Komatsu 860E-1KT Dump Truck Field Assembly Instruction CEAW005702

Description

• Model List:
  • 860E-1KT Dump Truck

• 1. COVER
• 2. FOREWORD
• 3. TABLE OF CONTENTS
• 4. SAFETY RULES, TOOLS EQUIPMENT
• 4.1. SAFETY RULES
• 4.2. TOOLS AND EQUIPMENT FOR ASSEMBLY
• 4.3. LIFTING SLING GENERAL INFORMATION
• 4.4. HYDRAULIC SYSTEM FLUSHING TOOLS
• 4.5. HYDRAULIC SYSTEM VACUUM PUMP
• 5. TRUCK COMPONENTS AND SPECIFICATIONS
• 5.1. Truck And Engine
• 5.2. Main Alternator
• 5.3. AC Induction Traction Motorized Wheels
• 5.4. Suspension
• 5.5. Operators Cab
• 5.6. Power Steering
• 5.7. Dynamic Retarding
• 5.8. Brake System
• 5.9. SPECIFICATIONS
• 5.9.1. ENGINE
• 5.9.2. AC ELECTRIC DRIVE SYSTEM
• 5.9.3. DYNAMIC RETARDING
• 5.9.4. BATTERY ELECTRIC SYSTEM
• 5.9.5. SERVICE CAPACITIES
• 5.9.6. HYDRAULIC SYSTEMS
• 5.9.7. SERVICE BRAKES
• 5.9.8. STEERING
• 5.9.9. TIRES
• 5.9.10. STANDARD DUMP BODY CAPACITIES AND DIMENSIONS
• 5.9.11. WEIGHT DISTRIBUTION
• 6. MAJOR COMPONENT WEIGHTS
• 6.1. CHASSIS
• 6.2. DECK AND DECK SUPPORT COMPONENTS
• 6.3. POWER MODULE
• 6.4. HYDRAULIC COMPONENTS
• 6.5. FRONT AXLE COMPONENTS
• 6.6. REAR AXLE COMPONENTS
• 7. FIELD WELDING FOR ASSEMBLY OR REPAIR
• 7.1. WELDER QUALIFICATION AND TRAINING
• 7.2. WELD PROCEDURES
• 7.3. APPROVED CONSUMABLES
• 7.4. WELD QUALITY REQUIREMENTS
• 7.5. MATERIALS, CONTROLS, AND PRECAUTIONS
• 7.6. WELD INSPECTION
• 7.7. RECORDS
• 7.8. ANNEX A
• 7.9. ANNEX B
• 7.9.1. TOE HAMMER PEENING
• 7.9.1.1. Procedure
• 7.9.2. TOE GRINDING WITH A ROTARY BURR
• 7.9.2.1. Procedure
• 7.10. BIBLIOGRAPHY
• 7.10.1. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
• 7.10.1.1. Engine Shutdown Procedure Before Welding or Performing Maintenance
• 7.10.1.2. Precautions Before Welding or Performing Maintenance
• 8. RECEIVING ASSEMBLY PREPARATION
• 8.1. Color Coded Boxes
• 8.2. ASSEMBLY LAYOUT
• 9. CHASSIS ASSEMBLY
• 9.1. RECOMMENDED ASSEMBLY DATA
• 9.2. BASIC ASSEMBLY PROCEDURE
• 9.3. ORDER OF ASSEMBLY
• 9.4. CHASSIS ASSEMBLY
• 9.5. GENERAL PRECAUTIONS AND INSTRUCTION
• 9.5.1. Upper Mounting Joint 60 Advance
• 9.5.2. Front Wheel Installation
• 9.5.3. Rear Wheel Installation
• 10. DUMP BODY ASSEMBLY
• 10.1. GENERAL INFORMATION
• 10.2. BODY WELDING INFORMATION
• 10.3. BODY ASSEMBLY
• 11. FINAL ASSEMBLY
• 11.1. SAFETY
• 11.2. BEFORE STARTING THE ENGINE
• 12. FINAL CHECKOUT
• 13. APPENDIX
• 13.1. LUBRICATION CHART
• 13.1.1. 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 CHECKOUT PROCEDURE
• 13.4.1. GREASE REQUIREMENTS
• 13.4.1.1. Required Lubricant
• 13.4.2. SYSTEM PRIMING
• 13.4.2.1. Pump Pressure Control
• 13.4.2.2. Pressure Control Valve Adjustment
• 13.4.2.3. Flow Control Valve Adjustment
• 13.4.3. PUMP HOUSING OIL
• 13.4.4. SYSTEM CHECKOUT
• 13.4.4.1. Lubrication Cycle Operation
• 13.4.5. PREVENTATIVE MAINTENANCE
• 13.4.5.1. Daily Lubrication System Inspection
• 13.4.5.2. SYSTEM TROUBLESHOOTING CHART
• 13.5. RESERVE OIL SYSTEM CHECKOUT PROCEDURE
• 13.6. A/C CHECKOUT PROCEDURE
• 13.7. A/C DRIVE BELT ADJUSTMENT PROCEDURE
• 13.8. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 13.9. BRAKE SYSTEM CHECKOUT PROCEDURE
• 13.10. VHMS SETUP PROCEDURE
• 13.11. VHMS CHECKOUT PROCEDURE
• 13.12. INTERFACE MODULE CHECKOUT PROCEDURE
• 13.13. PLM III CHECKOUT PROCEDURE
• 13.14. ELECTRICAL CHECKOUT PROCEDURE
• 13.15. KOMATSU HAUL TRUCK COMMISSIONING PROCEDURE
• 13.16. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 13.16.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 13.16.2. STANDARD ASSEMBLY TORQUES For 12Point, Grade 9 Cap Screws (SAE)
• 13.16.3. STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews Class 10 Nuts
• 13.17. HYDRAULIC SYSTEM FLUSHING PROCEDURE
• 13.17.1. SYSTEM FLUSHING
• 13.17.1.1. Hydraulic System Flushing Procedure
• 13.18. FIELD ASSEMBLY INSPECTION REPORT
• 13.19. HOUR POST COMMISSIONING CHECKSHEET