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KOMATSU 860E-1KT DUMP TRUCK Operation & Maintenance Manual (SN:A30003) KOMATSU 860E-1KT – PDF DOWNLOAD
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- KOMATSU 860E-1KT DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER:A30003
- PUBLICATION NUMBER:CEAM019604
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Description
KOMATSU 860E-1KT DUMP TRUCK Operation & Maintenance Manual (SN:A30003) KOMATSU 860E-1KT
KOMATSU 860E-1KT DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30003) KOMATSU 860E-1KT – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1KT DUMP TRUCK Operation & Maintenance Manual (SN:A30003) KOMATSU 860E-1KT
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operatin the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
- The KOMATSU truck model designation consists of three numbers and one letter (i.e. 930E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system.
The letter “E”, when present, designates an Electrical wheel motor drive system. - The Product Identification Number (vehicle serial number) contains information which identifies the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 860E-1KT DUMP TRUCK Operation & Maintenance Manual (SN:A30003) KOMATSU 860E-1KT
COVER..................................................................................... 1 INTRODUCTION.............................................................................. 5 FOREWORD.............................................................................. 5 TRUCK MODEL ILLUSTRATION.............................................................. 6 ABOUT THIS MANUAL..................................................................... 7 ALERTS PAGE........................................................................... 8 TABLE OF CONTENTS......................................................................... 9 STANDARD CHARTS AND TABLES................................................................ 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values.................. 17 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)...................... 18 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts................... 18 SAFETY.................................................................................... 23 GENERAL............................................................................... 23 Safety Rules...................................................................... 23 Safety Features................................................................... 23 Fire Extinguisher And First Aid Kit............................................... 23 Clothing And Personal Items....................................................... 23 Leaving The Operator’s Seat....................................................... 24 Mounting And Dismounting.......................................................... 24 Fire Prevention For Fuel And Oil.................................................. 24 Precautions With High Temperature Fluids.......................................... 25 Asbestos Dust Hazard Prevention................................................... 25 Prevention Of Injury By Work Equipment............................................ 25 Unauthorized Modification......................................................... 25 ROPS Precautions.................................................................. 25 Precautions For Attachments....................................................... 26 Precautions For Starting The Truck................................................ 26 PRECAUTIONS BEFORE OPERATION.......................................................... 26 Safety At The Worksite............................................................ 26 Fire Prevention................................................................... 27 Preparing For Operation........................................................... 27 Ventilation In Enclosed Areas..................................................... 27 In Operator’s Cab - Before Starting The Engine.................................... 27 Mirrors, Windows And Lights....................................................... 27 OPERATING THE TRUCK................................................................... 28 When Starting The Engine.......................................................... 28 General Truck Operation........................................................... 28 Traveling In Reverse.............................................................. 29 Traveling......................................................................... 29 Traveling On Slopes............................................................... 29 Ensuring Good Visibility.......................................................... 29 Operating On Snow Or Ice.......................................................... 29 Avoiding Damage To Dump Body...................................................... 29 Driving Near High Voltage Cables.................................................. 30 When Dumping...................................................................... 30 Working On Loose Ground........................................................... 30 When Loading...................................................................... 30 Parking The Truck................................................................. 30 TOWING................................................................................ 30 WORKING NEAR BATTERIES................................................................ 31 Battery Hazard Prevention......................................................... 31 Jump Starting With Booster Cables................................................. 32 Jump Starting With Receptacles.................................................... 32 BEFORE PERFORMING MAINTENANCE......................................................... 33 Warning Tag....................................................................... 33 Stopping The Engine Before Service................................................ 33 Proper Tools...................................................................... 33 Securing The Dump Body............................................................ 33 WHILE PERFORMING MAINTENANCE.......................................................... 34 Keep The Truck Clean.............................................................. 34 Attachments....................................................................... 34 Working Under The Truck........................................................... 34 Rotating Fan And Belts............................................................ 34 Adding Fuel Or Oil................................................................ 34 Radiator Coolant Level............................................................ 35 Use Of Lighting................................................................... 35 Precautions With The Battery...................................................... 35 Handling High Pressure Hoses...................................................... 35 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 35 Precautions With High Pressure Oil................................................ 35 Waste Materials................................................................... 35 TIRES................................................................................. 36 Handling Tires.................................................................... 36 Tire Maintenance.................................................................. 37 Storing Tires After Removal....................................................... 37 WHEN REPAIRS ARE NECESSARY............................................................ 38 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.................................... 39 Engine Shutdown Procedure Before Welding or Performing Maintenance................ 39 Precautions Before Welding or Performing Maintenance.............................. 40 ADDITIONAL JOB SITE RULES............................................................. 42 WARNINGS AND CAUTIONS..................................................................... 43 GRADE/SPEED CHART..................................................................... 43 INSTRUMENT PANEL...................................................................... 43 BATTERIES............................................................................. 44 HIGH VOLTAGE.......................................................................... 44 RADIATOR.............................................................................. 45 CRUSHING HAZARD....................................................................... 45 CYLINDER PRESSURE..................................................................... 45 FILLING THE HYDRAULIC TANK............................................................ 46 HYDRAULIC OIL PRESSURE................................................................ 46 EMERGENCY TOWING PROCEDURE............................................................ 47 EMERGENCY DUMP PROCEDURE.............................................................. 47 ACCUMULATOR DRAIN VALVES.............................................................. 47 GREASE POINT.......................................................................... 47 WELDING............................................................................... 48 EMERGENCY SHUTDOWN.................................................................... 48 LIFTING POINT......................................................................... 48 SPRING PRESSURE....................................................................... 49 ROPS/FOPS............................................................................. 49 EMERGENCEY EGRESS..................................................................... 49 PRODUCT IDENTIFICATION PLATE.......................................................... 50 LUBRICATION CHART..................................................................... 50 OPERATING INSTRUCTIONS.................................................................... 51 PREPARING FOR OPERATION............................................................... 51 WALK AROUND INSPECTION................................................................ 51 ENGINE START-UP....................................................................... 56 AFTER ENGINE HAS STARTED.............................................................. 57 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 58 OPERATING ON THE HAUL ROAD............................................................ 59 STARTING ON A GRADE WITH A LOADED TRUCK............................................... 59 PASSING............................................................................... 60 LOADING............................................................................... 60 DUMPING............................................................................... 60 Raising The Dump Body............................................................. 60 Lowering The Dump Body (When dumping on flat ground):............................. 61 Lowering The Dump Body (When dumping over a berm or into a crusher):.............. 61 Operating in trolley line mode.................................................... 62 Getting on line................................................................... 62 Operating on trolley.............................................................. 63 Getting off line.................................................................. 63 Line status signals............................................................... 64 Trolley disconnect................................................................ 64 Traffic consideration for trolley line operation.................................. 65 Approaching slow moving vehicles in a trolley assisted truck...................... 65 Operating slow moving vehicles on trolley assist ramps............................ 66 Truck failure while on trolley.................................................... 66 USING THE SPEED CONTROL FEATURE....................................................... 67 SAFE PARKING PROCEDURES............................................................... 67 NORMAL ENGINE SHUTDOWN PROCEDURE...................................................... 68 SUDDEN LOSS OF ENGINE POWER........................................................... 69 FUEL DEPLETION........................................................................ 69 TOWING................................................................................ 70 Special Wiring Harness............................................................ 70 Towing Procedure.................................................................. 70 DISABLED TRUCK OPERATION.............................................................. 73 GENERAL............................................................................... 73 STEERING AND BRAKE SYSTEM............................................................. 73 Components Required............................................................... 73 Hookup............................................................................ 74 DISABLED TRUCK DUMPING PROCEDURE...................................................... 75 Hookup............................................................................ 75 Raising the Body.................................................................. 75 Lowering the Body................................................................. 76 RESERVE ENGINE OIL SYSTEM............................................................. 77 OPERATOR CAB AND CONTROLS................................................................. 79 STEERING WHEEL AND CONTROLS........................................................... 80 Horn Button....................................................................... 80 Tilt / Telescope Lever............................................................ 80 Speed Control Lever............................................................... 80 Multi-Function Turn Signal Switch................................................. 80 DYNAMIC RETARDING..................................................................... 81 Dynamic Retarder/Service Brake Pedal.............................................. 81 Throttle/Accelerator Pedal........................................................ 81 GRADE/SPEED RETARD CHART.............................................................. 82 OVERHEAD PANEL COMPONENTS............................................................. 82 CENTER CONSOLE........................................................................ 83 Directional Control Lever......................................................... 83 Override/Fault Reset Switch....................................................... 84 Engine Shutdown Switch............................................................ 84 L.H. Window Control Switch R.H. Window Control Switch............................. 84 Hoist Control Lever............................................................... 84 Ashtray........................................................................... 85 Lighter........................................................................... 85 Data Store Button................................................................. 85 Service Engine Light.............................................................. 85 12V Auxiliary Power Outlets....................................................... 85 DIAGNOSTIC PORTS...................................................................... 85 Drive System #1................................................................... 85 Engine (QUANTUM).................................................................. 85 Drive System #3................................................................... 85 Engine (CENSE).................................................................... 85 Interface Module.................................................................. 85 VHMS.............................................................................. 85 Payload Meter..................................................................... 85 OPERATOR’S SEAT....................................................................... 86 Adjustment........................................................................ 86 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 87 Fan Speed Control Knob............................................................ 87 Temperature Control Knob.......................................................... 87 Air Flow Directional Knob......................................................... 87 Heater/Air Conditioner Vents...................................................... 87 INSTRUMENT PANEL...................................................................... 88 Control Symbols................................................................... 88 Key Switch........................................................................ 90 Speed Control Switch.............................................................. 90 Traction Control Switch........................................................... 90 Retarding Grid Drier Switch....................................................... 90 AC Drive System Rest Switch....................................................... 90 Wheel Brake Lock Switch........................................................... 91 Pantograph Switch................................................................. 91 Hazard Warning Lights............................................................. 91 Heater/Air Conditioner Vents...................................................... 91 Fuel Level Gauge.................................................................. 91 Hydraulic Oil Temperature Gauge................................................... 91 Speedometer/Digital Display....................................................... 92 Coolant Temperature Gauge......................................................... 92 Drive System Temperature Gauge.................................................... 92 Headlight/Panel Illumination Light Switch......................................... 92 Ladder Light Switch (3-Way)....................................................... 92 Backup Light Switch............................................................... 92 Fog Light Switch.................................................................. 92 Mode Switches..................................................................... 93 Panel Illumination Light Dimmer Switch............................................ 93 Right/Left Turn Signal Indicators................................................. 93 Digital Display Contrast Buttons.................................................. 93 Warning Light..................................................................... 93 STATUS INDICATOR LIGHTS............................................................... 94 Body Up........................................................................... 94 Parking Brake Applied............................................................. 94 Propulsion System Not Ready....................................................... 94 No Propel......................................................................... 95 Engine Warming Up................................................................. 95 Engine Delay...................................................................... 95 Grid Drier........................................................................ 95 Wheel Brake Lock Applied.......................................................... 95 Traction Control.................................................................. 95 Repair Monitor.................................................................... 95 Snapshot.......................................................................... 95 Pantograph Energized.............................................................. 96 Pantograph Up..................................................................... 96 Service Brake Applied............................................................. 96 Dynamic Retarding................................................................. 96 No DC Link Voltage................................................................ 96 DIGITAL DISPLAY OPERATION............................................................. 97 Toggling Through Main Level Screens............................................... 97 Toggling Through Warning Screens.................................................. 98 Entering Payload Meter Data....................................................... 99 VEHICLE HEALTH MONITORING SYSTEM (VHMS)...............................................100 Operation.........................................................................100 Basic Precautions.................................................................101 FUSES AND CIRCUIT BREAKERS............................................................102 LUBRICATION AND SERVICE...................................................................107 GENERAL...............................................................................107 860E-1K SERVICE CAPACITIES............................................................107 HYDRAULIC TANK SERVICE................................................................107 Adding Hydraulic Oil..............................................................107 WHEEL MOTOR SERVICE...................................................................107 COOLING SYSTEM SERVICE................................................................108 Radiator Filling Procedure........................................................108 RESERVE ENGINE OIL SYSTEM.............................................................108 Reserve Oil Tank Filling Procedure (Remote Fill)..................................108 LUBRICATION CHART.....................................................................109 10 HOUR (DAILY) INSPECTIONS...........................................................110 50 HOUR LUBRICATION AND MAINTENANCE CHECKS............................................113 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................113 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................114 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................116 1,000 HOURS LUBRICATION AND MAINTENANCE CHECKS........................................118 2,000 HOUR MAINTENANCE CHECKS.........................................................119 5,000 HOUR MAINTENANCE CHECKS.........................................................119 6,000 HOUR MAINTENANCE CHECKS.........................................................120 AUTOMATIC LUBRICATION SYSTEM..............................................................121 GENERAL DESCRIPTION...................................................................121 SYSTEM COMPONENTS.....................................................................123 Filter............................................................................123 Hydraulic Motor and Pump..........................................................123 Grease Reservoir..................................................................123 Pressure Reducing Valve...........................................................123 Flow Control Valve................................................................123 Solenoid Valve....................................................................123 Vent Valve........................................................................123 Lubrication Cycle Timer...........................................................123 Over Pressure Cut Off Switch......................................................123 Grease System Failure Switch......................................................123 Injectors.........................................................................123 Unloader Valve....................................................................123 SYSTEM OPERATION......................................................................124 GENERAL INSTRUCTIONS..................................................................125 Required Lubricant................................................................125 System Priming....................................................................125 Filter Assembly...................................................................125 LUBRICANT PUMP........................................................................126 Pump Housing Oil Level............................................................126 Pump Pressure Control.............................................................126 INJECTORS (SL-1 Series “H”)...........................................................127 Injector Specifications...........................................................127 Injector Adjustment...............................................................127 INJECTOR OPERATION................................................................128 PREVENTIVE MAINTENANCE PROCEDURES.....................................................129 Daily Lubrication System Inspection...............................................129 250 Hour Inspection...............................................................129 1000 Hour Inspection..............................................................129 SYSTEM CHECKOUT.......................................................................130 Lubrication Controller Check......................................................130 Lubrication Controller Operation..................................................130 Lubrication Controller Components.................................................130 Lubrication Controller Adjustment.................................................130 SYSTEM TROUBLESHOOTING CHART..........................................................132 COMPONENTS & SPECIFICATIONS...............................................................135 MAJOR COMPONENT DESCRIPTIONS..........................................................135 Truck And Engine..................................................................135 Main Alternator...................................................................135 AC Induction Traction Motorized Wheels............................................135 Suspension........................................................................135 Operator's Cab....................................................................135 Power Steering....................................................................135 Dynamic Retarding.................................................................135 Brake System......................................................................135 SPECIFICATIONS........................................................................137 ENGINE............................................................................137 AC ELECTRIC DRIVE SYSTEM..........................................................137 DYNAMIC RETARDING.................................................................137 BATTERY ELECTRIC SYSTEM...........................................................137 SERVICE CAPACITIES................................................................137 HYDRAULIC SYSTEMS.................................................................138 SERVICE BRAKES....................................................................138 STEERING..........................................................................138 TIRES.............................................................................138 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS......................................138 WEIGHT DISTRIBUTION...............................................................139 PAYLOAD METER III™........................................................................141 Introduction..........................................................................141 Data Summary......................................................................141 Data Gathering....................................................................141 COMPONENT DESCRIPTION.................................................................142 System Diagram....................................................................142 Suspension Pressure Sensors.......................................................142 Inclinometer......................................................................142 Speedometer/Load Display..........................................................142 Operator Switches.................................................................143 Speed Input.......................................................................143 Body-Up Switch....................................................................143 Brake Lock Switch.................................................................143 Payload Meter.....................................................................143 Communications Ports..............................................................143 Key Switch Input..................................................................144 Payload Meter Power...............................................................144 Load Lights.......................................................................144 Wiring and Termination............................................................144 LOAD DISPLAY AND OPERATOR SWITCHES....................................................145 Setting the Operator ID...........................................................145 Total Ton and Total Load Counters.................................................145 Viewing Live Sensor Data..........................................................145 Other Display Messages............................................................146 PAYLOAD OPERATION & CALCULATION.......................................................146 Description of Haul Cycles........................................................146 Load Calculation..................................................................147 Carry Back........................................................................147 Measurement Accuracy..............................................................147 SOURCES FOR PAYLOAD ERROR.............................................................148 Suspensions.......................................................................148 Loading Conditions................................................................148 Pressure Sensors..................................................................148 Swingloads........................................................................148 Speed and Distance................................................................148 HAUL CYCLE DATA.......................................................................149 Haul Cycle Warning Flags..........................................................149 Frame Torque Data.................................................................150 Sprung Weight Data................................................................150 Maximum Speed Data................................................................150 Alarm Records.....................................................................152 PDM SOFTWARE OVERVIEW.................................................................153 System Configuration..............................................................153 Installing the PDM Software.......................................................153 DOWNLOADING DATA......................................................................153 PLM III SYSTEM CONFIGURATION..........................................................154 Starting Communications...........................................................154 Connection Menu...................................................................154 Connecting to the Payload Meter...................................................155 Configuring the Payload Meter.....................................................155 Setting the Date and Time.........................................................155 Setting the Truck Type............................................................156 Setting the Display Units.........................................................156 Setting the Frame Serial Number...................................................156 Setting the Truck Number..........................................................156 Setting the Komatsu Distributor...................................................156 Setting the Komatsu Customer......................................................156 Clean Truck Tare..................................................................157 Inclinometer Calibration..........................................................157 DATA ANALYSIS.........................................................................158 Creating a Query..................................................................158 Sorting on Truck Unit Number......................................................158 Sorting on Truck Type.............................................................158 Sorting on Date Range.............................................................159 Sorting on Time Range.............................................................159 Payload Detail Screen.............................................................160 Creating Reports..................................................................161 Creating Graphs...................................................................162 Exporting Data....................................................................162 Importing Data....................................................................164 Deleting Haul Cycle Records.......................................................164 Viewing Alarms....................................................................164 Deleting Alarm Records............................................................164 AM/FM RADIO / CD PLAYER...................................................................167 OPERATING INSTRUCTIONS................................................................167 GENERAL RADIO RECEIVER FUNCTIONS..................................................167 Turning On the Power..........................................................167 One-Hour Timer................................................................167 Display.......................................................................168 Setting a Default Display.....................................................168 Adjusting the Brightness of the Display.......................................168 Auxiliary Mode................................................................168 Adjusting the Receiver Settings...............................................168 USING THE CLOCK...................................................................169 Setting the Clock.............................................................169 USING THE ALARM...................................................................169 Setting the Alarm.............................................................169 Turning the Alarm Off.........................................................169 Activating Snooze.............................................................169 Setting Alarm Volume..........................................................169 USING THE RADIO...................................................................170 Finding a Station.............................................................170 Setting the Presets...........................................................171 SATELLITE RADIO SERVICE (Optional)................................................171 Activating Satellite Radio (Optional).........................................171 USING THE WEATHERBAND.............................................................172 USING THE COMPACT DISC PLAYER.....................................................172 Playing a Compact Disc........................................................172 Button Functions..............................................................172 PLAYING AN MP3 DISC...............................................................173 MP3 Format Compatibility......................................................173 Root Directory................................................................173 Empty Directory or Folder.....................................................173 No Folder.....................................................................173 File Name Display.............................................................173 Pre-Programmed Playlists......................................................174 Playing MP3 Files.............................................................174 Button Functions..............................................................174 TROUBLESHOOTING...................................................................175
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