Komatsu 830E-5 Dump Truck Field Assembly Instruction CEAW012201

Description

• Model List:
  • 830E-5 Dump Truck

• 1. FOREWORD
• 2. TABLE OF CONTENTS
• 3. SAFETY RULES, TOOLS EQUIPMENT
• 3.1. SAFETY RULES
• 3.2. NITROGEN CHARGING VALVE
• 3.3. ROLLOUT ASSEMBLY
• 3.4. SLEEVE ALIGNMENT TOOLS
• 3.5. QUICK DISCONNECT COUPLING
• 3.6. HARNESS
• 3.7. PULLER TOOL
• 3.8. SOCKETS AND ADAPTERS
• 3.9. DUST CAPS
• 3.10. HYDRAULIC SYSTEM FLUSHING TOOLS
• 3.11. JUMPER CABLE
• 3.12. AHT CALIBRATION TOOLS (IF EQUIPPED)
• 3.13. AHT DIAGNOSTIC TOOLS (IF EQUIPPED)
• 3.14. MISCELLANEOUS SERVICE TOOLS
• 3.15. PAYLOAD DATA MANAGER
• 3.16. HYDRAULIC SYSTEM VACUUM PUMP
• 3.17. KOMVISION CALIBRATION TOOLS (IF EQUIPPED)
• 3.18. HEATED EXHAUST TOOL (IF EQUIPPED)
• 3.19. BRAKE PISTON TOOL
• 3.20. HIGH VOLTAGE TOOLS
• 3.20.1. VDC CUSTOM METER KIT (58B0600800)
• 3.21. SUSPENSION TOOLS
• 3.21.1. SUSPENSION OILING AND CHARGING BLOCK KIT (58E0011190)
• 3.22. BODY PAD SPACER TOOL
• 4. TRUCK COMPONENTS AND SPECIFICATIONS
• 4.1. Truck and Engine
• 4.2. AC Induction Traction Motorized Wheels
• 4.3. Suspension
• 4.4. Operators Cab
• 4.5. Power Steering
• 4.6. Dynamic Retarding Grid
• 4.7. Brake System
• 4.8. Selective Catalytic Reduction (SCR)
• 4.9. Diesel Exhaust Fluid (DEF)
• 5. SPECIFICATIONS
• 6. MAJOR COMPONENT WEIGHTS
• 6.1. REAR AXLE COMPONENTS
• 7. RECEIVING ASSEMBLY PREPARATION
• 7.1. Preparation
• 7.2. Coded Boxes
• 8. CHASSIS ASSEMBLY
• 9. DUMP BODY ASSEMBLY
• 9.1. GENERAL INFORMATION
• 9.2. BODY ASSEMBLY
• 9.3. BODY WELDING
• 10. FINAL ASSEMBLY
• 10.1. Mount Tires, Rim Adapter, and Torque
• 10.2. Rear Wheel Installation
• 10.3. Body
• 10.4. Body Pad Shimming Procedure
• 10.5. Rock Ejectors
• 10.6. Mud Flaps
• 10.7. Guide Brackets
• 10.8. Retention Sling
• 10.9. Body Up Switch Adjustment
• 10.10. Hoist limit switch adjustment
• 10.11. Bolt in Lubrication System
• 10.12. Isolation Box Installation
• 10.13. Camera and Radar
• 11. FINAL CHECKOUT
• 12. APPENDIX
• 12.1. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 12.2. SUSPENSION OILING AND CHARGING PROCEDURE
• 12.3. SUSPENSION OILING AND CHARGING BLOCK KIT INSTALLATION PROCEDURE
• 12.4. OIL AND NITROGEN SPECIFICATIONS CHART
• 12.5. FAN CLUTCH CHECKOUT PROCEDURE
• 12.6. ENGINE EMISSIONS AFTERTREATMENT SYSTEMS
• 12.7. TOEIN ADJUSTMENT
• 12.8. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
• 12.9. ELECTRIC CHECKOUT PROCEDURE
• 12.10. INTERFACE MODULE CHECKOUT PROCEDURE
• 12.11. ADDITIONAL ELECTRICAL CHECKOUT FOR TRUCKS WITH IM CONTROLS
• 12.12. HYDRAULIC CHECKOUT PROCEDURE
• 12.13. Brake Test PreShift Checkout Procedure
• 12.14. BRAKE SYSTEM CHECKOUT PROCEDURE
• 12.15. AUTOMATIC LUBRICATION SYSTEM
• 12.16. AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
• 12.17. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
• 12.18. TIRE MONITORING SYSTEM CHECKOUT PROCEDURE
• 12.19. PAYLOAD METER IV CHECKOUT PROCEDURE
• 12.20. ALTERNATOR LOCK CHECKOUT PROCEDURE
• 12.21. KOMTRAX PLUS 2 SHOP SETUP CHECKOUT PROCEDURE
• 12.22. KOMTRAX PLUS 2 SITE SETUP CHECKOUT PROCEDURE
• 12.23. KOMVISION CHECKOUT PROCEDURE
• 12.24. KOMATSU WIRELESS BRIDGE CHECKOUT PROCEDURE
• 12.25. RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
• 12.26. FIELD ASSEMBLY INSPECTION REPORT
• 12.27. HOUR POSTCOMMISSIONING CHECKSHEET