KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30240- A30261) – PDF DOWNLOAD

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KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30240- A30261)

KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30240- A30261) – PDF DOWNLOAD:

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KOMATSU 830E-1AC DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30240- A30261)

• 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 (SN:A30240- A30261)

COVER……………………………………………….. 1
FOREWORD…………………………………………….. 3
TABLE OF CONTENTS…………………………………….. 5
SAFETY RULES…………………………………………. 7
TRUCK COMPONENTS AND SPECIFICATIONS…………………….. 17
MAJOR COMPONENT WEIGHTS……………………………….. 21
FIELD WELDING FOR ASSEMBLY OR REPAIR……………………. 23
WELDER QUALIFICATION AND TRAINING…………………… 23
WELD PROCEDURES…………………………………… 23
APPROVED CONSUMABLES………………………………. 23
WELD QUALITY REQUIREMENTS………………………….. 23
MATERIALS, CONTROLS, AND PRECAUTIONS………………… 24
WELD INSPECTION…………………………………… 24
RECORDS………………………………………….. 25
RECEIVING AND ASSEMBLY PREPARATION……………………… 33
CHASSIS ASSEMBLY…………………………………….. 35
BASIC ASSEMBLY PROCEDURE…………………………… 35
ORDER OF ASSEMBLY……………………………… 36
GENERAL PRECAUTIONS AND INSTRUCTION……………… 38
“Turn-Of-The-Nut” Tightening Procedure……….. 58
Upper Mounting Joint – 60 Advance…………… 58
Lower Mounting Joint – 90 Advance…………… 59
Inspection………………………………… 60
DUMP BODY ASSEMBLY…………………………………….119
BODY ASSEMBLY……………………………………..120
BODY WELDING………………………………………122
FINAL ASSEMBLY………………………………………..127
FINAL CHECKOUT………………………………………..157
APPENDIX……………………………………………..159
LUBRICATION CHART………………………………….161
OILING AND CHARGING PROCEDURE……………………….163
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS….165
FRONT SUSPENSION……………………………….165
Front Suspension Oiling……………………..165
Front Suspension Nitrogen Charging……………167
REAR SUSPENSION………………………………..168
Rear Suspension Oiling………………………169
Rear Suspension Nitrogen Charging…………….169
TOE-IN ADJUSTMENT………………………………….173
AUTOMATIC LUBRICATION SYSTEM………………………..175
A/C CHECKOUT PROCEDURE……………………………..185
A/C DRIVE BELT ADJUSTMENT PROCEDURE………………….187
HYDRAULIC CHECKOUT PROCEDURE………………………..189
BRAKE SYSTEM CHECKOUT PROCEDURE……………………..201
VHMS CHECKOUT PROCEDURE…………………………….209
INTERFACE MODULE CHECKOUT PROCEDURE………………….213
ADDITIONAL INTERFACE MODULE CHECKOUT PROCEDURE………..221
PAYLOAD METER III CHECKOUT PROCEDURE…………………229
ELECTRICAL CHECKOUT PROCEDURE……………………….243
STANDARD TORQUE CHARTS AND CONVERSION TALBLES…………331
FIELD ASSEMBLY INSPECTION REPORT…………………….337
50 HOUR POST COMMISSIONING CHECK SHEET……………….343

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.