Komatsu 830E-1AC Dump Truck Field Assembly Instruction CEAW006700

Description

• Model List:
  • 830E-1AC Dump Truck

• 1. COVER
• 2. FOREWORD
• 3. TABLE OF CONTENTS
• 4. SAFETY RULES, TOOLS EQUIPMENT
• 4.1. SAFETY RULES
• 4.1.1. BODYUP RETENTION CABLE
• 4.2. HYDRAULIC SYSTEM FLUSHING TOOLS
• 4.3. HYDRAULIC SYSTEM VACUUM PUMP
• 5. TRUCK COMPONENTS AND SPECIFICATIONS
• 5.1. Truck And Engine
• 5.2. AC Induction Traction Motorized Wheels
• 5.3. Suspension
• 5.4. Operators Cab
• 5.5. Power Steering
• 5.6. Dynamic Retarding
• 5.7. Brake System
• 5.8. SPECIFICATIONS
• 6. MAJOR COMPONENT WEIGHTS
• 7. FIELD WELDING FOR ASSEMBLY OR REPAIR
• 7.1. WELD PROCEDURES
• 7.2. APPROVED CONSUMABLES
• 7.3. WELD QUALITY REQUIREMENTS
• 7.4. MATERIALS, CONTROLS, AND PRECAUTIONS
• 7.5. WELD INSPECTION
• 7.6. RECORDS
• 7.7. ANNEX A
• 7.8. ANNEX B
• 7.8.1. TOE HAMMER PEENING
• 7.8.1.1. Procedure
• 7.8.2. TOE GRINDING WITH A ROTARY BURR
• 7.8.2.1. Procedure
• 7.9. BIBLIOGRAPHY
• 7.9.1. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
• 7.9.1.1. General Welding Guidelines
• 8. RECEIVING ASSEMBLY PREPARATION
• 8.1. ASSEMBLY LAYOUT
• 9. CHASSIS ASSEMBLY
• 9.1. RECOMMENDED ASSEMBLY DATA
• 9.2. BASIC ASSEMBLY PROCEDURE
• 9.2.1. ORDER OF ASSEMBLY
• 9.2.2. LEVEL 1
• 9.2.3. LEVEL 2
• 9.2.4. LEVEL 7
• 9.3. GENERAL PRECAUTIONS AND INSTRUCTION
• 9.3.1. TurnOfTheNut Tightening Procedure
• 9.3.2. Upper Mounting Joint 60 Advance
• 9.3.3. Lower Mounting Joint 90 Advance
• 9.3.4. Inspection
• 10. DUMP BODY ASSEMBLY
• 10.1. BODY ASSEMBLY
• 10.2. BODY WELDING
• 11. FINAL ASSEMBLY
• 12. FINAL CHECKOUT
• 13. APPENDIX
• 13.1. LUBRICATION CHART
• 13.2. OILING AND CHARGING PROCEDURE
• 13.2.1. GENERAL
• 13.2.2. EQUIPMENT LIST
• 13.2.3. HYDRAIR CHARGING KIT
• 13.2.3.1. Installation of Charging Kit
• 13.2.3.2. Removal of Charging Kit
• 13.2.4. SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
• 13.2.5. FRONT SUSPENSION
• 13.2.5.1. Front Suspension Oiling
• 13.2.5.2. Front Suspension Nitrogen Charging
• 13.2.6. REAR SUSPENSION
• 13.2.6.1. Rear Suspension Oiling
• 13.2.6.2. Rear Suspension Nitrogen Charging
• 13.2.7. OIL AND NITROGEN SPECIFICATIONS CHART
• 13.3. TOEIN ADJUSTMENT
• 13.4. AUTOMATIC LUBRICATION SYSTEM
• 13.4.1. GENERAL DESCRIPTION
• 13.4.2. SYSTEM COMPONENTS
• 13.4.2.1. Filter
• 13.4.2.2. Hydraulic Motor and Pump
• 13.4.2.3. Grease Reservoir
• 13.4.2.4. Pressure Reducing Valve
• 13.4.2.5. Flow Control Valve
• 13.4.2.6. Solenoid Valve
• 13.4.2.7. Vent Valve
• 13.4.2.8. Lubrication Cycle Timer
• 13.4.2.9. Over Pressure Cut Off Switch
• 13.4.2.10. Grease Pressure Failure Switch
• 13.4.2.11. Injectors
• 13.4.2.12. Relief Valve (unloader valve)
• 13.4.3. SYSTEM OPERATION
• 13.4.3.1. Normal Operation
• 13.4.3.2. Lubricant Required For System
• 13.4.3.3. System Priming
• 13.4.3.4. Filter Assembly
• 13.4.4. LUBRICANT PUMP
• 13.4.4.1. Pump Housing Oil Level
• 13.4.4.2. Pump Pressure Control
• 13.4.5. SYSTEM CHECKOUT
• 13.4.5.1. Lubrication Controller Check
• 13.4.5.2. Lubrication Controller Components
• 13.4.5.3. Lubrication Controller Adjustment
• 13.4.6. SYSTEM TROUBLESHOOTING CHART
• 13.4.7. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 13.5. A/C CHECKOUT PROCEDURE
• 13.6. A/C DRIVE BELT
• 13.7. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 13.8. BRAKE SYSTEM CHECKOUT
• 13.9. VHMS CHECKOUT PROCEDURE
• 13.10. INTERFACE MODULE CHECKOUT PROCEDURE
• 13.11. ADDITIONAL INTERFACE MODULE CHECKOUT PROCEDURES
• 13.12. PAYLOAD METER CHECKOUT PROCEDURE
• 13.13. ELECTRIC DRIVE SYSTEM CHECKOUT PROCEDURE
• 13.14. AMENDMENTS TO ELECTRIC DRIVE SYSTEM CHECKOUT PROCEDURE
• 13.15. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 13.16. HYDRAULIC SYSTEM FLUSHING PROCEDURE
• 13.16.1. SYSTEM FLUSHING
• 13.16.1.1. Hydraulic System Flushing Procedure
• 13.17. STATIC BRAKE SYSTEM CHECKOUT
• 13.17.1. STATIC BRAKE SYSTEM CHECKOUT
• 13.17.1.1. Events
• 13.17.1.2. OPERATION
• 13.17.1.2.1. Description
• 13.17.1.2.2. Brake Test Exit Criteria
• 13.17.1.3. PERFORMING THE BRAKE TESTS
• 13.17.1.3.1. Setup
• 13.17.1.3.2. Service Brake Test
• 13.17.1.3.3. Parking Brake Test
• 13.17.1.3.4. Retard System Test
• 13.18. FIELD ASSEMBLY INSPECTION REPORT
• 13.19. HOUR POST COMMISSIONING CHECKSHEET