Komatsu 860E-1KT - User Manual

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Overview

Maintenance Features

The Komatsu 860E-1KT is an off-highway, rear dump truck with an AC Electric Drive system, designed for mining operations. It has a gross vehicle weight of 454,363 kg (1,001,700 lbs) and is powered by a Komatsu SSDA16V160 engine rated at 2700 HP (2014 kW) at 1900 RPM. The flywheel HP is 2550 HP (1902 kW) at 1900 RPM. The truck's empty vehicle weight is 200,351 kg (441,700 lbs) with a maximum nominal payload of 254,012 kg (560,000 lbs).

AC Electric Drive System: The diesel engine drives an in-line alternator (DRLDZ5010-AL) which produces AC current, rectified to DC within the main control cabinet. This DC power is then converted back to AC by inverters, each consisting of six phase modules with insulated gate bipolar transistors (IGBTs). These IGBTs cycle on and off at varying frequencies to create a variable-voltage, variable-frequency (VVVF) AC power signal for the two wheel motors attached to the rear axle housing. Cooling air for the control/power group, wheel motors, and alternator is provided by a main blower. The standard gear ratio for the motorized wheels is 35.526:1, allowing a maximum speed of 64.5 km/h (40 mph).

Dynamic Retarding: The truck features electric dynamic retarding, which is used to slow the truck and control speed on grades. It has a continuously rated high-density blown grid system with retard at engine idle and retard in reverse propulsion, capable of 3469 kW (4650 HP). The operator controls retarding via a pedal in the cab and a Retarder Speed Control (RSC) system. Dynamic retarding is automatically activated if the truck speed exceeds a preset overspeed setting.

Brake System: Service brakes at each wheel are oil-cooled multiple disc brakes with all-hydraulic actuation. Depressing the brake pedal applies both front and rear brakes after first applying the retarder. All wheel brakes are automatically applied if the brake system pressure drops below a preset minimum. The maximum apply pressure is 16,545 kPa (2,400 psi). The parking brake is a wet disc type, integral to the service brakes, spring-applied and hydraulically released, with wheel speed application protection to prevent engagement while the truck is moving.

Steering System: The truck is equipped with a full-time power steering system using twin hydraulic cylinders with accumulator assist, providing constant rate steering with minimum operator effort. Nitrogen-charged accumulators automatically provide emergency power steering if hydraulic pressure is reduced below a minimum. The turning circle (SAE) is 31.1 m (102 ft. 0 in.).

Hydraulic System: The hydraulic system includes a hoist and brake cooling pump (tandem gear, 931 L/min (246 gpm) at 1900 RPM and 17,237 kPa (2,500 psi)) and a steering/brake pump (pressure compensated piston, 246 L/min (65 gpm) at 1900 RPM and 18,961 kPa (2,750 psi)). Relief pressures are 17,237 kPa (2,500 psi) for hoist and 18,961 kPa (2,750 psi) for steering/brake. The system uses 3-stage hydraulic hoist cylinders and a non-pressurized tank with a capacity of 947 liters (250 gallons). Filtration is achieved through in-line replaceable elements (single, full flow, 100 mesh for suction, and Beta 12 Rating=200 for hoist and steering filters).

Tires: The truck uses radial tires (standard) of rock service, deep tread type, and tubeless flange mount rims.

Dump Body: Standard dump body capacities are 169 m³ (221 yd³) heaped at 2:1 (SAE) and 122 m³ (160 yd³) struck. The dump body has a width (front inside) of 7.64 m (25 ft. 1 in.), a depth of 7.87 m (25 ft. 10 in.), a loading height of 6.38 m (20 ft 11 in.), and a dumping angle of 45°. Optional capacity dump bodies are available.

Operator's Cab: The cab is rubber-mounted to reduce noise and vibration, offering wide visibility with an integral 4-post ROPS/FOPS structure. It features a tinted safety-glass windshield, power-operated side windows, a deluxe interior with a fully adjustable seat with lumbar support, and a fully adjustable/tilt steering wheel. Controls are within easy reach, and a digital/analog instrument panel provides all necessary instruments and gauges.

Payload Meter III (PLMIII): This system measures, displays, and records material weight. It consists of a payload meter, a gauge display, deck-mounted lights, and sensors (four suspension pressures and an inclinometer). It records 5208 haul cycles, including payload, operator ID, distance traveled, time spent in various states (empty run/stop, loading, loaded run/stop, dumping), maximum and average speeds, empty carry-back load, haul-cycle start time, peak positive and negative frame torque, and tire ton-mph. Lifetime data, including top 5 maximum payloads, frame torque, and speeds, is also stored. The system can be configured via Windows software for truck type, ID, and display units (metric or English).

Automatic Lubrication System: This pressurized lubricant delivery system delivers controlled amounts of lubricant to designated lube points. It is controlled by an electronic timer that signals a solenoid valve to operate a hydraulic motor-powered grease pump, with hydraulic oil supplied from the truck's steering circuit. Grease output is proportional to the hydraulic motor input flow. The system uses SL-1 Series "H" injectors, adjustable from 0.13 - 1.31 cc (0.008 - 0.08 in³) per injection cycle, with an operating pressure range of 12,755 kPa (1850 psi) to 24,133 kPa (3500 psi). A pressure switch monitors grease pressure, activating a warning system if pressure is not achieved. The system includes a filter assembly, pressure reducing valve, flow control valve, solenoid valve, and vent valve. The grease reservoir has an approximate capacity of 41 kg (90 lb).

KOMTRAX Plus System: This system gathers truck operation data from sensors and controllers via a KOMTRAX Plus controller. Data can be downloaded by computer or transmitted via Orbcomm satellite. This data is compiled at a Komatsu server to suggest improvements and provide information to reduce machine repair costs and downtime. The Orbcomm antenna adds 410 mm (16.2 in.) to the machine's height (260 mm (10.2 in.) with guard). The system transmits at 5-10 Watts in the 148-150 MHz frequency range.

Maintenance Features:

10 Hour (Daily) Inspections: Include checking for leaks, worn parts, damage, turbocharger condition, coolant level, engine oil level (sump and reserve tank), exhaust piping, fluid leaks, eliminator filter, hydraulic tank oil level, tire wear and inflation, embedded debris, wheel mounting hardware, cooling air ductwork, drive system coolant, and wiper/washer condition.
Initial 50 Hour Checks: Include changing Stage 1 and 2 fuel filters, replacing hydraulic system filter elements, and checking torque for fan mounting cap screws (237 N·m (175 ft lb)).
Initial 100 Hour Checks: Include replacing hydraulic system filter elements.
250 Hour Checks: Include changing engine oil and filters (intervals extend beyond 250 hours with Centinel™ oil system and/or Eliminator™ filter system), checking cooling fan torque (237 N·m (175 ft lb)), accessory drive belt tension, fuel filters, air intake piping, coolant mixture, steering pin retaining nuts (712 N·m (525 ft lbs)), tie rod retaining nuts (420 N·m (310 ft lbs)), hydraulic pump driveshaft & U-joints, rear wheel mounting hardware, rear axle housing for oil leaks, front wheel hub for debris, wheel motor oil level and magnetic plugs, batteries, dump body pads, body-up and hoist limit switches, cab recirculation air filter, and cab air filter.
500 Hour Checks: Include replacing hydraulic tank breathers and high pressure filter elements, checking Hydair® suspension piston extension, lubricating throttle and brake pedal, checking hoist lever linkage, parking brake inspection, checking reserve engine oil system electrical connections and hoses, inspecting IGBT control box for moisture/dirt, downloading event statistics, parameter settings, motor temps, and coolant level, checking bladder accumulators precharge pressure, HVAC drains and condenser, KOMTRAX Plus data download, grid blower shaft bearings, control cabinet coolant, frame and axle box inspection, and retard grid resistors, and main blower motor and terminal box.
1,000 Hour Checks: Include draining and cleaning hydraulic tank inlet strainers, cleaning fuel tank breather, lubricating operator's seat slide rails, checking automatic brake application, main blower bearings, grid blower motor shaft bearings, inverter cabinet radiator cooling pump, IGBT control box radiator, eliminator filter, and automatic lube system pump housing oil level.
2,000 Hour Checks: Include draining and refilling wheel motor final drive oil, inspecting IGBT control box contactors (K103, K105, K109), and greasing grid blower shaft coupling.
3,000 Hour Checks: Include greasing main alternator bearings and cleaning condensation water drain holes.
5,000 Hour Checks: Include cleaning Donaclone tubes in the precleaner section of the air filter.
6,000 Hour Checks: Include greasing motorized wheel bearings (360 g (12.7 oz) per bearing), inspecting motor connections, and cleaning drainage holes.