komatsu 830e 1ac dump truck field assembly instruction ceaw008000 1 1

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Komatsu 830E-1AC Dump Truck Field Assembly Instruction CEAW008000

$20.00

Type Of Manual: Field Assembly Instruction
Manual ID: CEAW008000
Format: PDF
Size: 33.4MB
Number of Pages: 297

Category: Komatsu Operation and Maintenance Manual PDF

Model List:
- 830E-1AC Dump Truck

1. SAFETY RULES, TOOLS EQUIPMENT
1.1. SAFETY RULES
1.1.1. Use of TieOff Anchor During Maintenance and Repair
1.1.2. BODYUP RETENTION CABLE
1.2. NITROGEN CHARGING VALVE
1.3. ROLLOUT ASSEMBLY
1.4. SLEEVE ALIGNMENT TOOLS
1.5. QUICK DISCONNECT COUPLING
1.6. HARNESS
1.7. SEAL INSTALLATION RING
1.8. SOCKETS AND ADAPTERS
1.9. DUST CAPS
1.10. HYDRAULIC SYSTEM FLUSHING TOOLS
1.11. KOMVISION CALIBRATION TOOLS
1.12. MISCELLANEOUS SERVICE TOOLS
1.13. PAYLOAD DATA MANAGER
1.14. HYDRAULIC SYSTEM VACUUM PUMP
1.15. BRAKE PISTON TOOL
1.16. HIGH VOLTAGE TOOLS
1.17. VDC CUSTOM METER KIT (58B0600800)
1.18. BODY PAD SPACER TOOL
2. TRUCK COMPONENTS AND SPECIFICATIONS
2.1. Truck And Engine
2.2. AC Induction Traction Motorized Wheels
2.3. Suspension
2.4. Operators Cab
2.5. Power Steering
2.6. Dynamic Retarding
2.7. Brake System
3. SPECIFICATIONS
3.1. REAR AXLE COMPONENTS
4. FIELD WELDING FOR ASSEMBLY OR REPAIR
4.1. WELDER QUALIFICATION AND TRAINING
4.2. WELD PROCEDURES
4.3. APPROVED CONSUMABLES
4.4. WELD QUALITY REQUIREMENTS
4.5. MATERIALS, CONTROLS, AND PRECAUTIONS
4.6. WELD INSPECTION
4.7. RECORDS
4.8. ANNEX A
4.9. ANNEX B
4.9.1. TOE HAMMER PEENING
4.9.1.1. Procedure
4.9.2. TOE GRINDING WITH A ROTARY BURR
4.9.2.1. Procedure
4.10. BIBLIOGRAPHY
4.10.1. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
4.10.1.1. Engine Shutdown Procedure before Welding or Performing Maintenance
5. RECEIVING ASSEMBLY PREPARATION
5.1. Preparation
5.1.1. Inspection, Cleaning, Setup
5.1.2. Color Coded Boxes
5.2. ASSEMBLY LAYOUT
6. CHASSIS ASSEMBLY
6.1. RECOMMENDED ASSEMBLY DATA
6.2. BASIC ASSEMBLY PROCEDURE
6.2.1. ORDER OF ASSEMBLY
6.2.2. LEVEL 1
6.2.3. LEVEL 2
6.2.4. LEVEL 7
6.3. GENERAL PRECAUTIONS AND INSTRUCTION
6.3.1. Angle Advance Tightening Procedure
6.3.2. Upper Mounting Joint 60 Advance
6.3.3. Lower Mounting Joint 90 Advance
6.3.4. Inspection
6.4. GENERAL INFORMATION
6.5. BODY ASSEMBLY
6.6. BODY WELDING
7. FINAL ASSEMBLY
7.1. Body Pad Shimming Procedure
8. APPENDIX
8.1. LUBRICATION CHART
9. OILING AND CHARGING PROCEDURE
9.1. GENERAL
9.2. EQUIPMENT LIST
9.3. HYDRAIR CHARGING KIT
9.3.1. Installation of Charging Kit
9.3.2. Removal of Charging Kit
9.4. SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
9.5. FRONT SUSPENSION
9.5.1. Front Suspension Oiling
9.5.2. Front Suspension Nitrogen Charging
9.6. REAR SUSPENSION
9.6.1. Rear Suspension Oiling
9.6.2. Rear Suspension Nitrogen Charging
10. OIL AND NITROGEN SPECIFICATIONS CHART
11. TOEIN ADJUSTMENT
12. AUTO LUBE SYSTEM
12.1. Lincoln Flow master Phase I Auto Lube System with fixed Hydraulic Controls
12.2. Lube Pump Startup / Purging Procedure
12.3. Truck Lube System Purging Procedure After lube pump has been primed with grease.
12.4. INJECTOR SETTINGS
12.5. TIMER
12.6. WARNING SYSTEM
13. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
14. KOMTRAX PLUS SETUP PROCEDURE
14.1. Purpose
14.2. Preliminary Procedures
14.3. Necessary Equipment
14.4. Check for KOMTRAX Plus System Faults
14.5. KOMTRAX Plus Setup
14.6. Begin KOMTRAX Plus Setup
15. KOMTRAX PLUS CHECKOUT PROCEDURE
15.1. Purpose
15.2. Preliminary Procedures
15.3. Necessary Equipment
15.4. Check for KOMTRAX Plus System Faults
15.5. Checkout Procedure
16. IM CHECKOUT 830E1AC WITH DIGITAL DISPLAY
16.1. Purpose
16.2. Necessary Equipment
16.3. Install the application code
16.4. How to use the IM Realtime Data Monitor Software
16.5. Check for Fault Codes Associated with the Interface Module.
16.6. Interface Module I/O
16.7. Check Digital Inputs to the Interface Module
16.8. Check Analog Inputs to the Interface Module
16.9. Check Serial Interfaces to the IM
16.10. Check Outputs from the Interface Module
17. PAYLOAD METER IV CHECKOUT PROCEDURE
17.1. Necessary Equipment
17.2. Install the Application Code
17.3. General Instructions
17.4. Appendix A
17.4.1. Guide to Connect to Payload Meter IV
17.4.2. Configuring a PCs Static IP Address
17.5. Appendix B
17.5.1. Installing Payload Meter IV Truck Application Software via USB
17.6. Payload Meter IV Checkout Procedure Confirmation
18. Electric Checkout Procedure
18.1. Scope
18.2. General Description
18.3. General Precautions
18.4. Normal shutdown procedure
18.5. AC Drive System Description
18.6. Test equipment needed to fully test AC system
18.7. Visual Inspection
18.8. Resistance Check Preparation
18.9. Resistance Check
18.10. Voltage Check
18.11. Key Switch OFF Checks
18.12. Key Switch ON Check
18.13. GE Control Switch ON Check
18.14. Truck Function Check
18.15. Key Switch OFF
18.16. Key Switch ON
18.17. Interface Module (IM) System
18.18. Komtrax Plus (VHMS) Checkout
18.19. Payload Meter Checkout
18.20. GE Vehicle Test Instructions (VTI)
18.21. Digital I/O to GE
18.22. Engine Shutdown Smart Timer Check
18.23. Body Hoist Limit
18.24. Truck Function Check
19. RESERVE OIL SYSTEM R2000DF W/AUTO FILL
19.1. AFC Control StartUp / Fast Fill Procedure
19.2. Reserve pump R2000DF startup and led description.
20. AUTOMATIC LUBRICATION SYSTEM
20.1. GENERAL DESCRIPTION
20.2. SYSTEM COMPONENTS
20.2.1. Filter
20.2.2. Hydraulic Motor and Pump
20.2.3. Grease Reservoir
20.2.4. Pressure Reducing Valve
20.2.5. Flow Control Valve
20.2.6. Solenoid Valve
20.2.7. Vent Valve
20.2.8. Over Pressure Cut Off Switch
20.2.9. Grease Pressure Failure Switch
20.2.10. Injectors
20.2.11. Interface Module
20.2.12. Relief Valve (unloader valve)
20.3. SYSTEM OPERATION
20.3.1. Normal Operation
20.3.2. Lubricant Required For System
20.3.3. Filter Assembly
20.4. LUBRICANT PUMP
20.4.1. Pump Housing Oil Level
20.4.2. Pump Pressure Control
20.5. SYSTEM CHECKOUT
20.5.1. Lubrication Cycle Operation
21. SYSTEM TROUBLESHOOTING CHART
22. STANDARD TORQUE CHARTS AND CONVERSION TABLES
22.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
22.2. STANDARD ASSEMBLY TORQUES For 12Point, Grade 9 Capscrews (SAE)
22.3. STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews Class 10 Nuts
23. HYDRAULIC SYSTEM FLUSHING PROCEDURE
23.1. SYSTEM FLUSHING
23.1.1. Hydraulic System Flushing Procedure
24. STATIC BRAKE SYSTEM CHECKOUT
24.1. STATIC BRAKE SYSTEM CHECKOUT
24.1.1. Events
24.1.2. OPERATION
24.1.2.1. Description
24.1.2.2. Brake Test Exit Criteria
24.1.3. PERFORMING THE BRAKE TESTS
24.1.3.1. Setup
24.1.3.2. Service Brake Test
24.1.3.3. Parking Brake Test
24.1.3.4. Retard System Test
25. KOMVISION CHECKOUT PROCEDURE
25.1. Necessary Equipment
25.2. STEP 1 Settings
26. Wireless Bridge Checkout procedure
26.1. Purpose
26.2. Necessary Equipment
26.3. Communication Setup
26.4. Appendix A
26.5. Setting The Computer Subnet Mask And IP Address
26.6. Windows 2000
26.7. Windows XP
26.8. Windows Vista
26.9. Windows 7
26.10. Appendix B Troubleshooting

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