Komatsu Operation & Maintenance Manual (EN)

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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. 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. 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. 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.

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COVER

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.

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FOREWORD

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.

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ABOUT THIS MANUAL

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.

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