KOMATSU 960E-1 DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30003-A30024) – PDF DOWNLOAD

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KOMATSU 960E-1 DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30003-A30024)

KOMATSU 960E-1 DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30003-A30024) – PDF DOWNLOAD:

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KOMATSU 960E-1 DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30003-A30024)

• 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 960E-1 DUMP TRUCK FIELD ASSEMBLY MANUAL (SN:A30003-A30024)

COVER...................................................  1
FOREWORD................................................  3
TABLE OF CONTENTS.......................................  5
SAFETY RULES, TOOL & EQUIPMENT..........................  7
TRUCK COMPONENTS AND SPECIFICATIONS..................... 19
MAJOR COMPONENTS WEIGHTS................................ 25
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
	BIBLIOGRAPHY........................................ 34
RECEIVING & ASSEMBLY PREPARATION........................ 37
CHASSIS ASSEMBLY........................................ 39
	RECOMMENDED ASSEMBLY DATA........................... 39
	BASIC ASSEMBLY PROCEDURE............................ 39
	ORDER OF ASSEMBLY................................... 40
	CHASSIS ASSEMBLY.................................... 41
		HARDWARE TIGHTENING METHOD...................... 41
		GENERAL PRECAUTIONS AND INSTRUCTION............. 42
		HYDRAULIC SYSTEM FLUSHING....................... 42
DUMP BODY ASSEMBLY...................................... 91
	GENERAL INFORMATION................................. 91
	BODY WELDING INFORMATION............................ 92
	BODY ASSEMBLY....................................... 92
FINAL ASSEMBLY.......................................... 99
FINAL CHECKOUT..........................................115
APPENDIX................................................117
	LUBRICATION CHART...................................119
	SUSPENSION OILING AND CHARGING PROCEDURE............121
	OIL AND NITROGEN SPECIFICATIONS CHARTS..............128
	TOE-IN ADJUSTMENT...................................129
	INTERFACE MODULE CHECKOUT PROCEDURE.................131
	AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE.....143
	RESERVE OIL SYSTEM CHECKOUT PROCEDURE...............145
	AIR CONDITIONING CHECKOUT PROCEDURE.................147
	AIR CONDITIONING DRIVE BELT ADJUSTMENT PROCEDURE....149
	HYDRAULIC SYSTEM CHECKOUT PROCEDURE.................151
	BRAKE SYSTEM CHECKOUT PROCEDURE.....................175
	VHMS SETUP PROCEDURE................................197
	VHMS CHECKOUT PROCEDURE.............................211
	PAYLOAD METER III CHECKOUT PROCEDURE................215
	ELECTRICAL CHECKOUT PROCEDURE.......................229
	AMENDMENTS TO ELECTRICAL CHECKOUT PROCEDURE.........317
	STANDARD TORQUE CHARTS AND CONVERSION TABLES........321
	FIELD ASSEMBLY INSPECTION REPORT....................327
	50 HOUR POST-COMMISIONING CHECKSHEET................333

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.