Komatsu A30036 Manual

CEAM026004
Operation&MaintenanceManual
DumpTruck860E-1KT
SerialNumbersA30036&Up

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INTRODUCTION
FOREWORD..................................................................................................................................1-2
ABOUTTHISMANUAL...................................................................................................................1-3
WARNINGS....................................................................................................................................1-4
CaliforniaProposition65Warnings.....................................................................................1-4
ALERTS.........................................................................................................................................1-5
TRUCKMODELILLUSTRATION.....................................................................................................1-6
NON-OEMPARTSINCRITICALSYSTEMS.....................................................................................1-7
STANDARDCHARTSANDTABLES
GENERALINFORMATION..............................................................................................................2-2
EffectOfSpecialLubricants...............................................................................................2-2
SuggestedSourcesForRustPreventiveGrease.................................................................2-2
STANDARDTIGHTENINGTORQUES.............................................................................................2-3
Class10.9CapscrewsAndClass10Nuts...........................................................................2-3
SAEGrade5AndGrade8Capscrews................................................................................2-4
SAEGrade9Capscrews...................................................................................................2-5
T-BoltClamps....................................................................................................................2-5
SplitFlangeClamps...........................................................................................................2-6
FlaredTubeAndHoseFittings...........................................................................................2-6
JIC37°SwivelNuts...........................................................................................................2-7
PipeThreadFittings...........................................................................................................2-8
O-RingBossFittings..........................................................................................................2-9
O-RingFaceSealFittings................................................................................................2-10
CONVERSIONMULTIPLIERS........................................................................................................2-11
MetricT oEnglish..............................................................................................................2-11
EnglishT oMetric.............................................................................................................2-12
TemperatureConversions................................................................................................2-13
GENERALSAFETY
GENERALSAFETY........................................................................................................................3-2
SafetyRules......................................................................................................................3-2
TruckSafetyFeatures........................................................................................................3-2
ClothingAndPersonalItems..............................................................................................3-2
UnauthorizedModication..................................................................................................3-2
LeavingTheOperator’sSeat..............................................................................................3-2
MountingAndDismounting................................................................................................3-2
FireExtinguishersAndFirstAidKits...................................................................................3-3
PrecautionsForHighT emperatureFluids............................................................................3-3
AsbestosDustHazardPrevention......................................................................................3-3
FirePrevention..................................................................................................................3-3
ROPSPrecautions.............................................................................................................3-3
PreventingInjuryFromWorkEquipment.............................................................................3-4
PrecautionsForOptionalAttachments................................................................................3-4
PrecautionsWhenStartingTheMachine.............................................................................3-4
PRECAUTIONSFORTRUCKOPERATION.....................................................................................3-5
SafetyIsThinkingAhead...................................................................................................3-5
SafetyAtTheWorksite......................................................................................................3-5
PreparingForOperation.....................................................................................................3-5
VentilationForEnclosedAreas...........................................................................................3-5
Mirrors,Windows,AndLights.............................................................................................3-5
BeforeStartingTheEngine................................................................................................3-5
SeatBeltsAndT ethers.......................................................................................................3-5
EmergencyEgressLadders...............................................................................................3-6
OPERATINGTHEMACHINE...........................................................................................................3-7
GeneralInformation...........................................................................................................3-7
860E-1KT3
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StartingTheEngine...........................................................................................................3-7
TravelingInTheMachine...................................................................................................3-7
TravelingInReverse..........................................................................................................3-8
TravelingOnSlopes..........................................................................................................3-8
TravelingOnSnow............................................................................................................3-8
TravelingNearHighVoltageCables....................................................................................3-8
TravelingOnLooseGround...............................................................................................3-8
EnsuringGoodVisibility.....................................................................................................3-8
AvoidDamageT oTheDumpBody.....................................................................................3-8
SafeParkingOfTheMachine.............................................................................................3-9
LoadingTheMachine........................................................................................................3-9
DumpingTheMachine.......................................................................................................3-9
TowingTheMachine..........................................................................................................3-9
EXTERIORLIGHTING...........................................................................................................3-10
FogLights.......................................................................................................................3-10
Headlights.......................................................................................................................3-10
LadderLightsandDeckMountedFloodLights..................................................................3-10
MirrorMountedBackupLights..........................................................................................3-10
BrakeLight.......................................................................................................................3-11
RetardLight.....................................................................................................................3-11
Clearance/TurnSignalLights.............................................................................................3-11
BackupLights...................................................................................................................3-11
RetardLights....................................................................................................................3-11
BrakeLights.....................................................................................................................3-11
BackupAlarm...................................................................................................................3-11
PRECAUTIONSFORMAINTENANCE...........................................................................................3-12
BEFOREPERFORMINGMAINTENANCE...............................................................................3-12
SecuringTheDumpBody................................................................................................3-12
DURINGMAINTENANCE.......................................................................................................3-12
WarningT ag....................................................................................................................3-12
ProperT ools....................................................................................................................3-13
Attachments....................................................................................................................3-13
WorkingUnderTheMachine............................................................................................3-13
KeepingTheMachineClean............................................................................................3-13
AddingFuelOrOilToTheMachine..................................................................................3-13
RadiatorCoolantLevel.....................................................................................................3-13
UseOfLighting................................................................................................................3-13
HandlingHighPressureHoses.........................................................................................3-14
PrecautionsWithHighPressureOil..................................................................................3-14
MaintenanceNearHighT emperaturesAndHighPressures................................................3-14
RotatingFanAndBelts....................................................................................................3-14
WasteMaterials...............................................................................................................3-14
UseOfTie-OffAnchorDuringMaintenance.......................................................................3-14
HandlingTires.................................................................................................................3-14
TireMaintenance.............................................................................................................3-15
StoringTiresAfterRemoval..............................................................................................3-15
BatteryHazardPrevention......................................................................................................3-15
JumpStartingWithJumperCables...................................................................................3-16
JumpStartingWithReceptacles.......................................................................................3-17
WHENREPAIRSARENECESSARY.............................................................................................3-18
ObserveTheFollowingPrecautions..................................................................................3-18
SPECIALPRECAUTIONS.............................................................................................................3-19
PreliminaryProceduresBeforeWeldingOrPerformingMaintenance..................................3-19
EngineShutdownProcedureBeforeWeldingorPerformingMaintenance...........................3-19
4860E-1KT
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BeforeWeldingOnTheMachine,ObeyTheFollowingGuidelines:.....................................3-19
WARNINGANDCAUTIONS
GENERALINFORMATION..............................................................................................................4-2
PINPLATE.....................................................................................................................................4-2
GRADESPEEDCHART.................................................................................................................4-3
GREASEPOINTS...........................................................................................................................4-3
MACHINESAFETY.........................................................................................................................4-4
KEYSWITCH.................................................................................................................................4-6
OILFILLANDCHECK....................................................................................................................4-6
HIGHPRESSURES........................................................................................................................4-7
SPRINGPRESSURE......................................................................................................................4-9
BATTERIES..................................................................................................................................4-10
HIGHVOLTAGE............................................................................................................................4-11
WELDING.....................................................................................................................................4-11
EMERGENCYDUMPING..............................................................................................................4-12
AUTOMATICLUBRICATIONFILL..................................................................................................4-12
ROPS/FOPS................................................................................................................................4-12
TOWING......................................................................................................................................4-13
LUBRICATIONCHART.................................................................................................................4-13
OPERATINGINSTRUCTIONS
PREPARINGFOROPERATION......................................................................................................5-2
SafetyIsThinkingAhead...................................................................................................5-2
WalkAroundInspection.....................................................................................................5-2
TRUCKOPERATION......................................................................................................................5-6
ENGINESTART-UPSAFETY...................................................................................................5-6
AfterEngineHasStarted....................................................................................................5-6
MACHINEOPERATIONSAFETYPRECAUTIONS.....................................................................5-7
MachineOperationOnTheHaulRoad................................................................................5-8
StartingOnAGradeWithALoadedTruck..........................................................................5-8
Passing.............................................................................................................................5-8
Loading.............................................................................................................................5-9
OverloadSpeedLimitFunction...........................................................................................5-9
Dumping...........................................................................................................................5-9
LoweringTheDumpBody(WhenDumpingOnFlatGround)..............................................5-10
LoweringTheDumpBody(WhenDumpingOverABermOrIntoACrusher).......................5-10
TROLLEYOPERATINGINSTRUCTIONS.................................................................................5-11
OperatinginTrolleyLineMode..........................................................................................5-11
GettingonLine.................................................................................................................5-11
OperatingonTrolley........................................................................................................5-12
GettingoffLine................................................................................................................5-12
LineStatusSignals..........................................................................................................5-13
TrolleyDisconnect...........................................................................................................5-13
TrafcConsiderationforTrolleyLineOperation..................................................................5-13
ApproachingSlowMovingVehiclesinaTrolleyAssistedTruck...........................................5-13
OperatingSlowMovingVehiclesonTrolleyAssistRamps..................................................5-14
TruckFailureWhileonTrolley..........................................................................................5-14
SUDDENLOSSOFENGINEPOWERORLOSSOFDRIVESYSTEMFUNCTION...................5-14
FUELDEPLETION.................................................................................................................5-15
SAFEPARKINGPROCEDURES............................................................................................5-15
NORMALENGINESHUTDOWNPROCEDURE......................................................................5-15
DISABLEDTRUCKCONNECTORS..............................................................................................5-17
GENERALINFORMATION.....................................................................................................5-17
STEERINGANDBRAKESYSTEM.........................................................................................5-17
ComponentsRequired.....................................................................................................5-17
860E-1KT5
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Hookup...........................................................................................................................5-17
HOISTSYSTEM....................................................................................................................5-18
Hookup...........................................................................................................................5-18
DumpingProcedure.........................................................................................................5-18
TOWING......................................................................................................................................5-20
SPECIALWIRINGHARNESS.................................................................................................5-20
TOWINGPROCEDURE.........................................................................................................5-20
PAYLOADMETERIIISYSTEM......................................................................................................5-23
GENERALINFORMATION.....................................................................................................5-23
DataSummary................................................................................................................5-23
DataGathering................................................................................................................5-23
COMPONENTDESCRIPTION................................................................................................5-23
OperatorDisplay.............................................................................................................5-23
OperatorSwitches...........................................................................................................5-23
BrakeLockSwitch...........................................................................................................5-23
PayloadMeterModule.....................................................................................................5-23
CommunicationsPorts.....................................................................................................5-24
LoadLights.....................................................................................................................5-24
OPERATOR’SDISPLAYANDSWITCH...................................................................................5-24
ReadingtheLoadDisplay................................................................................................5-24
SettingtheOperatorID....................................................................................................5-24
LoadandTonCounter......................................................................................................5-24
ViewingLiveSensorData................................................................................................5-25
OtherDisplayMessages..................................................................................................5-25
HAULCYCLEWARNINGFLAGS...........................................................................................5-25
HaulCycleData..............................................................................................................5-25
HaulCycleWarningFlags................................................................................................5-27
PCSOFTWAREOVERVIEW..................................................................................................5-28
SYSTEMCONFIGURATION...................................................................................................5-29
ConnectingtothePayloadMeter......................................................................................5-29
DisplayedPayloadUnits..................................................................................................5-29
ConnectionMenu............................................................................................................5-30
CongurethePayloadMeter............................................................................................5-30
SettingtheDateandTime................................................................................................5-30
SettingtheTruckTypeandSerialNumber.........................................................................5-31
SettingtheGaugeDisplayUnits.......................................................................................5-31
SettingtheCarrybackAlarmThreshold.............................................................................5-31
SettingtheTruckNumber.................................................................................................5-31
SettingtheKomatsuDistributor........................................................................................5-32
SettingtheKomatsuCustomer.........................................................................................5-32
CleanTruckTareCalibration............................................................................................5-32
InclinometerCalibration...................................................................................................5-33
DOWNLOADINGPAYLOADDATA..........................................................................................5-33
UploadingData......................................................................................................................5-34
CreatingaQuery.............................................................................................................5-35
DetailedMulti-PageReport..............................................................................................5-35
CreatingGraphs..............................................................................................................5-36
DATAANALYSIS....................................................................................................................5-36
CreatingaQuery.............................................................................................................5-36
PayloadDetailScreen......................................................................................................5-36
CreatingReports.............................................................................................................5-37
CreatingGraphs..............................................................................................................5-37
ExportingData................................................................................................................5-38
ImportingData.................................................................................................................5-38
6860E-1KT
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DeletingHaulCycleRecords............................................................................................5-38
ViewingAlarms................................................................................................................5-39
DeletingAlarmRecords...................................................................................................5-39
PatentAcknowledgment...................................................................................................5-39
AUTOMATICLUBRICATIONSYSTEM...........................................................................................5-40
GENERALINFORMATION.....................................................................................................5-40
COMPONENTDESCRIPTION................................................................................................5-40
Filter...............................................................................................................................5-41
HydraulicMotorandPump...............................................................................................5-41
GreaseReservoir............................................................................................................5-41
PressureReducingValve.................................................................................................5-41
FlowControlValve...........................................................................................................5-41
SolenoidValve.................................................................................................................5-42
VentValve.......................................................................................................................5-42
InterfaceModule..............................................................................................................5-42
Injectors..........................................................................................................................5-43
GreasePressureFailureSwitch.......................................................................................5-43
ReliefValve(unloadervalve)............................................................................................5-43
SYSTEMOPERATION...........................................................................................................5-43
FillingTheReservoir........................................................................................................5-43
PrimingTheAutomaticLubricationSystem........................................................................5-44
PREVENTIVEMAINTENANCEPROCEDURES......................................................................5-44
DailyLubricationSystemInspection..................................................................................5-44
250HourInspection.........................................................................................................5-45
1000HourInspection.......................................................................................................5-45
SYSTEMCHECKOUT............................................................................................................5-45
GeneralChecks...............................................................................................................5-45
LubricationCycleOperation.............................................................................................5-46
RESERVEENGINEOILSYSTEM.................................................................................................5-47
Operation........................................................................................................................5-47
LEDMonitorLight............................................................................................................5-47
ChangingOil...................................................................................................................5-47
OPERATORCABANDCONTROLS
CABINTERIOR..............................................................................................................................6-2
STEERINGWHEELANDCONTROLS.............................................................................................6-3
HornButton.......................................................................................................................6-3
Tilt/TelescopeLever.........................................................................................................6-3
Multi-FunctionTurnSignalSwitch.......................................................................................6-3
SpeedControlLever..........................................................................................................6-3
TurnSignalOperation........................................................................................................6-3
HighBeamHeadlightOperation.........................................................................................6-4
WindshieldWiperOperation...............................................................................................6-4
PEDALS.........................................................................................................................................6-5
DYNAMICRETARDING.....................................................................................................6-5
DynamicRetarder/ServiceBrakePedal...............................................................................6-5
ACCELERATORPEDAL....................................................................................................6-5
OVERHEADPANELANDDISPLAYS...............................................................................................6-6
RadioSpeakers.................................................................................................................6-6
WarningAlarmBuzzer.......................................................................................................6-6
CabRadio.........................................................................................................................6-6
AirCleanerVacuumGauges..............................................................................................6-6
CENTERCONSOLE.......................................................................................................................6-7
DIRECTIONALCONTROLLEVER.....................................................................................6-7
OVERRIDE/FAULTRESETSWITCH..................................................................................6-7
860E-1KT7
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ENGINESTOPSWITCH....................................................................................................6-8
WINDOWCONTROLSWITCHES......................................................................................6-8
HOISTCONTROLLEVER.................................................................................................6-8
RaisingTheDumpBody....................................................................................................6-8
LoweringTheDumpBody..................................................................................................6-8
ASHTRAY.........................................................................................................................6-8
LIGHTER..........................................................................................................................6-8
DATASTOREBUTTON.....................................................................................................6-9
12VAUXILIARYPOWEROUTLETS..................................................................................6-9
DIAGNOSTICPORTS...................................................................................................................6-10
DRIVESYSTEM#1.........................................................................................................6-10
ENGINE(QUANTUM)......................................................................................................6-10
DRIVESYSTEM#3.........................................................................................................6-10
ENGINE(CENSE)...........................................................................................................6-10
INTERFACEMODULE(IM)..............................................................................................6-10
KOMTRAXPlus..............................................................................................................6-10
PAYLOADMETER...........................................................................................................6-10
OPERATORSEAT(Standard)........................................................................................................6-11
SeatBeltsAndT ethers......................................................................................................6-11
Adjustment.......................................................................................................................6-11
PASSENGERSEAT(Standard).....................................................................................................6-13
SeatBeltsAndT ethers.....................................................................................................6-13
Adjustment......................................................................................................................6-13
OPERATORSEAT(Optional)........................................................................................................6-14
SeatBeltsAndT ethers.....................................................................................................6-14
Adjustment......................................................................................................................6-14
PASSENGERSEAT(Optional)......................................................................................................6-16
SeatBeltsAndT ethers.....................................................................................................6-16
Adjustment......................................................................................................................6-16
HEATER/AIRCONDITIONERCONTROLS...................................................................................6-17
FanSpeedControlKnob..................................................................................................6-17
TemperatureControlKnob...............................................................................................6-17
AirFlowDirectionalKnob.................................................................................................6-17
Heater/AirConditionerVents............................................................................................6-17
INSTRUMENTPANEL.................................................................................................................6-18
CONTROLSYMBOLS.....................................................................................................6-18
KeySwitch......................................................................................................................6-19
SpeedControlSwitch......................................................................................................6-19
TractionControlSwitch....................................................................................................6-19
RetardingGridDrierSwitch..............................................................................................6-20
ACDriveSystemRestSwitch...........................................................................................6-20
WheelBrakeLockSwitch.................................................................................................6-20
PantographSwitch...........................................................................................................6-20
HazardLightSwitch.........................................................................................................6-21
Heater/AirConditionerVents............................................................................................6-21
DriveSystemTemperatureGauge....................................................................................6-21
FuelLevelGauge............................................................................................................6-21
Speedometer/DigitalDisplay............................................................................................6-21
CoolantT emperatureGauge............................................................................................6-21
HydraulicOilTemperatureGauge.....................................................................................6-21
StatusIndicatorLightPanel..............................................................................................6-21
Headlight/PanelIlluminationLightSwitch..........................................................................6-21
LadderLightSwitch.........................................................................................................6-22
BackupLightSwitch........................................................................................................6-22
8860E-1KT
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FogLightSwitch..............................................................................................................6-22
ModeSwitches................................................................................................................6-22
PanelLightsDimmerSwitch.............................................................................................6-22
TurnSignalIndicators......................................................................................................6-22
DigitalDisplayContrastButtons........................................................................................6-22
WarningLight..................................................................................................................6-22
STATUSINDICATORLIGHTPANEL..............................................................................................6-23
STATUSINDICATORLIGHTSYMBOLS..................................................................................6-23
BodyUp..........................................................................................................................6-23
ParkingBrake..................................................................................................................6-23
PropelSystemNotReady................................................................................................6-23
NoPropel........................................................................................................................6-24
EngineWarmUp.............................................................................................................6-24
EngineShutdownDelay...................................................................................................6-24
RetardingGridDrier.........................................................................................................6-24
WheelBrakeLock...........................................................................................................6-24
TractionControl...............................................................................................................6-24
RepairMonitor.................................................................................................................6-24
RetractableLadderDown.................................................................................................6-24
SnapshotInProgress......................................................................................................6-24
PantographEnergized.....................................................................................................6-24
PantographUp................................................................................................................6-25
ServiceBrake..................................................................................................................6-25
DynamicRetarding..........................................................................................................6-25
NoDCLinkVoltage.........................................................................................................6-25
DIGITALDISPLAYOPERATION....................................................................................................6-26
TogglingThroughMainLevelScreens...............................................................................6-26
TogglingThroughWarningScreens..................................................................................6-27
EnteringPayloadMeterData............................................................................................6-28
KOMTRAXPlus............................................................................................................................6-29
KOMTRAXPlusOPERATION.................................................................................................6-29
BasicPrecautions............................................................................................................6-29
InterfaceModule..............................................................................................................6-30
DOWNLOADINGKOMTRAXPlusDATA.................................................................................6-31
GeneralInformation.........................................................................................................6-31
KOMTRAXPlusDownloadingProcedure..........................................................................6-31
LocationOfDownloadedFiles..........................................................................................6-31
UPLOADINGKOMTRAXPlusDATA.......................................................................................6-32
ORBCOMM...........................................................................................................................6-33
KOMATSUWIRELESSBRIDGE(Optional)..............................................................................6-34
GeneralInformation.........................................................................................................6-34
CommunicationSetup......................................................................................................6-34
SwitchingT oTheKWB_SETUPNetwork..........................................................................6-34
SettingTheComputerSubnetMaskAndIPAddress.........................................................6-35
SettingUpTheKWB........................................................................................................6-35
AddingEncryption...........................................................................................................6-36
FinalComputerSettings...................................................................................................6-36
DownloadingData...........................................................................................................6-36
ResettingTheKWB.........................................................................................................6-37
FUSESANDCIRCUITBREAKERS...............................................................................................6-38
FUSEBLOCK#1...................................................................................................................6-39
FUSEBLOCK#2...................................................................................................................6-40
FUSEBLOCK#3...................................................................................................................6-40
FUSEHOLDERS...................................................................................................................6-40
860E-1KT9
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CIRCUITBREAKERS.............................................................................................................6-41
LUBRICATIONANDSERVICE
GENERALINFORMATION..............................................................................................................7-2
HYDRAULICSYSTEMSERVICE..............................................................................................7-2
HydraulicT ank...................................................................................................................7-2
HydraulicFilters.................................................................................................................7-3
HydraulicPumpDriveShaft................................................................................................7-3
WHEELMOTORSERVICE.......................................................................................................7-3
COOLANTLEVELSERVICE....................................................................................................7-3
RadiatorFillingProcedure..................................................................................................7-4
CoolantSpecications........................................................................................................7-4
UnacceptablePractices.....................................................................................................7-4
IGBTCOOLANTSERVICE.......................................................................................................7-4
RadiatorFillingProcedure..................................................................................................7-5
CoolantSpecications........................................................................................................7-5
RESERVEENGINEOILSERVICE............................................................................................7-5
ReserveOilTankFillingProcedure(RemoteFill).................................................................7-6
InlineScreen.....................................................................................................................7-6
CABAIRFILTERSERVICE......................................................................................................7-6
FUELSYSTEMSERVICE.........................................................................................................7-7
FuelT ankCleaning............................................................................................................7-7
FuelFilterService..............................................................................................................7-7
INTAKEAIRCLEANERSERVICE.............................................................................................7-8
FRONTENGINEMOUNTTRUNNIONSERVICE.......................................................................7-9
QUICKFILLSERVICECENTER...............................................................................................7-9
TIERODINSPECTIONANDTORQUEPROCEDURE...............................................................7-9
LUBRICATIONCHART..................................................................................................................7-11
EVERY10HOUR(DAILY)MAINTENANCE...................................................................................7-12
INITIAL50HOURLUBRICATIONANDMAINTENANCEINSPECTION............................................7-14
INITIAL100HOURLUBRICATIONANDMAINTENANCEINSPECTION..........................................7-15
EVERY250HOURLUBRICATIONANDMAINTENANCE...............................................................7-16
EVERY500HOURLUBRICATIONANDMAINTENANCE...............................................................7-18
EVERY1000HOURSLUBRICATIONANDMAINTENANCE...........................................................7-21
EVERY1500HOURLUBRICATIONANDMAINTENANCEINSPECTION........................................7-22
EVERY2000HOURLUBRICATIONANDMAINTENANCEINSPECTION........................................7-23
EVERY3000HOURLUBRICATIONANDMAINTENANCEINSPECTION........................................7-24
EVERY4000HOURMAINTENANCE............................................................................................7-25
EVERY5000HOURMAINTENANCE............................................................................................7-26
EVERY6000HOURMAINTENANCE............................................................................................7-27
EVERY12,000HOURMAINTENANCE..........................................................................................7-28
EVERY18,000HOURMAINTENANCE..........................................................................................7-29
EVERY24,000HOURMAINTENANCE..........................................................................................7-30
25,000HOURLUBRICATIONANDMAINTENANCECHECKS........................................................7-31
30,000HOURLUBRICATIONANDMAINTENANCECHECKS........................................................7-32
SPECIFICATIONS
MAJORCOMPONENTDESCRIPTION............................................................................................8-2
TruckAndEngine.....................................................................................................................8-2
TractionAlternator....................................................................................................................8-2
MainControlCabinet................................................................................................................8-2
ACInductionTractionMotorizedWheels....................................................................................8-2
Suspension..............................................................................................................................8-2
Operator'sCab.........................................................................................................................8-2
PowerSteering........................................................................................................................8-2
DynamicRetardingGrid............................................................................................................8-2
10860E-1KT
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