Komatsu 960E-2KT Dump Truck Field Assembly Instruction CEAW006511

Description

• Model List:
  • 960E-2KT Dump Truck

• 1. FOREWORD
• 2. TABLE OF CONTENTS
• 3. SAFETY RULES, TOOLS EQUIPMENT
• 3.1. TOOLS AND EQUIPMENT FOR ASSEMBLY
• 3.2. LIFTING SLING GENERAL INFORMATION
• 3.3. HIGH VOLTAGE TOOLS
• 3.4. SUSPENSION TOOLS
• 4. TRUCK COMPONENTS SPECIFICATIONS
• 4.1. MAJOR COMPONENT DESCRIPTIONS
• 4.2. SPECIFICATIONS
• 5. MAJOR COMPONENT WEIGHTS
• 5.1. CHASSIS
• 5.2. DECK AND DECK SUPPORT COMPONENTS
• 5.3. POWER MODULE
• 5.4. HYDRAULIC COMPONENTS
• 5.5. FRONT AXLE COMPONENTS
• 5.6. 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
• 6.6. WELD INSPECTION
• 6.7. RECORDS
• 6.8. ANNEX A
• 6.9. ANNEX B
• 6.10. BIBLIOGRAPHY
• 6.11. SPECIAL PRECAUTIONS WHEN SERVICING AN AC DRIVE SYSTEM TRUCK
• 6.12. Engine Shutdown Procedure BeforeWelding Or Performing Maintenance
• 6.13. Before Welding On The Machine, ObeyThe Following Guidelines
• 7. RECEIVING ASSEMBLY PREPARATION
• 7.1. Preparation
• 7.2. Color Coded Boxes
• 8. CHASSIS ASSEMBLY
• 9. DUMP BODY ASSEMBLY
• 9.1. GENERAL INFORMATION
• 9.2. BODY WELDING INFORMATION
• 9.3. BODY ASSEMBLY
• 10. FINAL ASSEMBLY
• 10.1. Dump Body Installation
• 10.2. Body Pad Body Guide Installation
• 10.3. Body Pad Shimming Procedure
• 10.4. Body Up Switch Hoist Limit Switch Installation
• 10.5. Miscellaneous Installations
• 11. FINAL CHECKOUT
• 12. APPENDIX
• 12.1. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 12.2. SUSPENSION OILING AND CHARGING PROCEDURE
• 12.3. SUSPENSION OILING AND CHARGING BLOCK KIT INSTALLATION PROCEDURE
• 12.4. OIL AND NITROGEN SPECIFICATIONS CHART
• 12.5. TOEIN ADJUSTMENT PROCEDURE
• 12.6. HYDRAULIC SYSTEM FLUSHING PROCEDURE
• 12.7. AUTOMATIC LUBRICATION SYSTEM PRIMING
• 12.8. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE
• 12.9. AUTOMATIC LUBRICATION CHECKOUT PROCEDURE
• 12.10. RESERVE OIL SYSTEM CHECKOUT PROCEDURE
• 12.11. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
• 12.12. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 12.13. BRAKE SYSTEM CHECKOUT
• 12.14. KOMTRAX PLUS SETUP PROCEDURE
• 12.15. KOMTRAX PLUS CHECKOUT PROCEDURE
• 12.16. PAYLOAD METER IV CHECKOUT PROCEDURE
• 12.17. WIRELESS BRIDGE CHECKOUT PROCEDURE
• 12.18. ADDITIONAL ELECTRICAL CHECKOUT FOR TRUCKS WITH IM CONTROLS
• 12.19. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
• 12.20. FIELD ASSEMBLY INSPECTION REPORT
• 12.21. HOUR POSTCOMMISSIONING CHECKSHEET