Komatsu 930E-4 Dump Truck Field Assembly Instruction CEAW007711

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Komatsu 930E-4 Dump Truck Field Assembly Instruction CEAW007711

$20.00

Type Of Manual: Field Assembly Instruction
Manual ID: CEAW007711
Format: PDF
Size: 11.8MB
Number of Pages: 323

Category: Komatsu Operation and Maintenance Manual PDF

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

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