Komatsu 860e-1kt Manual

CEAM022401

Operation

Maintenance

Manual

860E-1KT

DUMP TRUCK

SERIAL NUMBERS A30015 - A30030

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit

chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

CALIFORNIA

Proposition 65 Warning

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known

to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands

after handling.

Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel

must read and understand this manual before operating or maintaining this machine.

This manual should be kept in or near the machine for reference, and periodically reviewed by all per-

sonnel who will come into contact with it.

This material is proprietary to Komatsu America

Corp (KAC), and is not to be reproduced, used, or

disclosed except in accordance with written autho-

rization from KAC.

It is the policy of the Company to improve products

whenever it is possible and practical to do so. The

Company reserves the right to make changes or

add improvements at any time without incurring

any obligation to install such changes on products

sold previously.

Because of continuous research and development,

periodic revisions may be made to this publication.

Customers should contact their local Komatsu dis-

tributor for information on the latest revision.

CALIFORNIA

Proposition 65 Warning

Mercury and mercury compounds are known to the State of California to cause developmental prob-

lems. This machine may be equipped with optional HID lamps which contain mercury. There is no risk

of exposure unless the lamps are broken. However, the lamps must be reused, recycled or properly

disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.

NON-OEM PARTS IN CRITICAL SYSTEMS

For safety reasons, Komatsu America Corp. strongly recommends against the use

of non-OEM replacement parts in critical systems of all Komatsu equipment. Critical

systems include but are not limited to steering, braking and operator safety sys-

tems.

Replacement parts manufactured and supplied by unauthorized sources may not be

designed, manufactured or assembled to Komatsu's design specifications; accord-

ingly, use of such parts may compromise the safe operation of Komatsu products

and place the operator and others in danger should the part fail.

Komatsu is also aware of repair companies that will rework or modify an OEM part

for reuse in critical systems. Komatsu does not generally authorize such repairs or

modifications for the same reasons as noted above.

Use of non-OEM parts places full responsibility for the safe performance of the Kom-

atsu product on the supplier and user. Komatsu will not in any case accept responsi-

bility for the failure or performance of non-OEM parts in its products, including any

damages or personal injury resulting from such use.

OM1078 Introduction - Section 10

Page 10-1

INTRODUCTION

FOREWORD

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.

To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck

(which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and

subtract it from the GVW. The result is the allowable payload.

NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload.

To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be

removed as often as practical.

Exceeding the allowable payload will reduce the expected life of truck components.

Introduction - Section 10 OM1078

Page 10-2

TRUCK MODEL ILLUSTRATION

KOMATSU MODEL 860E Dump Truck

OM1078 Introduction - Section 10

Page 10-3

ABOUT THIS MANUAL

The front cover of this manual includes a form number. This form number should be referenced when ordering

additional copies of this manual or for any other correspondence regarding the coverage in this manual.

Direct all inquiries to:

Komatsu America Corp.

Technical Publications - Mining Equipment

P.O. Box 240

Peoria, IL 61650-0240

(309)-672-7072 - FAX

This first section is an Introduction to the manual. It contains the Table of Contents for locating specific areas of

interest. Other sections include:

• Standard Charts and Tables

• Safety

• Warnings and Cautions

• Operating Instructions

• Operator Cab and Controls

• Lubrication and Service

• Automatic Lubrication System

• Major Component Descriptions/Specifications

• Payload Meter III

• Radio, AM/FM Stereo Cassette

When searching for a specific area of interest, go first to the Table of Contents to locate the section in which the

subject might generally be included. Then, find a subject description that most closely describes the specific area

of interest and go to that page. Section numbers and page numbers are located at the top, outside corner of the

page.

At the top, inside corner of the page is a document (module) number. If there is ever a question regarding the

information in a particular section, refer to the document (module) number, the manual form number, and use the

address shown above to correspond. If there is a date (month/year) behind the document (module) number, that

date indicates the latest revision date of that page.

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.

This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,”

“front,” or “rear” are made with respect to the operator's normal seated position unless specifically stated otherwise.

When assembly instructions are provided without references to specific torque values, standard torque values

should be used. Standard torque values are shown in torque charts in the Standard Charts and Tables section in

this manual and in the General Information section of the truck shop manual. Specific torques, when provided in

the text, are in bold face type, such as 135 N•m (100 ft lbs). All torque specifications have ±10% tolerance unless

otherwise specified.

Introduction - Section 10 OM1078

Page 10-4

ALERTS PAGE

This ALERT symbol is used in this manual, along with

the signal words “CAUTION”, “DANGER” and

“WARNING”, to alert the reader to hazards arising from

improper operating and maintenance practices.

“DANGER” identifies a specific potential hazard

WHICH WILL RESULT

in either INJURY OR DEATH

if proper precautions are not taken.

“WARNING” identifies a specific potential hazard

WHICH MAY RESULT

in either INJURY OR DEATH

if proper precautions are not taken.

“CAUTION” is used for general reminders

of proper safety practices

to direct the reader’s attention to avoid unsafe

or improper practices which may result

in damage to the equipment.

OM1078 Introduction - Section 10

Page 10-5

TABLE OF CONTENTS

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

FOREWARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

TRUCK MODEL ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

ABOUT THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

ALERTS PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-4

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5

STANDARD CHARTS AND TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Fire Extinguisher And First Aid Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Clothing And Personal Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

Leaving The Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Mounting And Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Fire Prevention For Fuel And Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-2

Precautions With High Temperature Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

Asbestos Dust Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

Prevention Of Injury By Work Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

Unauthorized Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

ROPS Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3

Precautions For Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4

Precautions For Starting The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4

PRECAUTIONS BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4

Safety At The Worksite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-4

Fire Prevention. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

Preparing For Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

Ventilation In Enclosed Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

In Operator’s Cab - Before Starting The Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

Mirrors, Windows And Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-5

OPERATING THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6

When Starting The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6

General Truck Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-6

Traveling In Reverse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Traveling On Slopes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Ensuring Good Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Operating On Snow Or Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Avoiding Damage To Dump Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-7

Driving Near High Voltage Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-8

Introduction - Section 10 OM1078

Page 10-6

TABLE OF CONTENTS (cont.)

When Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

Working On Loose Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

When Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

Parking The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8

WORKING NEAR BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9

Battery Hazard Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9

Jump Starting With Booster Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

Jump Starting With Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10

BEFORE PERFORMING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11

Warning Tag. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11

Stopping The Engine Before Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11

Proper Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11

Securing The Dump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11

WHILE PERFORMING MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Keep The Truck Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Attachments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Working Under The Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Rotating Fan And Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Adding Fuel Or Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12

Radiator Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Use Of Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Precautions With The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Handling High Pressure Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Precautions When Performing Maintenance Near High Temperature Or High Pressure . . . . 20-13

Precautions With High Pressure Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

Waste Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-13

TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14