Komatsu 960E-2 Dump Truck Operation and Maintenance Manual (CEAM026102)

📘 Show Index

Komatsu 960E-2 Dump Truck Index:

1 INTRODUCTION
- FOREWORD
- ABOUT THIS MANUAL
- WARNINGS
  - California Proposition 65 Warnings
- ALERTS
- TRUCK MODEL ILLUSTRATION
- NON-OEM PARTS IN CRITICAL SYSTEMS
2 STANDARD CHARTS AND TABLES
- GENERAL INFORMATION
  - Effect Of Special Lubricants
  - Suggested Sources For Rust Preventive Grease
- STANDARD TIGHTENING TORQUES
  - Class 10.9 Capscrews And Class 10 Nuts
  - SAE Grade 5 And Grade 8 Capscrews
  - SAE Grade 9 Capscrews
  - T-Bolt Clamps
  - Split Flange Clamps
  - Flared Tube And Hose Fittings
  - JIC 37° Swivel Nuts
  - Pipe Thread Fittings
  - O-Ring Boss Fittings
  - O-Ring Face Seal Fittings
- CONVERSION MULTIPLIERS
  - Metric To English
  - English To Metric
  - Temperature Conversions
3 GENERAL SAFETY
- GENERAL SAFETY
  - Safety Rules
  - Truck Safety Features
  - Clothing And Personal Items
  - Unauthorized Modification
  - Leaving The Operator’s Seat
  - Mounting And Dismounting
  - Fire Extinguishers And First Aid Kits
  - Precautions For High Temperature Fluids
  - Asbestos Dust Hazard Prevention
  - Fire Prevention
  - ROPS Precautions
  - Preventing Injury From Work Equipment
  - Precautions For Optional Attachments
  - Precautions When Starting The Machine
- PRECAUTIONS FOR TRUCK OPERATION
  - Safety Is Thinking Ahead
  - Safety At The Worksite
  - Preparing For Operation
  - Ventilation For Enclosed Areas
  - Mirrors, Windows, And Lights
  - Before Starting The Engine
  - Seat Belts And Tethers
  - Emergency Egress Ladders
- OPERATING THE MACHINE
  - General Information
  - Starting The Engine
  - Traveling In The Machine
  - Traveling In Reverse
  - Traveling On Slopes
  - Traveling On Snow
  - Traveling Near High Voltage Cables
  - Traveling On Loose Ground
  - Ensuring Good Visibility
  - Avoid Damage To The Dump Body
  - Safe Parking Of The Machine
  - Loading The Machine
  - Dumping The Machine
  - Towing The Machine
- EXTERIOR LIGHTING
  - Fog Lights
  - Headlights
  - Ladder Lights and Deck Mounted Flood Lights
  - Mirror Mounted Backup Lights
  - Brake Light
  - Retard Light
  - Clearance/Turn Signal Lights
  - Backup Alarm
- PRECAUTIONS FOR MAINTENANCE
  - BEFORE PERFORMING MAINTENANCE
  - DURING MAINTENANCE
- WHEN REPAIRS ARE NECESSARY
  - Observe The Following Precautions
- SPECIAL PRECAUTIONS
  - Preliminary Procedures Before Welding Or Performing Maintenance
  - Engine Shutdown Procedure Before Welding or Performing Maintenan
  - Before Welding On The Machine, Obey The Following Guidelines:
  - Discharging Control Cabinet Capacitors
4 WARNING AND CAUTIONS
- GENERAL INFORMATION
- PIN PLATE
- GRADE SPEED CHART
- MACHINE SAFETY
- KEY SWITCH
- OIL FILL AND CHECK
- HIGH PRESSURES
- BATTERY AND ENGINE SHUTDOWN
- HIGH VOLTAGE
- WELDING
- LIFTING POINTS
- EMERGENCY DUMPING
- ROPS/FOPS
- TOWING
- LUBRICATION CHART
5 OPERATING INSTRUCTIONS
- PREPARING FOR OPERATION
  - Safety Is Thinking Ahead
  - Walk Around Inspection
- RETRACTABLE LADDER SYSTEM (If Equipped)
  - General Information
  - Ladder System Description
  - Ladder System Operation
  - In-Cab Control Panel
  - Ground Level Control Box
  - Emergency Down Valve
- PRE-SHIFT BRAKE TEST
  - OPERATION
  - Service Brake Test
  - Parking Brake Test
  - Retard System Test
  - Brake Test Exit Criteria
- TRUCK OPERATION
  - ENGINE START-UP SAFETY
  - MACHINE OPERATION SAFETY PRECAUTIONS
  - SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
  - EMERGENCY STEERING SYSTEM
  - FUEL DEPLETION
  - SAFE PARKING PROCEDURES
  - NORMAL ENGINE SHUTDOWN PROCEDURE
- DISABLED TRUCK CONNECTORS
  - GENERAL INFORMATION
  - HOIST SYSTEM
- TOWING
  - SPECIAL WIRING HARNESS
  - TOWING PROCEDURE
- PAYLOAD METER III SYSTEM
  - GENERAL INFORMATION
  - COMPONENT DESCRIPTION
  - OPERATOR’S DISPLAY AND SWITCH
  - HAUL CYCLE WARNING FLAGS
  - PC SOFTWARE OVERVIEW
  - SYSTEM CONFIGURATION
  - DOWNLOADING PAYLOAD DATA
  - UPLOADING DATA
  - DATA ANALYSIS
- AUTOMATIC LUBRICATION SYSTEM
  - GENERAL INFORMATION
  - COMPONENT DESCRIPTION
  - SYSTEM OPERATION
  - PREVENTIVE MAINTENANCE PROCEDURES
- SYSTEM CHECKOUT
  - General Checks
  - Lubrication Cycle Operation
- RESERVE ENGINE OIL SYSTEM
  - Operation
  - LED Monitor Light
  - Changing Oil
6 OPERATOR CAB AND CONTROLS
- CAB INTERIOR
- STEERING WHEEL AND CONTROLS
  - Horn Button
  - Tilt / Telescope Lever
  - Multi-Function Turn Signal Switch
  - Turn Signal Operation
  - High Beam Headlight Operation
  - Windshield Wiper Operation
- PEDALS AND RETARDER LEVER
  - Dynamic Retarding
  - Retarder Lever
  - Brake/Retarder Pedal
  - Accelerator Pedal
- OVERHEAD PANEL AND DISPLAYS
  - Radio Speakers
  - Warning Alarm Buzzer
  - Cab Radio
  - Air Cleaner Vacuum Gauges
- CENTER CONSOLE
  - Directional Control Lever
  - Override/Fault Reset Switch
  - Engine Stop Switch
  - Window Control Switches
  - Hoist Control Lever
  - Raising The Dump Body
  - Lowering The Dump Body
  - Retard Speed Control (RSC) Adjust Dial
  - Retard Speed Control (RSC) Switch
  - Data Store Button
  - 12V Auxiliary Power Outlets
  - Fire Suppression Control Outlet
  - Communication Radio Outlet
- DIAGNOSTIC PORTS
  - KOMTRAX Plus
  - Interface Module (IM)
  - Truck Control Interface (TCI)
  - Propulsion System Controller (PSC)
  - Engine (CENSE)
  - Engine (QUANTUM)
- OPERATOR SEAT (Standard)
  - Seat Belts And Tethers
  - Adjustment
- PASSENGER SEAT (Standard)
  - Seat Belts And Tethers
  - Adjustment
- OPERATOR SEAT (Optional)
  - Seat Belts And Tethers
  - Adjustment
- PASSENGER SEAT (Optional)
  - Seat Belts And Tethers
  - Adjustment
- HEATER / AIR CONDITIONER CONTROLS
  - Fan Speed Control Knob
  - Temperature Control Knob
  - Air Flow Directional Knob
  - Heater/Air Conditioner Vents
- INSTRUMENT PANEL
  - CONTROL SYMBOLS
  - Key Switch
  - Engine Warming Switch
  - AC Drive System Rest Switch
  - Wheel Brake Lock Control Switch
  - Hazard Warning Lights
  - Heater/Air Conditioner Vents
  - Fuel Level Gauge
  - Hydraulic Oil Temperature Gauge
  - Speedometer/Digital Display
  - Coolant Temperature Gauge
  - Drive System Temperature Gauge
  - Status Indicator Light Panel
  - Headlight/Panel Illumination Light Switch (3-Way)
  - Ladder Light Switch
  - Backup Light Switch
  - Fog Light Switch
  - Mode Switches
  - Panel Illumination Light Dimmer Switch
  - Right/Left Turn Signal Indicators
  - Digital Display Contrast Buttons
  - Warning Light
- STATUS INDICATOR LIGHT PANEL
  - STATUS INDICATOR LIGHT SYMBOLS
- OVERHEAD DASH PANEL
  - Brake Test Switch (If Equipped)
  - Brake Test Light (If Equipped)
- DIGITAL DISPLAY OPERATION
  - Toggling Through Main Level Screens
  - Toggling Through Warning Screens
  - Entering Payload Meter Data
- KOMTRAX Plus
  - KOMTRAX Plus OPERATION
  - DOWNLOADING KOMTRAX Plus DATA
  - UPLOADING KOMTRAX Plus DATA
  - ORBCOMM
  - KOMATSU WIRELESS BRIDGE (Optional)
- FUSES AND CIRCUIT BREAKERS
  - FUSE BLOCK #1
  - FUSE BLOCK #2
  - FUSE BLOCK #3
  - FUSE BLOCK #4
  - FUSE HOLDERS
  - CIRCUIT BREAKERS
7 LUBRICATION AND SERVICE
- GENERAL INFORMATION
  - HYDRAULIC SYSTEM SERVICE
  - WHEEL MOTOR SERVICE
  - COOLANT LEVEL SERVICE
  - RESERVE ENGINE OIL SERVICE
  - CAB AIR FILTER SERVICE
  - FUEL SYSTEM SERVICE
  - INTAKE AIR CLEANER SERVICE
  - QUICK FILL SERVICE CENTER
  - TIE ROD INSPECTION AND TORQUE PROCEDURE
- LUBRICATION CHART
- EVERY 10 HOUR (DAILY) MAINTENANCE
- INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
- EVERY 250 HOUR LUBRICATION AND MAINTENANCE
- EVERY 500 HOUR LUBRICATION AND MAINTENANCE
- EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
- EVERY 3000 HOUR LUBRICATION AND MAINTENANCE
- EVERY 5000 HOUR MAINTENANCE
- EVERY 18,000 HOUR MAINTENANCE
8 SPECIFICATIONS
- MAJOR COMPONENT DESCRIPTION
  - Truck and Engine
  - Traction Alternator
  - Main Control Cabinet
  - AC Induction Traction Motorized Wheels
  - Suspension
  - Operator’s Cab
  - Power Steering
  - Dynamic Retarding Grid
  - Brake System
- SPECIFICATIONS
  - Engine
  - AC Electric Drive System
  - Dynamic Retarding
  - Battery Electric System
  - Service Capacities
  - Hydraulic Systems
  - Service Brakes
  - Steering
  - Standard Dump Body Capacities and Dimensions
  - Tires
  - Weight Distribution
  - Overall Truck Dimensions
9 RADIO
- RADIO OPERATION
  - General Radio Receiver Functions
  - Turning On The Power
  - One-Hour Timer
  - Finding A Station
  - Setting The Presets
  - Adjusting The Receiver Audio Settings
  - Display
  - Adjusting The Receiver Menu Settings
  - Front Auxiliary Mode
  - Rear Auxiliary Mode
- CLOCK
  - Clock/Alarm Button
  - Setting The Clock
  - Setting The Alarm
  - Turning The Alarm Off
  - Activating Snooze
- CD PLAYER
  - Playing A Compact Disc
  - Playing An MP3 DISC
  - CD Mode Displays
  - Button Functions
- MP3 PLAYER
  - Playing MP3 Files
  - MP3 Mode Displays
  - Button Functions
- iPod®
  - Playing An iPod®
  - iPod® Mode Displays
  - Button Functions
- WEATHERBAND (USA Only)
- TROUBLESHOOTING
  - Tips About the Audio System
  - Understanding Radio Reception
  - Care Of The Compact Discs