Komatsu 860E-1KT Dump Truck Operation and Maintenance Manual (CEAM039000)
On a truck like the Komatsu 860E-1KT, working hard in mines or large earthmoving sites, this Operation and Maintenance Manual is what you lean on to keep it running day in, day out. It helps you set a sensible service rhythm, know what to look at and when, and avoid guessing in the field. If a driver reports sluggish hoist performance at the start of shift, this is the book you use to trace through basic checks, verify safe operating procedures, and decide whether it’s something you can resolve in the pit or needs shop time.
Applications & Use Cases
- Plan preventive maintenance so inspections, filter changes, and adjustments are done before components start to fail.
- Walk-around inspections: use the guidance to inspect critical areas and catch leaks, cracks, or loose hardware early.
- Operator training: standardize how new operators start, operate, and shut down the truck to reduce abuse and downtime.
- Troubleshoot minor issues like warning lights or abnormal noises by following the recommended checks before calling in major repairs.
- Coordinate parts and labor by knowing what’s due next and scheduling work around production needs.
FAQ
Q: Can I keep this manual on a tablet in the cab?
A: Yes, that’s common; just make sure it’s accessible offline and protected from dust and vibration.
Q: Is it worth printing sections of this manual?
A: Many shops print the routines they use most and keep them in a plastic binder at the service bay or lube truck.
Safety Note
Always follow the manual’s safety instructions and lockout procedures before inspecting, adjusting, or servicing this truck.
Komatsu 860E-1KT Dump Truck Index:
- Contents
- INTRODUCTION
- FOREWORD
- ABOUT THIS MANUAL
- WARNINGS
- ALERTS
- TRUCK MODEL ILLUSTRATION
- NON-OEM PARTS IN CRITICAL SYSTEMS
- SOFTWARE LICENSE INFORMATION
- STANDARD CHARTS AND TABLES
- GENERAL INFORMATION
- STANDARD TIGHTENING TORQUES
- CONVERSION MULTIPLIERS
- GENERAL SAFETY
- GENERAL SAFETY
- PRECAUTIONS FOR TRUCK OPERATION
- OPERATING THE MACHINE
- PRECAUTIONS FOR MAINTENANCE
- BEFORE PERFORMING MAINTENANCE
- DURING MAINTENANCE
- BATTERY HAZARD PREVENTION
- WHEN REPAIRS ARE NECESSARY
- SPECIAL PRECAUTIONS
- WARNING AND CAUTIONS
- GENERAL INFORMATION
- PIN PLATE
- GRADE SPEED CHART
- GREASE POINTS
- MACHINE SAFETY
- KEY SWITCH
- OIL FILL AND CHECK
- HIGH PRESSURES
- SPRING PRESSURE
- BATTERIES
- HIGH VOLTAGE
- WELDING
- EMERGENCY DUMPING
- AUTOMATIC LUBRICATION FILL
- ROPS/FOPS
- COOLANT
- TOWING
- SEAT WEIGHT CAPACITY
- LUBRICATION CHART
- OPERATING INSTRUCTIONS
- PREPARING FOR OPERATION
- TROLLEY WALK AROUND INSPECTION
- PRE-SHIFT BRAKE TEST
- TRUCK OPERATION
- ENGINE START-UP SAFETY
- MACHINE OPERATION SAFETY PRECAUTIONS
- EMERGENCY STEERING SYSTEM
- TROLLEY OPERATING INSTRUCTIONS
- SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
- FUEL DEPLETION
- SAFE PARKING PROCEDURES
- NORMAL ENGINE SHUTDOWN PROCEDURE
- DISABLED TRUCK CONNECTORS
- GENERAL INFORMATION
- STEERING AND BRAKE SYSTEM
- HOIST SYSTEM
- TOWING
- SPECIAL WIRING HARNESS
- TOWING PROCEDURE
- PAYLOAD METER IV SYSTEM
- GENERAL INFORMATION
- COMPONENT DESCRIPTION
- SCOREBOARD
- OPERATOR’S DISPLAY AND SWITCH
- PAYLOAD OPERATION & CALCULATION
- SOURCES FOR PAYLOAD ERROR
- Clean Truck Tare
- DOWNLOADING HAUL CYCLE DATA
- VIEWING ALARM DATA
- DOWNLOADING ALARM DATA
- AUTOMATIC LUBRICATION SYSTEM
- GENERAL INFORMATION
- COMPONENT DESCRIPTION
- SYSTEM OPERATION
- PREVENTIVE MAINTENANCE PROCEDURES
- SYSTEM CHECKOUT
- RESERVE ENGINE OIL SYSTEM
- OPERATOR CAB AND CONTROLS
- CAB INTERIOR
- STEERING WHEEL AND CONTROLS
- PEDALS
- OVERHEAD PANEL AND DISPLAYS
- CENTER CONSOLE
- DIAGNOSTIC PORTS
- OPERATOR SEAT (Standard)
- OPERATOR SEAT (Optional)
- PASSENGER SEAT (Standard)
- PASSENGER SEAT (Optional)
- HEATER / AIR CONDITIONER CONTROLS
- INSTRUMENT PANEL
- STATUS INDICATOR LIGHT PANEL
- STATUS INDICATOR LIGHT SYMBOLS
- DIGITAL DISPLAY OPERATIONS
- DIGITAL DISPLAY MENUS
- ACTIVE WARNINGS MENU
- PAYLOAD DATA MENU
- REPAIR ITEMS MENU
- MAINTENANCE ITEMS MENU
- CLEARED ITEMS MENU
- SYSTEM CONTROLS MENU
- TIRE DATA MENU
- LANGUAGES MENU
- CONFIGURE SYSTEM MENU
- KOMTRAX Plus
- KOMTRAX Plus OPERATION
- DOWNLOADING KOMTRAX Plus DATA
- UPLOADING KOMTRAX Plus DATA
- ORBCOMM
- KOMATSU WIRELESS BRIDGE (Optional)
- FUSES AND CIRCUIT BREAKERS
- FUSE BLOCK #1
- FUSE BLOCK #2
- FUSE BLOCK #3
- FUSE HOLDERS
- CIRCUIT BREAKERS
- LUBRICATION AND SERVICE
- GENERAL INFORMATION
- RECOMMENDED FUEL, COOLANT, AND LUBRICANT
- HYDRAULIC SYSTEM SERVICE
- WHEEL MOTOR SERVICE
- COOLANT LEVEL SERVICE
- IGBT COOLANT SERVICE
- RESERVE ENGINE OIL SERVICE
- CAB AIR FILTER SERVICE
- FUEL SYSTEM SERVICE
- INTAKE AIR CLEANER SERVICE
- FRONT ENGINE MOUNT TRUNNION SERVICE
- QUICK FILL SERVICE CENTER
- TIE ROD INSPECTION AND TORQUE PROCEDURE
- CHECK AUTOMATIC LUBRICATION (AUTOLUBE) SYSTEM PUMP OIL LEVEL
- CHANGE AUTOMATIC LUBRICATION (AUTOLUBE) SYSTEM PUMP OIL
- PERIODIC REPLACEMENT OF DEFINED LIFE PARTS
- INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- EVERY 250 HOUR LUBRICATION AND MAINTENANCE
- EVERY 500 HOUR LUBRICATION AND MAINTENANCE
- EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
- EVERY 1500 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- EVERY 4000 HOUR MAINTENANCE
- EVERY 5000 HOUR MAINTENANCE
- EVERY 6000 HOUR MAINTENANCE
- EVERY 12000 HOUR MAINTENANCE
- EVERY 18000 HOUR MAINTENANCE
- EVERY 24000 HOUR MAINTENANCE
- 30000 HOUR LUBRICATION AND MAINTENANCE CHECKS
- SPECIFICATIONS
- MAJOR COMPONENT DESCRIPTION
- Truck And Engine
- Traction Alternator
- Main Control Cabinet
- AC Induction Traction Motorized Wheels
- Suspension
- Operator’s Cab
- Power Steering
- Dynamic Retarding
- Brake System
- SPECIFICATIONS
- Engine
- AC Electric Drive System
- Dynamic Retarding
- Battery Electric System
- Service Capacities
- Hydraulic Systems
- Service Brakes
- Steering
- Standard Dump Body Capacities And Dimensions
- Tires
- Weight Distribution
- Overall Truck Dimensions
- RADIO
- AM/FM RADIO / MP3 / USB / iPOD™ / AUX PLAYER
- USB Connection Port
- Phone/Bluetooth Button
- Digital Display
- DISP (Display) Button
- SRC/PWR/ESC (Source/Power/Escape) Button
- Volume Knob/OK Button
- NEXT Button
- PREV (Previous) Button
- Preset Buttons
- RDM (Random) Button
- RPT (Repeat) Button
- Mute/Play/Pause Button
- Browse Button
- SCAN/ASCN (Scan/Autoscan) Button
- Auxiliary Jack Port
Link Belt
