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Komatsu 860E-1KT Dump Truck Field Assembly Manual SN A30003-A30030 and up – PDF DOWNLOAD
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Komatsu 860E-1KT Dump Truck Field Assembly Manual
Book Code: CEAW005702
SERIAL NUMBERS A30003 – A30030
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Description
Komatsu 860E-1KT Dump Truck Field Assembly Manual
TABLE OF CONTENTS:
Komatsu 860E-1KT Dump Truck Field Assembly Manual
COVER ............................................................................ 1 FOREWORD.......................................................................... 3 TABLE OF CONTENTS................................................................. 5 SAFETY RULES, TOOLS & EQUIPMENT................................................... 7 SAFETY RULES.................................................................. 7 TOOLS AND EQUIPMENT FOR ASSEMBLY.............................................. 8 LIFTING SLING GENERAL INFORMATION............................................. 9 HYDRAULIC SYSTEM FLUSHING TOOLS............................................... 15 HYDRAULIC SYSTEM VACUUM PUMP.................................................. 15 TRUCK COMPONENTS AND SPECIFICATIONS............................................... 19 Truck And Engine.............................................................. 19 Main Alternator............................................................... 19 AC Induction Traction Motorized Wheels........................................ 19 Suspension.................................................................... 19 Operator's Cab................................................................ 19 Power Steering................................................................ 19 Dynamic Retarding............................................................. 19 Brake System.................................................................. 19 SPECIFICATIONS................................................................ 21 ENGINE.................................................................... 21 AC ELECTRIC DRIVE SYSTEM.................................................. 21 DYNAMIC RETARDING......................................................... 21 BATTERY ELECTRIC SYSTEM................................................... 21 SERVICE CAPACITIES........................................................ 21 HYDRAULIC SYSTEMS......................................................... 21 SERVICE BRAKES............................................................ 22 STEERING.................................................................. 22 TIRES..................................................................... 22 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.............................. 22 WEIGHT DISTRIBUTION....................................................... 23 MAJOR COMPONENT WEIGHTS........................................................... 25 CHASSIS....................................................................... 25 DECK AND DECK SUPPORT COMPONENTS.............................................. 25 POWER MODULE.................................................................. 26 HYDRAULIC COMPONENTS.......................................................... 26 FRONT AXLE COMPONENTS......................................................... 26 REAR AXLE COMPONENTS.......................................................... 26 FIELD WELDING FOR ASSEMBLY OR REPAIR.............................................. 27 WELDER QUALIFICATION AND TRAINING............................................. 27 WELD PROCEDURES............................................................... 27 APPROVED CONSUMABLES.......................................................... 27 WELD QUALITY REQUIREMENTS..................................................... 27 MATERIALS, CONTROLS, AND PRECAUTIONS.......................................... 28 WELD INSPECTION............................................................... 28 RECORDS....................................................................... 29 ANNEX A....................................................................... 29 ANNEX B....................................................................... 31 1.0 TOE HAMMER PEENING.................................................... 31 Procedure............................................................. 31 2.0 TOE GRINDING WITH A ROTARY BURR....................................... 31 Procedure............................................................. 31 BIBLIOGRAPHY.................................................................. 34 SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK............... 34 Engine Shutdown Procedure Before Welding or Performing Maintenance.... 34 Precautions Before Welding or Performing Maintenance.................. 35 RECEIVING & ASSEMBLY PREPARATION.................................................. 37 Color Coded Boxes............................................................. 37 ASSEMBLY LAYOUT............................................................... 38 CHASSIS ASSEMBLY.................................................................. 39 RECOMMENDED ASSEMBLY DATA..................................................... 39 BASIC ASSEMBLY PROCEDURE...................................................... 39 ORDER OF ASSEMBLY............................................................. 40 LEVEL 1................................................................... 40 LEVEL 2................................................................... 40 LEVEL 3................................................................... 40 LEVEL 4................................................................... 40 LEVEL 5................................................................... 40 LEVEL 6................................................................... 40 LEVEL 7................................................................... 40 LEVEL 8................................................................... 40 LEVEL 9................................................................... 40 LEVEL 10.................................................................. 40 LEVEL 11.................................................................. 40 CHASSIS ASSEMBLY.............................................................. 41 GENERAL PRECAUTIONS AND INSTRUCTION........................................... 42 Upper Mounting Joint - 60° Advance........................................ 63 Front Wheel Installation.................................................. 88 Rear Wheel Installation................................................... 90 DUMP BODY ASSEMBLY................................................................ 95 GENERAL INFORMATION........................................................... 95 BODY WELDING INFORMATION...................................................... 96 BODY ASSEMBLY................................................................. 96 FINAL ASSEMBLY....................................................................103 SAFETY........................................................................103 BEFORE STARTING THE ENGINE....................................................103 FINAL CHECKOUT....................................................................117 APPENDIX..........................................................................119 LUBRICATION CHART.............................................................121 LUBRICATION CHART.........................................................121 OILING AND CHARGING PROCEDURE.................................................123 GENERAL...................................................................123 EQUIPMENT LIST............................................................123 HYDRAIR® CHARGING KIT.....................................................124 Installation of Charging Kit..........................................124 Removal of Charging Kit...............................................124 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.........................125 FRONT SUSPENSION..........................................................125 Front Suspension Oiling...............................................125 Front Suspension Nitrogen Charging....................................127 REAR SUSPENSION...........................................................128 Rear Suspension Oiling................................................129 Rear Suspension Nitrogen Charging.....................................130 OIL AND NITROGEN SPECIFICATIONS CHART.....................................132 TOE-IN ADJUSTMENT.............................................................133 AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE...............................135 GREASE REQUIREMENTS.......................................................135 Required Lubricant....................................................135 SYSTEM PRIMING............................................................135 Pump Pressure Control.................................................136 Pressure Control Valve Adjustment.....................................136 Flow Control Valve Adjustment.........................................136 PUMP HOUSING OIL..........................................................136 SYSTEM CHECKOUT...........................................................136 Lubrication Cycle Operation...........................................136 PREVENTATIVE MAINTENANCE..................................................137 Daily Lubrication System Inspection...................................137 SYSTEM TROUBLESHOOTING CHART..........................................138 RESERVE OIL SYSTEM CHECKOUT PROCEDURE ........................................141 A/C CHECKOUT PROCEDURE .......................................................143 A/C DRIVE BELT ADJUSTMENT PROCEDURE ..........................................145 HYDRAULIC SYSTEM CHECKOUT PROCEDURE ..........................................147 BRAKE SYSTEM CHECKOUT PROCEDURE ..............................................173 VHMS SETUP PROCEDURE .........................................................199 VHMS CHECKOUT PROCEDURE ......................................................213 INTERFACE MODULE CHECKOUT PROCEDURE ..........................................217 PLM III CHECKOUT PROCEDURE ...................................................227 ELECTRICAL CHECKOUT PROCEDURE ................................................241 KOMATSU HAUL TRUCK COMMISSIONING PROCEDURE ...................................253 STANDARD TORQUE CHARTS AND CONVERSION TABLES..................................265 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values......265 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap Screws (SAE)..........266 STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews & Class 10 Nuts........266 HYDRAULIC SYSTEM FLUSHING PROCEDURE...........................................271 SYSTEM FLUSHING...........................................................271 Hydraulic System Flushing Procedure...................................271 FIELD ASSEMBLY INSPECTION REPORT .............................................279 50 HOUR POST COMMISSIONING CHECKSHEET ........................................285
KOMATSU 860E-1KT DUMP TRUCK FIELD ASSEMBLY MANUAL SN A30003-A30030 AND UP – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu 860E-1KT Dump Truck Field Assembly Manual
FOREWORD:
- This manual is provided to aid assemblers during field assembly of the standard Komatsu 860E-1K 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.
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
