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Komatsu A30036 Operation & Maintenance Manual

Dump truck
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CEAM026004
Operation & Maintenance Manual
Dump Truck
860E-1KT
A30036 & Up
Serial Numbers

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Summary of Contents for Komatsu A30036

  • Page 1 CEAM026004 Operation & Maintenance Manual Dump Truck 860E-1KT A30036 & Up Serial Numbers...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 INTRODUCTION FOREWORD ..........................1-2 ABOUT THIS MANUAL ........................1-3 WARNINGS............................ 1-4 California Proposition 65 Warnings ..................1-4 ALERTS ............................1-5 TRUCK MODEL ILLUSTRATION ..................... 1-6 NON-OEM PARTS IN CRITICAL SYSTEMS..................1-7 STANDARD CHARTS AND TABLES GENERAL INFORMATION ......................2-2 Effect Of Special Lubricants ....................2-2 Suggested Sources For Rust Preventive Grease ..............
  • Page 4 Starting The Engine ......................3-7 Traveling In The Machine ....................3-7 Traveling In Reverse ......................3-8 Traveling On Slopes ......................3-8 Traveling On Snow ......................3-8 Traveling Near High Voltage Cables..................3-8 Traveling On Loose Ground ....................3-8 Ensuring Good Visibility ..................... 3-8 Avoid Damage To The Dump Body ..................
  • Page 5 Before Welding On The Machine, Obey The Following Guidelines: ........3-19 WARNING AND CAUTIONS GENERAL INFORMATION ......................4-2 PIN PLATE ............................. 4-2 GRADE SPEED CHART ......................... 4-3 GREASE POINTS........................... 4-3 MACHINE SAFETY......................... 4-4 KEY SWITCH ..........................4-6 OIL FILL AND CHECK ........................4-6 HIGH PRESSURES ........................
  • Page 6 Setting the Gauge Display Units ..................5-31 Setting the Carryback Alarm Threshold ................5-31 Setting the Truck Number....................5-31 Setting the Komatsu Distributor ..................5-32 Setting the Komatsu Customer ..................5-32 Clean Truck Tare Calibration .................... 5-32 Inclinometer Calibration ....................5-33 DOWNLOADING PAYLOAD DATA ..................
  • Page 7 Deleting Haul Cycle Records .................... 5-38 Viewing Alarms........................ 5-39 Deleting Alarm Records ....................5-39 Patent Acknowledgment....................5-39 AUTOMATIC LUBRICATION SYSTEM................... 5-40 GENERAL INFORMATION ..................... 5-40 COMPONENT DESCRIPTION....................5-40 Filter ..........................5-41 Hydraulic Motor and Pump ....................5-41 Grease Reservoir ......................5-41 Pressure Reducing Valve ....................
  • Page 8 ENGINE STOP SWITCH....................6-8 WINDOW CONTROL SWITCHES ..................6-8 HOIST CONTROL LEVER ....................6-8 Raising The Dump Body ....................6-8 Lowering The Dump Body ....................6-8 ASHTRAY ......................... 6-8 LIGHTER .......................... 6-8 DATA STORE BUTTON ..................... 6-9 12V AUXILIARY POWER OUTLETS .................. 6-9 DIAGNOSTIC PORTS........................
  • Page 9 KOMTRAX Plus Downloading Procedure ................6-31 Location Of Downloaded Files ..................6-31 UPLOADING KOMTRAX Plus DATA ..................6-32 ORBCOMM ........................... 6-33 KOMATSU WIRELESS BRIDGE (Optional)................6-34 General Information ......................6-34 Communication Setup...................... 6-34 Switching To The KWB_SETUP Network ................6-34 Setting The Computer Subnet Mask And IP Address ............
  • Page 10 CIRCUIT BREAKERS......................6-41 LUBRICATION AND SERVICE GENERAL INFORMATION ......................7-2 HYDRAULIC SYSTEM SERVICE....................7-2 Hydraulic Tank........................7-2 Hydraulic Filters......................... 7-3 Hydraulic Pump Drive Shaft....................7-3 WHEEL MOTOR SERVICE....................... 7-3 COOLANT LEVEL SERVICE ....................7-3 Radiator Filling Procedure ....................7-4 Coolant Specifications......................7-4 Unacceptable Practices .....................
  • Page 11 Brake System .......................... 8-2 SPECIFICATIONS .......................... 8-3 Engine............................. 8-3 AC Electric Drive System ......................8-3 Dynamic Retarding........................8-3 Battery Electric System......................8-3 Service Capacities........................8-3 Hydraulic Systems........................8-3 Service Brakes......................... 8-4 Steering........................... 8-4 Standard Dump Body Capacities And Dimensions..............8-4 Tires ............................
  • Page 12 860E-1KT...
  • Page 13 INTRODUCTION 860E-1KT...
  • Page 14 (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E). The three numbers represent the basic truck model. The letter “M”, when present, designates a Mechanical drive system;...

  • Page 15: About This Manual

    The front cover of this manual includes a form number. This form number should be referenced when ordering additional copies of this manual, or for any other correspondence regarding the coverage in this manual. Direct all inquiries to: Komatsu America Corp. Peoria Technical Publications P.O. Box 240...
  • Page 16 INTRODUCTION WARNINGS WARNINGS F.3-0000051687 This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written authorization from KAC. It is the policy of the company to improve products whenever it is possible and practical to do so.
  • Page 17 INTRODUCTION ALERTS ALERTS D.2-0000051268 The ALERT symbol is used with the following signal words: • DANGER • WARNING • CAUTION This symbol is used to alert the reader of hazards that can arise from improper operating and maintenance practices. • DANGER identifies a specific potential hazard WHICH WILL RESULT in either INJURY OR DEATH if proper precautions are not taken.
  • Page 18 INTRODUCTION TRUCK MODEL ILLUSTRATION TRUCK MODEL ILLUSTRATION B.3-0000053365 860E-1KT...
  • Page 19 Komatsu products and place the operator and others in danger should the part fail. Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
  • Page 20 INTRODUCTION NON-OEM PARTS IN CRITICAL SYSTEMS 860E-1KT...
  • Page 21 STANDARD CHARTS AND TABLES 860E-1KT...

  • Page 22: General Information

    NOTE: This list represents the current engineering will be to one of the following tables. Do not approved sources for use in Komatsu manufacture. It use standard values to replace specific torque is not exclusive. Other products may meet the same values in assembly instructions.

  • Page 23: Standard Tightening Torques

    STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES STANDARD TIGHTENING Table 2-1 TORQUES F.6-0000051233 Standard Tightening Torque for Metric Class 10.9 Capscrews & Class 10 Nuts Class 10.9 Capscrews And Class 10 Nuts The following specifications apply to required assembly torques for all metric class 10.9 finished hexagon head capscrews and class 10 nuts.
  • Page 24 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES SAE Grade 5 And Grade 8 Capscrews Standard Tightening Torque for SAE Hex Head Capscrew And Nut Assembly The following specifications apply to required assembly torques for all grade 5 and grade 8 capscrews.
  • Page 25 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES SAE Grade 9 Capscrews Standard Tightening Torque for SAE Hex Head and 12-Point, Grade 9 Capscrews The following specifications apply to required assembly torques for SAE Hex Head and 12-point, grade 9 (170,000 psi minimum tensile), capscrews. NOTE: Capscrew threads and seats shall be lubricated when assembled.
  • Page 26 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES Split Flange Clamps Table 2-5 Tightening Torque For Split Flange Clamp Bolts Capscrew Width Newton Foot Kilogram Thread Across meters Pounds meters (kg·m) Diameter Flat (mm) (N·m) ± 10% (ft·lb) ± 10% ± 10% (mm) 11.5 28.5...
  • Page 27 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES JIC 37° Swivel Nuts Table 2-7 Torque Chart For JIC 37° Swivel Nuts With Or Without O-ring Seals Newton Size Tube Size Threads Foot Pounds meters Code (OD) UNF-2B (ft·lb) (N·m) – 2 0.125 0.312 –...
  • Page 28 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES Pipe Thread Fittings Table 2-8 Torque Chart For Pipe Thread Fittings With With Without Without Size Pipe Thread Sealant Sealant Sealant Sealant Code Size N·m ft·lb N·m ft·lb – 2 0.125 – 27 20 ±...
  • Page 29 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES O-Ring Boss Fittings Table 2-9 Torque Chart For O-ring Boss Fittings Newton Foot Tube Size Threads Size Code meters Pounds (OD) UNF-2B (N·m) (ft·lb) – 2 0.125 0.312 – 24 4 ± 3 4 ±...
  • Page 30 STANDARD CHARTS AND TABLES STANDARD TIGHTENING TORQUES O-Ring Face Seal Fittings Table 2-10 Torque Chart For O-ring Face Seal Fittings Foot Size Tube Size Threads Newton Pounds Code (O.D.) UNF-2B meters (N·m) (ft·lb) – 4 0.250 0.438 – 20 15 ± 1 11 ±...
  • Page 31 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

860e-1kt