• 1,001,700 lbs Max Gross Vehicle Weight
  • 2,700 @1900 rpm Gross HP
  • 280 U.S. tons Capacity

860E-1K

The 860E-1K utilizes Komatsu Drive with Siemens AC control and liquid cooled Insulated Gate Bipolar Transistor (IGBT) inverter system for the highest available reliability. Hill Start allows the operator to start on a grade without roll back. Traction control assists the operator to power through wet sloppy underfoot condition. Oil cooled multi-disc brakes and retarder give the operator confidence in his control and stopping ability, especially when fully loaded. A front mounted elevating pantagraph can be mounted to allow the 860E-1K to utilize electrified overhead trolley lines.

Features

4650 Horsepower Continuous Retarding Capability

The 3469 kW 4,650 HP retarding system provides state of-the-art braking capacity for navigating today’s mining applications which contain steep continuous descents and sharp switchbacks.

This power capacity, coupled with the ultra-quiet, high volume, low speed fan makes it possible for the operator to maintain control with confidence while hauling downhill. Electric retard reduces the need for service brake applications.

Castings Used in High Stress Areas

To increase frame reliability, steel castings have been incorporated at key frame pivot points and key load bearing critical portions of the frame. This includes the rear body pivot and horsecollar sections.

By using advanced computer-aided design, finite element analysis, and full-scale dynamic and static testing, the frame design has been structurally enhanced to carry 254 t 280 short tons and provide high reliability.

Dynamic Retarding

For daily operation, the 860E-1K is equipped with an electric retarding package which can supply up to 3469 kW 4,650 hp of resistance. When requested, the wheel motors switch from motors to electrical generators. The resistive force created from this process is used to slow the truck to the desired speed. The power generated is then run over an 18 element grid which converts the electricity into heat. The heat is then dissipated into the atmosphere by the quietest grid blower Komatsu has ever used.

Ergonomically Designed Cab

The Komatsu 860E-1K cab design provides the operator with an environment where they can be comfortable and confident during operation. The rubber mounted isolated cab includes tinted safety glass, power windows, heating and air conditioning, acoustical insulation, double sealed doors, and filtered, pressurized air.

Fully Hydraulic Controlled Multiple-Disc Wet Brakes

The 860E-1K comes standard with four-wheel, hydraulically actuated, oil cooled service brakes. In the event that the truck’s hydraulic system pressure drops below an acceptable level, accumulator tanks will automatically apply all wheel brakes to bring the truck to a complete stop.

  • Max. service apply pressure: 16547 kPa 2,400 psi
  • Total friction area per brake: 75439 cm² 11,693 in²

Hill Start

With the new Komatsu Drive System comes a new innovation in electric truck technology. The Hill Start feature allows the operator to start the machine on a grade without roll back.

Hydropneumatic Suspensions

Hydrair® II suspension cylinders located at each wheel provide a smooth and comfortable ride for the operator and dampen shock loads to the chassis during loading and operation.

Komatsu AC Electric Drive System

The Komatsu drive system, utilizing Siemens AC control, offers independent control of the rear wheelmotors. This provides outstanding traction during wet and slippery conditions, thus improving tire wear and operator confidence.

The liquid cooled Insulated Gate Bipolar Transistor (IGBT) inverter system technology provides the highest available reliability.

Payload Policy

Recognizing that variation occurs naturally in material density, fill factors, and loading equipment, Komatsu America Corp. deems it necessary to establish a consistent loading policy for the 860E-1K. This loading policy is intended to identify the guidelines for the loading of Komatsu Mining Trucks, and is valid for approved applications and haul profiles only (see chart below).

10-10-20 Load Policy Criteria

  1. 10% of all loads may be between 110% and 120% of the rated payload of the truck
  2. 90% of all loads must be below 110% of the rated payload of the truck
  3. The average monthly payload must not exceed the rated payload of the truck
  4. No single payload may exceed 120% of the rated payload of the truck

Steering

By using double acting hydraulic steering cylinders with a six-point articulation linkage, the 860E-1K power steering system provides positive steering control with minimal operator effort. The turning circle has a diameter of 31 m 102 ft. The accumulator-assist steering system surpasses requirements set forth by ISO 5010.

Traction Control

During slippery conditions caused by inclement weather and/or application severity, the 860E-1K traction control technology utilizes information from all four wheels to detect and correct wheel spin and/or slide events. Traction Control operates automatically and independently of the service brakes, providing a more efficient means of controlling the machine in inclement conditions.

Trolley (optional)

The factory installed 860E-1KT trolley system allows for faster ascent up grades, providing higher production and lower fuel consumption compared to conventional diesel systems.

Specifications

Body

All-welded steel flat floor body with horizontal bolsters and full canopy. Tapered body, body up sling and frame mounted rubber pads are standard. Heated body optional. 

Floor sheet
200,000 psi / 1379 mPa tensile strength steel / Outer
0.63'' 16 mm
Floor sheet
200,000 psi / 1379 mPa tensile strength steel / Center
0.75'' 19 mm
Front sheet
200,000 psi / 1379 mPa tensile strength steel / Outer
0.39' 10 mm
Front sheet
200,000 psi / 1379 mPa tensile strength steel / Center
0.39' 10 mm
Side sheet
200,000 psi / 1379 mPa tensile strength steel
0.31'' 8 mm
Canopy sheet
100,000 psi / 690 mPa tensile strength steel
0.24'' 6 mm
Capacity struck 160 yd³ 122 m³
SAE heaped 2:1 221 yd³ 169 m³
Standard Komatsu body weight 74,171 lb 33643 kg

Braking System

Service brakes: oil-cooled, hydraulic-actuated, multiple disc brakes at each wheel. Traction system wheel spin control.

Max. service apply pressure 2,400 psi 16547 kPa
Total friction area per brake 11,693 in² 75439 cm²
Secondary brakes Automatically applied prior to hydraulic system pressure dropping below level required to meet secondary stopping requirements.
Wheel brake locks Switch activated
Parking brakes Multiple disc, spring-applied, hydraulically-released, dry brakes on inboard end of each wheel motor rotor shaft. Rated to hold on ±15% grade at maximum gross vehicle weight.
Electric dynamic retarder 4,650 hp 3469 kW
Continuously rated high-density blown grids w/retard capacity at low speeds and retard in reverse propulsion.

Cab

Advanced Operator Environment with isolation mounted, integral 4- post ROPS/FOPS Level 2 structure. Adjustable air suspension seat w/lumbar support, arm rests, and 3-point seat belt, full-size passenger seat, thermal insulation, tilt and telescoping steering wheel, electric windshield wipers w/washer, tinted safety glass, power windows, Komatsu Payload Weighing System, 61,000 Btu/hr heater and defroster, 19,900 Btu/hr air conditioning (HFC - 134A refrigerant).

Cooling System

L&M radiator assembly, split-flow, with deaerator-type top tank. 

Radiator frontal area 62.5 ft² 5.81 m²

Electric Drive

AC/DC CURRENT
Drive System* Komatsu AC Drive
Alternator DRLDZ5010-AL
Dual Fan Main Blower 14,800 cfm 419 m³/min
Control IGBT AC Torque Control System
Ratio 35.52:1
Speed (maximum) 40 mph 64.5 km/h
* Wheel motor drive system application depends upon gross vehicle weight, haul road grade, haul road length, rolling resistance and other parameters. Komatsu must analyze each job condition to assure proper application.

Electric System

4 x 8D 1450 CCA, 12 volt, in series/parallel, 220-ampere-hour batteries, bumper-mounted with disconnect switch.

Alternator 24 volt, 140 amp
Lighting 24 volt
Cranking motors Two/24 volt

Engine

Make and model Komatsu SSDA16V160 Tier 2
Fuel Diesel
Number of cylinders 16
Operating cycle 4 cycle
Gross horsepower* @ 1900 rpm 2,700 HP 2014 kW
Net flywheel power** @ 1900 rpm 2,550 HP 1902 kW
Weight (wet) 21,182 lb 9608 kg
* Gross horsepower is the output of the engine as installed in this machine, at governed rpm and with engine manufacturer’s approved fuel setting. Accessory losses included are water pump, fuel pump and oil pump.
**Net flywheel power is the rated power at the engine flywheel minus the average accessory losses. Accessories include fan and charging alternator. Rating(s) represent net engine performance in accordance with SAE J1349 conditions.

Frame

Advanced technology, full butt-welded box sectional ladder-type frame with integral ROPS supports, integral front bumper, rear tubular cross members, steel castings at all critical stress transition zones, rugged continuous horsecollar.

Plate material
tensile strength steel
70,000 psi 482.6 mPa
Casting material
tensile strength steel
90,000 psi 620.5 mPa
Rail width 12'' 305 mm
Rail depth (minimum) 34'' 864 mm
Top and bottom plate thickness 1.57'' 40 mm
Side plate thickness / Rear 0.75'' 19 mm
Side plate thickness / Front 0.87'' 22 mm
Drive axle mounting
Pin and spherical bushing
Drive axle alignment
Swing link between frame and axle

Hydraulic System

Steering Accumulator assisted with twin double acting cylinders provide constant rate steering. Secondary steering automatically supplied by accumulator.
Turning circle diameter (SAE) 102' 31 m
Reservoir 250 U.S. gal 947 L
Filtration In-line replaceable elements
Suction Single, full flow, 100 mesh
Hoist and steering Dual, in-line, high pressure
Brake component cabinet Above deck, easily accessible with diagnostic test connections
Hoist Two 3-stage dual-acting outboard cylinders, internal cushion valve, over-center dampening
Hoist times:
Power-up loaded 22 sec
Power-down (high idle) 13 sec
Float-down (low idle) 23 sec
Pumps Two pumps, single package, end of alternator
Hoist and brake cooling Tandem gear pump with output of 931 lpm / 246 gpm at 1900 rpm and 17237 kPa / 2,500 psi
Steering and brake Pressure-compensating piston pump with output of 246 lpm / 65 gpm at 1900 rpm and 18960 kPa / 2,750 psi
System relief pressures:
Hoist and brake cooling 2,500 psi 17237 kPa
Steering and brake 3,000 psi 20685 kPa
Quick disconnects standard for powering disabled truck and for systems diagnostics.

Service Capacities

Cooling System 125 U.S. gal 473 L
Crankcase 74 U.S. gal 280 L
Hydraulic system 350 U.S. gal 1325 L
Motor gear box (each) 32 U.S. gal 121 L
Inverter cooling system 6.5 U.S. gal 25 L
Fuel 1,200 U.S. gal 4542 L
Reserve Oil® System 30 U.S. gal 114 L

Suspension

Variable rate hydro-pneumatic with integral rebound control

Max. front stroke 12.32'' 313 mm
Max. rear stroke 11.50'' 292 mm
Max. rear axle oscillation ±10.4°

Tires and Rims

Rock service, tubeless, radial tires:
Standard tire* 50/80 R57
Optional tire* 50/90 R57
Flange mount rim 34'' x 57'' x 6'' rim assembly 864 mm x 1448 mm x 152 mm rim assembly
Typical total tire weight 50,780 lb 23033 kg
* Tires should meet application requirements for tkph/tmph, tread, compound, inflation pressure, ply rating or equivalent, etc.

standard

  • Air cleaners, with dust evacuators
  • Alternator (24 volt/140A)
  • Auto lubrication system w/ground level fill & low level indicator
  • Batteries–4 x 8D (1450 CCA’s)
  • Battery charging cable and socket
  • Body impact plate
  • Body over center device
  • Body up sling
  • Brakes: oil-cooled, multiple disc front & rear
  • Control cabinet
  • Electric start
  • Eliminator®, Centinel®, Cense®
  • Fast-fill fuel system (in tank and left side remote)
  • Filters, high pressure hydraulic
  • Ground level radiator fill
  • Mirrors, LH flat and RH rectangular convex
  • Mud flaps
  • Muffled exhaust–deck-mounted
  • Power supply, 24 volt and 12 volt DC
  • Quick disconnects (hoist and diagnostics)
  • Radiator sight gauge
  • Removable power module unit (radiator, engine, alternator, blower)
  • Reverse retarding
  • Service center–LH
  • Speed Control (Propel & Retard)
  • Thermostatic fan clutch

OPERATOR ENVIRONMENT & CONTROL

  • All hydraulic service brakes with emergency auto apply
  • Back up alarm
  • Battery disconnect switch
  • Brake lock and drive system interlock
  • Circuit breakers, 24 volt
  • Diagonal staircase across grille, L to R
  • Dynamic retarding with continuous rated element grids
  • Engine shutdown at ground level
  • Hoist propulsion interlock
  • Horns (electric–front)
  • Integral ROPS/FOPS Level 2
  • Maintenance and power lockout
  • Parking brakes with warning light & speed application protection
  • Power steering w/auto secondary steering
  • Protective deck handrails with kick plate
  • Pump driveline protector
  • Radiator fan guard
  • Seat belts 76 mm 3", 3-point, retractable
  • Skid-resistant surface on walkways

STANDARD HIGH VISIBILITY DELUXE CAB

  • Status and instrument panel
    - Body up
    - Parking brake
    - Propulsion system not ready
    - No DC link voltage
    - High engine oil temp
    - No propel
    - Service brake applied
    - Wheel brake lock applied
    - Repair monitor
    - Engine warming up
    - Engine shut down timer
    - Grid Drier
    - Traction control
    - Dynamic Retarding
  • Air cleaner restriction gauges
  • Air conditioner HFC-134A
  • AM/FM radio with CD & USB
  • Column-mounted speed control
  • Digital tachometer and speedometer
  • Dome light
  • Engine hourmeter
  • Engine shutdown w/ “Smart Timer” delay
  • Floor mat (double barrier)
  • Fuel gauge in cab and site gauge on tank
  • Fuel low level light and buzzer
  • Gauges (w/backlight)
    - Oil Pressure
    - Coolant Temperature
    - Hydraulic Oil Temperature
  • Headlight switch
  • Heater and defroster (heavy-duty)
  • High beam selector and indicator
  • Horn (center of steering wheel)
  • Indicator lights (blue)
    - Engine service
    - KOMTRAX Plus snapshot (IM)
  • Komatsu Payload Meter III®
  • Operator seat, adjustable w/air suspension, lumbar support and arm rests
  • Panel lighting (adjustable)
  • Passenger seat, full size, heavy duty mechanical suspension
  • Power windows
  • Pressurized cab air system w/fan on
  • Single brake/retarder pedal
  • Starter key switch
  • Sunvisor (adjustable)
  • Thermal insulation
  • Tilt & telescoping steering wheel
  • KOMTRAX Plus
  • Voltmeter (battery output)
  • Windshield (tinted safety plate)
  • Windshield wiper (dual) and washer (electric)

LIGHTING

  • Back-up lights–rear mount (2, halogen)
  • Back-up lights–R and L - deck mount (2, halogen)
  • Brake and retard lights on top of cab
  • Clearance lights (LED)
  • Control cabinet service light (LED)
  • Dynamic retarding, rear (2, LED)
  • Engine compartment service lights
  • Fog lights (2, halogen)
  • Headlights (8, halogen)
  • Manual back-up light, switch and indicator
  • Payload lights R and L (LED)
  • Platform lights R, L and Center (3, halogen)
  • Stairway lights (1, halogen)
  • Stop & tail lights (2, LED)
  • Turn signals (LED)

optional

  • Body Liners
  • Fire extinguisher 9 kg / 20 lb
  • Heated body
  • Hot start engine coolant (220V 2-2500W)
  • Hot start engine oil (220V 2-500W)
  • Hot start hydraulic oil
  • Hubodometer
  • Lights (HID)
  • Mufflers between frame rails
  • PLM III®scoreboards
  • Reversed access ladder, R to L
  • Service center - RH
  • Shutters (radiator)
  • Special language decals
  • Suspensions, cold weather
  • Tires (50/90R57)
  • Trolley, factory installed