Komatsu 980E-5 Dump Truck Field Assembly Instruction CEAW013500

Description

• Model List:
  • 980E-5 Dump Truck

• 1. FOREWORD
• 2. TABLE OF CONTENTS
• 3. SAFETY RULES, TOOLS EQUIPMENT
• 3.1. SAFETY RULES
• 3.2. BODYUP RETENTION SLING
• 3.3. LIFTING SLING GENERAL INFORMATION
• 3.4. HEATED EXHAUST TOOL (IF EQUIPPED)
• 3.5. KomVision Calibration Tools (IF EQUIPPED)
• 3.6. HIGH VOLTAGE TOOLS
• 3.7. VDC CUSTOM METER KIT (58B0600800)
• 3.8. MISCELLANEOUS COMPONENTS
• 3.9. BODY PAD SPACER TOOL
• 4. TRUCK COMPONENTS AND SPECIFICATIONS
• 4.1. Selective Catalytic Reduction (SCR)
• 4.2. Diesel Exhaust Fluid (DEF)
• 4.3. SPECIFICATIONS
• 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
• 6.6. 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 Before Welding Or Performing Maintenance
• 6.13. Before Welding On The Machine, Obey The Following Guidelines
• 7. RECEIVING ASSEMBLY PREPARATION
• 7.1. Preparation
• 7.2. Coded Boxes
• 7.3. ASSEMBLY LAYOUT
• 8. CHASSIS ASSEMBLY
• 8.1. CHASSIS AND COMPONENT SERIAL NUMBER (SN) IDENTIFICATION
• 9. DUMP BODY ASSEMBLY
• 10. FINAL ASSEMBLY
• 11. FINAL CHECKOUT
• 12. APPENDIX
• 12.1. STANDARD TORQUE CHARTS AND CONVERSION TABLES
• 12.2. SUSPENSION OILING AND CHARGING PROCEDURE
• 12.3. OILING AND CHARGING BLOCK KIT INSTALLATION PROCEDURE
• 12.4. ENGINE EMISSIONS AFTERTREATMENT SYSTEMS
• 12.5. TOEIN ADJUSTMENT PROCEDURE
• 12.6. PRESHIFT BRAKE TEST TEST PROCEDURE
• 12.7. PARKING BRAKE BLEEDING/FLUSHING PROCEDURE
• 12.8. ALTERNATOR LOCK CHECKOUT PROCEDURE
• 12.9. INTERFACE MODULE CHECKOUT PROCEDURE
• 12.10. AUTOMATIC LUBRICATION SYSTEM CHECKOUT PROCEDURE
• 12.11. AUTOMATIC LUBRICATION SYSTEM
• 12.12. AUTOMATIC LUBRICATION SYSTEM PRIMING
• 12.13. AIR CONDITIONING SYSTEM CHECKOUT PROCEDURE
• 12.14. TIRE MONITORING SYSTEM CHECKOUT PROCEDURE
• 12.15. HYDRAULIC SYSTEM CHECKOUT PROCEDURE
• 12.16. BRAKE SYSTEM CHECKOUT PROCEDURE
• 12.17. KOMTRAX PLUS 2 SHOP SETUP CHECKOUT PROCEDURE
• 12.18. KOMTRAX PLUS 2 SITE SETUP CHECKOUT PROCEDURE
• 12.19. PAYLOAD METER IV CHECKOUT PROCEDURE
• 12.20. ELECTRIC CHECKOUT PROCEDURE
• 12.21. KOMVISION CHECKOUT PROCEDURE
• 12.22. KOMATSU WIRELESS BRIDGE CHECKOUT PROCEDURE
• 12.23. RETRACTABLE LADDER SYSTEM CHECKOUT PROCEDURE
• 12.24. SEAT BELTS AND TETHERS CHECKOUT PROCEDURE
• 12.25. FIELD ASSEMBLY INSPECTION REPORT
• 12.26. HOUR POSTCOMMISSIONING CHECKSHEET