Komatsu 860E-1K Electric Dump Truck Operation and Maintenance Manual CEAM021603

Description

• Model List:
  • 860E-1K Electric Dump Truck

• 1. OPERATION AND MAINTENANCE MANUAL 860E1KT DUMP TRUCK
• 2. CONTENTS
• 3. INTRODUCTIONSECTION 10
• 3.1. FOREWORD
• 3.2. TRUCK MODEL ILLUSTRATION
• 3.3. ABOUT THIS MANUAL
• 3.4. ALERTS PAGE
• 3.5. TABLE OF CONTENTS
• 4. TORQUE TABLES AND CONVERSION CHARTSSECTION 12
• 4.1. INDEX OF TABLES
• 4.2. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 4.3. STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws and Class 10 Nuts
• 4.4. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
• 4.5. STANDARD TIGHTENING TORQUES For SAE Hex Head and 12Point, Grade 9 Capscrews
• 5. GENERAL SAFETYSECTION 20
• 5.1. Safety Rules
• 5.2. Truck Safety Features
• 5.3. Clothing And Personal Items
• 5.4. Unauthorized Modification
• 5.5. Leaving The Operators Seat
• 5.6. Mounting And Dismounting
• 5.7. Fire Extinguishers And First Aid Kits
• 5.8. Precautions For High Temperature Fluids
• 5.9. Asbestos Dust Hazard Prevention
• 5.10. Fire And Explosion Prevention
• 5.11. Prevent Fire
• 5.12. ROPS Precautions
• 5.13. Preventing Injury From Work Equipment
• 5.14. Precautions For Optional Attachments
• 5.15. Precautions When Starting The Truck
• 5.16. PRECAUTIONS BEFORE OPERATION
• 5.17. OPERATING THE TRUCK
• 5.18. WORKING NEAR BATTERIES
• 5.19. BEFORE PERFORMING MAINTENANCE
• 5.20. WHILE PERFORMING MAINTENANCE
• 5.21. TIRES
• 5.22. WHEN REPAIRS ARE NECESSARY
• 5.23. SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS
• 5.24. ADDITIONAL JOB SITE RULES
• 6. WARNINGS AND CAUTIONSSECTION 22
• 6.1. GRADE/SPEED CHART
• 6.2. INSTRUMENT PANEL
• 6.3. BATTERIES
• 6.4. HIGH VOLTAGE
• 6.5. RADIATOR
• 6.6. CRUSHING HAZARD
• 6.7. CYLINDER PRESSURE
• 6.8. FILLING THE HYDRAULIC TANK
• 6.9. HYDRAULIC OIL PRESSURE
• 6.10. EMERGENCY TOWING PROCEDURE
• 6.11. EMERGENCY DUMP PROCEDURE
• 6.12. ACCUMULATOR DRAIN VALVES
• 6.13. GREASE POINT
• 6.14. WELDING
• 6.15. EMERGENCY SHUTDOWN
• 6.16. LIFTING POINT
• 6.17. SPRING PRESSURE
• 6.18. ROPS/FOPS
• 6.19. OIL FILL AND CHECK
• 6.20. EMERGENCEY EGRESS
• 6.21. Wireless Signal
• 6.22. PRODUCT IDENTIFICATION PLATE
• 6.23. LUBRICATION CHART
• 7. OPERATING INSTRUCTIONSSECTION 30
• 7.1. PREPARING FOR OPERATION
• 7.2. WALK AROUND INSPECTION
• 7.3. ENGINE STARTUP
• 7.4. AFTER ENGINE HAS STARTED
• 7.5. MACHINE OPERATION SAFETY PRECAUTIONS
• 7.6. OPERATING ON THE HAUL ROAD
• 7.7. STARTING ON A GRADE WITH A LOADED TRUCK
• 7.8. PASSING
• 7.9. LOADING
• 7.10. DUMPING
• 7.11. USING THE SPEED CONTROL FEATURE
• 7.12. SAFE PARKING PROCEDURES
• 7.13. NORMAL ENGINE SHUTDOWN PROCEDURE
• 7.14. SUDDEN LOSS OF ENGINE POWER
• 7.15. EMERGENCY STEERING SYSTEM
• 7.16. FUEL DEPLETION
• 7.17. TOWING
• 7.18. DISABLED TRUCK OPERATION
• 7.19. GENERAL
• 7.20. STEERING AND BRAKE SYSTEM
• 7.21. DISABLED TRUCK DUMPING PROCEDURE
• 7.22. RESERVE ENGINE OIL SYSTEM
• 8. OPERATOR CAB AND CONTROLSSECTION 32
• 8.1. STEERING WHEEL AND CONTROLS
• 8.2. DYNAMIC RETARDING
• 8.3. GRADE/SPEED RETARD CHART
• 8.4. OVERHEAD PANEL COMPONENTS
• 8.5. CENTER CONSOLE
• 8.6. DIAGNOSTIC PORTS
• 8.7. OPERATORS SEAT
• 8.8. PASSENGER SEAT (STANDARD SEAT)
• 8.9. HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS
• 8.10. INSTRUMENT PANEL
• 8.11. STATUS INDICATOR LIGHTS
• 8.12. DIGITAL DISPLAY OPERATION
• 8.13. REAR AXLE LIGHT BAR
• 8.14. KOMTRAX PLUS
• 8.15. FUSES AND CIRCUIT BREAKERS
• 9. LUBRICATION AND SERVICESECTION 40
• 9.1. GENERAL
• 9.2. SERVICE CAPACITIES
• 9.3. HYDRAULIC TANK SERVICE
• 9.4. COOLING SYSTEM SERVICE
• 9.5. RESERVE ENGINE OIL SYSTEM
• 9.6. QUICK FILL SERVICE CENTER
• 9.7. CHECK DUMP BODY PADS
• 9.8. LUBRICATION CHART
• 9.9. HOUR (DAILY) INSPECTIONS
• 9.10. HOUR (DAILY) INSPECTIONS (Cont.)
• 9.11. INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.12. INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.13. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.14. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.15. HOUR LUBRICATION AND MAINTENANCE (Cont.)
• 9.16. ,000 HOURS LUBRICATION AND MAINTENANCE CHECKS
• 9.17. ,000 HOURS LUBRICATION AND MAINTENANCE CHECKS (cont.)
• 9.18. ,000 HOUR MAINTENANCE CHECKS
• 9.19. ,000 HOUR MAINTENANCE CHECKS
• 9.20. ,000 HOUR MAINTENANCE CHECKS
• 9.21. ,000 HOUR MAINTENANCE CHECKS
• 10. AUTOMATIC LUBRICATION SYSTEMSECTION 42
• 10.1. GENERAL DESCRIPTION
• 10.2. SYSTEM COMPONENTS
• 10.3. SYSTEM OPERATION
• 10.4. GENERAL INSTRUCTIONS
• 10.5. LUBRICANT PUMP
• 10.6. INJECTORS (SL1 Series H)
• 10.7. PREVENTIVE MAINTENANCE PROCEDURES
• 10.8. SYSTEM CHECKOUT
• 10.9. SYSTEM TROUBLESHOOTING CHART
• 11. COMPONENTS SPECIFICATIONSSECTION 50
• 11.1. MAJOR COMPONENT DESCRIPTIONS
• 11.2. SPECIFICATIONS
• 12. PAYLOAD METER IIISECTION 60
• 12.1. Introduction
• 12.2. COMPONENT DESCRIPTION
• 12.3. LOAD DISPLAY AND OPERATOR SWITCHES
• 12.4. PAYLOAD OPERATION CALCULATION
• 12.5. SOURCES FOR PAYLOAD ERROR
• 12.6. HAUL CYCLE DATA
• 12.7. PDM SOFTWARE OVERVIEW
• 12.8. DOWNLOADING DATA
• 12.9. PLM III SYSTEM CONFIGURATION
• 12.10. DATA ANALYSIS
• 13. AM/FM RADIO / CD PLAYERSECTION 70
• 13.1. OPERATING INSTRUCTIONS