Komatsu Dump Truck 860E-1KT service & repair manual

Description Komatsu Dump Truck 860E-1KT service & repair manual

Komatsu Dump Truck 860E-1KT pdf workshop service manual + field assembly manual + operation & maintenance manual

Serial numbers:
A30001 - A30003
A30004 - A30030
A30036 and up
A30036 - A30040, A30043, A30047 - A30100
A30102 - A30106, A30111 - A30116

Specifications, testing, troubleshooting, technical data, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Index
Foreword, safety and general information
Operating instructions

Specification
Specification and technical data
Specification drawing
Weight table
Fuel, coolant and lubricants

Structure and functions
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

Standard value table
Standard value table for truck

Testing and adjusting
Service tools
Cab air conditioning
Steering, brake cooling and hoist hydraulic system
Brake system
Accumulators and suspensions
Payload meter IV
KOMTRAX Plus II
Interface module (IM1)
Interface module (IM2)
IGBT haul truck SIBAS® user manual
Installing ZR / DSP software
24V electrical system
Automatic lubrication (auto lube) system

Troubleshooting
Cab air conditioning
Fuse and circuit breaker locations
Troubleshooting by fault code
Drive system fault code table
Payload meter scoreboard
Electric wheel motor
Reserve engine oil system
Steering system
Automatic lubrication (auto lube) system

Disassembly and assembly
Service tools
Special tool list
Additional tool list
Wheel motor rebuild tools
Control cabinet
Cab air conditioning
Replacement of air conditioning system components
Wheels, spindles and rear axle
General precautions for tires and rims
Wheel stud maintenance
Front tires and rims
Rear tires and rims
Rim components
Rim and tire service
Removal and installation of front wheel hub and spindle
Disassembly and assembly of front wheel hub and spindle
Removal and installation of wheel motor
Removal and installation of rear axle
Removal and installation of anti-sway bar
Removal and installation of pivot pin
Pivot eye and bearing service
Removal and installation of electric motor
Disassembly and assembly of wheel motor transmission
Disassembly and assembly of low speed carrier
Disassembly and assembly of high speed carrier
Brake system
Removal and installation of brake valve
Disassembly and assembly of brake valve/pedal assembly
Removal and installation of dual relay valve
Removal and installation of brake manifold
Disassembly and assembly of brake manifold
Removal and installation of brake accumulator
Piston accumulator storage
Brake accumulator charging procedure
Disassembly and assembly of wheel brake
Removal and installation of rear brake assembly
Steering system
Removal and installation of steering control unit
Disassembly and assembly of steering control unit
Removal and installation of steering column
Removal and installation of steering wheel
Removal and installation of bleeddown manifold
Removal and installation of flow amplifier
Disassembly and assembly of flow amplifier
Removal and installation of steering cylinder
Disassembly and assembly of steering cylinders
Removal and installation of tie rod
Disassembly and assembly of tie rod
Removal and installation of steering/brake pump
Disassembly and assembly of steering/brake pump
Removal and installation of steering accumulators
Disassembly and assembly of steering accumulator
Piston accumulator storage
Steering accumulator charging procedure
Suspensions
Removal and installation of front suspension
Minor front suspension repairs (lower bearing and seals)
Major front suspension rebuild
Removal and installation of rear suspension
Disassembly and assembly of rear suspension
Hoist circuit
Removal and installation of hoist pump
Disassembly and assembly of hoist pump
Removal and installation of hoist valve
Disassembly and assembly of hoist valve
Overcenter manifold service
Removal and installation of hoist pilot valve
Disassembly and assembly of hoist pilot valve
Removal and installation of hoist cylinders
Disassembly and assembly of hoist cylinders
Replacement of hoist circuit filter
Operator cab
Removal and installation of operator cab
Removal and installation of cab door
Disassembly and assembly of cab door
Adjustment of cab door
Removal and installation of side window glass
Removal and installation of windshield and rear window glass
Removal and installation of windshield wiper motor
Removal and installation of windshield wiper arm
Removal and installation of windshield wiper linkage
Removal and installation of operator seat (standard seat)
Removal and installation of passenger seat (standard seat)
Removal and installation of seat belts (standard seat)
Operator seat (optional seat)
Passenger seat (optional seat)
Removal and installation of seat belts (optional seat)
Body and structures
Removal and installation of dump body
Removal and installation of body pads
Body pad shimming procedure
Removal and installation of diagonal ladder/ hood and grille assembly
Removal and installation of right deck
Removal and installation of left deck
Removal and installation of fuel tank
Removal and installation of horizontally mounted fuel gauge sender
Removal and installation of vertically mounted fuel gauge sender
Disassembly and assembly of fuel tank breather
Removal and installation of hydraulic tank
Three phase wheel motor
Motor
Transport
Storage of new motors
Storage of used motors
Safety guidelines
Checking for external damage
Checking the connections
Regreasing the bearings
Applying grease to the bearings
Checking the interior of the motor for water
Pressing off the coupling
Disassembly
Removing the rubber seals and the air baffles
Bearing and labyrinth ring
Stator Inspection
Rotor Inspection
Testing the insulation
Work on the bearings
Assembling the rubber seals and the air baffles
Assembly after special repair work
Assembling the bearing shield (N-end) at the stator frame
Bearing installation
Rotor installation
Labyrinth ring
Installing accessories (D- and N-end)
Running in the bearings
Coupling
Assembly conditions and instructions
Tests
Replacing defective connecting leads
Repairing the stator winding insulation
Recommended consumables
Chemical cleaning agents
Chemical cleaning agents for windings
Rolling-contact bearing grease
Assembly/disassembly agents for bearing seat
Sealants for joining parts or gaps
Locking agents for connecting elements
Anti-corrosion agent
Assembly paste for temperature sensors
Mounting devices for inserting and withdrawing the rotor horizontally
Press for expanding the coupling
Compression devices for pressing on or for support while pressing off
Pulling units with cross beam or disk
Aids
Extraction devices
Paints for refinishing the painted parts or touching up damaged parts
Power module
Removal and installation of power module
Exhaust tube installation
Exhaust blanket installation
Removal and installation of alternator
Removal and installation of engine
Removal and installation of radiator
Repairing the radiator
Auto lubrication system
Lubrication system priming
Removal and installation of lubrication pump
Disassembly and assembly of lubrication pump
Main blower
Removing the main blower motor
Disassembling the main blower motor
Assembling the main blower motor
Installing the main blower motor
Retarding grid
Removing the grid blower motor
Disassembling the grid blower motor
Assembling the grid blower motor
Installing the grid blower motor
Removing a grid element
Control cabinet
Removing the SIBAC Inverter Module
Installing the SIBAC Inverter Module
Draining and filling the IGBT coolant system
Removing and installing the IGBT coolant pump assembly

Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams - 24V system
Electrical circuit diagrams - drive system