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KOMATSU 860E-1KT Dump Truck Operation & Maintenance Manual (SN:A30036 & Up) KOMATSU 860E-1KT – PDF DOWNLOAD
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- KOMATSU 860E-1KT Dump Truck Operation & Maintenance Manual
- SERIAL NUMBER:A30036 & Up
- PUBLICATION NUMBER:CEAM026003
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Description
KOMATSU 860E-1KT Dump Truck Operation & Maintenance Manual (SN:A30036 & Up) KOMATSU 860E-1KT
KOMATSU 860E-1KT DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30036 & UP) KOMATSU 860E-1KT – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1KT Dump Truck Operation & Maintenance Manual (SN:A30036 & Up) KOMATSU 860E-1KT
- This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
- All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and 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. 830E).
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 will identify 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 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 total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload
TABLE OF CONTENTS:
KOMATSU 860E-1KT Dump Truck Operation & Maintenance Manual (SN:A30036 & Up) KOMATSU 860E-1KT
COVER .......................................................................... 1 TABLE OF CONTENTS .............................................................. 3 1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 WARNINGS.................................................................... 16 CALIFORNIA PROPOSITION 65 WARNINGS...................................... 16 ALERTS...................................................................... 17 TRUCK MODEL ILLUSTRATION.................................................... 18 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 19 2 STANDARD CHARTS AND TABLES.................................................... 22 GENERAL INFORMATION......................................................... 22 EFFECT OF SPECIAL LUBRICANTS............................................ 22 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 22 STANDARD TIGHTENING TORQUES................................................. 23 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 23 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 24 SAE GRADE 9 CAP SCREWS.................................................. 25 T-BOLT CLAMPS........................................................... 25 SPLIT FLANGE CLAMPS..................................................... 26 FLARED TUBE AND HOSE FITTINGS........................................... 26 JIC 37° SWIVEL NUTS..................................................... 27 PIPE THREAD FITTINGS.................................................... 28 O-RING BOSS FITTINGS.................................................... 29 O-RING FACE SEAL FITTINGS............................................... 30 CONVERSION MULTIPLIERS...................................................... 31 METRIC TO ENGLISH....................................................... 31 ENGLISH TO METRIC....................................................... 32 TEMPERATURE CONVERSIONS................................................. 33 3 GENERAL SAFETY................................................................ 36 GENERAL SAFETY.............................................................. 36 Safety Rules............................................................ 36 Truck Safety Features................................................... 36 Clothing And Personal Items............................................. 36 Unauthorized Modification............................................... 36 Leaving The Operator’s Seat............................................. 36 Mounting And Dismounting................................................ 36 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 ROPS Precautions........................................................ 37 Preventing Injury From Work Equipment................................... 38 Precautions For Optional Attachments.................................... 38 Precautions When Starting The Machine................................... 38 PRECAUTIONS FOR TRUCK OPERATION............................................. 39 Safety Is Thinking Ahead................................................ 39 Safety At The Worksite.................................................. 39 Preparing For Operation................................................. 39 Ventilation For Enclosed Areas.......................................... 39 Mirrors, Windows, And Lights............................................ 39 Before Starting The Engine.............................................. 39 Seat Belts.............................................................. 39 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 41 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 42 Avoid Damage To The Dump Body........................................... 42 Safe Parking Of The Machine............................................. 43 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING....................................................... 44 Fog Lights.......................................................... 44 Headlights.......................................................... 44 Brake Light......................................................... 44 Retard Light........................................................ 44 Clearance/Turn Signal Lights........................................ 45 Backup Alarm........................................................ 45 PRECAUTIONS FOR MAINTENANCE................................................. 46 BEFORE PERFORMING MAINTENANCE........................................... 46 Securing The Dump Body.............................................. 46 DURING MAINTENANCE...................................................... 47 Warning Tag......................................................... 47 Proper Tools........................................................ 47 Attachments......................................................... 47 Working Under The Machine........................................... 47 Keeping The Machine Clean........................................... 47 Adding Fuel Or Oil To The Machine................................... 47 Radiator Coolant Level.............................................. 48 Use of Lighting..................................................... 48 Handling High Pressure Hoses........................................ 48 Precautions With High Pressure Oil.................................. 48 Maintenance Near High Temperatures and High Pressures............... 48 Rotating Fan and Belts.............................................. 48 Waste Materials..................................................... 48 Use of Tie-Off Anchor During Maintenance............................ 48 Handling Tires...................................................... 49 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 49 BATTERY HAZARD PREVENTION............................................... 50 Jump Starting With Booster Cables................................... 50 Jump Starting With Receptacles...................................... 51 WHEN REPAIRS ARE NECESSARY.................................................. 52 Observe The Following Precautions....................................... 52 SPECIAL PRECAUTIONS......................................................... 53 Preliminary Procedures Before Welding or Performing Maintenance......... 53 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 53 Before welding on the machine, obey the following guidelines:........... 53 4 WARNING AND CAUTIONS.......................................................... 56 GENERAL INFORMATION......................................................... 56 PIN PLATE................................................................... 56 GRADE SPEED CHART........................................................... 57 GREASE POINTS............................................................... 57 MACHINE SAFETY.............................................................. 58 KEY SWITCH.................................................................. 60 OIL FILL AND CHECK.......................................................... 60 HIGH PRESSURES.............................................................. 61 SPRING PRESSURE............................................................. 63 BATTERIES................................................................... 64 HIGH VOLTAGE................................................................ 65 WELDING..................................................................... 65 EMERGENCY DUMPING........................................................... 66 AUTOMATIC LUBRICATION FILL.................................................. 66 ROPS/FOPS................................................................... 66 TOWING...................................................................... 67 LUBRICATION CHART........................................................... 67 5 OPERATING INSTRUCTIONS........................................................ 70 PREPARING FOR OPERATION..................................................... 70 Safety Is Thinking Ahead................................................ 70 Walk Around Inspection.................................................. 70 TRUCK OPERATION............................................................. 74 ENGINE START-UP SAFETY.................................................. 74 After Engine Has Started............................................ 74 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 75 Machine Operation on the Haul Road.................................. 76 Starting on a Grade With a Loaded Truck............................. 76 Passing............................................................. 76 Loading............................................................. 76 Overload Speed Limit Function....................................... 77 Dumping............................................................. 77 Lowering the Dump Body (When Dumping on Flat Ground)................ 78 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 78 TROLLEY OPERATING INSTRUCTIONS.......................................... 79 Operating in Trolley Line Mode...................................... 79 Getting on Line..................................................... 79 Operating on Trolley................................................ 79 Getting off Line.................................................... 80 Line Status Signals................................................. 80 Trolley Disconnect.................................................. 81 Traffic Consideration for Trolley Line Operation.................... 81 Approaching Slow Moving Vehicles in a Trolley Assisted Truck........ 81 Operating Slow Moving Vehicles on Trolley Assist Ramps.............. 81 Truck Failure While on Trolley...................................... 82 SUDDEN LOSS OF ENGINE POWER............................................. 82 FUEL DEPLETION.......................................................... 82 SAFE PARKING PROCEDURES................................................. 83 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 83 DISABLED TRUCK CONNECTORS................................................... 85 GENERAL INFORMATION..................................................... 85 STEERING AND BRAKE SYSTEM............................................... 85 Components Required................................................. 85 Hookup.............................................................. 85 HOIST SYSTEM............................................................ 86 Hookup.............................................................. 86 Dumping Procedure................................................... 86 TOWING...................................................................... 88 SPECIAL WIRING HARNESS.................................................. 88 TOWING PROCEDURE........................................................ 88 PAYLOAD METER III SYSTEM.................................................... 90 GENERAL INFORMATION..................................................... 90 Data Summary........................................................ 90 Data Gathering...................................................... 90 COMPONENT DESCRIPTION................................................... 90 Operator Display.................................................... 90 Operator Switches................................................... 90 Brake Lock Switch................................................... 91 Payload Meter Module................................................ 91 Communications Ports................................................ 91 Load Lights......................................................... 91 OPERATOR’S DISPLAY AND SWITCH........................................... 91 Reading the Load Display............................................ 91 Setting the Operator ID............................................. 92 Load and Ton Counter................................................ 92 Viewing Live Sensor Data............................................ 92 Other Display Messages.............................................. 93 HAUL CYCLE WARNING FLAGS................................................ 93 Haul Cycle Data..................................................... 93 Haul Cycle Warning Flags............................................ 95 PC SOFTWARE OVERVIEW.................................................... 96 SYSTEM CONFIGURATION.................................................... 96 Connecting to the Payload Meter..................................... 96 Displayed Payload Units............................................. 97 Connection Menu..................................................... 97 Configure the Payload Meter......................................... 97 Setting the Date and Time........................................... 97 Setting the Truck Type and Serial Number............................ 98 Setting the Gauge Display Units..................................... 98 Setting the Carryback Alarm Threshold............................... 98 Setting the Truck Number............................................ 99 Setting the Komatsu Distributor..................................... 99 Setting the Komatsu Customer........................................ 99 Clean Truck Tare Calibration........................................ 99 Inclinometer Calibration............................................100 DOWNLOADING PAYLOAD DATA................................................100 UPLOADING DATA..........................................................101 DATA ANALYSIS...........................................................102 Creating a Query....................................................102 Payload Detail Screen...............................................103 Creating Reports....................................................103 Creating Graphs.....................................................103 Exporting Data......................................................104 Importing Data......................................................104 Deleting Haul Cycle Records.........................................104 Viewing Alarms......................................................105 Deleting Alarm Records..............................................105 Patent Acknowledgment...............................................105 AUTOMATIC LUBRICATION SYSTEM................................................106 GENERAL INFORMATION.....................................................106 COMPONENT DESCRIPTION...................................................106 Filter..............................................................107 Hydraulic Motor and Pump............................................107 Grease Reservoir....................................................107 Pressure Reducing Valve.............................................107 Flow Control Valve..................................................107 Solenoid Valve......................................................108 Vent Valve..........................................................108 Interface Module....................................................108 Pressure Cut Off Switch.............................................108 Injectors...........................................................109 Grease Pressure Failure Switch......................................109 Relief Valve (unloader valve).......................................109 SYSTEM OPERATION........................................................109 Filling The Reservoir...............................................109 Priming The Automatic Lubrication System............................110 PREVENTIVE MAINTENANCE PROCEDURES.......................................110 Daily Lubrication System Inspection.................................110 250 Hour Inspection.................................................111 1000 Hour Inspection................................................111 SYSTEM CHECKOUT.........................................................112 General Checks......................................................112 Lubrication Cycle Operation.........................................112 RESERVE ENGINE OIL SYSTEM...................................................113 Operation...............................................................113 Changing Oil............................................................113 6 OPERATOR CAB AND CONTROLS.....................................................116 CAB INTERIOR................................................................116 STEERING WHEEL AND CONTROLS.................................................117 Horn Button.............................................................117 Tilt / Telescope Lever..................................................117 Multi-Function Turn Signal Switch.......................................117 Speed Control Lever.....................................................117 Turn Signal Operation...................................................117 High Beam Headlight Operation...........................................118 Windshield Wiper Operation..............................................118 PEDALS......................................................................119 DYNAMIC RETARDING.......................................................119 Dynamic Retarder/Service Brake Pedal....................................119 ACCELERATOR PEDAL.......................................................119 OVERHEAD PANEL AND DISPLAYS.................................................120 RADIO SPEAKERS..........................................................120 WARNING ALARM BUZZER....................................................120 CAB RADIO...............................................................120 AIR CLEANER VACUUM GAUGES...............................................120 CENTER CONSOLE..............................................................121 DIRECTIONAL CONTROL LEVER...............................................121 OVERRIDE/FAULT RESET SWITCH.............................................121 ENGINE STOP SWITCH......................................................122 WINDOW CONTROL SWITCHES.................................................122 HOIST CONTROL LEVER.....................................................122 Raising The Dump Body...................................................122 Lowering The Dump Body..................................................122 ASHTRAY.................................................................122 LIGHTER.................................................................122 DATA STORE BUTTON.......................................................123 12V AUXILIARY POWER OUTLETS.............................................123 DIAGNOSTIC PORTS............................................................124 Drive System #1.........................................................124 ENGINE (QUANTUM)........................................................124 Drive System #3.........................................................124 ENGINE (CENSE)..........................................................124 INTERFACE MODULE (IM)...................................................124 KOMTRAX Plus ...........................................................124 PAYLOAD METER...........................................................124 OPERATOR SEAT (Standard)....................................................125 SEAT BELTS..............................................................125 ADJUSTMENT..............................................................125 PASSENGER SEAT (Standard)...................................................127 SEAT BELTS..............................................................127 ADJUSTMENT..............................................................127 OPERATOR SEAT (Optional)....................................................128 SEAT BELTS..............................................................128 ADJUSTMENT..............................................................128 PASSENGER SEAT (Optional)...................................................129 SEAT BELTS..............................................................129 ADJUSTMENT..............................................................129 HEATER / AIR CONDITIONER CONTROLS...........................................130 Fan Speed Control Knob..................................................130 Temperature Control Knob................................................130 Air Flow Directional Knob...............................................130 Heater/Air Conditioner Vents............................................130 INSTRUMENT PANEL ...........................................................131 CONTROL SYMBOLS.........................................................131 Key Switch..............................................................132 Speed Control Switch....................................................132 Traction Control Switch.................................................132 Retarding Grid Drier Switch.............................................133 AC Drive System Rest Switch.............................................133 Wheel Brake Lock Switch.................................................133 Hazard Light Switch.....................................................133 Heater/Air Conditioner Vents............................................133 Drive System Temperature Gauge..........................................134 Fuel Level Gauge........................................................134 Speedometer/Digital Display.............................................134 Coolant Temperature Gauge...............................................134 Hydraulic Oil Temperature Gauge.........................................134 Status Indicator Light Panel............................................134 Headlight/Panel Illumination Light Switch...............................134 Ladder Light Switch.....................................................134 Backup Light Switch.....................................................135 Fog Light Switch........................................................135 Mode Switches...........................................................135 Panel Lights Dimmer Switch..............................................135 Turn Signal Indicators..................................................135 Digital Display Contrast Buttons........................................135 Warning Light...........................................................135 STATUS INDICATOR LIGHT PANEL................................................136 STATUS INDICATOR LIGHT SYMBOLS..........................................136 Body Up.............................................................136 Parking Brake.......................................................136 Propel System Not Ready.............................................136 No Propel...........................................................137 Not used............................................................137 Engine Delay........................................................137 Retarding Grid Drier................................................137 Wheel Brake Lock....................................................137 Traction Control....................................................137 Repair Monitor......................................................137 Snapshot In Progress................................................137 Pantograph Energized................................................137 Pantograph Up.......................................................137 Service Brake.......................................................138 Dynamic Retarding...................................................138 No DC Link Voltage..................................................138 DIGITAL DISPLAY OPERATION...................................................139 Toggling Through Main Level Screens.....................................139 Toggling Through Warning Screens........................................140 Entering Payload Meter Data.............................................141 KOMTRAX Plus................................................................142 KOMTRAX Plus OPERATION..................................................142 Basic Precautions...................................................142 Interface Module....................................................143 DOWNLOADING KOMTRAX Plus DATA...........................................144 GENERAL INFORMATION.................................................144 KOMTRAX Plus DOWNLOADING PROCEDURE..................................144 Location of Downloaded Files........................................144 UPLOADING KOMTRAX Plus DATA.............................................145 ORBCOMM.................................................................146 KOMATSU WIRELESS BRIDGE (Optional)......................................147 General Information.................................................147 Communication Setup.................................................147 Switching to the KWB_SETUP Network..................................147 Setting the Computer Subnet Mask and IP Address.....................148 Setting Up the KWB..................................................148 Adding Encryption...................................................149 Final Computer Settings.............................................149 Downloading Data....................................................149 Resetting the KWB...................................................150 FUSES AND CIRCUIT BREAKERS..................................................151 FUSE BLOCK #1...........................................................152 FUSE BLOCK #2...........................................................153 FUSE BLOCK #3...........................................................153 FUSE HOLDERS............................................................153 CIRCUIT BREAKERS........................................................154 7 LUBRICATION AND SERVICE.......................................................156 GENERAL INFORMATION.........................................................156 HYDRAULIC SYSTEM SERVICE................................................156 Hydraulic Tank......................................................156 Hydraulic Filters...................................................157 Hydraulic Pump Drive Shaft..........................................157 WHEEL MOTOR SERVICE.....................................................157 COOLANT LEVEL SERVICE...................................................157 Radiator Filling Procedure..........................................158 Coolant Specifications..............................................158 Unacceptable Practices..............................................158 RESERVE ENGINE OIL SERVICE..............................................158 Reserve Oil Tank Filling Procedure (Remote Fill)....................159 Inline Screen.......................................................159 CAB AIR FILTER SERVICE..................................................159 FUEL SYSTEM SERVICE.....................................................160 Fuel Tank Cleaning..................................................160 Fuel Filter Service.................................................160 INTAKE AIR CLEANER SERVICE..............................................161 FRONT ENGINE MOUNT TRUNION SERVICE......................................162 QUICK FILL SERVICE CENTER...............................................162 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................162 LUBRICATION CHART...........................................................164 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................165 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................167 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................168 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................169 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................171 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................173 EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................174 EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................175 EVERY 5000 HOUR MAINTENANCE.................................................176 EVERY 6000 HOUR MAINTENANCE.................................................177 30,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................178 8 SPECIFICATIONS................................................................180 MAJOR COMPONENT DESCRIPTION.................................................180 Truck And Engine........................................................180 Traction Alternator.....................................................180 Main Control Cabinet....................................................180 AC Induction Traction Motorized Wheels..................................180 Suspension..............................................................180 Operator's Cab..........................................................180 Power Steering..........................................................180 Dynamic Retarding Grid..................................................180 Brake System............................................................180 SPECIFICATIONS..............................................................181 Engine..................................................................181 AC Electric Drive System................................................181 Dynamic Retarding.......................................................181 Battery Electric System.................................................181 Service Capacities......................................................181 Hydraulic Systems.......................................................181 Service Brakes..........................................................182 Steering................................................................182 Standard Dump Body Capacities And Dimensions............................182 Tires...................................................................182 Weight Distribution.....................................................182 Overall Truck Dimensions................................................183 9 RADIO.........................................................................186 RADIO OPERATION.............................................................186 GENERAL RADIO RECEIVER FUNCTIONS........................................186 Turning On the Power....................................................186 One-Hour Timer..........................................................186 Finding a Station.......................................................186 Setting the Presets.....................................................187 Adjusting the Receiver Audio Settings...................................187 Display.................................................................188 Adjusting the Receiver Menu Settings....................................188 Front Auxiliary Mode....................................................188 Rear Auxiliary Mode.....................................................188 CLOCK.......................................................................189 Clock/Alarm Button......................................................189 Setting the Clock.......................................................189 Setting the Alarm.......................................................189 Turning the Alarm Off...................................................190 Activating Snooze.......................................................190 CD PLAYER...................................................................191 Playing a Compact Disc..................................................191 Playing an MP3 DISC.....................................................191 CD Mode Displays........................................................191 Button Functions........................................................191 MP3 PLAYER..................................................................193 Playing MP3 Files.......................................................193 MP3 Mode Displays.......................................................193 Button Functions........................................................193 iPod®.......................................................................195 Playing an iPod®........................................................195 iPod® Mode Displays.....................................................195 Button Functions........................................................195 WEATHERBAND (USA Only)......................................................197 TROUBLESHOOTING.............................................................198 Tips About the Audio System.............................................198 Understanding Radio Reception...........................................198 Care of the Compact Discs...............................................198
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