Komatsu 980E-5 Dump Truck Operation and Maintenance Manual CEAM035900

Description

• Model List:
  • 980E-5 Dump Truck

• 1. OPERATION AND MAINTENANCE MANUAL 980E5 DUMP TRUCK
• 2. Contents
• 3. INTRODUCTION
• 3.1. WARNINGS
• 3.2. Foreword
• 3.3. Safety Alert Symbol and Signal Words
• 3.4. Basic Machine Introduction
• 3.5. Visibility
• 3.6. Noise And Vibration
• 3.7. Exhaust Gas Regulations
• 3.8. Declaration of Conformity
• 3.9. Komatsu Machine Operator Privacy Policy
• 3.10. Product Information
• 4. SAFETY
• 4.1. Safety Labels
• 4.1.1. Locations of Safety Labels
• 4.1.2. Illustrations of Safety Labels
• 4.2. General Precautions Common to Operation and Maintenance
• 4.2.1. Precautions Before Starting Operation
• 4.2.2. Preparations for Safe Operation
• 4.2.3. Fire and Explosion Prevention
• 4.2.4. Precautions When Getting On or Off the Machine
• 4.2.5. Precautions for Cab and Working Around Machine
• 4.2.6. Precautions for Diesel Exhaust Fluid (DEF)
• 4.3. Operation Precautions
• 4.3.1. Precautions at Jobsite
• 4.3.2. Precautions in Starting Engine
• 4.3.3. Precautions During Operation
• 4.4. Maintenance Precautions
• 4.4.1. Precautions Before Inspection and Maintenance
• 4.4.2. Precautions During Inspection and Maintenance
• 4.5. End of Service Life
• 5. OPERATION
• 5.1. Visual Overview of Machine
• 5.1.1. Machine Components Front And Rear Views
• 5.1.2. Machine Components Inside Frame View
• 5.1.3. Machine Components Left Side View
• 5.1.4. Machine Components Right Side View
• 5.1.5. Exterior Lights
• 5.1.6. Cab Interior View
• 5.2. Steering Wheel and Controls
• 5.3. Pedals
• 5.4. Center Console Controls
• 5.5. Instrument Panel Switches
• 5.6. Multifunction Operator Display
• 5.6.1. Instrument Panel Status Indicators
• 5.6.2. Instrument Panel Gauges and Meters
• 5.6.3. Digital Display Menus
• 5.6.3.1. Active Warnings Menu
• 5.6.3.2. Menu System Outline
• 5.6.3.3. Truck Data Menu
• 5.6.3.4. Diagnostics Menu
• 5.6.3.5. Payload Data Menu
• 5.6.3.6. Settings Menu
• 5.7. Heater and Air Conditioner Controls
• 5.8. Seat Heater/Ventilation System (HVS)
• 5.9. Retractable Ladder Operations
• 5.10. Radio Operations
• 5.10.1. AM/FM RADIO / MP3 / USB / iPOD / AUX PLAYER
• 5.10.1.1. USB Connection Port
• 5.10.1.2. Phone/Bluetooth Button
• 5.10.1.3. Digital Display
• 5.10.1.4. DISP (Display) Button
• 5.10.1.5. SRC/PWR/ESC (Source/Power/Escape) Button
• 5.10.1.6. Volume Knob/OK Button
• 5.10.1.7. NEXT Button
• 5.10.1.8. PREV (Previous) Button
• 5.10.1.9. Preset Buttons
• 5.10.1.10. RDM (Random) Button
• 5.10.1.11. RPT (Repeat) Button
• 5.10.1.12. Mute/Play/Pause Button
• 5.10.1.13. Browse Button
• 5.10.1.14. SCAN/ASCN (Scan/Autoscan) Button
• 5.10.1.15. Auxiliary Jack Port
• 5.11. KomVision
• 5.11.1. KomVision Monitor Panel
• 5.11.2. KomVision Monitor Display
• 5.11.3. KomVision Object Detection
• 5.12. Cab Connectors
• 5.13. Vehicle Information Display (VID) Panel
• 5.14. KOMTRAX
• 5.15. Payload Meter IV
• 5.15.1. Payload Meter IV Communication Module
• 5.15.2. Payload Lights/Scoreboard
• 5.15.3. Haul Cycle
• 5.15.4. Payload Calculations
• 5.15.5. Clean Truck Tare
• 5.15.6. Viewing and Downloading Data
• 5.16. Battery Disconnect Switches
• 5.17. Ground Level Engine Shutdown Switch
• 5.18. Preparations Before Operating the Machine
• 5.18.1. WalkAround Inspection
• 5.18.1.1. Zone 1 In Front of Left Front Tire
• 5.18.1.2. Zone 2 Behind Left Front Tire
• 5.18.1.3. Zone 3 In Front of Left Rear Tires
• 5.18.1.4. Zone 4 Rear of Truck
• 5.18.1.5. Zone 5 In Front of Right Rear Tires
• 5.18.1.6. Zone 6 Behind Right Front Tire
• 5.18.1.7. Zone 7 In Front of Right Front Tire
• 5.18.1.8. Zone 8 Front of Truck
• 5.18.1.9. Zone 9 Decks and Cab
• 5.18.2. PreShift Brake Tests
• 5.18.3. Emergency Steering Test
• 5.18.4. Adjusting the Mirrors
• 5.18.5. Adjusting the Cab Seat
• 5.18.5.1. Seat Adjustment Controls
• 5.18.6. KomVision StartUp Inspection
• 5.19. Starting the Engine
• 5.20. Checks After Starting the Engine
• 5.21. Operating the Machine
• 5.21.1. Traveling on a Haul Road
• 5.21.2. Initial Propulsion on a Grade
• 5.21.3. Assisted Brake Management (ABM)
• 5.21.4. Retarding on a Grade
• 5.21.4.1. Dynamic Retarding Operation
• 5.21.5. Loading the Dump Body
• 5.21.5.1. Overload Speed Limit Function
• 5.21.6. Dumping the Load
• 5.22. Shutting Down the Machine
• 5.23. Hydraulic System Bleeddown Procedure
• 5.24. Disabled Machine Operations
• 5.24.1. Stopping the Machine After Loss of Power
• 5.24.2. Dumping the Load From a Disabled Machine
• 5.24.3. Towing a Disabled Machine
• 5.24.3.1. Enabling the Steering and Braking Circuits
• 5.24.3.2. Releasing the Parking Brake
• 5.24.3.3. Towing Procedure
• 5.24.4. Jump Starting a Disabled Machine
• 5.25. Engine Emissions AfterTreatment System Operations
• 6. MAINTENANCE
• 6.1. Rules for Maintenance
• 6.2. Recommended Fuel, Coolant, and Lubricant
• 6.3. Oil Clinic Inspection
• 6.4. Remote Fill Service Centers
• 6.5. Torque Specifications
• 6.6. Maintenance Schedule
• 6.6.1. Wheel Motor Maintenance Intervals
• 6.6.2. Engine Maintenance Intervals
• 6.6.3. Safety Critical Parts
• 6.6.4. Maintenance Schedule Table
• 6.7. Maintenance Procedures as Required
• 6.7.1. Replace Engine Air Cleaner Filter Elements
• 6.7.2. Maintain Correct Hydraulic Oil Level
• 6.7.3. Maintain Correct Coolant Level
• 6.7.4. Replace Autolube Filter Element
• 6.7.5. Fuses, Diodes and Relays
• 6.8. Maintenance For First 500 Hours
• 6.8.1. Initial 50 Hours Maintenance
• 6.8.2. Initial 100 Hours Maintenance
• 6.8.3. Initial 250 Hours Maintenance
• 6.8.4. Initial 500 Hours Maintenance
• 6.9. Every 250 Hours Maintenance
• 6.9.1. Check Cab External Air Filter
• 6.9.2. Check HVAC Recirculation Air Filter
• 6.9.3. Lubricate Pump Driveshaft
• 6.9.4. Collect Wheel Motor Oil Sample
• 6.9.5. Collect Hydraulic Oil Sample
• 6.9.6. Check Automatic Lubrication (Autolube) System
• 6.9.7. Check Retractable Ladder
• 6.10. Every 500 Hours Maintenance
• 6.10.1. Clean A/C Condenser
• 6.10.2. Check A/C Drain Hose
• 6.10.3. Lubricate Pedals
• 6.10.4. Clean Control Cabinet Interior
• 6.10.5. Check Tie Rod
• 6.10.6. Check Engine Air Intake Piping
• 6.10.7. Check Dump Body Up and Hoist Limit Switches
• 6.10.8. Replace Hydraulic Tank Breather Elements
• 6.10.9. Cooling System Service
• 6.10.10. Fuel System Service
• 6.10.11. Check Automatic Lubrication (Autolube) System Pump Oil Level
• 6.11. Every 1000 Hours Maintenance
• 6.11.1. Change Hydraulic Oil
• 6.11.2. Replace Hydraulic Filter Elements
• 6.11.3. Replace DEF System Filters
• 6.11.4. Lubricate Retractable Ladder
• 6.11.5. Check Dump Body Pads
• 6.11.6. Check/Lubricate Hoist Lever
• 6.11.7. Check Cab Seat Suspension
• 6.11.8. Lubricate Electronic Fan Clutch
• 6.12. Every 2000 Hours Maintenance
• 6.12.1. Change Automatic Lubrication (Autolube) System Pump Oil
• 6.13. Every 2500 Hours Maintenance
• 6.13.1. Change Front Wheel Hub Oil
• 6.14. Every 3000 Hours Maintenance
• 6.15. Every 5000 Hours Maintenance
• 6.15.1. Check Engine Air Cleaner Vacuator Valves
• 6.15.2. Check Steering Wheel Retaining Nut
• 6.16. EVERY 6000 HOUR MAINTENANCE
• 6.17. Every 6500 Hours Maintenance
• 6.17.1. Lubricate Traction Alternator Bearing
• 7. SPECIFICATION
• 7.1. Specifications 980E5