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KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30027 & UP) KOMATSU 960E-2 – PDF DOWNLOAD
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- KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A30027 & UP
- PUBLICATION NUMBER:CEAM026101
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Description
KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30027 & UP) KOMATSU 960E-2
KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30027 & UP) KOMATSU 960E-2 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30027 & UP) KOMATSU 960E-2
- 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.
- To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which includes all accessories, body liners, tailgates, etc.) and then weigh truck. Record this value and subtract from the GVW rating. The result is the allowable payload.
TABLE OF CONTENTS:
KOMATSU 960E-2 DUMP TRUCK OPERATION & MAINTENANCE MANUAL (SN:A30027 & UP) KOMATSU 960E-2
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............................................ 44 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............................ 49 Handling Tires...................................................... 49 Tire Maintenance.................................................... 49 Storing Tires After Removal......................................... 50 BATTERY HAZARD PREVENTION........................................... 50 Jump Starting With Booster Cables............................... 51 Jump Starting With Receptacles.................................. 51 WHEN REPAIRS ARE NECESSARY.................................................. 52 Observe The Following Precautions....................................... 52 SPECIAL PRECAUTIONS......................................................... 53 Preliminary Procedures Before Welding or Performing Maintenance......... 53 Engine Shutdown Procedure Before Welding or Performing Maintenan........ 53 Discharging Control Cabinet Capacitors.................................. 54 4 WARNING AND CAUTIONS.......................................................... 56 GENERAL INFORMATION......................................................... 56 PIN PLATE................................................................... 56 GRADE SPEED CHART........................................................... 57 MACHINE SAFETY.............................................................. 57 KEY SWITCH.................................................................. 59 OIL FILL AND CHECK.......................................................... 59 HIGH PRESSURES.............................................................. 60 BATTERY AND ENGINE SHUTDOWN................................................. 63 HIGH VOLTAGE................................................................ 64 WELDING..................................................................... 67 LIFTING POINTS.............................................................. 67 EMERGENCY DUMPING........................................................... 69 ROPS/FOPS................................................................... 69 TOWING...................................................................... 69 LUBRICATION CHART........................................................... 70 5 OPERATING INSTRUCTIONS........................................................ 72 PREPARING FOR OPERATION..................................................... 72 Safety Is Thinking Ahead................................................ 72 Walk Around Inspection.................................................. 72 RETRACTABLE LADDER SYSTEM (If Equipped)..................................... 76 GENERAL INFORMATION..................................................... 76 LADDER SYSTEM DESCRIPTION............................................... 76 LADDER SYSTEM OPERATION................................................. 76 In-Cab Control Panel.................................................... 77 Ground Level Control Box................................................ 79 Emergency Down Valve.................................................... 79 PRE-SHIFT BRAKE TEST........................................................ 80 OPERATION............................................................... 80 Service Brake Test...................................................... 81 Parking Brake Test...................................................... 81 Retard System Test...................................................... 82 Brake Test Exit Criteria................................................ 82 TRUCK OPERATION............................................................. 83 ENGINE START-UP SAFETY.................................................. 83 After Engine Has Started............................................ 83 MACHINE OPERATION SAFETY PRECAUTIONS.................................... 84 Machine Operation on the Haul Road.................................. 85 Starting on a Grade With a Loaded Truck............................. 85 Retarding on a Grade................................................ 85 Passing............................................................. 86 Loading............................................................. 86 Overload Speed Limit Function....................................... 86 Dumping............................................................. 87 Lowering the Dump Body (When Dumping on Flat Ground)................ 88 Lowering the Dump Body (When Dumping Over a Berm Or Into a Crush.... 89 SUDDEN LOSS OF ENGINE POWER............................................. 89 EMERGENCY STEERING SYSTEM............................................... 89 Operation........................................................... 89 Pre-Operation Testing............................................... 90 Additional Guidelines............................................... 90 FUEL DEPLETION.......................................................... 91 SAFE PARKING PROCEDURES................................................. 91 NORMAL ENGINE SHUTDOWN PROCEDURE........................................ 91 DISABLED TRUCK CONNECTORS................................................... 93 GENERAL INFORMATION..................................................... 93 HOIST SYSTEM............................................................ 93 Hookup.............................................................. 93 Dumping Procedure................................................... 93 TOWING...................................................................... 95 SPECIAL WIRING HARNESS.................................................. 95 TOWING PROCEDURE........................................................ 95 PAYLOAD METER III SYSTEM.................................................... 97 GENERAL INFORMATION..................................................... 97 Data Summary........................................................ 97 Data Gathering...................................................... 97 COMPONENT DESCRIPTION................................................... 97 Operator Display.................................................... 97 Operator Switch..................................................... 97 Brake Lock Switch................................................... 97 Payload Meter Module................................................ 98 Communications Ports................................................ 98 Load Lights......................................................... 98 OPERATORS DISPLAY AND SWITCH............................................ 98 Reading the Load Display............................................ 98 Setting the Operator ID............................................. 99 Load and Ton Counter................................................ 99 Viewing Live Sensor Data............................................ 99 Other Display Messages.............................................. 99 HAUL CYCLE WARNING FLAGS................................................100 Haul Cycle Data.....................................................100 Haul Cycle Warning Flags............................................101 PC SOFTWARE OVERVIEW....................................................103 SYSTEM CONFIGURATION....................................................103 Connecting to the Payload Meter.....................................103 Displayed Payload Units.............................................104 Connection Menu.....................................................104 Configure the Payload Meter.........................................104 Setting the Date and Time...........................................104 Setting the Truck Type and Serial Number............................105 Setting the Gauge Display Units.....................................105 Setting the Carryback Alarm Threshold...............................105 Setting the Truck Number............................................106 Setting the Komatsu Distributor.....................................106 Setting the Komatsu Customer........................................106 Clean Truck Tare Calibration........................................106 Inclinometer Calibration............................................107 DOWNLOADING PAYLOAD DATA................................................107 UPLOADING DATA..........................................................108 DATA ANALYSIS...........................................................109 Creating a Query....................................................109 Payload Detail Screen...............................................110 Creating Reports....................................................110 Creating Graphs.....................................................110 Exporting Data......................................................111 Importing Data......................................................111 Deleting Haul Cycle Records.........................................111 Viewing Alarms......................................................112 Deleting Alarm Records..............................................112 Patent Acknowledgment...............................................112 AUTOMATIC LUBRICATION SYSTEM................................................113 GENERAL INFORMATION.....................................................113 COMPONENT DESCRIPTION...................................................113 Filter..............................................................114 Hydraulic Motor and Pump............................................114 Grease Reservoir....................................................114 Pressure Reducing Valve.............................................114 Flow Control Valve..................................................114 Solenoid Valve......................................................115 Vent Valve..........................................................115 Interface Module....................................................115 Injectors...........................................................117 Grease Pressure Failure Switch......................................117 Relief Valve (unloader valve).......................................117 SYSTEM OPERATION........................................................117 Filling The Reservoir...............................................117 Priming The Automatic Lubrication System............................118 PREVENTIVE MAINTENANCE PROCEDURES.......................................118 Daily Lubrication System Inspection.................................118 250 Hour Inspection.................................................119 1000 Hour Inspection................................................119 SYSTEM CHECKOUT.............................................................120 General Checks..........................................................120 Lubrication Cycle Operation.............................................120 RESERVE ENGINE OIL SYSTEM...................................................121 Operation...............................................................121 Changing Oil............................................................121 6 OPERATOR CAB AND CONTROLS.....................................................124 CAB INTERIOR................................................................124 STEERING WHEEL AND CONTROLS.................................................125 Horn Button.............................................................125 Tilt / Telescope Lever..................................................125 Multi-Function Turn Signal Switch.......................................125 Turn Signal Operation...................................................125 High Beam Headlight Operation...........................................125 Windshield Wiper Operation..............................................125 PEDALS AND RETARDER LEVER...................................................126 DYNAMIC RETARDING.......................................................126 RETARDER LEVER..........................................................126 BRAKE/RETARDER PEDAL....................................................126 ACCELERATOR PEDAL.......................................................126 OVERHEAD PANEL AND DISPLAYS.................................................127 RADIO SPEAKERS..........................................................127 WARNING ALARM BUZZER....................................................127 CAB RADIO...............................................................127 AIR CLEANER VACUUM GAUGES...............................................127 CENTER CONSOLE..............................................................128 DIRECTIONAL CONTROL LEVER...............................................128 OVERRIDE/FAULT RESET SWITCH.............................................128 ENGINE STOP SWITCH......................................................128 WINDOW CONTROL SWITCHES.................................................129 HOIST CONTROL LEVER.....................................................129 Raising The Dump Body...................................................129 Lowering The Dump Body..................................................129 RETARD SPEED CONTROL (RSC) ADJUST DIAL..................................129 RETARD SPEED CONTROL (RSC) SWITCH.......................................130 DATA STORE BUTTON.......................................................130 12V AUXILIARY POWER OUTLETS.............................................130 FIRE SUPPRESSION CONTROL OUTLET.........................................130 COMMUNICATION RADIO OUTLET..............................................130 DIAGNOSTIC PORTS............................................................131 KOMTRAX Plus ...........................................................131 INTERFACE MODULE (IM)...................................................131 PAYLOAD METER...........................................................131 TRUCK CONTROL INTERFACE (TCI)...........................................131 PROPULSION SYSTEM CONTROLLER (PSC)......................................131 ENGINE (CENSE)..........................................................131 ENGINE (QUANTUM)........................................................131 OPERATOR SEAT (Standard)....................................................132 SEAT BELTS..............................................................132 ADJUSTMENT..............................................................132 PASSENGER SEAT (Standard)...................................................134 SEAT BELTS..............................................................134 ADJUSTMENT..............................................................134 OPERATOR SEAT (Optional)....................................................135 SEAT BELTS..............................................................135 ADJUSTMENT..............................................................135 PASSENGER SEAT (Optional)...................................................136 SEAT BELTS..............................................................136 ADJUSTMENT..............................................................136 HEATER / AIR CONDITIONER CONTROLS...........................................137 Fan Speed Control Knob..................................................137 Temperature Control Knob................................................137 Air Flow Directional Knob...............................................137 Heater/Air Conditioner Vents............................................137 INSTRUMENT PANEL ...........................................................138 CONTROL SYMBOLS.........................................................138 Key Switch..............................................................139 Engine Warming Switch...................................................139 AC Drive System Rest Switch.............................................139 Wheel Brake Lock Control Switch.........................................140 Hazard Warning Lights...................................................140 Heater/Air Conditioner Vents............................................140 Fuel Level Gauge........................................................140 Hydraulic Oil Temperature Gauge.........................................140 Speedometer/Digital Display.............................................141 Coolant Temperature Gauge...............................................141 Drive System Temperature Gauge..........................................141 Status Indicator Light Panel............................................141 Headlight/Panel Illumination Light Switch (3-Way).......................141 Ladder Light Switch.....................................................141 Backup Light Switch.....................................................141 Fog Light Switch........................................................141 Mode Switches...........................................................141 Panel Illumination Light Dimmer Switch..................................142 Right/Left Turn Signal Indicators.......................................142 Digital Display Contrast Buttons........................................142 Warning Light...........................................................142 STATUS INDICATOR LIGHT PANEL................................................143 STATUS INDICATOR LIGHT SYMBOLS..........................................143 Body Up.............................................................143 Parking Brake.......................................................143 Propel System Not Ready.............................................143 No Propel...........................................................144 Engine Warm Up......................................................144 Engine Shutdown Timer...............................................144 Not used............................................................144 Wheel Brake Lock....................................................144 Traction Control....................................................144 Repair Monitor......................................................144 Snapshot In Progress................................................144 Not used............................................................144 Not used............................................................144 Service Brake.......................................................145 Dynamic Retarding...................................................145 No DC Link Voltage..................................................145 OVERHEAD DASH PANEL.........................................................146 Brake Test Switch (If Equipped).........................................146 Brake Test Light (If Equipped)..........................................146 DIGITAL DISPLAY OPERATION...................................................147 Toggling Through Main Level Screens.....................................147 Toggling Through Warning Screens........................................148 Entering Payload Meter Data.............................................149 KOMTRAX Plus................................................................150 KOMTRAX Plus OPERATION..................................................150 Basic Precautions...................................................150 Interface Module....................................................151 DOWNLOADING KOMTRAX Plus DATA...........................................152 GENERAL INFORMATION.................................................152 KOMTRAX Plus DOWNLOADING PROCEDURE..................................152 Location of Downloaded Files........................................153 UPLOADING KOMTRAX Plus DATA.............................................153 ORBCOMM.................................................................154 KOMATSU WIRELESS BRIDGE (Optional)......................................155 General Information.................................................155 Communication Setup.................................................155 Switching to the KWB_SETUP Network..................................155 Setting the Computer Subnet Mask and IP Address.....................156 Setting Up the KWB..................................................156 Adding Encryption...................................................157 Final Computer Settings.............................................157 Downloading Data....................................................157 Resetting the KWB...................................................158 FUSES AND CIRCUIT BREAKERS..................................................159 FUSE BLOCK #1...........................................................159 FUSE BLOCK #2...........................................................160 FUSE BLOCK #3...........................................................160 FUSE BLOCK #4...........................................................161 FUSE HOLDERS............................................................161 CIRCUIT BREAKERS........................................................161 7 LUBRICATION AND SERVICE.......................................................164 GENERAL INFORMATION.........................................................164 HYDRAULIC SYSTEM SERVICE................................................164 Hydraulic Tank......................................................164 Hydraulic Filters...................................................165 Hydraulic Pump Drive Shaft..........................................165 WHEEL MOTOR SERVICE.....................................................165 COOLANT LEVEL SERVICE...................................................165 Radiator Filling Procedure..........................................166 Coolant Specifications..............................................166 Unacceptable Practices..............................................166 RESERVE ENGINE OIL SERVICE..............................................166 Reserve Oil Tank Filling Procedure (Remote Fill)....................167 Inline Screen.......................................................167 CAB AIR FILTER SERVICE..................................................167 FUEL SYSTEM SERVICE.....................................................168 Fuel Tank Cleaning..................................................168 Fuel Filter Service.................................................168 INTAKE AIR CLEANER SERVICE..............................................169 QUICK FILL SERVICE CENTER...............................................170 TIE ROD INSPECTION AND TORQUE PROCEDURE.................................170 LUBRICATION CHART...........................................................171 EVERY 10 HOUR (DAILY) MAINTENANCE...........................................172 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION......................174 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION.....................175 EVERY 250 HOUR LUBRICATION AND MAINTENANCE..................................176 EVERY 500 HOUR LUBRICATION AND MAINTENANCE..................................178 EVERY 1000 HOURS LUBRICATION AND MAINTENANCE................................180 EVERY 3000 HOUR LUBRICATION AND MAINTENANCE.................................181 EVERY 5000 HOUR MAINTENANCE.................................................182 8 SPECIFICATIONS................................................................184 MAJOR COMPONENT DESCRIPTION.................................................184 Truck and Engine........................................................184 Traction Alternator.....................................................184 Main Control Cabinet....................................................184 AC Induction Traction Motorized Wheels..................................184 Suspension..............................................................184 Operator's Cab..........................................................184 Power Steering..........................................................184 Dynamic Retarding Grid..................................................184 Brake System............................................................184 SPECIFICATIONS..............................................................185 Engine..................................................................185 AC Electric Drive System................................................185 Dynamic Retarding.......................................................185 Battery Electric System.................................................185 Service Capacities......................................................185 Hydraulic Systems.......................................................185 Service Brakes..........................................................186 Steering................................................................186 Standard Dump Body Capacities and Dimensions............................186 Tires...................................................................186 Weight Distribution.....................................................186 Overall Truck Dimensions................................................186 9 RADIO.........................................................................190 RADIO OPERATION.............................................................190 GENERAL RADIO RECEIVER FUNCTIONS........................................190 Turning On the Power....................................................190 One-Hour Timer..........................................................190 Finding a Station.......................................................190 Setting the Presets.....................................................191 Adjusting the Receiver Audio Settings...................................191 Display.................................................................192 Adjusting the Receiver Menu Settings....................................192 Front Auxiliary Mode....................................................192 Rear Auxiliary Mode.....................................................192 CLOCK.......................................................................193 Clock/Alarm Button......................................................193 Setting the Clock.......................................................193 Setting the Alarm.......................................................193 Turning the Alarm Off...................................................194 Activating Snooze.......................................................194 CD PLAYER...................................................................195 Playing a Compact Disc..................................................195 Playing an MP3 DISC.....................................................195 CD Mode Displays........................................................195 Button Functions........................................................195 MP3 PLAYER..................................................................197 Playing MP3 Files.......................................................197 MP3 Mode Displays.......................................................197 Button Functions........................................................197 iPod®.......................................................................199 Playing an iPod®........................................................199 iPod® Mode Displays.....................................................199 Button Functions........................................................199 WEATHERBAND (USA Only)......................................................201 TROUBLESHOOTING.............................................................202 Tips About the Audio System.............................................202 Understanding Radio Reception...........................................202 Care of the Compact Discs...............................................202
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
