Komatsu 860E-1KT Dump Truck Operation & Maintenance Manual Serial NumberA30004 - A30014 PDF

Komatsu 860E-1KT Dump Truck Operation & Maintenance Manual Serial Number: A30004-A30014

Description:

• Komatsu 860E-1KT Dump Truck Operation & Maintenance Manual
• Serial Number: A30004-A30014
• 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 operating 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. 860E). 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
• Serial Number: A30004-A30014
• COVER .................................................................................... 1 INTRODUCTION.............................................................................. 5 FOREWORD.............................................................................. 5 TRUCK MODEL ILLUSTRATION.............................................................. 6 ABOUT THIS MANUAL..................................................................... 7 ALERTS PAGE........................................................................... 8 TABLE OF CONTENTS......................................................................... 9 TORQUE TABLES AND CONVERSION CHARTS....................................................... 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values.................. 18 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts................. 18 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws.................... 19 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws................................ 20 SAFETY.................................................................................... 27 GENERAL............................................................................... 27 Safety Rules...................................................................... 27 Safety Features................................................................... 27 Fire Extinguisher And First Aid Kit............................................... 27 Clothing And Personal Items....................................................... 27 Leaving The Operator’s Seat....................................................... 28 Mounting And Dismounting.......................................................... 28 Fire Prevention For Fuel And Oil.................................................. 28 Precautions With High Temperature Fluids.......................................... 29 Asbestos Dust Hazard Prevention................................................... 29 Prevention Of Injury By Work Equipment............................................ 29 Unauthorized Modification......................................................... 29 ROPS Precautions.................................................................. 29 Precautions For Attachments....................................................... 30 Precautions For Starting The Truck................................................ 30 PRECAUTIONS BEFORE OPERATION.......................................................... 30 Safety At The Worksite............................................................ 30 Fire Prevention................................................................... 31 Ventilation In Enclosed Areas..................................................... 31 Preparing For Operation........................................................... 31 Mirrors, Windows And Lights....................................................... 31 In Operator Cab (Before Starting The Engine)...................................... 31 Seat Belts........................................................................ 31 OPERATING THE TRUCK................................................................... 32 When Starting The Engine.......................................................... 32 General Truck Operation........................................................... 32 Ensuring Good Visibility.......................................................... 32 Traveling......................................................................... 33 Traveling In Reverse.............................................................. 33 Traveling On Slopes............................................................... 33 Operating On Snow Or Ice.......................................................... 33 Avoiding Damage To Dump Body...................................................... 33 Driving Near High Voltage Cables.................................................. 34 Working On Loose Ground........................................................... 34 When Dumping...................................................................... 34 When Loading...................................................................... 34 Parking The Truck................................................................. 34 Towing............................................................................ 34 WORKING NEAR BATTERIES................................................................ 35 Battery Hazard Prevention......................................................... 35 Jump Starting With Booster Cables................................................. 36 Jump Starting With Receptacles.................................................... 36 BEFORE PERFORMING MAINTENANCE......................................................... 37 Stopping The Engine Before Service................................................ 37 Warning Tag....................................................................... 37 Proper Tools...................................................................... 37 Securing The Dump Body............................................................ 37 WHILE PERFORMING MAINTENANCE.......................................................... 38 Keep The Truck Clean.............................................................. 38 Attachments....................................................................... 38 Working Under The Truck........................................................... 38 Rotating Fan And Belts............................................................ 38 Waste Materials................................................................... 38 Adding Fuel Or Oil................................................................ 39 Radiator Coolant Level............................................................ 39 Use Of Lighting................................................................... 39 Precautions With The Battery...................................................... 39 Handling High Pressure Hoses...................................................... 39 Precautions With High Pressure Oil................................................ 39 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 39 TIRES................................................................................. 40 Handling Tires.................................................................... 40 Tire Maintenance.................................................................. 40 Storing Tires After Removal....................................................... 40 WHEN REPAIRS ARE NECESSARY............................................................ 41 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.................................... 42 Engine Shutdown Procedure Before Welding or Performing Maintenance................ 42 Precautions Before Welding or Performing Maintenance.............................. 43 ADDITIONAL JOB SITE RULES............................................................. 45 WARNINGS AND CAUTIONS..................................................................... 47 GRADE/SPEED CHART..................................................................... 47 INSTRUMENT PANEL...................................................................... 47 BATTERIES............................................................................. 48 HIGH VOLTAGE.......................................................................... 48 RADIATOR.............................................................................. 49 CRUSHING HAZARD....................................................................... 49 CYLINDER PRESSURE..................................................................... 49 FILLING THE HYDRAULIC TANK............................................................ 50 HYDRAULIC OIL PRESSURE................................................................ 50 EMERGENCY TOWING PROCEDURE............................................................ 51 EMERGENCY DUMP PROCEDURE.............................................................. 51 ACCUMULATOR DRAIN VALVES.............................................................. 51 GREASE POINT.......................................................................... 51 WELDING............................................................................... 52 EMERGENCY SHUTDOWN.................................................................... 52 LIFTING POINT......................................................................... 52 SPRING PRESSURE....................................................................... 53 ROPS/FOPS............................................................................. 53 OIL FILL AND CHECK.................................................................... 53 EMERGENCEY EGRESS..................................................................... 53 Wireless Signal....................................................................... 53 PRODUCT IDENTIFICATION PLATE.......................................................... 54 LUBRICATION CHART..................................................................... 54 OPERATING INSTRUCTIONS.................................................................... 55 PREPARING FOR OPERATION............................................................... 55 WALK AROUND INSPECTION................................................................ 55 ENGINE START-UP....................................................................... 60 AFTER ENGINE HAS STARTED.............................................................. 61 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 62 OPERATING ON THE HAUL ROAD............................................................ 63 STARTING ON A GRADE WITH A LOADED TRUCK............................................... 63 PASSING............................................................................... 64 LOADING............................................................................... 64 DUMPING............................................................................... 64 Raising The Dump Body............................................................. 64 Lowering The Dump Body (When dumping on flat ground):............................. 65 Lowering The Dump Body (When dumping over a berm or into a crusher):.............. 65 TROLLEY OPERATING INSTRUCTIONS ....................................................... 66 Operating in trolley line mode.................................................... 66 Getting on line................................................................... 66 Operating on trolley.............................................................. 67 Getting off line.................................................................. 67 Line status signals............................................................... 68 Trolley disconnect................................................................ 68 Traffic consideration for trolley line operation.................................. 69 Approaching slow moving vehicles in a trolley assisted truck...................... 69 Operating slow moving vehicles on trolley assist ramps............................ 70 Truck failure while on trolley.................................................... 70 USING THE SPEED CONTROL FEATURE....................................................... 71 SAFE PARKING PROCEDURES............................................................... 71 NORMAL ENGINE SHUTDOWN PROCEDURE...................................................... 72 SUDDEN LOSS OF ENGINE POWER........................................................... 73 FUEL DEPLETION........................................................................ 73 TOWING................................................................................ 74 Special Wiring Harness............................................................ 74 Towing Procedure.................................................................. 74 DISABLED TRUCK OPERATION.............................................................. 77 GENERAL............................................................................... 77 STEERING AND BRAKE SYSTEM............................................................. 77 Components Required............................................................... 77 Hookup............................................................................ 78 DISABLED TRUCK DUMPING PROCEDURE...................................................... 79 Hookup............................................................................ 79 Raising the Body.................................................................. 79 Lowering the Body................................................................. 80 RESERVE ENGINE OIL SYSTEM............................................................. 81 OPERATOR CAB AND CONTROLS................................................................. 83 STEERING WHEEL AND CONTROLS........................................................... 84 Horn Button....................................................................... 84 Tilt / Telescope Lever............................................................ 84 Speed Control Lever............................................................... 84 Multi-Function Turn Signal Switch................................................. 84 DYNAMIC RETARDING..................................................................... 85 Dynamic Retarder/Service Brake Pedal.............................................. 85 Throttle/Accelerator Pedal........................................................ 85 GRADE/SPEED RETARD CHART.............................................................. 86 OVERHEAD PANEL COMPONENTS............................................................. 86 CENTER CONSOLE........................................................................ 87 Directional Control Lever......................................................... 87 Override/Fault Reset Switch....................................................... 88 Engine Shutdown Switch............................................................ 88 L.H. Window Control Switch R.H. Window Control Switch............................. 88 Hoist Control Lever............................................................... 88 Ashtray........................................................................... 89 Lighter........................................................................... 89 Data Store Button................................................................. 89 Service Engine Light.............................................................. 89 12V Auxiliary Power Outlets....................................................... 89 DIAGNOSTIC PORTS...................................................................... 89 Drive System #1................................................................... 89 Engine (QUANTUM).................................................................. 89 Drive System #3................................................................... 89 Engine (CENSE).................................................................... 89 Interface Module.................................................................. 89 VHMS.............................................................................. 89 Payload Meter..................................................................... 89 OPERATOR’S SEAT....................................................................... 90 Seat Belts........................................................................ 90 Adjustment........................................................................ 90 PASSENGER SEAT (STANDARD SEAT)........................................................ 91 Seat Belts........................................................................ 91 Adjustment........................................................................ 91 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 92 Fan Speed Control Knob............................................................ 92 Temperature Control Knob.......................................................... 92 Air Flow Directional Knob......................................................... 92 Heater/Air Conditioner Vents...................................................... 92 INSTRUMENT PANEL...................................................................... 93 Control Symbols................................................................... 93 Key Switch........................................................................ 95 Speed Control Switch.............................................................. 95 Traction Control Switch........................................................... 95 Retarding Grid Drier Switch....................................................... 95 AC Drive System Rest Switch....................................................... 95 Wheel Brake Lock Switch........................................................... 96 Pantograph Switch................................................................. 96 Hazard Warning Lights............................................................. 96 Heater/Air Conditioner Vents...................................................... 96 Fuel Level Gauge.................................................................. 96 Hydraulic Oil Temperature Gauge................................................... 96 Speedometer/Digital Display....................................................... 97 Coolant Temperature Gauge......................................................... 97 Drive System Temperature Gauge.................................................... 97 Headlight/Panel Illumination Light Switch......................................... 97 Ladder Light Switch (3-Way)....................................................... 97 Backup Light Switch............................................................... 97 Fog Light Switch.................................................................. 97 Mode Switches..................................................................... 98 Panel Illumination Light Dimmer Switch............................................ 98 Right/Left Turn Signal Indicators................................................. 98 Digital Display Contrast Buttons.................................................. 98 Warning Light..................................................................... 98 STATUS INDICATOR LIGHTS............................................................... 99 Body Up........................................................................... 99 Parking Brake Applied............................................................. 99 Propulsion System Not Ready....................................................... 99 No Propel.........................................................................100 Engine Warming Up.................................................................100 Engine Delay......................................................................100 Grid Drier........................................................................100 Wheel Brake Lock Applied..........................................................100 Traction Control..................................................................100 Repair Monitor....................................................................100 Snapshot..........................................................................100 Pantograph Energized..............................................................101 Pantograph Up.....................................................................101 Service Brake Applied.............................................................101 Dynamic Retarding.................................................................101 No DC Link Voltage................................................................101 DIGITAL DISPLAY OPERATION.............................................................102 Toggling Through Main Level Screens...............................................102 Toggling Through Warning Screens..................................................103 Entering Payload Meter Data.......................................................104 REAR AXLE LIGHT BAR...................................................................105 Backup Lights.....................................................................105 Retard Lights.....................................................................105 Brake Light.......................................................................105 Backup Alarm......................................................................105 KOMTRAX PLUS..........................................................................106 Operation.........................................................................106 Basic Precautions.................................................................108 FUSES AND CIRCUIT BREAKERS............................................................109 LUBRICATION AND SERVICE...................................................................113 GENERAL...............................................................................113 860E-1K SERVICE CAPACITIES............................................................113 HYDRAULIC TANK SERVICE................................................................113 Adding Oil........................................................................113 COOLING SYSTEM SERVICE................................................................114 Radiator Filling Procedure........................................................114 Coolant Specifications............................................................114 Unacceptable Practices............................................................114 RESERVE ENGINE OIL SYSTEM.............................................................115 Reserve Oil Tank Filling Procedure (Remote fill)..................................115 Inline Screen.....................................................................115 QUICK FILL SERVICE CENTER.............................................................116 LUBRICATION CHART.....................................................................117 10 HOUR (DAILY) INSPECTIONS...........................................................118 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................121 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................121 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................122 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................125 1,000 HOURS LUBRICATION AND MAINTENANCE CHECKS........................................127 1,000 HOURS LUBRICATION AND MAINTENANCE CHECKS (cont.)................................128 2,000 HOUR MAINTENANCE CHECKS.........................................................129 3,000 HOUR MAINTENANCE CHECKS.........................................................129 5,000 HOUR MAINTENANCE CHECKS.........................................................130 6,000 HOUR MAINTENANCE CHECKS.........................................................130 AUTOMATIC LUBRICATION SYSTEM..............................................................131 GENERAL DESCRIPTION...................................................................131 SYSTEM COMPONENTS.....................................................................133 Filter Assembly...................................................................133 Hydraulic Motor and Pump..........................................................133 Grease Reservoir..................................................................133 Pressure Reducing Valve...........................................................133 Flow Control Valve................................................................133 Solenoid Valve....................................................................133 Vent Valve........................................................................133 Interface Module..................................................................133 Grease System Failure Switch......................................................133 Injectors.........................................................................133 Unloader Valve....................................................................133 SYSTEM OPERATION......................................................................134 GENERAL INSTRUCTIONS..................................................................135 Required Lubricant................................................................135 System Priming....................................................................135 Filter Assembly...................................................................135 LUBRICANT PUMP........................................................................136 Pump Housing Oil Level............................................................136 Pump Pressure Control.............................................................136 INJECTORS (SL-1 Series “H”)...........................................................137 Injector Specifications...........................................................137 Injector Adjustment...............................................................137 INJECTOR OPERATION....................................................................138 PREVENTIVE MAINTENANCE PROCEDURES.....................................................139 Daily Lubrication System Inspection...............................................139 250 Hour Inspection...............................................................139 1000 Hour Inspection..............................................................139 SYSTEM CHECKOUT.......................................................................140 Lubrication Cycle Operation.......................................................140 SYSTEM TROUBLESHOOTING CHART..........................................................141 COMPONENTS & SPECIFICATIONS...............................................................143 MAJOR COMPONENT DESCRIPTIONS..........................................................143 Truck And Engine..................................................................143 Main Alternator...................................................................143 AC Induction Traction Motorized Wheels............................................143 Suspension........................................................................143 Operator's Cab....................................................................143 Power Steering....................................................................143 Dynamic Retarding.................................................................143 Brake System......................................................................143 SPECIFICATIONS........................................................................145 ENGINE............................................................................145 AC ELECTRIC DRIVE SYSTEM..........................................................145 DYNAMIC RETARDING.................................................................145 BATTERY ELECTRIC SYSTEM...........................................................145 SERVICE CAPACITIES................................................................145 HYDRAULIC SYSTEMS.................................................................146 SERVICE BRAKES....................................................................146 STEERING..........................................................................146 TIRES.............................................................................146 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS......................................146 WEIGHT DISTRIBUTION...............................................................147 PAYLOAD METER III™........................................................................149 Introduction..........................................................................149 Data Summary......................................................................149 Data Gathering....................................................................149 COMPONENT DESCRIPTION.................................................................150 System Diagram....................................................................150 Suspension Pressure Sensors.......................................................150 Inclinometer......................................................................150 Speedometer/Load Display..........................................................150 Operator Switches.................................................................151 Speed Input.......................................................................151 Body-Up Switch....................................................................151 Brake Lock Switch.................................................................151 Payload Meter.....................................................................151 Communications Ports..............................................................151 Key Switch Input..................................................................152 Payload Meter Power...............................................................152 Load Lights.......................................................................152 Wiring and Termination............................................................152 LOAD DISPLAY AND OPERATOR SWITCHES....................................................153 Setting the Operator ID...........................................................153 Total Ton and Total Load Counters.................................................153 Viewing Live Sensor Data..........................................................153 Other Display Messages............................................................154 PAYLOAD OPERATION & CALCULATION.......................................................154 Description of Haul Cycles........................................................154 Load Calculation..................................................................155 Carry Back........................................................................155 Measurement Accuracy..............................................................155 SOURCES FOR PAYLOAD ERROR.............................................................156 Suspensions.......................................................................156 Loading Conditions................................................................156 Pressure Sensors..................................................................156 Swingloads........................................................................156 Speed and Distance................................................................156 HAUL CYCLE DATA.......................................................................157 Haul Cycle Warning Flags..........................................................157 Frame Torque Data.................................................................158 Sprung Weight Data................................................................158 Maximum Speed Data................................................................158 Alarm Records.....................................................................160 PDM SOFTWARE OVERVIEW.................................................................161 System Configuration..............................................................161 Installing the PDM Software.......................................................161 DOWNLOADING DATA......................................................................161 PLM III SYSTEM CONFIGURATION..........................................................162 Starting Communications...........................................................162 Connection Menu...................................................................162 Connecting to the Payload Meter...................................................163 Configuring the Payload Meter.....................................................163 Setting the Date and Time.........................................................163 Setting the Truck Type............................................................164 Setting the Display Units.........................................................164 Setting the Frame Serial Number...................................................164 Setting the Truck Number..........................................................164 Setting the Komatsu Distributor...................................................164 Setting the Komatsu Customer......................................................164 Clean Truck Tare..................................................................165 Inclinometer Calibration..........................................................165 DATA ANALYSIS.........................................................................166 Creating a Query..................................................................166 Sorting on Truck Unit Number......................................................166 Sorting on Truck Type.............................................................166 Sorting on Date Range.............................................................167 Sorting on Time Range.............................................................167 Payload Detail Screen.............................................................168 Creating Reports..................................................................169 Creating Graphs...................................................................170 Exporting Data....................................................................170 Importing Data....................................................................172 Deleting Haul Cycle Records.......................................................172 Viewing Alarms....................................................................172 Deleting Alarm Records............................................................172 AM/FM RADIO / CD PLAYER...................................................................175 GENERAL RADIO RECEIVER FUNCTIONS......................................................175 Turning On the Power..............................................................175 One-Hour Timer....................................................................175 Display...........................................................................176 Setting a Default Display.........................................................176 Adjusting the Brightness of the Display...........................................176 Auxiliary Mode....................................................................176 Adjusting the Receiver Settings...................................................176 USING THE CLOCK.......................................................................177 Setting the Clock.................................................................177 USING THE ALARM.......................................................................177 Setting the Alarm.................................................................177 Turning the Alarm Off.............................................................177 Activating Snooze.................................................................177 Setting Alarm Volume..............................................................177 USING THE RADIO.......................................................................178 Finding a Station.................................................................178 Setting the Presets...............................................................178 USING THE WEATHERBAND.................................................................179 USING THE COMPACT DISC PLAYER.........................................................179 Playing a Compact Disc............................................................179 Button Functions..................................................................179 PLAYING AN MP3 DISC...................................................................180 MP3 Format Compatibility..........................................................180 Root Directory....................................................................180 Empty Directory or Folder.........................................................180 No Folder.........................................................................180 File Name Display.................................................................180 Pre-Programmed Playlists..........................................................181 Playing MP3 Files.................................................................181 Button Functions..................................................................181 TROUBLESHOOTING.......................................................................182

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