Komatsu 960E-2KT Dump Truck Operation & Maintenance Manual CEAM028204 – PDF DOWNLOAD

Description

Komatsu 960E-2KT Dump Truck Operation & Maintenance Manual CEAM028204 – PDF DOWNLOAD

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TABLE OF CONTENTS:

Komatsu 960E-2KT Dump Truck Operation & Maintenance Manual CEAM028204 – PDF DOWNLOAD

INTRODUCTION 1-1
FOREWORD 1-2
ABOUT THIS MANUAL 1-3
WARNINGS 1-4
ALERTS 1-5
TRUCK MODEL ILLUSTRATION 1-6
NON-OEM PARTS IN CRITICAL SYSTEMS 1-7
SOFTWARE LICENSE INFORMATION 1-8
STANDARD CHARTS AND TABLES 2-1
GENERAL INFORMATION 2-2
STANDARD TIGHTENING TORQUES 2-3
CONVERSION MULTIPLIERS 2-11
GENERAL SAFETY 3-1
GENERAL SAFETY 3-2
PRECAUTIONS FOR TRUCK OPERATION 3-5
OPERATING THE MACHINE 3-7
EXTERIOR LIGHTING 3-11
PRECAUTIONS FOR MAINTENANCE 3-13
BEFORE PERFORMING MAINTENANCE 3-13
Securing the Dump Body 3-13
DURING MAINTENANCE 3-14
BATTERY HAZARD PREVENTION 3-17
WHEN REPAIRS ARE NECESSARY 3-20
SPECIAL PRECAUTIONS 3-21
WARNING AND CAUTIONS 4-1
GENERAL INFORMATION 4-2
PIN PLATE 4-3
GRADE SPEED CHART 4-4
GREASE POINTS 4-5
MACHINE SAFETY 4-6
KEY SWITCH 4-8
OIL FILL AND CHECK 4-9
HIGH PRESSURES 4-10
BATTERIES 4-13
HIGH VOLTAGE 4-15
WELDING 4-16
EMERGENCY DUMPING 4-17
AUTOMATIC LUBRICATION FILL 4-18
ROPS/FOPS 4-19
TOWING 4-20
SEAT WEIGHT CAPACITY 4-21
LUBRICATION CHART 4-22
CONTENTS
960E-2KT 0-1
OPERATING INSTRUCTIONS 5-1
PREPARING FOR OPERATION 5-2
RETRACTABLE LADDER SYSTEM (If Equipped) 5-7
TRUCK OPERATION 5-11
ENGINE START-UP SAFETY 5-11
MACHINE OPERATION SAFETY PRECAUTIONS 5-12
TROLLEY OPERATING INSTRUCTIONS 5-17
SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION 5-20
EMERGENCY STEERING SYSTEM 5-20
FUEL DEPLETION 5-23
SAFE PARKING PROCEDURES 5-23
NORMAL ENGINE SHUTDOWN PROCEDURE 5-23
DISABLED TRUCK CONNECTORS 5-25
GENERAL INFORMATION 5-25
STEERING AND BRAKE SYSTEM 5-25
HOIST SYSTEM 5-26
TOWING 5-28
SPECIAL WIRING HARNESS 5-28
TOWING PROCEDURE 5-28
PAYLOAD METER IV SYSTEM 5-31
GENERAL INFORMATION 5-31
COMPONENT DESCRIPTION 5-31
SCOREBOARD 5-34
OPERATOR’S DISPLAY AND SWITCH 5-35
PAYLOAD OPERATION & CALCULATION 5-35
SOURCES FOR PAYLOAD ERROR 5-37
Clean Truck Tare 5-37
DOWNLOADING HAUL CYCLE DATA 5-38
VIEWING ALARM DATA 5-39
DOWNLOADING ALARM DATA 5-40
AUTOMATIC LUBRICATION SYSTEM 5-42
GENERAL INFORMATION 5-42
COMPONENT DESCRIPTION 5-42
SYSTEM OPERATION 5-46
PREVENTIVE MAINTENANCE PROCEDURES 5-47
SYSTEM CHECKOUT 5-48
RESERVE ENGINE OIL SYSTEM 5-50
OPERATOR CAB AND CONTROLS 6-1
CAB INTERIOR 6-3
STEERING WHEEL AND CONTROLS 6-4
PEDALS 6-6
OVERHEAD PANEL AND DISPLAYS 6-7
CENTER CONSOLE 6-8
DIAGNOSTIC PORTS 6-11
OPERATOR SEAT (Standard) 6-12
OPERATOR SEAT (Optional) 6-14
PASSENGER SEAT (Standard) 6-16
PASSENGER SEAT (Optional) 6-17
HEATER / AIR CONDITIONER CONTROLS 6-19
INSTRUMENT PANEL 6-20
STATUS INDICATOR LIGHT PANEL 6-25
STATUS INDICATOR LIGHT SYMBOLS 6-25
CONTENTS
0-2 960E-2KT
Body Up 6-25
Parking Brake 6-25
Propel System Not Ready 6-25
No Propel 6-26
Engine Warm Up 6-26
Engine Shutdown Delay 6-26
Retarding Grid Dryer 6-26
Wheel Brake Lock 6-26
Traction Control OFF 6-26
Repair Monitor 6-26
Retractable Ladder Down 6-26
Snapshot In Progress 6-26
Pantograph Energized 6-26
Pantograph Up 6-26
Service Brake 6-27
Dynamic Retarding 6-27
No DC Link Voltage 6-27
DIGITAL DISPLAY OPERATIONS 6-28
DIGITAL DISPLAY MENUS 6-29
ACTIVE WARNINGS MENU 6-30
PAYLOAD DATA MENU 6-30
REPAIR ITEMS MENU 6-31
MAINTENANCE ITEMS MENU 6-31
CLEARED ITEMS MENU 6-32
SYSTEM CONTROLS MENU 6-32
TIRE DATA MENU 6-33
LANGUAGES MENU 6-33
CONFIGURE SYSTEM MENU 6-34
ORBCOMM 6-35
KOMATSU WIRELESS BRIDGE (Optional) 6-36
KOMTRAX Plus 6-40
KOMTRAX Plus OPERATION 6-40
DOWNLOADING KOMTRAX Plus DATA 6-41
UPLOADING KOMTRAX Plus DATA 6-43
FUSES AND CIRCUIT BREAKERS 6-45
FUSE BLOCK #1 6-46
FUSE BLOCK #2 6-47
FUSE BLOCK #3 6-47
FUSE HOLDERS 6-47
CIRCUIT BREAKERS 6-48
LUBRICATION AND SERVICE 7-1
GENERAL INFORMATION 7-2
RECOMMENDED FUEL, COOLANT, AND LUBRICANT 7-2
HYDRAULIC SYSTEM SERVICE 7-3
WHEEL MOTOR SERVICE 7-4
WHEEL MOUNTING 7-4
COOLANT LEVEL SERVICE 7-4
IGBT COOLANT SERVICE 7-5
RESERVE ENGINE OIL SERVICE 7-6
CAB AIR FILTER SERVICE 7-7
FUEL SYSTEM SERVICE 7-7
INTAKE AIR CLEANER SERVICE 7-8
FRONT ENGINE MOUNT TRUNNION SERVICE 7-9
QUICK FILL SERVICE CENTER 7-9
CONTENTS
960E-2KT 0-3
TIE ROD INSPECTION AND TORQUE PROCEDURE 7-10
LUBRICATION CHART 7-11
PERIODIC REPLACEMENT OF DEFINED LIFE PARTS 7-12
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION 7-13
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION 7-14
EVERY 250 HOUR LUBRICATION AND MAINTENANCE 7-15
EVERY 500 HOUR LUBRICATION AND MAINTENANCE 7-16
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE 7-20
EVERY 1500 HOUR LUBRICATION AND MAINTENANCE INSPECTION 7-22
EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION 7-23
EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION 7-24
EVERY 4000 HOUR MAINTENANCE 7-25
EVERY 5000 HOUR MAINTENANCE 7-26
EVERY 6000 HOUR MAINTENANCE 7-27
EVERY 12000 HOUR MAINTENANCE 7-28
EVERY 18000 HOUR MAINTENANCE 7-29
EVERY 24000 HOUR MAINTENANCE 7-30
30000 HOUR LUBRICATION AND MAINTENANCE CHECKS 7-31
SPECIFICATIONS 8-1
MAJOR COMPONENT DESCRIPTION 8-2
Truck and Engine 8-2
Traction Alternator 8-2
Main Control Cabinet 8-2
AC Induction Traction Motorized Wheels 8-2
Suspension 8-2
Operator’s Cab 8-2
Power Steering 8-2
Dynamic Retarding 8-2
Brake System 8-3
SPECIFICATIONS 8-4
Engine 8-4
AC Electric Drive System 8-4
Dynamic Retarding 8-4
Battery Electric System 8-4
Service Capacities 8-4
Hydraulic Systems 8-4
Service Brakes 8-5
Steering 8-5
Standard Dump Body Capacities and Dimensions 8-5
Tires 8-5
Weight Distribution 8-5
Overall Truck Dimensions 8-6
RADIO 9-1
AM/FM RADIO / MP3 / USB / iPOD™ / AUX PLAYER 9-2
USB Connection Port 9-2
Phone/Bluetooth Button 9-2
Digital Display 9-2
DISP (Display) Button 9-2
SRC/PWR/ESC (Source/Power/Escape) Button 9-3
Volume Knob/OK Button 9-3
NEXT Button 9-3
PREV (Previous) Button 9-3
CONTENTS
0-4 960E-2KT
Preset Buttons 9-3
RDM (Random) Button 9-3
RPT (Repeat) Button 9-3
Mute/Play/Pause Button 9-4
Browse Button 9-4
SCAN/ASCN (Scan/Autoscan) Button 9-4
Auxiliary Jack Port 9-4
CONTENTS

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DESCRIPTION:

Komatsu 960E-2KT Dump Truck Operation & Maintenance Manual CEAM028204 – PDF DOWNLOAD

SERIAL NUMBERS 960E-2KT A50028 – A50088
ENGINE 18V170

FOREWORD
 DANGER
• Unsafe use of this machine may cause serious injury or death. Operators and maintenance personnel
must read and understand this manual before operating or maintaining this machine.
• This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
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.

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]

S.V