01 - Overview 860E - AC - Mech

Welcome
Komatsu Training
Page 1 (10/07) Media # CTMDT936 860E-AC

Course Objectives
After successful completion the student will……
Understand the Features, functions and structures of the Komatsu 860E-2 Rear Dump Truck
Learn about the Safety aspects
Learn about operational aspects
Obtain a basic understanding of the Electrical system, where it interacts with Mechanicals
Understand operation and maintenance of the following systems

• Suspension
• Hydraulics
• Brakes
• Axles
• Options
Learn about all Preventative Maintenance aspects and Programs

Course Out Line and Contents
Enrollment and Introduction
860E-2 Over View
Safety and Operational Aspects
12 and 24 volt
Operators Cab
Electrical System (Non-Propulsion)
Wheels and Axles
Front and Rear Suspensions
Pay Load Meter (PLMIII)
Hydraulic System Overview
Steering system
Hoist System
Brake System
Brake Cooling
Grease System & Pantograph control
Options / Special Equipment and PM
Eliminator
Reserve
Preventative Maintenance

KOMATSU Illinois, U.S.A.
Main Products:
• Large-sized dump trucks
Komatsu America Corp.

Peoria Manufacturing Operation

Komatsu Proving Grounds – Tucson, AZ
All new prototype trucks are

tested at our Proving
Grounds. Komatsu confirms
the quality before delivering
new equipment to the market
2.25 km (1.4 mi)
X – 530 m (1755 ft) elevation
- Shop space:
-6,000 m2 (64,372 ft2).
-Cranes: 2 x 10-ton, 1 x 15-ton.
- Office space:
-1450 m2 (15,500 ft2)

PMO Products: Electric Dump Truck

KOMSATSU 860 & 960 Siemens Drive
Page 7 (10/07) Media # 860-2

KOMATSU 860 Specifications Dimensions

Specifications Lubrication

Specifications 860E Systems

Specifications Engine
Make and model Komatsu SDA16V160

Fuel Diesel
Number of cylinders 16
Operating cycle 4 stroke
Rated brake power 2700 hp (2014 kW) @ 1900 rpm
Flywheel power 2550 hp (1902 kW) @ 1900 rpm
Weight (dry) 21207 lb (9619 kg)
Specifications Drive System
SIEMENS IGBT Drive System

AC/DC Drive System
Alternator VEM Brush-less Rotor

Control SIEMENS SIBAS
Motorized wheels Siemens 3S / KAC Transmission
Ratio 35.52 : 1
Speed (maximum) 40.0 mph (64.4 km/h)
Specifications Traction Alternator
Brushless Design
8 Pole Rotor
1500V / 965A / 120 Hz
4000 kg

Specifications WHEEL MOTOR COOLING

Specifications Siemens IGBT Drive Cabinet

Specifications Motorized Wheel
KAC/Siemens 3S Wheel Motor
2327 HP max retard/wheel
1275 HP, 17000 ft.lbs propel Torque per wheel

Specifications Retard Grid Group
Continuous rated grids
14-element grids
4654 hp (3471 kw)

continuous

Specifications Main Frame

Specifications Dump Body
Canopy Sheet and Bolster Capacity
6 mm 100,000 psi (690 mPa) 150 cubic metre heaped Clay
tensile strength steel 136 cubic metre heaped Calcrete
Floor Sheet
Front Sheet
19 mm
12 mm
200,000 Psi / 1379 mPa
200,000 Psi
Bolster
12 & 10 mm floor and side. Side Sheet
8 mm front, 10mm (center) 10 mm
100,000 psi (690 mPa) tensile strength steel 200,000 Psi / 1379 m Pa

860E Electric Drive Truck

Hydraulic System

Hydraulic System Features
Common tank for steering, hoist and brake systems

Fewer components, less hydraulic hose and tubing
Reduced maintenance, simple servicing
Externally mounted filter keeps system clean, easy to service

Compensated Piston pump for steering and braking
Gear-type pump for Hoist and Brake cooling

Hydraulic Pumps
Hoist & Cooling Pump

Gear-type with output of
270 gpm (1022 liters/min)
at 1900 rpm and 2500 psi
(17.2 mPa)
Steering and Brake Pump

Piston type with an output of
66 gpm (246 liters/min) at
1900 rpm and 3050 psi
(21.0 mPa)

Hydraulic System Components
Hydraulic System
250 U.S. gal (947 L)

Hoist
3-stage, dual-acting outboard

cylinders
24 second hoist time

Steering
Accumulator-assisted twin cylinders provide constant rate

power steering and automatic emergency backup
Six-point Articulation Linkage

Steering Performance
Maneuverability
860E
97.7’ (29.7 m) Steering meets

Turning Circle SAE J1511 standards

Suspension
HYDRAIR® II Provides Smooth Ride

and excellent Handling Characteristics
Front Suspension
• Forged front suspension 15” rod
• Large casting steel mounts
• Extra-length Glass filled Nylon bearings
• Maximum front stroke 12.9” (327 mm)

Rear Suspension, rod down style
Rear suspension pin and clevis
Variable rate hydro-pneumatic with
integral rebound control
Maximum stroke 11.5” (317 mm)

Rear Axle Mounting
High Mounted Rear

Axle Hitch Pin
Maximum rear axle

oscillation ± 6.5°

Braking System
Dynamic retarding is the primary means of controlling
speed and deceleration.
Service brakes are the primary means of stopping a truck
All-hydraulic, Wet-disc mechanical service brakes are

designed to stop the truck anywhere within its performance
envelope

Front Service Brakes
Front inboard-mounted multi Wet-Disk wheel speed Service

Brakes with integral spring applied Park Brake Function

Rear Service Brakes
Rear inboard-mounted multi Wet-Disk wheel speed Service

Brakes with integral spring applied oil released Park Brake
Function which holds the 860E at max GVW on 15% grade
Emergency Brakes
Front, and rear service brakes - apply automatically when

hydraulic system pressure drops below the level necessary to
meet secondary stopping requirements

Safe and Reliable Service Brakes
• Exceeds SAE J/ISO 3450 brake performance standard
• SAE J/ISO 3450 test summary:
• Truck tested at max. GVW
• Tested on 9 % grade
• 5 consecutive stops at a speed 50 km/h
• Tests are to be run at 10 to 20 minute intervals
• Additional stop simulates worst-case single brake failure at a
speed of 25 Km/h
• Results of test: Average of 6 consecutive stops was 65% of
allowed braking distance.
65%

Cab
Highly productive
equipment starts with a
safe and comfortable
operator environment
Integral R.O.P.S
Structure
Rubber mounted for

improved sound
isolation

Cab (Cont’d)

Tires
Standard 5 piece rim

TOPY, Phase I style
Rims
60 Mounting Nuts/wheel
Rock service, tubeless

radial tires 50/80 R57

860E-AC Electric Drive Truck

End of 860E-AC Truck Review

01 - Overview 860E - AC - Mech

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Welcome

Page 1 (10/07) Media # CTMDT936 860E-AC

Learn about the Safety aspects

Learn about operational aspects

Understand operation and maintenance of the following systems

Learn about all Preventative Maintenance aspects and Programs

Page 2 (10/07) Media # CTMDT936 860E-AC

Page 3 (10/07) Media # CTMDT936 860E-AC

Komatsu America Corp.

Page 4 (10/07) Media # CTMDT936 860E-AC

All new prototype trucks are

X – 530 m (1755 ft) elevation

Page 5 (10/07) Media # CTMDT936 860E-AC

Page 6 (10/07) Media # CTMDT936 860E-AC

Page 7 (10/07) Media # 860-2

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Page 9 (10/07) Media # CTMDT936 860E-AC

Page 10 (10/07) Media # CTMDT936 860E-AC

Make and model Komatsu SDA16V160

SIEMENS IGBT Drive System

Alternator VEM Brush-less Rotor

1500V / 965A / 120 Hz

Page 14 (10/07) Media # CTMDT936 860E-AC

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KAC/Siemens 3S Wheel Motor

2327 HP max retard/wheel

1275 HP, 17000 ft.lbs propel Torque per wheel

Page 17 (10/07) Media # CTMDT936 860E-AC

Continuous rated grids

4654 hp (3471 kw)

Page 18 (10/07) Media # CTMDT936 860E-AC

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Common tank for steering, hoist and brake systems

Externally mounted filter keeps system clean, easy to service

Page 23 (10/07) Media # CTMDT936 860E-AC

Hoist & Cooling Pump

Steering and Brake Pump

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3-stage, dual-acting outboard

Page 26 (10/07) Media # CTMDT936 860E-AC

Accumulator-assisted twin cylinders provide constant rate

Six-point Articulation Linkage

Page 27 (10/07) Media # CTMDT936 860E-AC

97.7’ (29.7 m) Steering meets

Page 28 (10/07) Media # CTMDT936 860E-AC

HYDRAIR® II Provides Smooth Ride

• Large casting steel mounts

• Extra-length Glass filled Nylon bearings

• Maximum front stroke 12.9” (327 mm)

Page 30 (10/07) Media # CTMDT936 860E-AC

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High Mounted Rear

Maximum rear axle

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