komatsu 830e 1ac dump truck field assembly instruction ceaw008001 1 1

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Komatsu 830E-1AC Dump Truck Field Assembly Instruction CEAW008001

$20.00

Type Of Manual: Field Assembly Instruction
Manual ID: CEAW008001
Format: PDF
Size: 7.2MB
Number of Pages: 304

Category: Komatsu Operation and Maintenance Manual PDF

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. Use of TieOff Anchor During Maintenance and Repair
4.1.2. BODYUP RETENTION CABLE
4.2. NITROGEN CHARGING VALVE
4.3. ROLLOUT ASSEMBLY
4.4. SLEEVE ALIGNMENT TOOLS
4.5. QUICK DISCONNECT COUPLING
4.6. HARNESS
4.7. SEAL INSTALLATION RING
4.8. SOCKETS AND ADAPTERS
4.9. DUST CAPS
4.10. HYDRAULIC SYSTEM FLUSHING TOOLS
4.11. KOMVISION CALIBRATION TOOLS
4.12. MISCELLANEOUS SERVICE TOOLS
4.13. PAYLOAD DATA MANAGER
4.14. HYDRAULIC SYSTEM VACUUM PUMP
4.15. BRAKE PISTON TOOL
4.16. HIGH VOLTAGE TOOLS
4.17. VDC CUSTOM METER KIT (58B0600800)
4.18. BODY PAD SPACER TOOL
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
6. SPECIFICATIONS
6.1. 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
8. RECEIVING ASSEMBLY PREPARATION
8.1. Preparation
8.1.1. Inspection, Cleaning, Setup
8.1.2. Color Coded Boxes
8.2. 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. Angle Advance Tightening Procedure
9.3.2. Upper Mounting Joint 60 Advance
9.3.3. Lower Mounting Joint 90 Advance
9.3.4. Inspection
9.4. GENERAL INFORMATION
9.5. BODY ASSEMBLY
9.6. BODY WELDING
10. FINAL ASSEMBLY
10.1. Body Pad Shimming Procedure
11. APPENDIX
11.1. LUBRICATION CHART
11.2. OILING AND CHARGING PROCEDURE
11.2.1. GENERAL
11.2.2. EQUIPMENT LIST
11.2.3. HYDRAIR CHARGING KIT
11.2.3.1. Installation of Charging Kit
11.2.3.2. Removal of Charging Kit
11.2.4. SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
11.2.5. FRONT SUSPENSION
11.2.5.1. Front Suspension Oiling
11.2.5.2. Front Suspension Nitrogen Charging
11.2.6. REAR SUSPENSION
11.2.6.1. Rear Suspension Oiling
11.2.6.2. Rear Suspension Nitrogen Charging
11.3. OIL AND NITROGEN SPECIFICATIONS CHART
11.4. TOEIN ADJUSTMENT
11.5. AUTO LUBE SYSTEM
11.5.1. Lincoln Flow master Phase I Auto Lube System with fixed Hydraulic Controls
11.5.2. Lube Pump Startup / Purging Procedure
11.5.3. Truck Lube System Purging Procedure After lube pump has been primed with grease.
11.5.4. INJECTOR SETTINGS
11.5.5. TIMER
11.5.6. WARNING SYSTEM
11.6. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
11.7. KOMTRAX PLUS SETUP PROCEDURE
11.7.1. Purpose
11.7.2. Preliminary Procedures
11.7.3. Necessary Equipment
11.7.4. Check for KOMTRAX Plus System Faults
11.7.5. KOMTRAX Plus Setup
11.7.6. Begin KOMTRAX Plus Setup
11.8. KOMTRAX PLUS CHECKOUT PROCEDURE
11.8.1. Purpose
11.8.2. Preliminary Procedures
11.8.3. Necessary Equipment
11.8.4. Check for KOMTRAX Plus System Faults
11.8.5. Checkout Procedure
11.9. IM CHECKOUT 830E1AC WITH DIGITAL DISPLAY
11.9.1. Purpose
11.9.2. Necessary Equipment
11.9.3. Install the application code
11.9.4. How to use the IM Realtime Data Monitor Software
11.9.5. Check for Fault Codes Associated with the Interface Module.
11.9.6. Interface Module I/O
11.9.7. Check Digital Inputs to the Interface Module
11.9.8. Check Analog Inputs to the Interface Module
11.9.9. Check Serial Interfaces to the IM
11.9.10. Check Outputs from the Interface Module
11.10. PAYLOAD METER IV CHECKOUT PROCEDURE
11.10.1. Necessary Equipment
11.10.2. Install the Application Code
11.10.3. General Instructions
11.10.4. Appendix A
11.10.4.1. Guide to Connect to Payload Meter IV
11.10.4.2. Configuring a PCs Static IP Address
11.10.5. Appendix B
11.10.5.1. Installing Payload Meter IV Truck Application Software via USB
11.10.6. Payload Meter IV Checkout Procedure Confirmation
11.11. Electric Checkout Procedure
11.11.1. Scope
11.11.2. General Description
11.11.3. General Precautions
11.11.4. Normal shutdown procedure
11.11.5. AC Drive System Description
11.11.6. Test equipment needed to fully test AC system
11.11.7. Visual Inspection
11.11.8. Resistance Check Preparation
11.11.9. Resistance Check
11.11.10. Voltage Check
11.11.11. Key Switch OFF Checks
11.11.12. Key Switch ON Check
11.11.13. GE Control Switch ON Check
11.11.14. Truck Function Check
11.11.15. Key Switch OFF
11.11.16. Key Switch ON
11.11.17. Interface Module (IM) System
11.11.18. Komtrax Plus (VHMS) Checkout
11.11.19. Payload Meter Checkout
11.11.20. GE Vehicle Test Instructions (VTI)
11.11.21. Digital I/O to GE
11.11.22. Engine Shutdown Smart Timer Check
11.11.23. Body Hoist Limit
11.11.24. Truck Function Check
11.12. RESERVE OIL SYSTEM R2000DF W/AUTO FILL
11.12.1. AFC Control StartUp / Fast Fill Procedure
11.12.2. Reserve pump R2000DF startup and led description.
11.13. AUTOMATIC LUBRICATION SYSTEM
11.13.1. GENERAL DESCRIPTION
11.13.2. SYSTEM COMPONENTS
11.13.2.1. Filter
11.13.2.2. Hydraulic Motor and Pump
11.13.2.3. Grease Reservoir
11.13.2.4. Pressure Reducing Valve
11.13.2.5. Flow Control Valve
11.13.2.6. Solenoid Valve
11.13.2.7. Vent Valve
11.13.2.8. Over Pressure Cut Off Switch
11.13.2.9. Grease Pressure Failure Switch
11.13.2.10. Injectors
11.13.2.11. Interface Module
11.13.2.12. Relief Valve (unloader valve)
11.13.3. SYSTEM OPERATION
11.13.3.1. Normal Operation
11.13.3.2. Lubricant Required For System
11.13.3.3. Filter Assembly
11.13.4. LUBRICANT PUMP
11.13.4.1. Pump Housing Oil Level
11.13.4.2. Pump Pressure Control
11.13.5. SYSTEM CHECKOUT
11.13.5.1. Lubrication Cycle Operation
11.14. SYSTEM TROUBLESHOOTING CHART
11.15. STANDARD TORQUE CHARTS AND CONVERSION TABLES
11.15.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
11.15.2. STANDARD ASSEMBLY TORQUES Grade 9 Capscrews (SAE)
11.15.3. STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews Class 10 Nuts
11.16. HYDRAULIC SYSTEM FLUSHING PROCEDURE
11.16.1. SYSTEM FLUSHING
11.16.1.1. Hydraulic System Flushing Procedure
11.17. STATIC BRAKE SYSTEM CHECKOUT
11.17.1. STATIC BRAKE SYSTEM CHECKOUT
11.17.1.1. Events
11.17.1.2. OPERATION
11.17.1.2.1. Description
11.17.1.2.2. Brake Test Exit Criteria
11.17.1.3. PERFORMING THE BRAKE TESTS
11.17.1.3.1. Setup
11.17.1.3.2. Service Brake Test
11.17.1.3.3. Parking Brake Test
11.17.1.3.4. Retard System Test
11.18. KOMVISION CHECKOUT PROCEDURE
11.18.1. Necessary Equipment
11.18.2. STEP 1 Settings
11.19. Wireless Bridge Checkout procedure
11.19.1. Purpose
11.19.2. Necessary Equipment
11.19.3. Communication Setup
11.19.4. Appendix A
11.19.5. Setting The Computer Subnet Mask And IP Address
11.19.6. Windows 2000
11.19.7. Windows XP
11.19.8. Windows Vista
11.19.9. Windows 7
11.19.10. Appendix B Troubleshooting
11.20. FIELD ASSEMBLY INSPECTION REPORT
11.21. HOUR CHECKSHEET

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