Komatsu 960E-1K Dump Truck Operation and Maintenance Manual (CEAM022100)

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Komatsu 960E-1K Dump Truck Index:

COVER
INTRODUCTION
- FOREWORD
- TRUCK MODEL ILLUSTRATION
- ABOUT THIS MANUAL
- ALERTS PAGE
TABLE OF CONTENTS
STANDARD CHARTS AND TABLES
- EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
- STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)
- STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts
SAFETY
- GENERAL
  - Safety Rules
  - Safety Features
  - Fire Extinguisher And First Aid Kit
  - Clothing And Personal Items
  - Leaving The Operator’s Seat
  - Mounting And Dismounting
  - Fire Prevention For Fuel And Oil
  - Precautions With High Temperature Fluids
  - Asbestos Dust Hazard Prevention
  - Prevention Of Injury By Work Equipment
  - Unauthorized Modification
  - ROPS Precautions
  - Precautions For Attachments
  - Precautions For Starting The Truck
- PRECAUTIONS BEFORE OPERATION
  - Safety At The Worksite
  - Fire Prevention
  - Ventilation In Enclosed Areas
  - Preparing For Operation
  - Mirrors, Windows And Lights
  - In Operator Cab (Before Starting The Engine)
  - Seat Belts
- OPERATING THE TRUCK
  - When Starting The Engine
  - General Truck Operation
  - Traveling In Reverse
  - Traveling
  - Traveling On Slopes
  - Ensuring Good Visibility
  - Operating On Snow Or Ice
  - Avoiding Damage To Dump Body
  - Driving Near High Voltage Cables
  - When Dumping
  - Working On Loose Ground
  - When Loading
  - Parking The Truck
- TOWING
- WORKING NEAR BATTERIES
  - Battery Hazard Prevention
  - Jump Starting With Booster Cables
  - Jump Starting With Receptacles
- BEFORE PERFORMING MAINTENANCE
  - Warning Tag
  - Stopping The Engine Before Service
  - Proper Tools
  - Securing The Dump Body
- WHILE PERFORMING MAINTENANCE
  - Keep The Truck Clean
  - Attachments
  - Working Under The Truck
  - Rotating Fan And Belts
  - Adding Fuel Or Oil
  - Radiator Coolant Level
  - Use Of Lighting
  - Precautions With The Battery
  - Handling High Pressure Hoses
  - Precautions When Performing Maintenance Near High Temperature Or High Pressure
  - Precautions With High Pressure Oil
  - Waste Materials
- TIRES
  - Handling Tires
  - Tire Maintenance
  - Storing Tires After Removal
- WHEN REPAIRS ARE NECESSARY
- SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS
  - Engine Shutdown Procedure Before Welding or Performing Maintenance
  - Precautions Before Welding or Performing Maintenance
- ADDITIONAL JOB SITE RULES
WARNINGS AND CAUTIONS
- GRADE/SPEED CHART
- INSTRUMENT PANEL
- BATTERIES
- HIGH VOLTAGE
- RADIATOR
- CRUSHING HAZARD
- CYLINDER PRESSURE
- FILLING THE HYDRAULIC TANK
- HYDRAULIC OIL PRESSURE
- EMERGENCY TOWING PROCEDURE
- EMERGENCY DUMP PROCEDURE
- GREASE POINT
- WELDING
- EMERGENCY SHUTDOWN
- SPRING PRESSURE
- ROPS/FOPS
- EMERGENCEY EGRESS
- PRODUCT IDENTIFICATION PLATE
- LUBRICATION CHART
OPERATING INSTRUCTIONS
- PREPARING FOR OPERATION
- WALK AROUND INSPECTION
- ENGINE START-UP
- AFTER ENGINE START-UP
- EMERGENCY STEERING SYSTEM
  - Operation
  - Pre-Operation Testing
- PRECAUTIONS DURING TRUCK OPERATION
- OPERATING ON A HAUL ROAD
- STARTING ON A GRADE WITH A LOADED TRUCK
- LOADING THE DUMP BODY
- DUMPING A LOAD
  - Raising The Dump Body
  - Lowering The Dump Body (on flat ground)
  - Lowering The Dump Body (over a berm or into a crusher)
- USING THE SPEED CONTROL FEATURE
- SAFE PARKING PROCEDURE
- NORMAL ENGINE SHUTDOWN PROCEDURE
- SUDDEN LOSS OF ENGINE POWER
- FUEL DEPLETION
- TOWING
  - Special Wiring Harness
  - Towing Procedure
- DISABLED TRUCK OPERATION
  - Components Required
  - Hookup
- DISABLED TRUCK DUMPING PROCEDURE
  - Hookup
  - Raising the body
  - Lowering the body
- RESERVE ENGINE OIL SYSTEM
  - Changing Oil
OPERATOR CAB AND CONTROLS
- STEERING WHEEL AND CONTROLS
  - Horn Button
  - Tilt / Telescope Lever
  - Speed Control Lever
  - Multi-Function Turn Signal Switch
- PEDALS
  - Retarder/Service Brake Pedal
  - Throttle/Accelerator Pedal
- GRADE/SPEED CHART
- OVERHEAD PANEL COMPONENTS
- CENTER CONSOLE
  - Diectional Control Lever
  - Override/Fault Reset Switch
  - Engine Shutdown Switch
  - Window Control Switches
  - Hoist Control Lever
  - Ashtray
  - Lighter
  - Data Store Button
  - Service Engine Light
  - 12V Auxiliary Power Outlets
- DIAGNOSTIC PORTS
  - Drive System #1
  - Engine (QUANTUM)
  - Drive System #2
  - Engine (CENSE)
  - Interface Module
  - VHMS
  - Payload Meter
- OPERATOR’S SEAT
  - Seat Belts
  - Adjustment
- HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS
  - Fan Speed Control Knob
  - Temperature Control Knob
  - Air Flow Directional Knob
  - Heater/Air Conditioner Vents
- INSTRUMENT PANEL
  - Control Symbols
  - Key Switch
  - Speed Control Switch
  - Traction Control Switch
  - Retarding Grid Drier Switch
  - AC Drive System Rest Switch
  - Wheel Brake Lock 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
  - Headight/Panel Illumination Light Switch
  - Ladder Light Switch (3-Way)
  - 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 LIGHTS
  - Body Up
  - Parking Brake Applied
  - Propulsion System Not Ready
  - No Propel
  - Engine Warming Up
  - Engine Delay
  - Grid Drier
  - Wheel Brake Lock Applied
  - Traction Control
  - Repair Monitor
  - Snapshot
  - Pantograph Energized
  - Pantograph Up
  - Service Brake Applied
  - Dynamic Retarding
  - No DC Link Voltage
- DIGITAL DISPLAY OPERATION
  - Toggling Through Main Level Screens
  - Toggling Through Warning Screens
  - Entering Payload Meter Data
- VEHICLE HEALTH MONITORING SYSTEM (VHMS)
  - Operation
  - Basic Precautions
- FUSES AND CIRCUIT BREAKERS
LUBRICATION AND SERVICE
- 960E-1K SERVICE CAPACITIES
- HYDRAULIC TANK SERVICE
  - Adding Oil
- COOLING SYSTEM SERVICE
  - Adding Coolant
- WHEEL MOTOR SERVICE
- RESERVE OIL TANK SERVICE
  - Filling the Reserve Oil Tank (Remote Fill)
  - Inline Screen
- AIR CLEANER SERVICE
  - Replacing the Elements
  - Cleaning the Primary Element
  - Cleaning the Precleaner Section
- LUBRICATION CHART
- 10 HOUR (DAILY) INSPECTION
- 10 HOUR (DAILY) INSPECTION (cont.)
- INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
- INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
- INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 500 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 2000 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS
- 6000 HOUR LUBRICATION AND MAINTENANCE CHECKS
AUTOMATIC LUBRICATION SYSTEM
- GENERAL DESCRIPTION
- SYSTEM COMPONENTS
  - Filter Assembly
  - Hydraulic Motor and Pump
  - Grease Reservoir
  - Pressure Reducing Valve
  - Flow Control Valve
  - Solenoid Valve
  - Vent Valve
  - Interface Module
  - Grease System Failure Switch
  - Injectors
  - Unloader Valve
- SYSTEM OPERATION
- GENERAL INSTRUCTIONS
  - Required Lubricant
  - System Priming
  - Filter Assembly
- LUBRICANT PUMP
  - Pump Housing Oil Level
  - Pump Pressure Control
- INJECTORS (SL-1 Series “H”)
  - Injector Specifications
  - Injector Adjustment
  - INJECTOR OPERATION
- PREVENTIVE MAINTENANCE PROCEDURES
  - Daily Lubrication System Inspection
  - 250 Hour Inspection
  - 1000 Hour Inspection
- SYSTEM CHECKOUT
  - Lubrication Cycle Operation
- SYSTEM TROUBLESHOOTING CHART
COMPONENTS & SPECIFICATIONS
- MAJOR COMPONENT DESCRIPTIONS
  - Truck And Engine
  - Main Alternator
  - AC Induction Traction Motorized Wheels
  - Suspension
  - Operator’s Cab
  - Power Steering
  - Dynamic Retarding
  - Brake System
- SPECIFICATIONS
  - ENGINE
  - AC ELECTRIC DRIVE SYSTEM
  - DYNAMIC RETARDING
  - BATTERY ELECTRIC SYSTEM
  - SERVICE CAPACITIES
  - HYDRAULIC SYSTEMS
  - SERVICE BRAKES
  - STEERING
  - TIRES
  - STANDARD DUMP BODY CAPACITIES AND DIMENSIONS
  - WEIGHT DISTRIBUTION
PAYLOAD METER III™
- Introduction
  - Data Summary
  - Data Gathering
- COMPONENT DESCRIPTION
  - System Diagram
  - Suspension Pressure Sensors
  - Inclinometer
  - Speedometer/Load Display
  - Operator Switches
  - Speed Input
  - Body-Up Switch
  - Brake Lock Switch
  - Payload Meter
  - Communications Ports
  - Key Switch Input
  - Payload Meter Power
  - Load Lights
  - Wiring and Termination
- LOAD DISPLAY AND OPERATOR SWITCHES
  - Setting the Operator ID
  - Total Ton and Total Load Counters
  - Viewing Live Sensor Data
  - Other Display Messages
- PAYLOAD OPERATION & CALCULATION
  - Description of Haul Cycles
  - Load Calculation
  - Carry Back
  - Measurement Accuracy
- SOURCES FOR PAYLOAD ERROR
  - Suspensions
  - Loading Conditions
  - Pressure Sensors
  - Swingloads
  - Speed and Distance
- HAUL CYCLE DATA
  - Haul Cycle Warning Flags
  - Frame Torque Data
  - Sprung Weight Data
  - Maximum Speed Data
  - Alarm Records
- PDM SOFTWARE OVERVIEW
  - System Configuration
  - Installing the PDM Software
- DOWNLOADING DATA
- PLM III SYSTEM CONFIGURATION
  - Starting Communications
  - Connection Menu
  - Connecting to the Payload Meter
  - Configuring the Payload Meter
  - Setting the Date and Time
  - Setting the Truck Type
  - Setting the Display Units
  - Setting the Frame Serial Number
  - Setting the Truck Number
  - Setting the Komatsu Distributor
  - Setting the Komatsu Customer
  - Clean Truck Tare
  - Inclinometer Calibration
- DATA ANALYSIS
  - Creating a Query
  - Sorting on Truck Unit Number
  - Sorting on Truck Type
  - Sorting on Date Range
  - Sorting on Time Range
  - Payload Detail Screen
  - Creating Reports
  - Creating Graphs
  - Exporting Data
  - Importing Data
  - Deleting Haul Cycle Records
  - Viewing Alarms
  - Deleting Alarm Records
AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER
- OPERATING INSTRUCTIONS
  - GENERAL RADIO RECEIVER FUNCTIONS
  - USING THE RADIO
  - USING THE CLOCK
  - USING THE ALARM
  - USING THE WEATHERBAND (USA Only)
  - USING THE COMPACT DISC PLAYER/USB
  - PLAYING AN MP3 DISC/USB
  - PLAYING MP3 FILES
  - USING AN iPOD®
  - OPERATING TIPS
  - TROUBLESHOOTING