Komatsu Dump Truck 860E-1K, 860E–1KT Field Assembly Manual – PDF DOWNLOAD

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Komatsu Dump Truck 860E-1K, 860E–1KT Field Assembly Manual

FILE DETAILS:

Komatsu Dump Truck 860E-1K, 860E–1KT Field Assembly Manual

Size : 11.5 MB
Format : PDF
Language : English
Brand: Komatsu
Type of machine: Mining Rigid Dump Truck
Type of document: Field Assembly Manual
Model: Komatsu Mining Rigid Dump Trucks 860E-1K, 860E-1KT
Number of Pages: 290 Pages
Serial Number: A30031-UP, A30036-UP
Form No: CEAW007201

KOMATSU DUMP TRUCK 860E-1K, 860E–1KT FIELD ASSEMBLY MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu Dump Truck 860E-1K, 860E–1KT 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.

TABLE OF CONTENTS:

Komatsu Dump Truck 860E-1K, 860E–1KT Field Assembly Manual

COVER
............................................................................  1
FOREWORD..........................................................................  3
TABLE OF CONTENTS.................................................................  5
SAFETY RULES, TOOLS & EQUIPMENT...................................................  7
	SAFETY RULES..................................................................  7
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......................................................... 22
		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 STARING THE ENGINE.....................................................103
FINAL CHECKOUT....................................................................119
APPENDIX..........................................................................121
	LUBRICATION CHART.............................................................123
		LUBRICATION CHART.........................................................123
	OILING AND CHARGING PROCEDURE.................................................125
		GENERAL...................................................................125
		EQUIPMENT LIST............................................................125
		HYDRAIR® CHARGING KIT.....................................................126
			Installation of Charging Kit..........................................126
			Removal of Charging Kit...............................................126
		SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS.........................127
		FRONT SUSPENSION..........................................................127
			Front Suspension Oiling...............................................127
			Front Suspension Nitrogen Charging....................................129
		REAR SUSPENSION...........................................................130
			Rear Suspension Oiling................................................131
			Rear Suspension Nitrogen Charging.....................................132
		OIL AND NITROGEN SPECIFICATIONS CHART.....................................134
	TOE-IN ADJUSTMENT.............................................................135
	AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE...............................137
		GREASE REQUIREMENTS.......................................................137
			Required Lubricant....................................................137
		SYSTEM PRIMING............................................................137
			Pump Pressure Control.................................................138
			Pressure Control Valve Adjustment.....................................138
			Flow Control Valve Adjustment.........................................138
		PUMP HOUSING OIL..........................................................138
		SYSTEM CHECKOUT...........................................................138
			Lubrication Cycle Operation...........................................138
		PREVENTATIVE MAINTENANCE..................................................139
			Daily Lubrication System Inspection...................................139
			SYSTEM TROUBLESHOOTING CHART..........................................140
	RESERVE OIL SYSTEM CHECKOUT PROCEDURE
........................................143
	A/C CHECKOUT PROCEDURE
.......................................................145
	HYDRAULIC 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 SYSTEM 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 CHECK SHEET
.......................................285

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]