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KOMATSU 960E-1 DUMP TRUCK Operation & Maintenance Manual (SN :A30025 – A30026) KOMATSU 960E-1 – PDF DOWNLOAD
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- KOMATSU 960E-1 DUMP TRUCK Operation & Maintenance Manual
- SERIAL NUMBER :A30025 – A30026
- PUBLICATION NUMBER:CEAM022901
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Description
KOMATSU 960E-1 DUMP TRUCK Operation & Maintenance Manual (SN :A30025 – A30026) KOMATSU 960E-1
KOMATSU 960E-1 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN :A30025 – A30026) KOMATSU 960E-1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 960E-1 DUMP TRUCK Operation & Maintenance Manual (SN :A30025 – A30026) KOMATSU 960E-1
- This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck. All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck.
- A product identification plate is located on the frame in front of the right side front wheel. It 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. 960E).
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 identifies 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 Gross Vehicle Weight (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 maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload.
TABLE OF CONTENTS:
KOMATSU 960E-1 DUMP TRUCK Operation & Maintenance Manual (SN :A30025 – A30026) KOMATSU 960E-1
INTRODUCTION................................................................. 5 FOREWORD................................................................. 5 TRUCK MODEL ILLUSTRATION................................................. 6 ABOUT THIS MANUAL........................................................ 7 ALERTS PAGE.............................................................. 8 TABLE OF CONTENTS............................................................ 9 TORQUE TABLES AND CONVERSION CHARTS.......................................... 19 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values..... 20 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts.... 20 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws....... 21 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws................... 22 SAFETY....................................................................... 29 General.................................................................. 29 Safety rules......................................................... 29 Safety features...................................................... 29 Fire extinguisher and first aid kit.................................. 29 Clothing and personal items.......................................... 29 Leaving the operator seat............................................ 30 Mounting and dismounting............................................. 30 Fire prevention for fuel and oil..................................... 30 Precautions with high temperature fluids............................. 31 Asbestos dust hazard prevention...................................... 31 Prevention of injury by work equipment............................... 31 Unauthorized modification............................................ 31 ROPS precautions..................................................... 31 Precautions for attachments.......................................... 32 Precautions for starting the truck................................... 32 Precautions before operating the truck................................... 32 Safety at the worksite............................................... 32 Fire prevention...................................................... 33 Ventilation in enclosed areas........................................ 33 Preparing for operation.............................................. 33 Mirrors, windows and lights.......................................... 33 In the operator cab (before starting the engine)..................... 33 Seat belts........................................................... 33 Precautions while operating the truck.................................... 34 When starting the engine............................................. 34 General truck operation.............................................. 34 Ensuring good visibility............................................. 34 Traveling............................................................ 35 Traveling in reverse................................................. 35 Traveling on slopes.................................................. 35 Operating on snow or ice............................................. 35 Avoiding damage to the dump body..................................... 35 Driving near high voltage cables..................................... 36 When dumping......................................................... 36 When loading......................................................... 36 Working on loose ground.............................................. 36 Parking the truck.................................................... 36 Towing............................................................... 36 Working near batteries................................................... 37 Battery hazard prevention............................................ 37 Starting with booster cables......................................... 37 Precautions before performing service.................................... 38 Stopping the engine.................................................. 38 Warning tag.......................................................... 38 Proper tools......................................................... 38 Securing the dump body............................................... 38 Precautions while performing service..................................... 39 Keeping the truck clean.............................................. 39 Attachments.......................................................... 39 Working under the truck.............................................. 39 Rotating fan and belts............................................... 39 Waste materials...................................................... 39 Adding fuel or oil................................................... 40 Radiator coolant level............................................... 40 Use of lighting...................................................... 40 Precautions with the battery......................................... 40 Handling high pressure hoses......................................... 40 Precautions with high pressure oil................................... 40 Performing maintenance near high temperature or high pressure........ 40 Tires.................................................................... 41 Handling tires....................................................... 41 Storing tires after removal.......................................... 41 Precautions for performing repairs....................................... 42 Engine shutdown procedure after AC drive system failure.............. 42 Precautions for welding on the truck..................................... 43 Capacitor discharge system............................................... 44 Necessary tools...................................................... 44 Warnings and cautions................................................ 45 Manual DC link capacitor discharge procedure......................... 46 Failure of the discharge system...................................... 48 Manual discharge of capacitors....................................... 49 Short isolated capacitor terminals................................... 51 WARNINGS AND CAUTIONS........................................................ 53 GRADE/SPEED CHART........................................................ 53 KEY SWITCH............................................................... 53 ROPS/FOPS................................................................ 53 BATTERIES................................................................ 54 EMERGENCY SHUTDOWN....................................................... 54 RADIATOR................................................................. 55 CRUSHING HAZARD.......................................................... 55 CYLINDER PRESSURE........................................................ 55 FILLING THE HYDRAULIC TANK............................................... 56 HYDRAULIC OIL PRESSURE................................................... 56 WHEEL MOTOR OIL LEVEL.................................................... 56 EMERGENCY TOWING PROCEDURE............................................... 56 EMERGENCY DUMP PROCEDURE................................................. 57 ACCUMULATOR DRAIN VALVES................................................. 57 HOT EXHAUST.............................................................. 57 WELDING.................................................................. 57 INFORMATION DISPLAY...................................................... 57 CAPACITORS............................................................... 58 HIGH VOLTAGE............................................................. 58 LIFTING INSTRUCTIONS..................................................... 59 WIRELESS SIGNALS......................................................... 59 PRODUCT IDENTIFICATION PLATE............................................. 60 LUBRICATION CHART........................................................ 60 OPERATING INSTRUCTIONS....................................................... 61 Preparing for operation.................................................. 61 Walk around inspection................................................... 61 Engine start-up.......................................................... 65 After engine start-up.................................................... 66 Emergency steering system................................................ 66 Operation............................................................ 66 Pre-operation testing................................................ 66 Precautions during truck operation....................................... 67 Operating on a haul road................................................. 68 Starting on a grade with a loaded truck.................................. 69 Sudden loss of engine power.............................................. 69 Fuel depletion........................................................... 70 Towing................................................................... 70 Special Wiring Harness............................................... 71 Loading the dump body.................................................... 73 Overload speed limit function........................................ 73 Dumping a load........................................................... 74 Raising the dump body................................................ 74 Lowering the dump body (on flat ground).............................. 75 Lowering the dump body (over a berm or into a crusher)............... 75 Disabled truck dumping procedure......................................... 76 Hookup............................................................... 76 Raising the body..................................................... 76 Lowering the body.................................................... 76 Safe parking procedure................................................... 77 Normal engine shutdown procedure......................................... 77 OPERATOR CAB AND CONTROLS.................................................... 79 STEERING WHEEL AND CONTROLS.............................................. 80 Horn Button.......................................................... 80 Tilt / Telescope Lever............................................... 80 Multi-Function Turn Signal Switch.................................... 80 Retarder Control Lever............................................... 81 PEDALS................................................................... 81 Retarder/Service Brake Pedal......................................... 81 Throttle/Accelerator Pedal........................................... 82 GRADE/SPEED CHART........................................................ 83 OVERHEAD PANEL AND DISPLAYS.............................................. 83 CENTER CONSOLE........................................................... 84 Directional Control Lever............................................ 84 Override/Fault Reset Switch.......................................... 85 Engine Shutdown Switch............................................... 85 Window Control Switches.............................................. 85 Hoist Control Lever.................................................. 85 Retard Speed Control (RSC) Adjustment Dial........................... 86 Retard Speed Control (RSC) Switch.................................... 86 Data Store Button.................................................... 86 12V Auxiliary Power Outlets.......................................... 86 DIAGNOSTIC PORTS......................................................... 87 KOMTRAX Plus Diagnostic Port......................................... 87 Interface Module (IM) Diagnostic Port................................ 87 Payload Meter Diagnostic Port........................................ 87 Truck Control Interface (TCI) Diagnostic Port........................ 87 Propulsion System Controller (PSC) Diagnostic Port................... 87 Engine Diagnostic Port (CENSE)....................................... 87 Engine Diagnostic Port (QUANTUM)..................................... 87 OPERATOR’S SEAT.......................................................... 88 Seat Belts........................................................... 88 Adjustment........................................................... 88 PASSENGER SEAT........................................................... 89 Seat Belts........................................................... 89 Adjustment........................................................... 89 HEATER / AIR CONDITIONER CONTROLS........................................ 90 Fan Speed Control Knob............................................... 90 Temperature Control Knob............................................. 90 Air Flow Directional Knob............................................ 90 Heater/Air Conditioner Vents......................................... 90 INSTRUMENT PANEL......................................................... 91 Control Symbols...................................................... 91 Key Switch........................................................... 93 Retarding Grid Drier Switch.......................................... 93 AC Drive System Rest Switch.......................................... 93 Wheel Brake Lock Switch.............................................. 94 Hazard Warning Lights................................................ 94 Heater/Air Conditioner Vents......................................... 94 Fuel Level Gauge..................................................... 94 Hydraulic Oil Temperature Gauge...................................... 94 Speedometer/Digital Display.......................................... 94 Coolant Temperature Gauge............................................ 94 Drive System Temperature Gauge....................................... 94 Headight/Panel Illumination Light Switch............................. 95 Ladder Light Switch (3-Way).......................................... 95 Backup Light Switch.................................................. 95 Fog Light Switch..................................................... 95 Mode Switches........................................................ 95 Panel Illumination Light Dimmer Switch............................... 95 Right/Left Turn Signal Indicators.................................... 95 Digital Display Contrast Buttons..................................... 95 Warning Light........................................................ 95 STATUS INDICATOR LIGHTS.................................................. 96 Body Up.............................................................. 96 Parking Brake Applied................................................ 96 Propulsion System Not Ready.......................................... 96 No DC Link Voltage................................................... 97 Not used............................................................. 97 No Propel............................................................ 97 Dynamic Retarding.................................................... 97 Service Brake Applied................................................ 97 Pantagraph Up........................................................ 97 Pantagraph Energized................................................. 97 Wheel Brake Lock Applied............................................. 97 Repair Monitor....................................................... 97 DIGITAL DISPLAY OPERATION................................................ 98 Toggling Through Main Level Screens.................................. 98 Toggling Through Warning Screens..................................... 99 Entering Payload Meter Data..........................................100 REAR AXLE LIGHT BAR......................................................101 Backup Lights........................................................101 Retard Lights........................................................101 Brake Light..........................................................101 Backup Alarm.........................................................101 KOMTRAX PLUS.............................................................102 Operation............................................................102 Interface Module.....................................................104 Basic Precautions....................................................104 KOMATSU WIRELESS BRIDGE (Optional).......................................105 General Information..................................................105 Communication Setup..................................................105 Switching to the KWB_SETUP Network...................................105 Setting the Computer Subnet Mask and IP Address......................106 Properties...........................................................106 Setting Up the KWB...................................................107 Adding Encryption....................................................107 Final Computer Settings..............................................107 Data Downloading.....................................................108 Resetting the KWB....................................................108 KWB Lights...........................................................108 FUSES AND CIRCUIT BREAKERS...............................................109 LUBRICATION AND SERVICE......................................................113 SERVICE CAPACITIES.......................................................113 HYDRAULIC TANK SERVICE...................................................113 Adding Oil...........................................................113 COOLING SYSTEM SERVICE...................................................114 Adding Coolant.......................................................114 Coolant Specifications...............................................114 Unacceptable Practices...............................................114 WHEEL MOTOR SERVICE......................................................114 RESERVE OIL TANK SERVICE.................................................115 Filling the Reserve Oil Tank (Remote Fill)...........................115 Inline Screen........................................................115 AIR CLEANER SERVICE......................................................116 Replacing the Elements...............................................116 Cleaning the Primary Element.........................................118 Cleaning the Precleaner Section......................................119 QUICK FILL SERVICE CENTER................................................120 TIE ROD INSPECTION AND TORQUE PROCEDURE..................................120 LUBRICATION CHART........................................................121 10 HOUR (DAILY) INSPECTION...............................................122 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS.......................124 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS......................124 INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS......................124 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................125 500 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................128 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................129 3000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................130 5000 HOUR MAINTENANCE CHECKS.............................................130 AUTOMATIC LUBRICATION SYSTEM.................................................131 GENERAL DESCRIPTION......................................................131 SYSTEM COMPONENTS........................................................133 Filter Assembly......................................................133 Hydraulic Motor and Pump.............................................133 Grease Reservoir.....................................................133 Pressure Reducing Valve..............................................133 Flow Control Valve...................................................133 Solenoid Valve.......................................................133 Vent Valve...........................................................133 Interface Module.....................................................133 Grease System Failure Switch.........................................133 Injectors............................................................133 Unloader Valve.......................................................133 SYSTEM OPERATION.........................................................134 GENERAL INSTRUCTIONS.....................................................135 Required Lubricant...................................................135 System Priming.......................................................135 Filter Assembly......................................................135 LUBRICANT PUMP...........................................................136 Pump Housing Oil Level...............................................136 Pump Pressure Control................................................136 INJECTORS (SL-1 Series “H”)..............................................137 Injector Specifications..............................................137 Injector Adjustment..................................................137 INJECTOR OPERATION...................................................138 PREVENTIVE MAINTENANCE PROCEDURES........................................139 Daily Lubrication System Inspection..................................139 250 Hour Inspection..................................................139 1000 Hour Inspection.................................................139 SYSTEM CHECKOUT..........................................................140 Lubrication Cycle Operation..........................................140 SYSTEM TROUBLESHOOTING CHART.............................................141 COMPONENTS & SPECIFICATIONS..................................................143 MAJOR COMPONENT DESCRIPTIONS.............................................143 Truck And Engine.....................................................143 Main Alternator......................................................143 AC Induction Traction Motorized Wheels...............................143 Suspension...........................................................143 Operator's Cab.......................................................143 Power Steering.......................................................143 Dynamic Retarding....................................................143 Brake System.........................................................143 SPECIFICATIONS...........................................................145 ENGINE...............................................................145 AC ELECTRIC DRIVE SYSTEM.............................................145 DYNAMIC RETARDING....................................................145 BATTERY ELECTRIC SYSTEM..............................................145 SERVICE CAPACITIES...................................................145 HYDRAULIC SYSTEMS....................................................146 SERVICE BRAKES.......................................................146 STEERING.............................................................146 TIRES................................................................146 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS.........................146 WEIGHT DISTRIBUTION..................................................146 PAYLOAD METER III............................................................149 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER............................179 OPERATING INSTRUCTIONS...................................................179 GENERAL RADIO RECEIVER FUNCTIONS.....................................179 Turning On the Power.............................................179 One-Hour Timer...................................................179 Adjusting the Volume.............................................180 Display..........................................................180 Radio Mode Displays..............................................180 CD Mode Displays.................................................180 MP3/USB/iPod Mode Displays.......................................180 AUX Input Displays...............................................181 CLOCK/ALARM Button...............................................181 Front Auxiliary Mode.............................................181 Rear Auxiliary Mode..............................................181 Adjusting the Receiver Audio Settings............................181 Adjusting the Receiver Menu Settings.............................182 USING THE RADIO......................................................183 Finding a Station................................................183 Setting the Presets..............................................183 USING THE CLOCK......................................................184 Setting the Clock................................................184 USING THE ALARM......................................................184 Setting the Alarm................................................184 Turning the Alarm Off............................................185 Activating Snooze................................................185 USING THE WEATHERBAND (USA Only).....................................185 USING THE COMPACT DISC PLAYER/USB....................................186 Playing A Compact Disc...........................................186 Button Functions.................................................186 PLAYING AN MP3 DISC/USB..............................................187 Root Directory...................................................187 Empty Directory or Folder........................................187 No Folder........................................................187 File Name Display................................................187 PLAYING MP3 FILES....................................................187 Button Functions.................................................187 USING AN iPOD®.......................................................188 Playing an iPod..................................................188 Button Functions.................................................188 OPERATING TIPS.......................................................189 Tips About The Audio System......................................189 Understanding Radio Reception....................................189 Care of The Compact Discs........................................189 TROUBLESHOOTING......................................................190
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