Komatsu 930E-4SE Dump Truck Field Assembly Instruction CEAW007011

Description

• Model List:
  • 930E-4SE Dump Truck

• 1. FOREWORD
• 2. TABLE OF CONTENTS
• 3. SAFETY RULES, TOOLS EQUIPMENT
• 3.1. SAFETY RULES
• 3.2. KOMVISION CALIBRATION TOOLS
• 3.3. HIGH VOLTAGE TOOLS
• 3.3.1. VDC CUSTOM METER KIT (58B0600800)
• 3.3.2. BODY PAD SPACER TOOL
• 4. TRUCK COMPONENTS AND SPECIFICATIONS
• 4.1. SPECIFICATIONS
• 4.2. WEIGHT DISTRIBUTION
• 5. MAJOR COMPONENT WEIGHTS
• 5.1. REAR AXLE COMPONENTS
• 6. FIELD WELDING FOR ASSEMBLY OR REPAIR
• 6.1. WELDER QUALIFICATION AND TRAINING
• 6.2. WELD PROCEDURES
• 6.3. APPROVED CONSUMABLES
• 6.4. WELD QUALITY REQUIREMENTS
• 6.5. MATERIALS, CONTROLS, AND PRECAUTIONS
• 6.5.1. WELD INSPECTION
• 6.5.2. RECORDS
• 6.5.3. ANNEX A
• 6.5.4. ANNEX B
• 6.5.5. BIBLIOGRAPHY
• 6.6. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
• 7. RECEIVING ASSEMBLY PREPARATION
• 7.1. Preparation
• 7.2. ASSEMBLY LAYOUT
• 8. CHASSIS ASSEMBLY
• 8.1. RECOMMENDED ASSEMBLY DATA
• 8.2. BASIC ASSEMBLY PROCEDURE
• 8.3. ORDER OF ASSEMBLY
• 8.4. CHASSIS ASSEMBLY
• 8.4.1. HARDWARE TIGHTENING METHOD
• 8.4.2. GENERAL PRECAUTIONS AND INSTRUCTION
• 8.4.3. HYDRAULIC SYSTEM FLUSHING PROCEDURE
• 8.4.4. Before Starting the Engine
• 9. DUMP BODY ASSEMBLY
• 9.1. GENERAL INFORMATION
• 9.2. LUBRICATION CHART
• 9.3. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 9.3.1. GENERAL DESCRIPTION
• 9.3.2. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 9.3.3. STANDARD ASSEMBLY TORQUES Grade 9 Capscrews (SAE)
• 9.3.4. STANDARD ASSEMBLY TORQUES For Class 10.9 Capscrews and Class 10 Nuts
• 9.4. TOEIN ADJUSTMENT PROCEDURE
• 9.5. SUSPENSION OILING AND CHARGING PROCEDURE
• 9.5.1. GENERAL
• 9.5.2. Front Suspension
• 9.5.3. Rear Suspension
• 9.6. OIL AND NITROGEN SPECIFICATIONS CHART
• 9.7. AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
• 9.7.1. Lincoln Flow Master Phase 1 Auto Lube System With Fixed Hydraulic Controls
• 9.7.2. Lube Pump Startup / Purging Procedure
• 9.7.3. Truck Lube System Purging Procedure
• 9.7.4. Adjust Injector Settings
• 9.7.5. Timer
• 9.7.6. Warning System
• 9.8. RESERVE OIL SYSTEM CHECKOUT PROCEDURE
• 9.9. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
• 9.10. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 9.10.1. Scope of Checkout Procedure
• 9.10.2. Data to be Recorded
• 9.10.3. Required Software
• 9.10.4. PreCheckout Items
• 9.10.5. Procedure for Bleeding Down Hydraulic Brake and Steering Accumulators
• 9.10.6. Accumulator Precharge Procedure
• 9.10.7. Pressure Gauge Installation
• 9.10.8. Initial StartUp and Flushing
• 9.10.9. Steering System Checkout and Adjustment
• 9.10.10. Steering Pump with Unloader Valve Adjustment
• 9.10.11. Hoist System Checkout and Adjustment
• 9.10.12. Hoist Counterbalance Valve Adjustment
• 9.10.13. Counterbalance Valve Setting Check
• 9.10.14. Oil Cleanliness Check
• 9.10.15. Hydraulic System Checkout Data Sheet
• 9.10.15.1. Accumulator Precharge procedure
• 9.10.15.2. Initial Startup and Flushing
• 9.10.15.3. Steering System Checkout and Adjustment
• 9.10.15.4. Steering Pump with Unloader Valve Adjustment
• 9.10.15.5. Steering System Diagnostic and Verification
• 9.10.15.6. Hoist System Checkout and Adjustment
• 9.10.15.7. Hoist Counterbalance Valve Adjustment
• 9.10.15.8. Oil Cleanliness Check
• 9.11. HYDRAULIC BRAKE SYSTEM CHECKOUT PROCEDURE
• 9.11.1. Scope of Checkout Procedure
• 9.11.2. Purpose of Checkout Procedure
• 9.11.3. Required Software
• 9.11.4. Necessary Equipment
• 9.11.5. PreCheckout Items
• 9.11.6. Bleed Down Procedure
• 9.11.7. Checkout Procedure Setup
• 9.11.8. Initial Startup and Service Brake Checks
• 9.11.9. Brake Lock System Check
• 9.11.10. Parking Brake System
• 9.11.11. Low Brake Pressure and Auto Apply
• 9.11.12. Brake Reapplications (Stored Energy Check)
• 9.11.13. Park Brake Control Logic Check
• 9.11.14. Brake Lock Control Logic Check
• 9.11.15. The Brake System Checkout Data Sheet follows
• 9.11.16. T Brake System Checkout Data Sheet
• 9.11.16.1. Brake Lock System
• 9.11.16.2. Park Brake System
• 9.11.16.3. Low Brake Pressure and Auto Apply
• 9.11.16.4. Brake Reapplications
• 9.11.16.5. Park Brake Control Logic Check
• 9.11.16.6. Brake Lock Control Logic Check
• 9.12. BRAKE TEST CHECKOUT PROCEDURE
• 9.13. REAR AXLE COOLING AIR PRESSURE SWITCH ADJUSTMENT AND TEST
• 9.14. KOMTRAX PLUS SETUP PROCEDURE
• 9.14.1. Purpose
• 9.14.2. Preliminary Procedures
• 9.14.3. Necessary Equipment
• 9.14.4. Check for KOMTRAX Plus System Faults
• 9.15. KOMTRAX Plus Setup
• 9.15.1. Begin KOMTRAX Plus Setup
• 9.16. KOMTRAX PLUS CHECKOUT PROCEDURE
• 9.16.1. Purpose
• 9.16.2. Preliminary Procedures
• 9.16.3. Necessary Equipment
• 9.16.4. Check for KOMTRAX Plus System Faults
• 9.16.5. Checkout Procedure
• 9.17. PAYLOAD METER IV CHECKOUT PROCEDURE
• 9.17.1. Appendix A
• 9.17.2. Appendix B
• 9.17.3. Appendix C
• 9.17.4. Payload Meter IV Checkout Procedure Confirmation
• 9.18. ELECTRICAL SYSTEM CHECKOUT PROCEDURE
• 9.18.1. General Description
• 9.18.2. Welding and Safety Procedures
• 9.18.3. AC System Description
• 9.18.4. Resistance Checks
• 9.18.5. Megger Preparation and Testing
• 9.18.6. Control System Checkout
• 9.18.7. IM System Checkout
• 9.18.8. Drive System Initial Checkout
• 9.18.9. Hydraulic System Checkout
• 9.18.10. Drive System Checkout
• 9.19. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
• 9.19.1. GENERAL DESCRIPTION
• 9.20. INTERFACE MODULE CHECKOUT PROCEDURE 930E WITH ACTIA
• 9.20.1. Purpose
• 9.20.2. Necessary Equipment
• 9.20.3. Install the Application Code
• 9.20.4. How to Use the IM Realtime Data Monitor Software
• 9.20.5. Check for Fault Codes Associated With the Interface Module
• 9.20.6. Interface Module I/O
• 9.20.6.1. S/N ___________________ IM Installation Checkout Checklist
• 9.21. KOMVISION CHECKOUT PROCEDURE
• 9.21.1. STEP 1 Settings
• 9.22. WIRELESS BRIDGE CHECKOUT PROCEDURE
• 9.23. FIELD ASSEMBLY INSPECTION REPORT
• 9.24. HOUR POSTCOMMISSIONING CHECKSHEET