Komatsu 860E-1K Dump Truck Operation and Maintenance Manual CEAM024706

Description

• Model List:
  • 860E-1K Dump Truck

• 1. OPERATION AND MAINTENANCE MANUAL 860E1K DUMP TRUCK
• 2. Contents
• 3. INTRODUCTION
• 3.1. WARNINGS
• 3.2. FOREWORD
• 3.3. ABOUT THIS MANUAL
• 3.4. ALERTS
• 3.5. TRUCK MODEL ILLUSTRATION
• 3.6. NONOEM PARTS IN CRITICAL SYSTEMS
• 4. STANDARD CHARTS AND TABLES
• 4.1. GENERAL INFORMATION
• 4.2. STANDARD TIGHTENING TORQUES
• 4.3. CONVERSION MULTIPLIERS
• 5. GENERAL SAFETY
• 5.1. GENERAL SAFETY
• 5.2. PRECAUTIONS FOR TRUCK OPERATION
• 5.3. OPERATING THE MACHINE
• 5.3.1. EXTERIOR LIGHTING
• 5.4. PRECAUTIONS FOR MAINTENANCE
• 5.4.1. BEFORE PERFORMING MAINTENANCE
• 5.4.1.1. Securing the Dump Body
• 5.4.2. DURING MAINTENANCE
• 5.5. BATTERY HAZARD PREVENTION
• 5.6. WHEN REPAIRS ARE NECESSARY
• 5.7. SPECIAL PRECAUTIONS
• 6. WARNING AND CAUTIONS
• 6.1. GENERAL INFORMATION
• 6.2. PIN PLATE
• 6.3. GRADE SPEED CHART
• 6.4. GREASE POINTS
• 6.5. MACHINE SAFETY
• 6.6. KEY SWITCH
• 6.7. OIL FILL AND CHECK
• 6.8. HIGH PRESSURES
• 6.9. SPRING PRESSURE
• 6.10. BATTERIES
• 6.11. HIGH VOLTAGE
• 6.12. WELDING
• 6.13. EMERGENCY DUMPING
• 6.14. AUTOMATIC LUBRICATION FILL
• 6.15. ROPS/FOPS
• 6.16. COOLANT
• 6.17. TOWING
• 6.18. SEAT WEIGHT CAPACITY
• 6.19. LUBRICATION CHART
• 7. OPERATING INSTRUCTIONS
• 7.1. PREPARING FOR OPERATION
• 7.2. PRESHIFT BRAKE TEST
• 7.3. TRUCK OPERATION
• 7.3.1. ENGINE STARTUP SAFETY
• 7.3.2. MACHINE OPERATION SAFETY PRECAUTIONS
• 7.3.3. SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
• 7.3.4. EMERGENCY STEERING SYSTEM
• 7.3.5. FUEL DEPLETION
• 7.3.6. SAFE PARKING PROCEDURES
• 7.3.7. NORMAL ENGINE SHUTDOWN PROCEDURE
• 7.4. DISABLED TRUCK CONNECTORS
• 7.4.1. GENERAL INFORMATION
• 7.4.2. STEERING AND BRAKE SYSTEM
• 7.4.3. HOIST SYSTEM
• 7.5. TOWING
• 7.5.1. SPECIAL WIRING HARNESS
• 7.5.2. TOWING PROCEDURE
• 7.6. PAYLOAD METER III SYSTEM
• 7.6.1. GENERAL INFORMATION
• 7.6.2. COMPONENT DESCRIPTION
• 7.6.3. SCOREBOARD
• 7.6.4. OPERATORS DISPLAY AND SWITCH
• 7.6.5. HAUL CYCLE WARNING FLAGS
• 7.6.6. PC SOFTWARE OVERVIEW
• 7.6.7. SYSTEM CONFIGURATION
• 7.6.8. DOWNLOADING PAYLOAD DATA
• 7.6.9. UPLOADING DATA
• 7.6.10. DATA ANALYSIS
• 7.7. AUTOMATIC LUBRICATION SYSTEM
• 7.7.1. GENERAL INFORMATION
• 7.7.2. COMPONENT DESCRIPTION
• 7.7.3. SYSTEM OPERATION
• 7.7.4. PREVENTIVE MAINTENANCE PROCEDURES
• 7.7.5. SYSTEM CHECKOUT
• 7.8. RESERVE ENGINE OIL SYSTEM
• 8. OPERATOR CAB AND CONTROLS
• 8.1. CAB INTERIOR
• 8.2. STEERING WHEEL AND CONTROLS
• 8.3. PEDALS
• 8.4. OVERHEAD PANEL AND DISPLAYS
• 8.5. CENTER CONSOLE
• 8.6. DIAGNOSTIC PORTS
• 8.7. OPERATOR SEAT (Standard)
• 8.8. OPERATOR SEAT (Optional)
• 8.9. PASSENGER SEAT (Standard)
• 8.10. PASSENGER SEAT (Optional)
• 8.11. HEATER / AIR CONDITIONER CONTROLS
• 8.12. INSTRUMENT PANEL
• 8.13. STATUS INDICATOR PANEL
• 8.13.1. STATUS INDICATORS
• 8.13.1.1. Body Up
• 8.13.1.2. Parking Brake
• 8.13.1.3. Propel System Not Ready
• 8.13.1.4. No Propel
• 8.13.1.5. Engine Warm Up
• 8.13.1.6. Engine Shutdown Delay
• 8.13.1.7. Retarding Grid Dryer
• 8.13.1.8. Wheel Brake Lock
• 8.13.1.9. Traction Control OFF
• 8.13.1.10. Repair Monitor
• 8.13.1.11. Retractable Ladder Down
• 8.13.1.12. Snapshot In Progress
• 8.13.1.13. Pantograph Energized
• 8.13.1.14. Pantograph Up
• 8.13.1.15. Service Brake
• 8.13.1.16. Dynamic Retarding
• 8.13.1.17. No DC Link Voltage
• 8.14. DIGITAL DISPLAY OPERATIONS
• 8.14.1. DIGITAL DISPLAY MENUS
• 8.14.2. ACTIVE WARNINGS MENU
• 8.14.3. PAYLOAD DATA MENU
• 8.14.4. REPAIR ITEMS MENU
• 8.14.5. MAINTENANCE ITEMS MENU
• 8.14.6. CLEARED ITEMS MENU
• 8.14.7. SYSTEM CONTROLS MENU
• 8.14.8. TIRE DATA MENU
• 8.14.9. LANGUAGES MENU
• 8.14.10. CONFIGURE SYSTEM MENU
• 8.15. KOMTRAX Plus
• 8.15.1. KOMTRAX Plus OPERATION
• 8.15.2. DOWNLOADING KOMTRAX Plus DATA
• 8.15.3. UPLOADING KOMTRAX Plus DATA
• 8.16. ORBCOMM
• 8.17. KOMATSU WIRELESS BRIDGE (Optional)
• 8.18. FUSES AND CIRCUIT BREAKERS
• 8.18.1. FUSE BLOCK 1
• 8.18.2. FUSE BLOCK 2
• 8.18.3. FUSE BLOCK 3
• 8.18.4. FUSE HOLDERS
• 8.18.5. CIRCUIT BREAKERS
• 9. LUBRICATION AND SERVICE
• 9.1. GENERAL INFORMATION
• 9.1.1. RECOMMENDED FUEL, COOLANT, AND LUBRICANT
• 9.1.2. HYDRAULIC SYSTEM SERVICE
• 9.1.3. WHEEL MOTOR SERVICE
• 9.1.4. COOLANT LEVEL SERVICE
• 9.1.5. IGBT COOLANT SERVICE
• 9.1.6. RESERVE ENGINE OIL SERVICE
• 9.1.7. CAB AIR FILTER SERVICE
• 9.1.8. FUEL SYSTEM SERVICE
• 9.1.9. INTAKE AIR CLEANER SERVICE
• 9.1.10. FRONT ENGINE MOUNT TRUNNION SERVICE
• 9.1.11. QUICK FILL SERVICE CENTER
• 9.1.12. TIE ROD INSPECTION AND TORQUE PROCEDURE
• 9.1.13. CHECK AUTOMATIC LUBRICATION (AUTOLUBE) SYSTEM PUMP OIL LEVEL
• 9.1.14. CHANGE AUTOMATIC LUBRICATION (AUTOLUBE) SYSTEM PUMP OIL
• 9.2. PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
• 9.3. INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
• 9.4. INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
• 9.5. EVERY 250 HOUR LUBRICATION AND MAINTENANCE
• 9.6. EVERY 500 HOUR LUBRICATION AND MAINTENANCE
• 9.7. EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
• 9.8. EVERY 1500 HOUR LUBRICATION AND MAINTENANCE INSPECTION
• 9.9. EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
• 9.10. EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
• 9.11. EVERY 4000 HOUR MAINTENANCE
• 9.12. EVERY 5000 HOUR MAINTENANCE
• 9.13. EVERY 6000 HOUR MAINTENANCE
• 9.14. EVERY 12000 HOUR MAINTENANCE
• 9.15. EVERY 18000 HOUR MAINTENANCE
• 9.16. EVERY 24000 HOUR MAINTENANCE
• 9.17. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 10. SPECIFICATIONS
• 10.1. MAJOR COMPONENT DESCRIPTION
• 10.1.1. Truck And Engine
• 10.1.2. Traction Alternator
• 10.1.3. Main Control Cabinet
• 10.1.4. AC Induction Traction Motorized Wheels
• 10.1.5. Suspension
• 10.1.6. Operators Cab
• 10.1.7. Power Steering
• 10.1.8. Dynamic Retarding
• 10.1.9. Brake System
• 10.2. SPECIFICATIONS
• 10.2.1. Engine
• 10.2.2. AC Electric Drive System
• 10.2.3. Dynamic Retarding
• 10.2.4. Battery Electric System
• 10.2.5. Service Capacities
• 10.2.6. Hydraulic Systems
• 10.2.7. Service Brakes
• 10.2.8. Steering
• 10.2.9. Standard Dump Body Capacities And Dimensions
• 10.2.10. Tires
• 10.2.11. Weight Distribution
• 10.2.12. Overall Truck Dimensions
• 11. RADIO
• 11.1. AM/FM RADIO / MP3 / USB / iPOD / AUX PLAYER
• 11.1.1. USB Connection Port
• 11.1.2. Phone/Bluetooth Button
• 11.1.3. Digital Display
• 11.1.4. DISP (Display) Button
• 11.1.5. SRC/PWR/ESC (Source/Power/Escape) Button
• 11.1.6. Volume Knob/OK Button
• 11.1.7. NEXT Button
• 11.1.8. PREV (Previous) Button
• 11.1.9. Preset Buttons
• 11.1.10. RDM (Random) Button
• 11.1.11. RPT (Repeat) Button
• 11.1.12. Mute/Play/Pause Button
• 11.1.13. Browse Button
• 11.1.14. SCAN/ASCN (Scan/Autoscan) Button
• 11.1.15. Auxiliary Jack Port