377 50 HOUR POST COMMISSIONING CHECKSHEET .............................383
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.
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