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Komatsu 860E-1KT Operation & Maintenance Manual

Dump truck
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Operation & Maintenance
Manual
860E-1KT
DUMP TRUCK
SERIAL NUMBERS
A30015 - A30030
CEAM022401
®

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Summary of Contents for Komatsu 860E-1KT

  • Page 1 CEAM022401 Operation & Maintenance Manual 860E-1KT DUMP TRUCK A30015 - A30030 SERIAL NUMBERS ®...
  • Page 3 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...
  • Page 4 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.

  • Page 5: Introduction

    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.

  • Page 6: Truck Model Illustration

    Introduction - Section 10 OM1078 Page 10-2 TRUCK MODEL ILLUSTRATION KOMATSU MODEL 860E Dump Truck...

  • Page 7: 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...

  • Page 8: Alerts Page

    Introduction - Section 10 OM1078 Page 10-4 ALERTS PAGE This ALERT symbol is used in this manual, along with signal words “CAUTION”, “DANGER” “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.

  • Page 9: Table Of Contents

    OM1078 Introduction - Section 10 Page 10-5 TABLE OF CONTENTS INTRODUCTION ..............10-1 FOREWARD .

  • Page 10: Table Of Contents

    Introduction - Section 10 OM1078 Page 10-6 TABLE OF CONTENTS (cont.) When Dumping ............. 20-8 Working On Loose Ground .
  • Page 11 OM1078 Introduction - Section 10 Page 10-7 TABLE OF CONTENTS (cont.) OPERATING INSTRUCTIONS ............30-1 PREPARING FOR OPERATION .
  • Page 12 Introduction - Section 10 OM1078 Page 10-8 TABLE OF CONTENTS (cont.) OPERATOR CAB AND CONTROLS ..........32-1 STEERING WHEEL AND CONTROLS .
  • Page 13 OM1078 Introduction - Section 10 Page 10-9 TABLE OF CONTENTS (cont.) Speed Control Switch ............32-13 Traction Control Switch .
  • Page 14 Introduction - Section 10 OM1078 Page 10-10 TABLE OF CONTENTS (cont.) REAR AXL LIGHT BAR ............32-23 Backup Lights .
  • Page 15 OM1078 Introduction - Section 10 Page 10-11 TABLE OF CONTENTS (cont.) Grease System Failure Switch ..........42-3 Injectors .
  • Page 16 Introduction - Section 10 OM1078 Page 10-12 TABLE OF CONTENTS (cont.) Rear Auxiliary Mode ............70-3 Adjusting the Receiver Audio Settings .
  • Page 17 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-1 TORQUE TABLES AND CONVERSION CHARTS This manual provides dual dimensioning for many specifications. Metric units are specified first, with References throughout the manual to standard U.S. standard units in parentheses. When torque val- torques or other standard values will be to one of ues are not specified in the assembly instructions the following tables.
  • Page 18 N•m ft lb kg•m NOTE: This list represents the current engineering M6 x1 1.22 approved sources for use in Komatsu manufacture. It M8 x 1.25 3.06 is not exclusive. Other products may meet the same M10 x 1.5 5.61 specifications of this list.
  • Page 19 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-3 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws The following specifications apply to required assem- • The maximum torque tolerance shall be ±10% of bly torques for all grade 5 and grade 8 cap screws.
  • Page 20 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-4 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws The following specifications apply to required assem- bly torques for all 12-point, grade 9 (170,000 psi min- imum tensile), cap screws. •...
  • Page 21 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-5 TABLE 4. Tightening Torque For T-Bolt Type Hose Clamp (SAE J1508 Type TB) Newton meters Inch Pounds Thread Size Band Width (N·m) (in. lb) 0.25-28 UNF 19.05 mm (0.75 in.) 8.5 ±...
  • Page 22 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-6 TABLE 7. Torque Chart For JIC 37° Swivel NutS With Or Without O-ring Seals Size Tube Size Threads UNF-2B Newton meters Foot Pounds Code (OD) (N·m) (ft lb) –...
  • Page 23 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-7 TABLE 9. Torque Chart For O-ring Boss Fittings Foot Pounds Newton meters Size Tube Size Threads UNF-2B (ft lb) (N·m) Code (OD) – 2 0.125 0.312 – 24 4 ±...
  • Page 24 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-8 TABLE11. Common Conversion Multipliers Metric To English Multiply To Convert From millimeter (mm) inch (in.) 0.0394 centimeter (cm) inch (in.) 0.3937 meter (m) foot (ft) 3.2808 meter (m) yard (yd) 1.0936 kilometer (km)
  • Page 25 OM1200 02/11 Torque Tables And Conversion Charts - Section 12 Page 12-9 TABLE 12. Common Conversion Multipliers English to Metric To Convert Multiply From inch (in.) millimeter (mm) 25.40 inch (in.) centimeter (cm) 2.54 foot (ft) meter (m) 0.3048 yard (yd) meter (m) 0.914 mile (mi)
  • Page 26 Torque Tables And Conversion Charts - Section 12 02/11 OM1200 Page 12-10 TABLE 13. Temperature Conversions Formula: F° - 32 ÷ 1.8 = C° or C° x 1.8 + 32 = F° Celsius Fahrenheit Celsius Fahrenheit Celsius Fahrenheit C° F° C°...

  • Page 27: Safety

    OM2041 8/11 Safety - Section 20 Page 20-1 SAFETY GENERAL Fire Extinguisher And First Aid Kit • Make sure that fire extinguishers are accessible Safety records from most organizations will show that and proper usage techniques are known. the greatest percentage of accidents are caused by unsafe acts performed by people.

  • Page 28: Leaving The Operator's Seat

    Safety - Section 20 8/11 OM2041 Page 20-2 Leaving The Operator’s Seat Fire Prevention For Fuel And Oil When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame. Fuel extremely flammable touch any control lever that is not locked.

  • Page 29: Precautions With High Temperature Fluids

    If it is modified or repaired without authorization from 3. Turn the cap slowly to release the pressure before Komatsu, or if it is damaged when the truck rolls removing the cap. over, the strength of the structure will be compromised and will not be able to fulfill its intended purpose.

  • Page 30: Precautions For Attachments

    • Any injuries, accidents, and product failures resulting from the use of unauthorized attachments Safety At The Worksite will not be the responsibility of Komatsu America • When walking to and from a truck, maintain a safe Corp. authorized...

  • Page 31: Fire Prevention

    OM2041 8/11 Safety - Section 20 Page 20-5 Fire Prevention Mirrors, Windows And Lights • Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the windshield, flammable items that have accumulated in the cab windows, mirrors and lights. Good visibility may engine compartment.

  • Page 32: Operating The Truck

    Safety - Section 20 8/11 OM2041 Page 20-6 OPERATING THE TRUCK When Starting The Engine • Never attempt to start the engine by shorting across cranking motor terminals. This may cause a fire, or serious injury or death to anyone in truck’s The tire and rim assembly may explode if subjected path.

  • Page 33: Traveling In Reverse

    OM2041 8/11 Safety - Section 20 Page 20-7 Traveling In Reverse Traveling On Slopes Before operating the truck: • Traveling on slopes could result in the truck tipping over or slipping. • Sound the horn to warn people in the area. Make •...

  • Page 34: Driving Near High Voltage Cables

    Safety - Section 20 8/11 OM2041 Page 20-8 Driving Near High Voltage Cables When Loading Driving near high-voltage cables can cause electric • Make sure that the surrounding area is safe. Stop the truck in the correct loading position, then load shock.

  • Page 35: Working Near Batteries

    OM2041 8/11 Safety - Section 20 Page 20-9 WORKING NEAR BATTERIES • Batteries generate hydrogen gas. Hydrogen gas is very explosive and can easily be ignited with a small spark or flame. Battery Hazard Prevention • Before working with batteries, stop the engine and •...

  • Page 36: Jump Starting With Booster Cables

    Safety - Section 20 8/11 OM2041 Page 20-10 Jump Starting With Booster Cables Jump Starting With Receptacles • Always wear safety glasses or goggles when • Always wear safety glasses or goggles when starting the machine with booster cables. starting the machine with booster cables. •...

  • Page 37: Before Performing Maintenance

    These tags are available from your Komtsu distributor. The Komatsu body-up safety sling can only be Warning tag part number: 09963-03001 used with a Komatsu body. Non-OEM body may not accommodate the Komatsu body-up safety sling. The end user must ensure that a proper cable/sling is used.

  • Page 38: While Performing Maintenance

    Safety - Section 20 8/11 OM2041 Page 20-12 WHILE PERFORMING MAINTENANCE Working Under The Truck • Always lower all movable work equipment to the NOTE: Only authorized personnel should service and ground or to their lowest position before performing repair the truck. service or repairs under the truck.

  • Page 39: Radiator Coolant Level

    OM2041 8/11 Safety - Section 20 Page 20-13 Radiator Coolant Level Precautions When Performing Maintenance Near High Temperature Or High Pressure If it is necessary to add coolant to the radiator, stop the engine and allow the engine and radiator to cool down Immediately after stopping operation, engine coolant before adding the coolant.

  • Page 40: Tires

    Improperly maintained or inflated tires can overheat even death. When performing such maintenance, con- and burst due to excessive pressure. Improper inflation sult your authorized regional Komatsu distributor, or the can also result in cuts in the tire caused by sharp tire manufacturer.

  • Page 41: Storing Tires After Removal

    OM2041 8/11 Safety - Section 20 Page 20-15 Storing Tires After Removal • As a basic rule, store the tires in a warehouse in which unauthorized persons cannot enter. If the tires are stored outside, always erect a fence around the tires and put up “No Entry” signs and other warning signs that even young children can understand.

  • Page 42: When Repairs Are Necessary

    (Also refer to the Operation and Maintenance Manual, Operating Instructions 2. Many components on the Komatsu truck are large - Towing.) and heavy. Ensure that lifting equipment - hoists, slings, chains, lifting eyes - are of adequate 10.

  • Page 43: Special Precautions For Working On Ac Drive Trucks

    Normal operation of the drive system at shutdown will Prior to welding and/or repairing an AC drive truck, leave the system safe to maintain. However, in the maintenance personnel should notify a Komatsu event of a system failure, performing the following pro- service representative.

  • Page 44: Precautions Before Welding Or Performing Maintenance

    4. Do not weld on any drive system components! hydraulic cylinders. Consult your Komatsu service representative 7. If the green link voltage light is off and the DC bus before attempting any welding procedures. voltage gauge reads more than 0.0 V after 5.
  • Page 45 OM2041 8/11 Safety - Section 20 Page 20-19...

  • Page 46: Additional Job Site Rules

    Safety - Section 20 8/11 OM2041 Page 20-20 ADDITIONAL JOB SITE RULES Use this space to add any additional job site rules not covered in any of the previous discussions. _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________...

  • Page 47: Warnings And Cautions

    The plates and decals right of the steering column on the instrument panel. listed here are typical of this Komatsu model, but The warning stresses the importance of reading the because of customer options, individual trucks may operator's manual before operation.
  • Page 48 Safety - Section 22 8/11 OM2221 Page 22-2 BATTERIES This decal is placed on the exterior of the battery box and near the battery disconnect switches to indicate Attached to the exterior of the battery box is a danger that the battery system (24VDC) is a negative (-) decal which stresses the need to keep from making ground system.
  • Page 49 OM2221 8/11 Safety - Section 22 Page 22-3 RADIATOR CYLINDER PRESSURE A warning plate is mounted on top of the radiator surge These danger plates are mounted on the outside of tank cover near the radiator cap. The engine cooling each frame rail to remind technicians to read the system is pressurized.
  • Page 50 Safety - Section 22 8/11 OM2221 Page 22-4 FILLING THE HYDRAULIC TANK HYDRAULIC OIL PRESSURE A plate mounted on the side of the hydraulic tank A warning plate is attached to the hydraulic tank to provides instructions for filling the hydraulic tank. warn technicians that high pressure hydraulic oil is present during operation.
  • Page 51 OM2221 8/11 Safety - Section 22 Page 22-5 EMERGENCY TOWING PROCEDURE ACCUMULATOR DRAIN VALVES A decal which provides the operator or technician with Warning decals are applied inside the brake system the emergency procedure for towing a disabled truck is cabinet behind the operator cab.
  • Page 52 Safety - Section 22 8/11 OM2221 Page 22-6 WELDING EMERGENCY SHUTDOWN This caution decal is placed near the battery This decal is placed on the ground level engine disconnect switches on the side of the battery box to shutdown switch, which is mounted on the right side of alert service technicians to always disconnect the the front bumper structure.
  • Page 53 OM2221 8/11 Safety - Section 22 Page 22-7 SPRING PRESSURE EMERGENCEY EGRESS This danger plate is mounted on each brake assembly. This caution decal is placed near both vertical ladders It warns the service technician that there are springs on either side of the radiator. It informs personnel that inside the brake assembly under pressure.
  • Page 54 (CL). The CL is used to verify the accuracy of the individual PIN. FC - Character positions 10 and 11 identify the Factory Code (FC). The FC identifies the Komatsu factory in charge of claims for the product. The FC for electric drive trucks is 61.

  • Page 55: Operating Instructions

    Komatsu truck. side of the truck to the original starting point. Safe practices start before the operator gets to the If these steps are performed in sequence and are equipment.
  • Page 56 Operating Instructions - Section 30 7/09 OM3050 Page 30-2 START HERE FIGURE 30-1. TOP VIEW...
  • Page 57 OM3050 7/09 Operating Instructions - Section 30 Page 30-3 5. Check that all suspension attaching hardware is secure. Inspect the mounting key area for FIGURE 30-1. TOP VIEW evidence of wear. Check that the suspension 1. Operator Cab extension (exposed piston rod) is correct and 2.
  • Page 58 Operating Instructions - Section 30 7/09 OM3050 Page 30-4 14. Look under the lower edge of the chassis to 23. Move around fuel tank (12). Inspect the fuel ensure that the flexible duct that carries the air gauge. This should agree with the fuel gauge in from the main blower to the final drive housing the cab.
  • Page 59 OM3050 7/09 Operating Instructions - Section 30 Page 30-5 29. Before climbing the ladder to first level, ensure 33. Check the coolant level in the inverter cabinet that the ground level engine shutdown switch is radiator. The coolant level must be visible at the activated.

  • Page 60: Engine Start-Up

    Operating Instructions - Section 30 7/09 OM3050 Page 30-6 ENGINE START-UP c. After the engine has started, place the rest switch in the OFF position to enable the drive system. Refer to the discussion on the rest switch in Section 32, Operator Cab Controls. NOTE: In cold ambient conditions and when the engine is cold, the engine rpm will not increase Never attempt to start the engine by shorting...

  • Page 61: After Engine Has Started

    OM3050 7/09 Operating Instructions - Section 30 Page 30-7 AFTER ENGINE HAS STARTED 4. If any application or release of any brake circuit appears sluggish or improper, or if warning alarms are activated on application or release, shut the engine off and notify maintenance per- sonnel.

  • Page 62: Machine Operation Safety Precautions

    Operating Instructions - Section 30 7/09 OM3050 Page 30-8 MACHINE OPERATION SAFETY 4. Observe all regulations pertaining to the job site's traffic pattern. Be alert to any unusual PRECAUTIONS traffic pattern. Obey the spotter's signals. After the engine is started and all systems are 5.

  • Page 63: Operating On The Haul Road

    OM3050 7/09 Operating Instructions - Section 30 Page 30-9 OPERATING ON THE HAUL ROAD 9. When operating the truck in darkness, or when visibility is poor, do not move the truck unless all 1. Always stay alert! If you are unfamiliar with the headlights, clearance lights, and tail lights are road, drive with extreme caution.

  • Page 64: Passing

    Operating Instructions - Section 30 7/09 OM3050 Page 30-10 PASSING 4. When the truck is stopped and in the dump position, apply the wheel brake lock and move 1. Do not pass another truck on a hill or blind the directional control lever to NEUTRAL. curve.

  • Page 65: Lowering The Dump Body (When Dumping On Flat Ground)

    OM3050 7/09 Operating Instructions - Section 30 Page 30-11 Lowering The Dump Body Lowering The Dump Body (When dumping on flat ground): (When dumping over a berm or into a crusher): It is very likely when dumping on flat ground that the 1.

  • Page 66: Operating In Trolley Line Mode

    Operating Instructions - Section 30 7/09 OM3050 Page 30-12 TROLLEY OPERATING Getting on line INSTRUCTIONS When operating a trolley truck, follow the procedure listed below to get on the trolley line. The instructions provided here are specifically for trolley use. General operating instructions outlined 1.

  • Page 67: Operating On Trolley

    OM3050 7/09 Operating Instructions - Section 30 Page 30-13 Operating on trolley Getting off line As the truck approaches the end of the trolley line, it 1. The directional control lever must remain in the must exit the line properly. There will be signs or sig- T position while on trolley.

  • Page 68: Line Status Signals

    Operating Instructions - Section 30 7/09 OM3050 Page 30-14 Line status signals Trolley disconnect Line status signals are lights that advise operators Trucks operating on trolley assist may be rejected whether segments of trolley lines are energized and from a trolley assist line for several reasons. They ready to accept haulage traffic.

  • Page 69: Traffic Consideration For Trolley Line Operation

    OM3050 7/09 Operating Instructions - Section 30 Page 30-15 Traffic consideration for trolley line operation If a slower moving vehicle, traveling in front of a trol- ley assisted haulage truck, does not take the Trucks operating on trolley assist will travel faster required action allowing the faster truck to overtake, than trucks unable to operate on trolley, most support the truck will reduce speed adequately to maintain...

  • Page 70: Operating Slow Moving Vehicles On Trolley Assist Ramps

    Operating Instructions - Section 30 7/09 OM3050 Page 30-16 Operating slow moving vehicles on trolley assist Truck failure while on trolley ramps If the truck fails while on trolley, perform the following: Personnel operating any vehicle on a trolley assist 1.

  • Page 71: Using The Speed Control Feature

    OM3050 7/09 Operating Instructions - Section 30 Page 30-17 USING THE SPEED CONTROL FEATURE SAFE PARKING PROCEDURES The speed control feature functions much like cruise The operator must continue to use safety precau- control in a car. The truck must be travelling faster tions when preparing for parking and stopping the than 5 kph (3 mph) before speed control will engage, engine.

  • Page 72: Normal Engine Shutdown Procedure

    Operating Instructions - Section 30 7/09 OM3050 Page 30-18 NORMAL ENGINE SHUTDOWN NOTE: If the engine must be shut down immediately, stop the truck, shift the directional control lever to PROCEDURE PARK, turn the key switch OFF, then pull up on the The following procedure must be followed to shut the engine stop switch located in the operator cab center engine off.

  • Page 73: Sudden Loss Of Engine Power

    Dynamic retarding will not be available! DO NOT use the service brakes for continuous Allowing the Komatsu truck to operate until fuel retarding purposes. depletion lead unsafe operating 2.

  • Page 74: Towing

    Operating Instructions - Section 30 7/09 OM3050 Page 30-20 TOWING Special Wiring Harness Before towing, a special wiring harness must be made in order to release the parking brake. The harness will require approximately 9 meters (30 ft) of #14 wire, and one ON/OFF switch (capable of carrying 2 amps of current) and two ring terminals.
  • Page 75 OM3050 7/09 Operating Instructions - Section 30 Page 30-21 FIGURE 30-3. PARKING BRAKE WIRING FOR TOWING 1. Switch 3. Harness 2. Ground Wire 8. If the truck is loaded, dump the entire load. Never pull or tow a loaded truck. Refer to “Disabled Truck Dumping Procedure”.
  • Page 76 Operating Instructions - Section 30 7/09 OM3050 Page 30-22 10. Ensure the operator in the towing vehicle has 2- 15. When the desired location has been reached, way radio communications with the driver in the the operator in the towed vehicle is to apply the disabled truck.

  • Page 77: Disabled Truck Operation

    OM3050 7/09 Operating Instructions - Section 30 Page 30-23 DISABLED TRUCK OPERATION 3. Remove the plug and install the necessary QD return fittings listed in Table 2 into the QD GENERAL Return port on the bleeddown manifold. Refer to the shop manual for repair and troubleshoot- ing procedures for the hoist system components and Table 2: QD Return Fittings steering system components.

  • Page 78: Hookup

    Operating Instructions - Section 30 7/09 OM3050 Page 30-24 Hookup 5. To disconnect the hoses, stop the engine(s) on both trucks. Wait two minutes for the hydraulic 1. When the good truck is in position, stop the systems on both trucks to bleed down. Ensure engine and wait two minutes to allow the all hydraulic pressure has been relieved before hydraulic system to bleed down.

  • Page 79: Disabled Truck Dumping Procedure

    The disabled truck may relief valve located hydraulics be another Model 860E, or a different Komatsu components cabinet behind the cab. While electric drive truck model. counting the number of turns, slowly turn the relief valve adjustment screw clockwise until Hookup it bottoms.

  • Page 80: Lowering The Body

    Operating Instructions - Section 30 7/09 OM3050 Page 30-26 Lowering the Body 1. Place the hoist lever of the good truck in FLOAT to lower the body. If necessary, momentarily place the hoist control in POWER UP until the body is able to descend in FLOAT. Do not accelerate the engine.

  • Page 81: Reserve Engine Oil System

    OM3050 7/09 Operating Instructions - Section 30 Page 30-27 RESERVE ENGINE OIL SYSTEM 5. The oil level in the reserve tank must also be checked at every shift change. Oil must be The reserve oil tank for the engine is designed to add visible in lower sight gauge (12).
  • Page 82 Operating Instructions - Section 30 7/09 OM3050 Page 30-28 NOTES:...

  • Page 83: Operator Cab And Controls

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-1 OPERATOR CAB AND CONTROLS FIGURE 32-1. CAB INTERIOR - OPERATOR VIEW 1. Steering Wheel 6. Instrument Panel 11. Radio/CD Player 2. Retarder/Service Brake Pedal 7. Status Indicator Lights 12. Air Cleaner Restriction Gauges 3.

  • Page 84: Steering Wheel And Controls

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-2 STEERING WHEEL AND CONTROLS Multi-Function Turn Signal Switch Horn Button Activate the horn by pushing button (2, Figure 32-2) in the center of steering wheel (1). Ensure that the horn operates before moving the truck.

  • Page 85: Dynamic Retarding

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-3 DYNAMIC RETARDING Dynamic Retarder/Service Brake Pedal Retarder/service brake pedal (2, Figure 32-1) is a Dynamic retarding is a braking torque (not a brake) single foot-operated pedal that controls both produced through electrical generation by the retarding and service brake functions.

  • Page 86: Grade/Speed Retard Chart

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-4 GRADE/SPEED RETARD CHART OVERHEAD PANEL COMPONENTS Grade/speed retard chart (8, Figure 32-1 and shown The components described below are located on the below) provides recommended MAXIMUM overhead panel. Refer to Figure 32-1. retarding limits at various truck speeds and grades Speakers with a fully loaded truck.

  • Page 87: Center Console

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-5 CENTER CONSOLE When the key switch is ON, and the control lever is in PARK, parking brake indicator light (2, Figure 32-9) on the instrument panel will be illuminated. The directional control lever must be in PARK to start the engine.

  • Page 88: Override/Fault Reset Switch

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-6 Override/Fault Reset Switch L.H. Window Control Switch R.H. Window Control Switch This push-button switch (3, Figure 32-3) is spring- loaded to the OFF position. When pushed in and Control switches (5) and (6, Figure 32-3) are spring- held, this switch may be used for several functions.

  • Page 89: Ashtray

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-7 DIAGNOSTIC PORTS Ashtray Ashtray (8, Figure 32-3) is to be used for Drive System #1 extinguishing and depositing smoking materials only. Diagnostic port (1, Figure 32-4) is used to access Ensure that all ashes are extinguished.

  • Page 90: Operator's Seat

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-8 OPERATOR’S SEAT 8. Suspension Dampener - Adjust suspension dampener (8) to obtain the desired stiffness of The operator's seat provides a fully adjustable the adjustable shock absorber. Move the lever cushioned ride for driver comfort and easy operation.

  • Page 91: Passenger Seat (Standard Seat)

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-9 PASSENGER SEAT (STANDARD SEAT) The passenger seat provides a fully adjustable cushioned ride for driver comfort and easy operation. Seat Belts • On both driver and passenger seats, check the seat belt fabric, buckle, all belt retractors and hardware for damage or wear.

  • Page 92: Heater/Air Conditioner Compartment And Controls

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-10 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS The heater/air conditioner compartment contains Heater/Air Conditioner Vents heater/air conditioner controls and some of the Heater/air conditioner vents (6, Figure 32-7) may be heater/air conditioner components, such as the rotated 360°.

  • Page 93: Instrument Panel

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-11 INSTRUMENT PANEL The operator must understand the function and operation of each instrument and control. Control functions are identified with "international" symbols that the operator should learn to recognize immediately. This knowledge is essential for proper and safe operation.
  • Page 94 Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-12 FIGURE 32-8. INSTRUMENT PANEL GAUGES, INDICATORS AND CONTROLS 1. Key Switch 14. Hydraulic Oil Temperature Gauge 2. Speed Control Switch 15. Status Indicator Lights (amber) 3. Traction Control Switch 16.

  • Page 95: Key Switch

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-13 Key Switch Retarding Grid Drier Switch Key switch (1, Figure 32-8) is a four-position (ACC, Retarding grid drier switch (4, Figure OFF, RUN, START) switch. The ACC position is not 32-8) is a rocker switch.

  • Page 96: Wheel Brake Lock Switch

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-14 Wheel Brake Lock Switch Hazard Warning Lights Wheel brake lock switch (6, Figure Hazard warning light switch (8, Figure 32-8) should be used with engine 32-8) flashes all the turn signal lights. running for dumping and loading Pressing the bottom side of the rocker operations only.

  • Page 97: Speedometer/Digital Display

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-15 Speedometer/Digital Display Headlight/Panel Illumination Light Switch Speedometer/digital display (12, Figure 32-8) has instrument panel lights, several functions: clearance lights, and the headlights are controlled by this three-position • The analog speedometer indicates the truck rocker type switch (16, Figure 32-8).

  • Page 98: Mode Switches

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-16 Mode Switches Right/Left Turn Signal Indicators Mode switches (20) and (21, Indicators (23, Figure 32-8) illuminate to indicate that Figure 32-8) two-way the right or left turn signals are operating when the momentary rocker switches.

  • Page 99: Status Indicator Lights

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-17 STATUS INDICATOR LIGHTS FIGURE 32-9. STATUS INDICATOR LIGHTS 1. Body Up 9. Traction Control 2. Parking Brake Applied 10. Repair Monitor 3. Propulsion System Not Ready 11. Snapshot In Progress 4.

  • Page 100: No Propel

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-18 No Propel Wheel Brake Lock Applied Indicator light (4, Figure 32-9) will Indicator light (8, Figure 32-8) will illuminate to indicate that a fault has illuminate when the wheel brake lock occurred which has eliminated the is on.

  • Page 101: Pantograph Energized

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-19 Pantograph Energized Dynamic Retarding Indicator light (12, Figure 32-9) will Indicator light (15, Figure 32-9) illuminate when the pantograph is illuminates whenever the retarder fully extended and is receiving power pedal is operated or the automatic from the electrical lines.

  • Page 102: Digital Display Operation

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-20 DIGITAL DISPLAY OPERATION Toggling Through Main Level Screens Standard Screens Notes: If a switch having no defined function for the current mode is actuated, the message "INVALID ENTRY" < will be displayed on the screen while the switch is being pressed.

  • Page 103: Toggling Through Warning Screens

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-21 Toggling Through Warning Screens Warning Screens Note: If a switch having no defined function for the current mode is actuated, the message "INVALID ENTRY" will be displayed on the screen while the switch is being pressed.

  • Page 104: Entering Payload Meter Data

    Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-22 Entering Payload Meter Data Data Entry Detail (Sublevel 2) Note: If a switch having no defined function for the current mode is actuated, the message "INVALID ENTRY" will be displayed on the screen while the switch is being pressed.

  • Page 105: Rear Axl Light Bar

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-23 REAR AXLE LIGHT BAR FIGURE 32-10. REAR AXLE LIGHT BAR 1. Backup Lights 3. Brake Lights 2. Retard Lights 4. Backup Alarm NOTE: The brake light is functional at all times Brake Light regardless of key switch position.

  • Page 106: Komtrax Plus

    Proper operation of the system is dependent on utilizing Orbcomm controller (1, Figure 32-12), if good reception. Operating in tunnels, mountain equipped. This data is then compiled at the Komatsu ranges and covered areas may prevent communi- computer server. Based on this information, the cation of the system.
  • Page 107 OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-25 During normal truck operation, the red LED digits on NOTE: The ORBCOMM modem installed from the the KOMTRAX Plus controller will count from 1-99 factory on all new trucks may not be approved for continuously.

  • Page 108: Basic Precautions

    If there is any abnormality with the KOMTRAX Plus controller. When the key switch is ON, the light system, consult the servicing Komatsu distributor. should be blinking. If the light is continuously illuminated, there is a problem in the controller.

  • Page 109: Fuses And Circuit Breakers

    OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-27 FUSES AND CIRCUIT BREAKERS The circuit breakers are located on the relay boards on the left inside wall of the auxiliary control cabinet. The fuses are located in three fuse blocks in the auxiliary control cabinet.
  • Page 110 Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-28 FUSE BLOCK #1 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT A/C, Heater Blower Motor Windshield Washer / Wiper Instrument Panel Gauges 712G Key Switch Power 712P Hoist Limit Switch 712H Turn Signal / Clearance Lights 712T Engine Options 712E...
  • Page 111 OM3232 8/11 Operator Cab And Controls - Section 32 Page 32-29 FUSE BLOCK #2 LOCATION AMPS DEVICES(S) PROTECTED CIRCUIT Engine Service Lights 11SL Cab Dome, Fog, Ladder Lights, Rotating Beacon Hazard Lights Interface Module 11INT Display Module 11DISP Modular Mining Hub VHMS &...
  • Page 112 Operator Cab And Controls - Section 32 8/11 OM3232 Page 32-30 The following circuit breakers are located on the relay boards on the left inside wall of the auxiliary control cabinet. Location Amps Devices protected Circuit RB1 - CB13 12.5 Turn Signals / Clearance Lights 11CL RB1 - CB14...

  • Page 113: Lubrication And Service

    For adjustments to these devices, refer to Section 42, Automatic Lubrication System. 860E-1K SERVICE CAPACITIES U.S. Component/System Liters Gallons Crankcase Komatsu SSDA16V160 Engine Cooling System Komatsu SSDA16V160 Engine Hydraulic System 1325 Refer to “Hydraulic Tank Service” Wheel Motors (each side) FIGURE 40-1. HYDRAULIC TANK SERVICE...

  • Page 114: Cooling System Service

    Lubrication and Service - Section 40 9/11 OM4057 Page 40-2 COOLING SYSTEM SERVICE Coolant Specifications • For ambient temperatures of -32° C (-25° F) and Check the coolant level sight gauge. If coolant above, use a standard 50/50 anti-freeze-to-water cannot be seen in the sight gauge, add coolant to the mixture.

  • Page 115: Reserve Engine Oil System

    OM4057 9/11 Lubrication and Service - Section 40 Page 40-3 RESERVE ENGINE OIL SYSTEM Oil should always be visible in the bottom sight gauge. If not, add oil to the reserve oil tank until oil is The reserve oil tank for the engine is designed to add visible in the top sight gauge.

  • Page 116: Quick Fill Service Center

    Lubrication and Service - Section 40 9/11 OM4057 Page 40-4 QUICK FILL SERVICE CENTER The service center can be located on either side of Table 1: Maximum Fill Pressures the machine (Figure 40-4) and is used to fill system Fill System fluids.
  • Page 117 OM4057 9/11 Lubrication and Service - Section 40 Page 40-5...

  • Page 118: 10 Hour (Daily) Inspections

    Lubrication and Service - Section 40 9/11 OM4057 Page 40-6 10 HOUR (DAILY) INSPECTIONS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS 1. MACHINE - Inspect the entire machine for leaks, worn parts and damage. Repair as necessary. 2.
  • Page 119 Komatsu SDA16V160 or SSDA16V160 Engines: ....625 mm (25 in.) of water vacuum. Refer to the shop manual for servicing instructions for the air cleaner elements.
  • Page 120 Lubrication and Service - Section 40 9/11 OM4057 Page 40-8 10 HOUR (DAILY) INSPECTIONS (Cont.) 11. FUEL FILTERS (Water Separators) - Drain water from the bottom drain valve on each Stage 1 fuel separator. See Figure 40-6. 12. AUTO LUBE SYSTEM a.

  • Page 121: Initial 50 Hour Lubrication And Maintenance Checks

    OM4057 9/11 Lubrication and Service - Section 40 Page 40-9 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS Truck Serial Number______________________ Site Unit Number_______________ Date_______________ Hourmeter_____________ Name of Service Technician___________________________________ TASK COMMENTS CHECKED INITIALS *1. FUEL FILTERS - Change the Stage 1 and Stage 2 fuel filters.

  • Page 122: 250 Hour Lubrication And Maintenance Checks

    Lubrication and Service - Section 40 9/11 OM4057 Page 40-10 250 HOUR LUBRICATION AND MAINTENANCE CHECKS All 10 Hour (Daily) Inspections should also be performed at this time. NOTE: “Lube Key” references are to the Lubrication Chart on page 40-5. Truck Serial Number______________________ Site Unit Number_______________ Date_______________...
  • Page 123 OM4057 9/11 Lubrication and Service - Section 40 Page 40-11 250 HOUR LUBRICATION AND MAINTENANCE (Cont.) TASK COMMENTS CHECKED INITIALS COOLING SYSTEM a. COOLANT MIXTURE - Check for proper coolant mixture. Add coolant as required. b. COOLANT FILTERS - Change coolant filters. c.
  • Page 124 Lubrication and Service - Section 40 9/11 OM4057 Page 40-12 250 HOUR LUBRICATION AND MAINTENANCE (Cont.) 10. REAR AXLE HOUSING - Check the rear axle housing for oil leaks by removing the two drain plugs on the bottom of the axle housing. If oil is present, the cause of the leak must be found and corrected before operating the truck.

  • Page 125: 500 Hour Lubrication And Maintenance Checks

    OM4057 9/11 Lubrication and Service - Section 40 Page 40-13 500 HOUR LUBRICATION AND MAINTENANCE CHECKS All 10 Hour (Daily) Inspections and 250 Hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key” references are to the Lubrication Chart on page 40-5. Truck Serial Number______________________ Site Unit Number_______________ Date_______________...
  • Page 126 Lubrication and Service - Section 40 9/11 OM4057 Page 40-14 500 HOUR LUBRICATION AND MAINTENANCE (Cont.) 8. BLADDER ACCUMULATORS - Check the precharge pressure. Failure to maintain the correct precharge pressure may result in bladder failures. 9. HVAC a. Ensure the air conditioner cab drains are clear of any obstructions.

  • Page 127: 1,000 Hours Lubrication And Maintenance Checks

    OM4057 9/11 Lubrication and Service - Section 40 Page 40-15 1,000 HOURS LUBRICATION AND MAINTENANCE CHECKS All 10 Hour (Daily) Inspections, 250 Hour Lubrication and Maintenance Checks, and 500 Hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key”...
  • Page 128 Lubrication and Service - Section 40 9/11 OM4057 Page 40-16 1,000 HOURS LUBRICATION AND MAINTENANCE CHECKS (cont.) TASK COMMENTS CHECKED INITIALS 7. INVERTER CABINET RADIATOR COOLING PUMP - Add one or two applications of grease to each bearing grease fitting. Ensure that each bearing is receiving grease.

  • Page 129: 2,000 Hour Maintenance Checks

    OM4057 9/11 Lubrication and Service - Section 40 Page 40-17 2,000 HOUR MAINTENANCE CHECKS All 10 Hour (Daily) Inspections, 250 Hour Lubrication and Maintenance Checks, 500 Hour Lubrication and Maintenance Checks, and 1000 Hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key”...

  • Page 130: 5,000 Hour Maintenance Checks

    Lubrication and Service - Section 40 9/11 OM4057 Page 40-18 5,000 HOUR MAINTENANCE CHECKS All 10 Hour (Daily) Inspections, 250 Hour Lubrication and Maintenance Checks, 500 Hour Lubrication and Maintenance Checks, and 1000 Hour Lubrication and Maintenance Checks should also be performed at this time. NOTE: “Lube Key”...

  • Page 131: Automatic Lubrication System

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-1 AUTOMATIC LUBRICATION SYSTEM GENERAL DESCRIPTION The reciprocating action causes the pump cylinder to move up and down. The pump is a positive The automatic lubrication system is a pressurized displacement, double-acting type as grease output lubricant delivery system which delivers a controlled occurs on both the up and the down stroke.
  • Page 132 Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-2 FIGURE 42-2. AUTOMATIC LUBRICATION SYSTEM INSTALLATION 1. L.H. Suspension, Bottom Bearing 13. R.H. Suspension, Top Bearing 2. L.H. Hoist Cylinder, Bottom Bearing 14. R.H. Body Pivot Pin 15. Truck Frame 3.

  • Page 133: System Components

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-3 SYSTEM COMPONENTS Filter Assembly Flow Control Valve Filter assembly (21, Figure 42-2), mounted on the Flow control valve (10, Figure 42-1), mounted on the grease reservoir, filters the grease prior to refilling the manifold, controls the amount of oil flow to the reservoir from the shop supply.

  • Page 134: System Operation

    Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-4 SYSTEM OPERATION 6. When grease pressure reaches the setting of pressure switch (18, Figure 42-2), the switch 1. During truck operation, the lubrication cycle contacts will close and energize relay RB7-K8, logic (in the interface module) will energize the disconnecting ground...

  • Page 135: General Instructions

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-5 GENERAL INSTRUCTIONS Required Lubricant Grease requirements will depend on ambient temperatures encountered during truck operation: • Above 32°C (90°F) - NLGI No. 2 multipurpose grease (MPG). • -32° to 32°C (-25° to 90°F) - Use NLGI No. 1 multipurpose grease (MPG).

  • Page 136: Lubricant Pump

    Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-6 LUBRICANT PUMP Pump Housing Oil Level The pump housing must be filled to the proper level with SAE 10W-30 motor oil. Check the oil level at at the 1,000 hour maintenance interval. To add oil, remove dipstick (4, Figure 42-5) on top of the pump housing and fill the housing to the proper level marked on the dipstick.

  • Page 137: Injectors (Sl-1 Series "H")

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-7 INJECTORS (SL-1 Series “H”) Injector Specifications Each lube injector services only one grease point. In case of pump malfunction, each injector is equipped with a covered grease fitting to allow the use of external lubricating equipment.

  • Page 138: Injector Operation

    Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-8 INJECTOR OPERATION STAGE 1. The injector piston (2) is in its normal or “rest” position. The discharge chamber (3) is filled with lubricant from the previous cycle. Under the pressure of incoming lubricant (6), the slide valve (5) is about to open the passage (4) leading to the measuring chamber...

  • Page 139: Preventive Maintenance Procedures

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-9 PREVENTIVE MAINTENANCE PROCEDURES Use the following maintenance procedures to ensure 4. Inspect all bearing points for a bead of lubricant proper system operation. around the bearing seal. NOTE: It is good practice to manually lube each Daily Lubrication System Inspection bearing point at the grease fitting provided on each 1.

  • Page 140: System Checkout

    Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-10 SYSTEM CHECKOUT Main Level Screens To check system operation, proceed as follows: Screen 1 Load = 240 t 1. Remove the dust covers from the injectors. LC = 25 TT = 6000 t <...

  • Page 141: System Troubleshooting Chart

    OM4212 10/10 Automatic Lubrication System - Section 42 Page 42-11 SYSTEM TROUBLESHOOTING CHART NOTE: If the following procedures do not correct the problem, contact a factory authorized service center. TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Lube system not grounded. Correct grounding connections to pump assembly and truck chassis.
  • Page 142 Automatic Lubrication System - Section 42 10/10 OM4212 Page 42-12 TROUBLE POSSIBLE CAUSES SUGGESTED CORRECTIVE ACTION Pump Pressure Builds No signal at solenoid. Check wiring for open circuit. Also check Very Slowly Or Not At All for fault codes on dash panel display. Turn on electric power to pump.

  • Page 143: Components & Specifications

    AC Electric Drive. The gross vehicle weight comfort and to allow for efficient and safe operation of is 454 363 kg (1,001,700 lbs). The engine is a Komatsu the truck. The cab is rubber-mounted to reduce noise SSDA16V160 rated @ 2700 HP (2014 kW).
  • Page 144 Components & Specifications - Section 5 5/11 OM5049 Page 50-2 FIGURE 30-1. TOP VIEW 1. Operator Cab 8. Wet Disc Brake 15. Wet Disc Brake 21. Hydraulic Tank 2. Auto Lubrication 9. Brake Accumulators 16. Wheel Motor Trans- 22. Steering Pump 3.

  • Page 145: Specifications

    Components & Specifications - Section 5 Page 50-3 SPECIFICATIONS These specifications are for the standard Komatsu 860E Dump Truck. Customer options may change this listing. ENGINE Komatsu SSDA16V160 No. of Cylinders ................16 Operating Cycle .
  • Page 146 Components & Specifications - Section 5 5/11 OM5049 Page 50-4 HYDRAULIC SYSTEMS Hoist and Brake Cooling Pump ........... . . Tandem Gear Rating .
  • Page 147 Rear Axle ( 66.5%) ..301 971 kg (665,829 lbs) Max. Nominal Payload* . . 254 012 kg (560,000 lbs) NOTE: All weights shown with 100% fuel load. * Nominal payload is defined within Komatsu America Corporation’s payload policy documentation.
  • Page 148 Components & Specifications - Section 5 5/11 OM5049 Page 50-6...

  • Page 149: Payload Meter Iii

    OM6012 2/11 Payload Meter III - Section 60 Page 60-1 PAYLOAD METER III™ INTRODUCTION Payload Meter III (PLMIII) measures, displays and records the weight of material being carried by an off-highway truck. The system generally consists of a payload meter, a gauge display, deck-mounted lights, and sensors. The primary sensors are four suspension pressures and an inclinometer.
  • Page 150 Payload Meter III - Section 60 2/11 OM6012 Page 60-2 COMPONENT DESCRIPTION System Diagram Suspension Pressure Sensors Speedometer/Load Display PLMIII uses a two-wire pressure sensor. The range speedometer/load display is used as a speedometer and as a payload information display. for the pressure sensor is 281 kg/cm (4000 psi) and The top display is used for speed and can display...
  • Page 151 The brake lock is used to lock the rear brakes on the uses a 3-wire hardware connection. Connections to truck. It is necessary for the accurate calculation of this serial port need to be approved by Komatsu. swingloads during the loading process. Without the Several protocol options are available and detailed...
  • Page 152 Payload Meter III - Section 60 2/11 OM6012 Page 60-4 Key Switch Input Load Lights PLMIII monitors the status of the key switch. 24VDC PLMIII uses load lights to indicate to the shovel indicates that the key switch is on. Open indicates operator the approximate weight of the material in the key switch is off.
  • Page 153 OM6012 2/11 Payload Meter III - Section 60 Page 60-5 LOAD DISPLAY AND OPERATOR Total Ton and Total Load Counters SWITCHES PLMIII allows the truck operator to monitor and track the total tons hauled and the number of haul cycles The top display on the speedometer/load display is during the shift.
  • Page 154 Payload Meter III - Section 60 2/11 OM6012 Page 60-6 PAYLOAD OPERATION & CALCULATION The inclinometer displays whole degrees of incline. Positive incline is truck nose up. The gauge will Description of Haul Cycles quickly display the type of information shown every 10 seconds.
  • Page 155 OM6012 2/11 Payload Meter III - Section 60 Page 60-7 The payload meter switches from loading state to Load Calculation maneuvering state as soon as the truck begins The final load calculation is different from the last moving. The maneuvering zone is 160m (0.1 mile) swingload calculation.
  • Page 156 Payload Meter III - Section 60 2/11 OM6012 Page 60-8 SOURCES FOR PAYLOAD ERROR Loading Conditions The final load calculation of the PLMIII system is not Suspensions sensitive to loading conditions. The final load is The number one source of error in payload calculated as the truck travels away from the shovel.
  • Page 157 OM6012 2/11 Payload Meter III - Section 60 Page 60-9 HAUL CYCLE DATA C: No Final Load This message is generated when the payload meter PLMIII records and stores data in its on-board flash is unable to determine the final payload in the truck. memory.
  • Page 158 Payload Meter III - Section 60 2/11 OM6012 Page 60-10 K: New Tare Not Calculated Frame Torque Data The payload meter was not able to accurately Payload meter records the top five peak positive and calculate a new empty sprung weight for the truck to negative frame torque values and the time they use as the tare value for the haul cycle.
  • Page 159 OM6012 2/11 Payload Meter III - Section 60 Page 60-11 Table 1: HAUL CYCLE DATA Data Unit Remark Truck # alpha- Up to 22 characters can be stored in this field to identify the truck. Typically this field will be just numeric the truck number.
  • Page 160 Payload Meter III - Section 60 2/11 OM6012 Page 60-12 Alarm Records code has a specific cause and should lead to an investigation for correction. Some failures can be The payload meter stores alarm records to give overcome by the payload meter. Haul cycle data will service personnel a working history of the system.
  • Page 161 OM6012 2/11 Payload Meter III - Section 60 Page 60-13 PDM SOFTWARE OVERVIEW DOWNLOADING DATA The Payload Data Management (PDM) software has PLMIII records many types of data. The PDM several basic functions: software is designed to download the data from a whole truck fleet.
  • Page 162 Payload Meter III - Section 60 2/11 OM6012 Page 60-14 PLM III SYSTEM CONFIGURATION Click “Done” to return to the main menu. From the main menu, select "Connect to Payload Meter". The Starting Communications computer will try to connect to the payload meter and request basic information from the system.
  • Page 163 OM6012 2/11 Payload Meter III - Section 60 Page 60-15 Connecting to the Payload Meter Setting the Date and Time Communications to the PLMIII requires a laptop computer running the PDM software. The software connects to the payload meter through the meter's serial port #1.
  • Page 164 This field in the haul cycle record can hold the name The payload units on the lower display can be of the Komatsu distributor that helped install the changed from metric to short tons or long tons using system. Komatsu also assigns a distributor number the Truck Configuration screen.
  • Page 165 OM6012 2/11 Payload Meter III - Section 60 Page 60-17 Clean Truck Tare Inclinometer Calibration The payload meter uses the clean truck tare value to The inclinometer calibration procedure is designed to calculate carry-back load for each haul cycle. The compensate for variations in the mounting attitude of carry-back stored in the haul cycle record is the new the inclinometer.
  • Page 166 The truck type is the size of the truck from the family to view and for what dates and times. of Komatsu trucks. This allows the user to quickly The query items are added in the "AND" condition. If view results from different models of trucks on the the user selects a truck # and date range, the query property.
  • Page 167 OM6012 2/11 Payload Meter III - Section 60 Page 60-19 Sorting on Date Range Sorting on Time Range The default query starts in 1995 and runs through the The time range sorts the times of the day for valid current date on the computer. To narrow the range to dates.
  • Page 168 Payload Meter III - Section 60 2/11 OM6012 Page 60-20 This query will display haul cycles from January 5 to Payload Detail Screen January 8, from 6:00 AM to 6:00 PM. The Payload Detail screen gives the details for any Date individual haul cycle.
  • Page 169 OM6012 2/11 Payload Meter III - Section 60 Page 60-21 Creating Reports Reports can be generated and viewed on-screen or printed. These reports are generated from the query displayed on the Payload Summary screen. From the example in Sorting on Time Range, the report printed would only contain data from truck 374 during the month of July 2000, from 8:00 AM to 5:00 PM.
  • Page 170 Payload Meter III - Section 60 2/11 OM6012 Page 60-22 Creating Graphs Exporting Data The PDM software can generate graphs that quickly summarize payload data. These graphs can be customized for printing. Just like the reports, the graphs are generated from the query displayed on the “Payload Summary”...
  • Page 171 OM6012 2/11 Payload Meter III - Section 60 Page 60-23 The second set of data below the haul cycle data is Two sets of data are exported. At the top of the file the alarms. The alarm columns, left to right are: will be the haul cycle data.
  • Page 172 Payload Meter III - Section 60 2/11 OM6012 Page 60-24 Importing Data Viewing Alarms From the Payload Summary screen, click on the This import function allows the data from one “Alarms” button to display the alarm screen. The computer to be transferred to another computer. This alarms are sorted by the query settings from the can be useful when a service laptop is used to Payload Summary screen.
  • Page 173 OM6012 2/11 Payload Meter III - Section 60 Page 60-25 NOTES...
  • Page 174 Payload Meter III - Section 60 2/11 OM6012 Page 60-26 NOTES...

  • Page 175: Radio/Cd Player

    OM7007 Radio / CD Player - Section 70 Page 70-1 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER FIGURE 70-1. AM/FM RADIO / CD PLAYER 12. OK - Enables selection on a menu - Turns the radio on or off 13.

  • Page 176: Adjusting The Volume

    Radio / CD Player - Section 70 OM7007 Page 70-2 Adjusting the Volume MP3/USB/iPod Mode Displays To increase volume, rotate the ON/AUDIO knob When playing MP3 or WMA files, press the “i Title/ clockwise. To decrease volume, rotate the knob Menu”...

  • Page 177: Aux Input Displays

    OM7007 Radio / CD Player - Section 70 Page 70-3 If RDM is pressed once, RANDOM FOLDER/PLST CLOCK/ALARM Button will appear and the RDM icon will turn on. Then the In any mode, pressing the CLOCK/ALARM button, display returns to its default. In iPod mode, the dis- the display will show the time for 3 seconds.

  • Page 178: Adjusting The Receiver Menu Settings

    Radio / CD Player - Section 70 OM7007 Page 70-4 TREBLE: Rotate the ON/AUDIO knob clockwise to ADVANCED: Rotate the ON/AUDIO knob or press increase the treble sound and counterclockwise to up/down button to select one of the following options: decrease it.

  • Page 179: Using The Radio

    OM7007 Radio / CD Player - Section 70 Page 70-5 USING THE RADIO SCAN: Press SCAN/PSCAN and release to scan all stations on the band that are being used. When a Finding a Station strong enough frequency is found, the radio will play for 8 seconds before continuing to scan.

  • Page 180: Using The Clock

    Radio / CD Player - Section 70 OM7007 Page 70-6 USING THE CLOCK USING THE ALARM The clock can function in a 12-hour or 24-hour mode. The alarm activates the radio at a set time. Pressing The 12-hour mode distinguishes between AM and the CLOCK/ALARM button for more than 2 seconds PM.

  • Page 181: Turning The Alarm Off

    OM7007 Radio / CD Player - Section 70 Page 70-7 USING THE WEATHERBAND (USA Only) If SET MUS is selected, the alarm sound will be whatever was playing when the radio was turned NOAA Weather Radio is a service of the U.S. OFF.

  • Page 182: Using The Compact Disc Player/Usb

    Radio / CD Player - Section 70 OM7007 Page 70-8 USING THE COMPACT DISC PLAYER/USB SEEK : Press for less than 2 seconds to go to the beginning of the current track. If pressed within The integrated CD player plays full size CDs, MP3 the first 10 seconds of the track, the radio goes to the and WMA discs.

  • Page 183: Playing An Mp3 Disc/Usb

    OM7007 Radio / CD Player - Section 70 Page 70-9 PLAYING AN MP3 DISC/USB PLAYING MP3 FILES The MP3 player will play files recorded on a CD-R up DISC: Insert a disc partway into the slot, label-side to 700 MB or on a USB stick of up to 1 GB. Files can up.

  • Page 184: Using An Ipod

    Radio / CD Player - Section 70 OM7007 Page 70-10 USING AN iPOD® 5/RDM: Pressing the RDM button activates random folder/playlist. The RDM icon on the display indicates The radio is capable of controlling and playing music that this feature is on. To cancel RANDOM FOLDER/ from some models of iPods.

  • Page 185: Operating Tips

    OM7007 Radio / CD Player - Section 70 Page 70-11 OPERATING TIPS 1/ESC: Press the ESC button to exit or go back to previous menu when in a menu. Tips About The Audio System 2/PAUSE/PLAY: Press the PAUSE/PLAY button to Hearing damage from loud noise is almost undetect- pause a track.

  • Page 186: Troubleshooting

    Radio / CD Player - Section 70 OM7007 Page 70-12 TROUBLESHOOTING NOTE: Sound quality, skipping, difficulty in finding tracks, and/or difficulty in loading or ejecting a CD-R The following error messages may appear while may be affected by a CD-R’s quality, the method of playing a CD, MP3 disc/USB, iPod: recording, the quality of the music that has been NO CD:...
  • Page 188 ® www.komatsuamerica.com Copyright 2011 Komatsu Komatsu America Corp. Printed in USA 2300 N.E. Adams Street Peoria, IL 61639 Phone: 309-672-7577 Fax: 309-672-7072...

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