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Komatsu A40052 Operation & Maintenance Manual
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Komatsu A40052 Operation & Maintenance Manual

Komatsu A40052 Operation & Maintenance Manual

Dump truck
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Operation & Maintenance
Manual
DUMP TRUCK
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
November 2016
-4
980E-4 A40052
18V170
CEAM032500
and up
Copyright 2016 Komatsu
Printed in U.S.A
Komatsu America Corp.

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Summary of Contents for Komatsu A40052

  • Page 1 18V170 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • 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 Engine Shutdown Procedure Before Welding or Performing Maintenance ......3-21 Before Welding On The Machine, Obey The Following Guidelines: ........3-21 Discharging Control Cabinet Capacitors ................3-22 WARNING AND CAUTIONS GENERAL INFORMATION ......................4-2 PIN PLATE ............................. 4-2 GRADE SPEED CHART ......................... 4-3 MACHINE SAFETY.........................
  • Page 6 SAFE PARKING PROCEDURES .................... 5-19 NORMAL ENGINE SHUTDOWN PROCEDURE ..............5-19 DISABLED TRUCK CONNECTORS ....................5-21 GENERAL INFORMATION ..................... 5-21 HOIST SYSTEM ........................5-21 Hookup ........................... 5-21 Dumping Procedure ......................5-21 TOWING ............................5-23 SPECIAL WIRING HARNESS....................5-23 TOWING PROCEDURE ......................5-23 PAYLOAD METER IV SYSTEM .....................
  • Page 7 Payload Gain Factor ......................5-44 Payload Light Test ......................5-44 Truck Tare Reset ......................5-44 Truck Data Configuration....................5-45 Inclinometer Calibration ....................5-45 Overload Threshold ......................5-46 Clean Truck Tare ......................5-47 Tare Reset ........................5-49 Custom Truck Configuration ..................... 5-49 Field Software Update......................
  • Page 8 High Beam Headlight Operation ..................6-3 Windshield Wiper Operation ....................6-3 PEDALS AND RETARDER LEVER ....................6-5 Dynamic Retarding ......................6-5 Retarder Lever ........................6-5 Brake/Retarder Pedal ......................6-5 Accelerator Pedal ......................6-5 OVERHEAD PANEL AND DISPLAYS....................6-6 Radio Speakers......................... 6-6 Warning Alarm Buzzer .......................
  • Page 9 Hydraulic Oil Temperature Gauge ..................6-19 Coolant Temperature Gauge .................... 6-19 Speedometer/Digital Display .................... 6-19 Fuel Level Gauge ......................6-19 Drive System Temperature Gauge ..................6-20 Hazard Warning Light Switch.................... 6-20 Pre-Shift Brake Test Switch ....................6-20 Wheel Brake Lock Control Switch ..................6-20 Rest Switch ........................
  • Page 10 UPLOADING KOMTRAX Plus DATA ..................6-33 ORBCOMM ........................... 6-34 KOMATSU WIRELESS BRIDGE (KWB) ..................6-36 General Information ......................6-36 VHMS DOWNLOADS......................6-36 General Information ......................6-36 VHMS Downloading Procedure ..................6-37 ONBOARD CONTROLLER ACCESS ..................6-37 Wireless Access ......................6-37 Wireless Access Procedure....................
  • Page 11 EVERY 18,000 HOUR MAINTENANCE..................7-24 SPECIFICATIONS MAJOR COMPONENT DESCRIPTION .................... 8-2 Truck and Engine ........................8-2 Traction Alternator ........................8-2 Main Control Cabinet ........................ 8-2 AC Induction Traction Motorized Wheels..................8-2 Suspension..........................8-2 Operator's Cab......................... 8-2 Power Steering ........................8-2 Dynamic Retarding Grid......................
  • Page 12 Station Presets......................... 9-6 Storing Radio Station Presets ....................9-7 Tuning Radio Station Presets ....................9-7 CD OPERATION..........................9-8 Using the CD Player ......................... 9-8 Playing a CD..........................9-8 Ejecting a CD........................... 9-8 IPOD OPERATION ......................... 9-9 iPod Support ..........................9-9 Connecting an iPod ........................
  • Page 13 INTRODUCTION 980E-4...
  • 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 A.1-0000072471 980E-4...
  • 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 980E-4...
  • Page 21 STANDARD CHARTS AND TABLES 980E-4...

  • 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:

980e-4