Komatsu 930E-4 Dump Truck Field Assembly Instruction CEAW007711

Description

• Model List:
  • 930E-4 Dump Truck

• 1. COVER
• 2. FOREWORD
• 3. SAFETY RULES, TOOLS EQUIPMENT
• 3.1. SAFETY RULES
• 3.1.1. Use of TieOff Anchor During Maintenance and Repair
• 3.2. KOMVISION CALIBRATION TOOLS
• 3.3. HIGH VOLTAGE TOOLS
• 3.4. VDC CUSTOM METER KIT (58B0600800)
• 3.5. BODY PAD SPACER TOOL
• 4. MAJOR COMPONENTS SPECIFICATIONS
• 4.1. TRUCK AND ENGINE
• 4.2. MAIN ALTERNATOR
• 4.3. AC INDUCTION TRACTION MOTORIZED WHEELS
• 4.4. SUSPENSION
• 4.5. OPERATORS CAB
• 4.6. POWER STEERING
• 4.7. DYNAMIC RETARDING
• 4.8. BRAKE SYSTEM
• 4.8.1. ENGINE
• 4.8.2. AC ELECTRIC DRIVE SYSTEM
• 4.8.3. DYNAMIC RETARDING
• 4.8.4. BATTERY ELECTRIC SYSTEM
• 4.8.5. SERVICE CAPACITIES
• 4.8.6. HYDRAULIC SYSTEMS
• 4.8.7. SERVICE BRAKES
• 4.8.8. STEERING
• 4.8.9. TIRES
• 4.8.10. STANDARD DUMP BODY CAPACITIES AND DIMENSIONS
• 4.8.11. WEIGHT DISTRIBUTION
• 5. FIELD WELDING FOR ASSEMBLY OR REPAIR
• 5.1. WELDER QUALIFICATION AND TRAINING
• 5.2. WELD PROCEDURES
• 5.3. APPROVED CONSUMABLES
• 5.4. WELD QUALITY REQUIREMENTS
• 5.5. MATERIALS, CONTROLS, AND PRECAUTIONS
• 5.6. WELD INSPECTION
• 5.7. RECORDS
• 5.8. ANNEX A
• 5.9. ANNEX B
• 5.9.1. TOE HAMMER PEENING
• 5.9.2. Procedure
• 5.9.3. TOE GRINDING WITH A ROTARY BURR
• 5.9.4. Procedure
• 5.10. BIBLIOGRAPHY
• 5.11. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
• 5.11.1. Engine Shutdown Procedure before Welding or Performing Maintenance
• 6. RECEIVING ASSEMBLY PREPARATION
• 6.1. Preparation
• 6.1.1. Inspection, Cleaning, Setup
• 6.1.2. Color Coded Boxes
• 6.2. ASSEMBLY LAYOUT
• 7. CHASSIS ASSEMBLY
• 7.1. RECOMMENDED ASSEMBLY DATA
• 7.2. BASIC ASSEMBLY PROCEDURE
• 7.3. ORDER OF ASSEMBLY
• 7.3.1. LEVEL 1
• 7.3.2. LEVEL 2
• 7.3.3. LEVEL 3
• 7.4. CHASSIS ASSEMBLY
• 7.5. HARDWARE TIGHTENING METHOD
• 7.6. GENERAL PRECAUTIONS AND INSTRUCTION
• 7.7. HYDRAULIC SYSTEM FLUSHING PROCEDURE
• 7.7.1. Deck Support Welding
• 7.7.2. Rear Suspension Installation
• 7.7.3. Before Starting the Engine
• 7.7.4. Front Suspension Installation
• 7.7.5. Upper Mounting Joint 60 Advance
• 7.7.6. Parking Brake Installation
• 7.7.7. Wheel Motor Installation
• 7.7.8. Front Wheel Installation
• 7.7.9. Rear Wheel Installation
• 7.7.10. Before Starting the Engine
• 8. DUMP BODY ASSEMBLY
• 8.1. GENERAL INFORMATION
• 8.2. BODY ASSEMBLY
• 8.3. BODY WELDING
• 9. FINAL ASSEMBLY
• 9.1. Body Pad Shimming Procedure
• 9.2. Miscellaneous Installations
• 10. APPENDIX
• 10.1. LUBRICATION CHART
• 10.2. TORQUE TABLES AND CONVERSION CHARTS
• 10.2.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 10.2.2. STANDARD TIGHTENING TORQUES For Class 10.9 Capscrews Class 10 Nuts
• 10.2.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Capscrews
• 10.2.4. STANDARD TIGHTENING TORQUES For SAE Grade 9 Capscrews
• 10.3. SUSPENSION OILING AND CHARGING PROCEDURE
• 10.3.1. GENERAL
• 10.3.2. Front Suspension
• 10.3.3. Rear Suspension
• 10.4. OIL AND NITROGEN SPECIFICATIONS CHART
• 10.5. TOEIN ADJUSTMENT PROCEDURE
• 10.6. AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
• 10.6.1. Lincoln Flow Master Phase 1 Auto Lube System With Fixed Hydraulic Controls
• 10.6.2. Lube Pump Startup / Purging Procedure
• 10.6.3. Truck Lube System Purging Procedure
• 10.6.4. Adjust Injector Settings
• 10.6.5. Timer
• 10.6.6. Warning System
• 10.7. RESERVE OIL SYSTEM CHECKOUT PROCEDURE
• 10.7.1. AFC control startup / fast fill procedure
• 10.7.2. Reserve pump R2000DF startup and led description
• 10.8. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
• 10.9. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 10.9.1. Hydraulic System Checkout Data Sheet
• 10.9.2. Scope of Checkout Procedure
• 10.9.3. Data to be Recorded
• 10.9.4. Required Software
• 10.9.5. PreCheckout Items
• 10.9.6. Procedure for Bleeding Down Hydraulic Brake and Steering Accumulators
• 10.9.7. Accumulator Precharge Procedure
• 10.9.8. Pressure Gauge Installation
• 10.9.9. Initial StartUp and Flushing
• 10.9.10. Steering System Checkout and Adjustment
• 10.9.11. Steering Pump with Unloader Valve Adjustment
• 10.9.12. Hoist System Checkout and Adjustment
• 10.9.13. Hoist Counterbalance Valve Adjustment
• 10.9.14. Counterbalance Valve Setting Check
• 10.9.15. Oil Cleanliness Check
• 10.10. HYDRAULIC BRAKE SYSTEM CHECKOUT PROCEDURE
• 10.10.1. Scope of Checkout Procedure
• 10.10.2. Purpose of Checkout Procedure
• 10.10.3. Required Software
• 10.10.4. Necessary Equipment
• 10.10.5. PreCheckout Items
• 10.10.6. Bleed Down Procedure
• 10.10.7. Checkout Procedure Setup
• 10.10.8. Initial Startup and Service Brake Checks
• 10.10.9. Brake Lock System Check
• 10.10.10. Parking Brake System
• 10.10.11. Low Brake Pressure and Auto Apply
• 10.10.12. Brake Reapplications (Stored Energy Check)
• 10.10.13. Park Brake Control Logic Check
• 10.10.14. Brake Lock Control Logic Check
• 10.10.15. The Brake System Checkout Data Sheet follows
• 10.10.16. T Brake System Checkout Data Sheet
• 10.11. BRAKE TEST CHECKOUT PROCEDURE
• 10.11.1. Prerequisites
• 10.11.2. Testing The Service Brake
• 10.11.3. Testing The Parking Brake
• 10.11.4. Testing The Retard System
• 10.12. REAR AXLE COOLING AIR PRESSURE SWITCH ADJUSTMENT AND TEST
• 10.12.1. Purpose
• 10.12.2. Necessary Equipment
• 10.12.3. Pressure Switch Adjustment Procedure
• 10.13. KOMTRAX PLUS SETUP PROCEDURE
• 10.13.1. Purpose
• 10.13.2. Preliminary Procedures
• 10.13.3. Necessary Equipment
• 10.13.4. Check for KOMTRAX Plus System Faults
• 10.13.5. KOMTRAX Plus Setup
• 10.13.6. Begin KOMTRAX Plus Setup
• 10.14. KOMTRAX PLUS CHECKOUT PROCEDURE
• 10.14.1. Purpose
• 10.14.2. Preliminary Procedures
• 10.14.3. Necessary Equipment
• 10.14.4. Check for KOMTRAX Plus System Faults
• 10.14.5. Checkout Procedure
• 10.15. PAYLOAD METER IV CHECKOUT PROCEDURE
• 10.15.1. Necessary Equipment
• 10.15.2. Install the Application Code
• 10.15.3. General Instructions
• 10.15.4. Appendix A
• 10.15.5. Appendix B
• 10.15.6. Payload Meter IV Checkout Procedure Confirmation
• 10.16. ELECTRICAL SYSTEM CHECKOUT PROCEDURE
• 10.16.1. General Description
• 10.16.2. General Precautions
• 10.16.3. AC System Description
• 10.16.4. Visual Inspection
• 10.16.5. Resistance Checks
• 10.16.6. Voltage Check
• 10.16.7. IM System Checkout
• 10.16.8. Checkout Completion Report
• 10.17. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
• 10.17.1. GENERAL DESCRIPTION
• 10.18. INTERFACE MODULE CHECKOUT PROCEDURE
• 10.18.1. Purpose
• 10.18.2. Necessary Equipment
• 10.18.3. Install the Application Code
• 10.18.4. How to Use the IM Realtime Data Monitor Software
• 10.18.5. Check for Fault Codes Associated With the Interface Module
• 10.18.6. Interface Module I/O
• 10.18.7. S/N ___________________ IM Installation Checkout Checklist
• 10.19. WIRELESS BRIDGE CHECKOUT PROCEDURE
• 10.19.1. Purpose
• 10.19.2. Necessary Equipment
• 10.19.3. Communication Setup
• 10.19.4. Appendix A
• 10.19.5. Setting The Computer Subnet Mask And IP Address
• 10.19.6. Windows 2000
• 10.19.7. Windows XP
• 10.19.8. Windows Vista
• 10.19.9. Windows 7
• 10.19.10. Appendix B Troubleshooting
• 10.20. KOMVISION CHECKOUT PROCEDURE
• 10.20.1. Necessary Equipment
• 10.20.2. STEP 1 Settings
• 10.21. ACCUMULATOR CHARGING
• 10.21.1. BRAKE ACCUMULATORS
• 10.21.2. STEERING ACCUMULATOR
• 10.21.3. EFFECT OF AMBIENT TEMPERATURE ON CHARGING PRESSURE
• 10.22. FIELD ASSEMBLY INSPECTION REPORT
• 10.23. HOUR POSTCOMMISSIONING CHECKSHEET