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KOMATSU 860E-1K Dump Truck Operation & Maintenance Manual (SN:A30031 & Up) KOMATSU 860E-1K – PDF DOWNLOAD
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- KOMATSU 860E-1K Dump Truck Operation & Maintenance Manual
- SERIAL NUMBER:A30031 & Up
- PUBLICATION NUMBER:CEAM024703
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Description
KOMATSU 860E-1K Dump Truck Operation & Maintenance Manual (SN:A30031 & Up) KOMATSU 860E-1K
KOMATSU 860E-1K DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30031 & UP) KOMATSU 860E-1K – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 860E-1K Dump Truck Operation & Maintenance Manual (SN:A30031 & Up) KOMATSU 860E-1K
- This manual is written for use by the operator and/or the service technician and is designed to help these persons become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.
- All operators and maintenance personnel must read and understand the materials in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions are to be understood and followed when operating or accomplishing repairs on the truck.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum GVW (Gross Vehicle Weight) rating.
The KOMATSU truck model designation consists of three numbers and one letter (i.e. 830E).
The three numbers represent the basic truck model.
The letter “M”, when present, designates a Mechanical drive system;
The letter “E”, when present, designates an Electrical wheel motor drive system. - The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
- The GVW is what determines the load on the drive train, frame, tires, and other components. The vehicle design and application guidelines are sensitive to the total maximum GVW. GVW is TOTAL WEIGHT: the Empty Vehicle Weight + the fuel & lubricants + the payload.
TABLE OF CONTENTS:
KOMATSU 860E-1K Dump Truck Operation & Maintenance Manual (SN:A30031 & Up) KOMATSU 860E-1K
COVER .......................................................................... 1 1 INTRODUCTION.................................................................. 14 FOREWORD.................................................................... 14 ABOUT THIS MANUAL........................................................... 15 WARNINGS.................................................................... 16 CALIFORNIA PROPOSITION 65 WARNINGS...................................... 16 ALERTS...................................................................... 17 TRUCK MODEL ILLUSTRATION.................................................... 18 NON-OEM PARTS IN CRITICAL SYSTEMS........................................... 19 2 STANDARD CHARTS AND TABLES.................................................... 22 GENERAL INFORMATION......................................................... 22 EFFECT OF SPECIAL LUBRICANTS............................................ 22 SUGGESTED SOURCES FOR RUST PREVENTIVE GREASE............................ 22 STANDARD TIGHTENING TORQUES................................................. 23 CLASS 10.9 CAP SCREWS & CLASS 10 NUTS................................... 23 SAE GRADE 5 AND GRADE 8 CAP SCREWS...................................... 24 SAE GRADE 9 CAP SCREWS.................................................. 25 T-BOLT CLAMPS........................................................... 25 SPLIT FLANGE CLAMPS..................................................... 26 FLARED TUBE AND HOSE FITTINGS........................................... 26 JIC 37° SWIVEL NUTS..................................................... 27 PIPE THREAD FITTINGS.................................................... 28 O-RING BOSS FITTINGS.................................................... 29 O-RING FACE SEAL FITTINGS............................................... 30 CONVERSION MULTIPLIERS...................................................... 31 METRIC TO ENGLISH....................................................... 31 ENGLISH TO METRIC....................................................... 32 TEMPERATURE CONVERSIONS................................................. 33 3 GENERAL SAFETY................................................................ 36 GENERAL SAFETY.............................................................. 36 Safety Rules............................................................ 36 Truck Safety Features................................................... 36 Clothing And Personal Items............................................. 36 Unauthorized Modification............................................... 36 Leaving The Operator’s Seat............................................. 36 Mounting And Dismounting................................................ 36 Fire Extinguishers And First Aid Kits................................... 37 Precautions For High Temperature Fluids................................. 37 Asbestos Dust Hazard Prevention......................................... 37 Fire Prevention......................................................... 37 ROPS Precautions........................................................ 37 Preventing Injury From Work Equipment................................... 38 Precautions For Optional Attachments.................................... 38 Precautions When Starting The Machine................................... 38 PRECAUTIONS FOR TRUCK OPERATION............................................. 39 Safety Is Thinking Ahead................................................ 39 Safety At The Worksite.................................................. 39 Preparing For Operation................................................. 39 Ventilation For Enclosed Areas.......................................... 39 Mirrors, Windows, And Lights............................................ 39 Before Starting The Engine.............................................. 39 Seat Belts.............................................................. 39 Emergency Egress Ladders................................................ 40 OPERATING THE MACHINE....................................................... 41 General Information..................................................... 41 Starting The Engine..................................................... 41 Traveling In The Machine................................................ 41 Traveling In Reverse.................................................... 41 Traveling On Slopes..................................................... 42 Traveling On Snow....................................................... 42 Traveling Near High Voltage Cables...................................... 42 Traveling On Loose Ground............................................... 42 Ensuring Good Visibility................................................ 42 Avoid Damage To The Dump Body........................................... 42 Safe Parking Of The Machine............................................. 42 Loading The Machine..................................................... 43 Dumping The Machine..................................................... 43 Towing The Machine...................................................... 43 EXTERIOR LIGHTING....................................................... 44 Fog Lights.......................................................... 44 Headlights.......................................................... 44 Brake Light......................................................... 44 Retard Light........................................................ 44 Clearance/Turn Signal Lights........................................ 45 Backup Lights....................................................... 45 Retard Lights....................................................... 45 Brake Lights........................................................ 45 Backup Alarm........................................................ 45 PRECAUTIONS FOR MAINTENANCE................................................. 46 BEFORE PERFORMING MAINTENANCE........................................... 46 Securing The Dump Body.............................................. 46 DURING MAINTENANCE...................................................... 47 Warning Tag......................................................... 47 Proper Tools........................................................ 47 Attachments......................................................... 47 Working Under The Machine........................................... 47 Keeping The Machine Clean........................................... 47 Adding Fuel Or Oil To The Machine................................... 47 Radiator Coolant Level.............................................. 48 Use of Lighting..................................................... 48 Handling High Pressure Hoses........................................ 48 Precautions With High Pressure Oil.................................. 48 Maintenance Near High Temperatures and High Pressures............... 48 Rotating Fan and Belts.............................................. 48 Waste Materials..................................................... 48 Use of Tie-Off Anchor During Maintenance............................ 48 Handling Tires...................................................... 49 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 49 BATTERY HAZARD PREVENTION................................................... 51 Jump Starting With Booster Cables....................................... 51 Jump Starting With Receptacles.......................................... 52 WHEN REPAIRS ARE NECESSARY.................................................. 53 Observe The Following Precautions....................................... 53 SPECIAL PRECAUTIONS......................................................... 54 Preliminary Procedures Before Welding or Performing Maintenance......... 54 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 54 Before welding on the machine, obey the following guidelines:........... 54 4 WARNING AND CAUTIONS.......................................................... 58 GENERAL INFORMATION......................................................... 58 PIN PLATE................................................................... 58 GRADE SPEED CHART........................................................... 59 GREASE POINTS............................................................... 59 MACHINE SAFETY.............................................................. 60 KEY SWITCH.................................................................. 62 OIL FILL AND CHECK.......................................................... 62 HIGH PRESSURES.............................................................. 63 SPRING PRESSURE............................................................. 66 BATTERIES................................................................... 66 HIGH VOLTAGE................................................................ 67 WELDING..................................................................... 67 LIFTING POINTS.............................................................. 68 EMERGENCY DUMPING........................................................... 69 AUTOMATIC LUBRICATION FILL.................................................. 69 ROPS/FOPS................................................................... 70 TOWING...................................................................... 70 LUBRICATION CHART........................................................... 70 5 OPERATING INSTRUCTIONS........................................................ 72 PREPARING FOR OPERATION..................................................... 72 Safety Is Thinking Ahead................................................ 72 Walk Around Inspection.................................................. 72 TRUCK OPERATION............................................................. 76 ENGINE START-UP SAFETY.................................................. 76 After Engine Has Started............................................ 76 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 77 Machine Operation on the Haul Road.................................. 78 Starting on a Grade With a Loaded Truck............................. 78 Passing............................................................. 78 Loading............................................................. 78 Overload Speed Limit Function....................................... 79 Dumping............................................................. 79 Lowering the Dump Body (When Dumping on Flat Ground)................ 80 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 80 SUDDEN LOSS OF ENGINE POWER............................................. 81 FUEL DEPLETION.......................................................... 81 SAFE PARKING PROCEDURES................................................. 81 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 82 DISABLED TRUCK CONNECTORS................................................... 83 GENERAL INFORMATION..................................................... 83 STEERING AND BRAKE SYSTEM............................................... 83 Components Required................................................. 83 Hookup.............................................................. 83 HOIST SYSTEM............................................................ 84 Hookup.............................................................. 84 Dumping Procedure................................................... 84 TOWING...................................................................... 86 SPECIAL WIRING HARNESS.................................................. 86 TOWING PROCEDURE........................................................ 86 PAYLOAD METER III SYSTEM.................................................... 88 GENERAL INFORMATION..................................................... 88 Data Summary........................................................ 88 Data Gathering...................................................... 88 COMPONENT DESCRIPTION................................................... 88 Operator Display.................................................... 88 Operator Switches................................................... 88 Brake Lock Switch................................................... 89 Payload Meter Module................................................ 89 Communications Ports................................................ 89 Load Lights......................................................... 89 OPERATOR’S DISPLAY AND SWITCH........................................... 89 Reading the Load Display............................................ 89 Setting the Operator ID............................................. 90 Load and Ton Counter................................................ 90 Viewing Live Sensor Data............................................ 90 Other Display Messages.............................................. 91 HAUL CYCLE WARNING FLAGS................................................ 91 Haul Cycle Data..................................................... 91 Haul Cycle Warning Flags............................................ 93 PC SOFTWARE OVERVIEW.................................................... 94 SYSTEM CONFIGURATION.................................................... 94 Connecting to the Payload Meter..................................... 94 Displayed Payload Units............................................. 95 Connection Menu..................................................... 95 Configure the Payload Meter......................................... 95 Setting the Date and Time........................................... 95 Setting the Truck Type and Serial Number............................ 96 Setting the Gauge Display Units..................................... 96 Setting the Carryback Alarm Threshold............................... 96 Setting the Truck Number............................................ 97 Setting the Komatsu Distributor..................................... 97 Setting the Komatsu Customer........................................ 97 Clean Truck Tare Calibration........................................ 97 Inclinometer Calibration............................................ 98 DOWNLOADING PAYLOAD DATA................................................ 98 UPLOADING DATA.......................................................... 99 DATA ANALYSIS...........................................................100 Creating a Query....................................................100 Payload Detail Screen...............................................101 Creating Reports....................................................101 Creating Graphs.....................................................101 Exporting Data......................................................102 Importing Data......................................................102 Deleting Haul Cycle Records.........................................102 Viewing Alarms......................................................103 Deleting Alarm Records..............................................103 Patent Acknowledgment...............................................103 AUTOMATIC LUBRICATION SYSTEM................................................104 GENERAL INFORMATION.....................................................104 COMPONENT DESCRIPTION...................................................104 Filter..............................................................105 Hydraulic Motor and Pump............................................105 Grease Reservoir....................................................105 Pressure Reducing Valve.............................................105 Flow Control Valve..................................................105 Solenoid Valve......................................................106 Vent Valve..........................................................106 Interface Module....................................................106 Pressure Cut Off Switch.............................................106 Injectors...........................................................107 Grease Pressure Failure Switch......................................107 Relief Valve (unloader valve).......................................107 SYSTEM OPERATION........................................................107 Filling The Reservoir...............................................107 Priming The Automatic Lubrication System............................108 PREVENTIVE MAINTENANCE PROCEDURES.......................................108 Daily Lubrication System Inspection.................................108 250 Hour Inspection.................................................109 1000 Hour Inspection................................................109 SYSTEM CHECKOUT.........................................................109 General Checks......................................................109 Lubrication Cycle Operation.........................................110 RESERVE ENGINE OIL SYSTEM...................................................111 Operation...............................................................111 Changing Oil............................................................111 6 OPERATOR CAB AND CONTROLS.....................................................114 CAB INTERIOR................................................................114 STEERING WHEEL AND CONTROLS.................................................115 Horn Button.............................................................115 Tilt / Telescope Lever..................................................115 Multi-Function Turn Signal Switch.......................................115 Speed Control Lever.....................................................115 Turn Signal Operation...................................................115 High Beam Headlight Operation...........................................116 Windshield Wiper Operation..............................................116 PEDALS......................................................................117 DYNAMIC RETARDING.......................................................117 Dynamic Retarder/Service Brake Pedal....................................117 ACCELERATOR PEDAL.......................................................117 OVERHEAD PANEL AND DISPLAYS.................................................118 RADIO SPEAKERS..........................................................118 WARNING ALARM BUZZER....................................................118 CAB RADIO...............................................................118 AIR CLEANER VACUUM GAUGES...............................................118 CENTER CONSOLE..............................................................119 DIRECTIONAL CONTROL LEVER...............................................119 OVERRIDE/FAULT RESET SWITCH.............................................119 ENGINE STOP SWITCH......................................................120 WINDOW CONTROL SWITCHES.................................................120 HOIST CONTROL LEVER.....................................................120 Raising The Dump Body...................................................120 Lowering The Dump Body..................................................120 DATA STORE BUTTON.......................................................120 SERVICE ENGINE LIGHT....................................................120 DIAGNOSTIC PORTS............................................................121 Drive System #1.........................................................121 ENGINE (QUANTUM)........................................................121 Drive System #3.........................................................121 ENGINE (CENSE)..........................................................121 INTERFACE MODULE (IM)...................................................121 KOMTRAX Plus ...........................................................121 PAYLOAD METER...........................................................121 OPERATOR SEAT (Standard)....................................................122 SEAT BELTS..............................................................122 ADJUSTMENT..............................................................122 PASSENGER SEAT (Standard)...................................................124 SEAT BELTS..............................................................124 ADJUSTMENT..............................................................124 OPERATOR SEAT (Optional)....................................................125 SEAT BELTS..............................................................125 ADJUSTMENT..............................................................125 PASSENGER SEAT (Optional)...................................................126 SEAT BELTS..............................................................126 ADJUSTMENT..............................................................126 HEATER / AIR CONDITIONER CONTROLS...........................................127 Fan Speed Control Knob..................................................127 Temperature Control Knob................................................127 Air Flow Directional Knob...............................................127 Heater/Air Conditioner Vents............................................127 INSTRUMENT PANEL ...........................................................128 CONTROL SYMBOLS.........................................................128 Key Switch..............................................................129 Speed Control Switch....................................................129 Traction Control Switch.................................................129 Retarding Grid Drier Switch.............................................130 AC Drive System Rest Switch.............................................130 Wheel Brake Lock Switch.................................................130 Hazard Light Switch.....................................................130 Heater/Air Conditioner Vents............................................130 Drive System Temperature Gauge..........................................131 Fuel Level Gauge........................................................131 Speedometer/Digital Display.............................................131 Coolant Temperature Gauge...............................................131 Hydraulic Oil Temperature Gauge.........................................131 Status Indicator Light Panel............................................131 Headlight/Panel Illumination Light Switch...............................131 Ladder Light Switch.....................................................131 Backup Light Switch.....................................................132 Fog Light Switch........................................................132 Mode Switches...........................................................132 Panel Lights Dimmer Switch..............................................132 Turn Signal Indicators..................................................132 Digital Display Contrast Buttons........................................132 Warning Light...........................................................132 STATUS INDICATOR LIGHT PANEL................................................133 STATUS INDICATOR LIGHT SYMBOLS..........................................133 Body Up.............................................................133 Parking Brake.......................................................133 Propel System Not Ready.............................................133 No Propel...........................................................134 Not used............................................................134 Engine Delay........................................................134 Retarding Grid Drier................................................134 Wheel Brake Lock....................................................134 Traction Control....................................................134 Repair Monitor......................................................134 Snapshot In Progress................................................134 Not used............................................................134 Not used............................................................134 Service Brake.......................................................135 Dynamic Retarding...................................................135 No DC Link Voltage..................................................135 DIGITAL DISPLAY OPERATION...................................................136 Toggling Through Main Level Screens.....................................136 Toggling Through Warning Screens........................................137 Entering Payload Meter Data.............................................138 KOMTRAX Plus................................................................139 KOMTRAX Plus OPERATION..................................................139 Basic Precautions...................................................139 Interface Module....................................................140 DOWNLOADING KOMTRAX Plus DATA...........................................141 GENERAL INFORMATION.................................................141 KOMTRAX Plus DOWNLOADING PROCEDURE..................................141 Location of Downloaded Files........................................142 UPLOADING KOMTRAX Plus DATA.............................................142 ORBCOMM.................................................................143 KOMATSU WIRELESS BRIDGE (Optional)......................................144 General Information.................................................144 Communication Setup.................................................144 Switching to the KWB_SETUP Network..................................144 Setting the Computer Subnet Mask and IP Address.....................145 Setting Up the KWB..................................................145 Adding Encryption...................................................146 Final Computer Settings.............................................146 Downloading Data....................................................146 Resetting the KWB...................................................147 FUSES AND CIRCUIT BREAKERS..................................................148 FUSE BLOCK #1...........................................................149 FUSE BLOCK #2...........................................................150 FUSE BLOCK #3...........................................................150 FUSE HOLDERS............................................................150 CIRCUIT BREAKERS........................................................151 7 LUBRICATION AND SERVICE.......................................................154 GENERAL INFORMATION.........................................................154 HYDRAULIC SYSTEM SERVICE................................................154 Hydraulic Tank......................................................154 Hydraulic Filters...................................................155 Hydraulic Pump Drive Shaft..........................................155 WHEEL MOTOR SERVICE.....................................................155 COOLANT LEVEL SERVICE...................................................155 Radiator Filling Procedure..........................................156 Coolant Specifications..............................................156 Unacceptable Practices..............................................156 RESERVE ENGINE OIL SERVICE..............................................156 Reserve Oil Tank Filling Procedure (Remote Fill)....................157 Inline Screen.......................................................157 CAB AIR FILTER SERVICE..................................................157 FUEL SYSTEM SERVICE.....................................................158 Fuel Tank Cleaning..................................................158 Fuel Filter Service.................................................158 INTAKE AIR CLEANER SERVICE..............................................159 FRONT ENGINE MOUNT TRUNION SERVICE......................................160 QUICK FILL SERVICE CENTER...............................................160 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................160 LUBRICATION CHART...........................................................162 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................163 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................165 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................166 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................167 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................169 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................171 EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................172 EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................173 EVERY 5000 HOUR MAINTENANCE.................................................174 EVERY 6000 HOUR MAINTENANCE.................................................175 30,000 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................176 8 SPECIFICATIONS................................................................178 MAJOR COMPONENT DESCRIPTION.................................................178 Truck And Engine........................................................178 Traction Alternator.....................................................178 Main Control Cabinet....................................................178 AC Induction Traction Motorized Wheels..................................178 Suspension..............................................................178 Operator's Cab..........................................................178 Power Steering..........................................................178 Dynamic Retarding Grid..................................................178 Brake System............................................................178 SPECIFICATIONS..............................................................179 Engine..................................................................179 AC Electric Drive System................................................179 Dynamic Retarding.......................................................179 Battery Electric System.................................................179 Service Capacities......................................................179 Hydraulic Systems.......................................................179 Service Brakes..........................................................180 Steering................................................................180 Standard Dump Body Capacities And Dimensions............................180 Tires...................................................................180 Weight Distribution.....................................................180 Overall Truck Dimensions................................................181 9 RADIO.........................................................................184 RADIO OPERATION.............................................................184 GENERAL RADIO RECEIVER FUNCTIONS........................................184 Turning On the Power....................................................184 One-Hour Timer..........................................................184 Finding a Station.......................................................184 Setting the Presets.....................................................185 Adjusting the Receiver Audio Settings...................................185 Display.................................................................186 Adjusting the Receiver Menu Settings....................................186 Front Auxiliary Mode....................................................186 Rear Auxiliary Mode.....................................................186 CLOCK.......................................................................187 Clock/Alarm Button......................................................187 Setting the Clock.......................................................187 Setting the Alarm.......................................................187 Turning the Alarm Off...................................................188 Activating Snooze.......................................................188 CD PLAYER...................................................................189 Playing a Compact Disc..................................................189 Playing an MP3 DISC.....................................................189 CD Mode Displays........................................................189 Button Functions........................................................189 MP3 PLAYER..................................................................191 Playing MP3 Files.......................................................191 MP3 Mode Displays.......................................................191 Button Functions........................................................191 iPod®.......................................................................193 Playing an iPod®........................................................193 iPod® Mode Displays.....................................................193 Button Functions........................................................193 WEATHERBAND (USA Only)......................................................195 TROUBLESHOOTING.............................................................196 Tips About the Audio System.............................................196 Understanding Radio Reception...........................................196 Care of the Compact Discs...............................................196
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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