Komatsu 860E-1K Dump Truck Service Repair Manual

Table of Content

00 Index and foreword
Index
Foreword, safety and general information
Operating instructions
01 Specification
Specification and technical data
10 Structure, function and maintenance standard
Cab air conditioning
Steering circuit
Hoist circuit
Brake circuits
Suspensions
Electrical system, 24 volt
Interface module (IM)
Drive system
SIBAS® IGBT rack components
Reserve engine oil system
Wheel motor transmission
20 Standard value table
Standard value table
30 Testing and adjusting
General information
Cab air conditioning
Steering, brake cooling and hoist hydraulic system
Brake system
Accumulators and suspensions
Payload meter
KOMTRAX Plus
Interface module (IM)
SIBAS® user manual
SIBAS® user manual
Installing ZR / DSP software
24V electrical system
Automatic lubrication system checkout
40 Troubleshooting
Cab air conditioning
Fuse locations
Troubleshooting by failure code
Drive system fault code table
Payload meter scoreboard
Electric wheel motor
Reserve engine oil system
Steering system
Automatic lubrication (auto lube) system
50 Disassembly and assembly
Service tools
Cab air conditioning
Wheels, spindle and rear axle
Brake system
Steering system
Suspensions
Hoist circuit
Operator cab
Body and structures
Three phase wheel motor
Power module
Main blower
Retarding grid
Control cabinet
90 Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams – 24V system
Electrical circuit diagrams – drive system

HOW TO READ THE SHOP MANUAL

Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.

00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.

01 SPECIFICATIONS
This section describes the specifications of the machine.

10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.

20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.

30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.

40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.

90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.