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

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OPERATION AND MAINTENANCE MANUAL 860E-1K DUMP TRUCK
Contents
INTRODUCTION
- WARNINGS
- FOREWORD
- ABOUT THIS MANUAL
- ALERTS
- TRUCK MODEL ILLUSTRATION
- NON-OEM PARTS IN CRITICAL SYSTEMS
STANDARD CHARTS AND TABLES
- GENERAL INFORMATION
- STANDARD TIGHTENING TORQUES
- CONVERSION MULTIPLIERS
GENERAL SAFETY
- GENERAL SAFETY
- PRECAUTIONS FOR TRUCK OPERATION
- OPERATING THE MACHINE
  - EXTERIOR LIGHTING
- 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
- PRE-SHIFT BRAKE TEST
- TRUCK OPERATION
  - ENGINE START-UP SAFETY
  - MACHINE OPERATION SAFETY PRECAUTIONS
  - SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
  - EMERGENCY STEERING SYSTEM
  - 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 III SYSTEM
  - GENERAL INFORMATION
  - COMPONENT DESCRIPTION
  - SCOREBOARD
  - OPERATOR’S DISPLAY AND SWITCH
  - HAUL CYCLE WARNING FLAGS
  - PC SOFTWARE OVERVIEW
  - SYSTEM CONFIGURATION
  - DOWNLOADING PAYLOAD DATA
  - UPLOADING DATA
  - DATA ANALYSIS
- 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 PANEL
  - STATUS INDICATORS
- 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