Komatsu 960E-1K Dump Truck Operation & Maintenance Manual Serial NumberA50003 &UP PDF DOWNLOAD

Komatsu 960E-1K Dump Truck Operation & Maintenance Manual Serial Number: A50003 & UP

Description:

• Komatsu 960E-1K Dump Truck Operation & Maintenance Manual
• Serial Number: A50003 & UP
• 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-1K Dump Truck Operation & Maintenance Manual
• Serial Number: A50003 & UP
• COVER..................................................................................... 1 INTRODUCTION.............................................................................. 5 FOREWORD.............................................................................. 5 TRUCK MODEL ILLUSTRATION.............................................................. 6 ABOUT THIS MANUAL..................................................................... 7 ALERTS PAGE........................................................................... 8 TABLE OF CONTENTS......................................................................... 9 STANDARD CHARTS AND TABLES................................................................ 17 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values.................. 17 STANDARD ASSEMBLY TORQUES For 12-Point, Grade 9 Cap screws (SAE)...................... 18 STANDARD ASSEMBLY TORQUES For Class 10.9 Cap screws & Class 10 Nuts................... 18 SAFETY.................................................................................... 23 GENERAL............................................................................... 23 Safety Rules...................................................................... 23 Safety Features................................................................... 23 Fire Extinguisher And First Aid Kit............................................... 23 Clothing And Personal Items....................................................... 23 Leaving The Operator’s Seat....................................................... 24 Mounting And Dismounting.......................................................... 24 Fire Prevention For Fuel And Oil.................................................. 24 Precautions With High Temperature Fluids.......................................... 25 Asbestos Dust Hazard Prevention................................................... 25 Prevention Of Injury By Work Equipment............................................ 25 Unauthorized Modification......................................................... 25 ROPS Precautions.................................................................. 25 Precautions For Attachments....................................................... 26 Precautions For Starting The Truck................................................ 26 PRECAUTIONS BEFORE OPERATION.......................................................... 26 Safety At The Worksite............................................................ 26 Fire Prevention................................................................... 27 Ventilation In Enclosed Areas..................................................... 27 Preparing For Operation........................................................... 27 Mirrors, Windows And Lights....................................................... 27 In Operator Cab (Before Starting The Engine)...................................... 27 Seat Belts........................................................................ 27 OPERATING THE TRUCK................................................................... 28 When Starting The Engine.......................................................... 28 General Truck Operation........................................................... 28 Traveling In Reverse.............................................................. 29 Traveling......................................................................... 29 Traveling On Slopes............................................................... 29 Ensuring Good Visibility.......................................................... 29 Operating On Snow Or Ice.......................................................... 29 Avoiding Damage To Dump Body...................................................... 29 Driving Near High Voltage Cables.................................................. 30 When Dumping...................................................................... 30 Working On Loose Ground........................................................... 30 When Loading...................................................................... 30 Parking The Truck................................................................. 30 TOWING................................................................................ 30 WORKING NEAR BATTERIES................................................................ 31 Battery Hazard Prevention......................................................... 31 Jump Starting With Booster Cables................................................. 32 Jump Starting With Receptacles.................................................... 32 BEFORE PERFORMING MAINTENANCE......................................................... 33 Warning Tag....................................................................... 33 Stopping The Engine Before Service................................................ 33 Proper Tools...................................................................... 33 Securing The Dump Body............................................................ 33 WHILE PERFORMING MAINTENANCE.......................................................... 34 Keep The Truck Clean.............................................................. 34 Attachments....................................................................... 34 Working Under The Truck........................................................... 34 Rotating Fan And Belts............................................................ 34 Adding Fuel Or Oil................................................................ 34 Radiator Coolant Level............................................................ 35 Use Of Lighting................................................................... 35 Precautions With The Battery...................................................... 35 Handling High Pressure Hoses...................................................... 35 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 35 Precautions With High Pressure Oil................................................ 35 Waste Materials................................................................... 35 TIRES................................................................................. 36 Handling Tires.................................................................... 36 Tire Maintenance.................................................................. 37 Storing Tires After Removal....................................................... 37 WHEN REPAIRS ARE NECESSARY............................................................ 38 SPECIAL PRECAUTIONS FOR WORKING ON AC DRIVE TRUCKS.................................... 39 Engine Shutdown Procedure Before Welding or Performing Maintenance................ 39 Precautions Before Welding or Performing Maintenance.............................. 40 ADDITIONAL JOB SITE RULES............................................................. 42 WARNINGS AND CAUTIONS..................................................................... 43 GRADE/SPEED CHART..................................................................... 43 INSTRUMENT PANEL...................................................................... 43 BATTERIES............................................................................. 44 HIGH VOLTAGE.......................................................................... 44 RADIATOR.............................................................................. 45 CRUSHING HAZARD....................................................................... 45 CYLINDER PRESSURE..................................................................... 45 FILLING THE HYDRAULIC TANK............................................................ 46 HYDRAULIC OIL PRESSURE................................................................ 46 EMERGENCY TOWING PROCEDURE............................................................ 47 EMERGENCY DUMP PROCEDURE.............................................................. 47 GREASE POINT.......................................................................... 47 WELDING............................................................................... 48 EMERGENCY SHUTDOWN.................................................................... 48 SPRING PRESSURE....................................................................... 49 ROPS/FOPS............................................................................. 49 EMERGENCEY EGRESS..................................................................... 49 PRODUCT IDENTIFICATION PLATE.......................................................... 50 LUBRICATION CHART..................................................................... 50 OPERATING INSTRUCTIONS.................................................................... 51 PREPARING FOR OPERATION............................................................... 51 WALK AROUND INSPECTION................................................................ 51 ENGINE START-UP....................................................................... 55 AFTER ENGINE START-UP................................................................. 56 EMERGENCY STEERING SYSTEM............................................................. 57 Operation......................................................................... 57 Pre-Operation Testing............................................................. 57 PRECAUTIONS DURING TRUCK OPERATION.................................................... 58 OPERATING ON A HAUL ROAD.............................................................. 59 STARTING ON A GRADE WITH A LOADED TRUCK............................................... 59 LOADING THE DUMP BODY................................................................. 60 DUMPING A LOAD........................................................................ 60 Raising The Dump Body............................................................. 60 Lowering The Dump Body (on flat ground)........................................... 61 Lowering The Dump Body (over a berm or into a crusher)............................ 62 USING THE SPEED CONTROL FEATURE....................................................... 62 SAFE PARKING PROCEDURE................................................................ 63 NORMAL ENGINE SHUTDOWN PROCEDURE...................................................... 63 SUDDEN LOSS OF ENGINE POWER........................................................... 64 FUEL DEPLETION........................................................................ 64 TOWING................................................................................ 65 Special Wiring Harness............................................................ 65 Towing Procedure.................................................................. 65 DISABLED TRUCK OPERATION.............................................................. 67 Components Required............................................................... 67 Hookup............................................................................ 68 DISABLED TRUCK DUMPING PROCEDURE...................................................... 69 Hookup............................................................................ 69 Raising the body.................................................................. 69 Lowering the body................................................................. 69 RESERVE ENGINE OIL SYSTEM............................................................. 70 Changing Oil...................................................................... 70 OPERATOR CAB AND CONTROLS................................................................. 71 STEERING WHEEL AND CONTROLS........................................................... 72 Horn Button....................................................................... 72 Tilt / Telescope Lever............................................................ 72 Speed Control Lever............................................................... 72 Multi-Function Turn Signal Switch................................................. 72 PEDALS................................................................................ 73 Retarder/Service Brake Pedal...................................................... 73 Throttle/Accelerator Pedal........................................................ 73 GRADE/SPEED CHART..................................................................... 74 OVERHEAD PANEL COMPONENTS............................................................. 74 CENTER CONSOLE........................................................................ 75 Diectional Control Lever.......................................................... 75 Override/Fault Reset Switch....................................................... 76 Engine Shutdown Switch............................................................ 76 Window Control Switches........................................................... 76 Hoist Control Lever............................................................... 76 Ashtray........................................................................... 77 Lighter........................................................................... 77 Data Store Button................................................................. 77 Service Engine Light.............................................................. 77 12V Auxiliary Power Outlets....................................................... 77 DIAGNOSTIC PORTS...................................................................... 77 Drive System #1................................................................... 77 Engine (QUANTUM).................................................................. 77 Drive System #2................................................................... 77 Engine (CENSE).................................................................... 77 Interface Module.................................................................. 77 VHMS.............................................................................. 77 Payload Meter..................................................................... 77 OPERATOR’S SEAT....................................................................... 78 Seat Belts........................................................................ 78 Adjustment........................................................................ 78 HEATER/AIR CONDITIONER COMPARTMENT AND CONTROLS....................................... 79 Fan Speed Control Knob............................................................ 79 Temperature Control Knob.......................................................... 79 Air Flow Directional Knob......................................................... 79 Heater/Air Conditioner Vents...................................................... 79 INSTRUMENT PANEL...................................................................... 80 Control Symbols................................................................... 80 Key Switch........................................................................ 82 Speed Control Switch.............................................................. 82 Traction Control Switch........................................................... 82 Retarding Grid Drier Switch....................................................... 82 AC Drive System Rest Switch....................................................... 82 Wheel Brake Lock Switch........................................................... 83 Hazard Warning Lights............................................................. 83 Heater/Air Conditioner Vents...................................................... 83 Fuel Level Gauge.................................................................. 83 Hydraulic Oil Temperature Gauge................................................... 83 Speedometer/Digital Display....................................................... 83 Coolant Temperature Gauge......................................................... 84 Drive System Temperature Gauge.................................................... 84 Headight/Panel Illumination Light Switch.......................................... 84 Ladder Light Switch (3-Way)....................................................... 84 Backup Light Switch............................................................... 84 Fog Light Switch.................................................................. 84 Mode Switches..................................................................... 84 Panel Illumination Light Dimmer Switch............................................ 85 Right/Left Turn Signal Indicators................................................. 85 Digital Display Contrast Buttons.................................................. 85 Warning Light..................................................................... 85 STATUS INDICATOR LIGHTS............................................................... 86 Body Up........................................................................... 86 Parking Brake Applied............................................................. 86 Propulsion System Not Ready....................................................... 86 No Propel......................................................................... 87 Engine Warming Up................................................................. 87 Engine Delay...................................................................... 87 Grid Drier........................................................................ 87 Wheel Brake Lock Applied.......................................................... 87 Traction Control.................................................................. 87 Repair Monitor.................................................................... 87 Snapshot.......................................................................... 87 Pantograph Energized.............................................................. 88 Pantograph Up..................................................................... 88 Service Brake Applied............................................................. 88 Dynamic Retarding................................................................. 88 No DC Link Voltage................................................................ 88 DIGITAL DISPLAY OPERATION............................................................. 89 Toggling Through Main Level Screens............................................... 89 Toggling Through Warning Screens.................................................. 90 Entering Payload Meter Data....................................................... 91 VEHICLE HEALTH MONITORING SYSTEM (VHMS)............................................... 92 Operation......................................................................... 92 Basic Precautions................................................................. 93 FUSES AND CIRCUIT BREAKERS............................................................ 94 LUBRICATION AND SERVICE................................................................... 99 960E-1K SERVICE CAPACITIES............................................................ 99 HYDRAULIC TANK SERVICE................................................................ 99 Adding Oil........................................................................ 99 COOLING SYSTEM SERVICE................................................................100 Adding Coolant....................................................................100 WHEEL MOTOR SERVICE...................................................................100 RESERVE OIL TANK SERVICE..............................................................101 Filling the Reserve Oil Tank (Remote Fill)........................................101 Inline Screen.....................................................................101 AIR CLEANER SERVICE...................................................................102 Replacing the Elements............................................................102 Cleaning the Primary Element......................................................104 Cleaning the Precleaner Section...................................................105 LUBRICATION CHART.....................................................................106 10 HOUR (DAILY) INSPECTION............................................................107 10 HOUR (DAILY) INSPECTION (cont.)....................................................108 INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS....................................109 INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................109 INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...................................109 250 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................110 500 HOUR LUBRICATION AND MAINTENANCE CHECKS...........................................112 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................113 2000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................114 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................114 6000 HOUR LUBRICATION AND MAINTENANCE CHECKS..........................................115 AUTOMATIC LUBRICATION SYSTEM..............................................................117 GENERAL DESCRIPTION...................................................................117 SYSTEM COMPONENTS.....................................................................119 Filter Assembly...................................................................119 Hydraulic Motor and Pump..........................................................119 Grease Reservoir..................................................................119 Pressure Reducing Valve...........................................................119 Flow Control Valve................................................................119 Solenoid Valve....................................................................119 Vent Valve........................................................................119 Interface Module..................................................................119 Grease System Failure Switch......................................................119 Injectors.........................................................................119 Unloader Valve....................................................................119 SYSTEM OPERATION......................................................................120 GENERAL INSTRUCTIONS..................................................................121 Required Lubricant................................................................121 System Priming....................................................................121 Filter Assembly...................................................................121 LUBRICANT PUMP........................................................................122 Pump Housing Oil Level............................................................122 Pump Pressure Control.............................................................122 INJECTORS (SL-1 Series “H”)...........................................................123 Injector Specifications...........................................................123 Injector Adjustment...............................................................123 INJECTOR OPERATION................................................................124 PREVENTIVE MAINTENANCE PROCEDURES.....................................................125 Daily Lubrication System Inspection...............................................125 250 Hour Inspection...............................................................125 1000 Hour Inspection..............................................................125 SYSTEM CHECKOUT.......................................................................126 Lubrication Cycle Operation.......................................................126 SYSTEM TROUBLESHOOTING CHART..........................................................127 COMPONENTS & SPECIFICATIONS...............................................................129 MAJOR COMPONENT DESCRIPTIONS..........................................................129 Truck And Engine..................................................................129 Main Alternator...................................................................129 AC Induction Traction Motorized Wheels............................................129 Suspension........................................................................129 Operator's Cab....................................................................129 Power Steering....................................................................129 Dynamic Retarding.................................................................129 Brake System......................................................................129 SPECIFICATIONS........................................................................131 ENGINE............................................................................131 AC ELECTRIC DRIVE SYSTEM..........................................................131 DYNAMIC RETARDING.................................................................131 BATTERY ELECTRIC SYSTEM...........................................................131 SERVICE CAPACITIES................................................................131 HYDRAULIC SYSTEMS.................................................................132 SERVICE BRAKES....................................................................132 STEERING..........................................................................132 TIRES.............................................................................132 STANDARD DUMP BODY CAPACITIES AND DIMENSIONS......................................132 WEIGHT DISTRIBUTION...............................................................132 PAYLOAD METER III™........................................................................135 Introduction..........................................................................135 Data Summary......................................................................135 Data Gathering....................................................................135 COMPONENT DESCRIPTION.................................................................136 System Diagram....................................................................136 Suspension Pressure Sensors.......................................................136 Inclinometer......................................................................136 Speedometer/Load Display..........................................................136 Operator Switches.................................................................137 Speed Input.......................................................................137 Body-Up Switch....................................................................137 Brake Lock Switch.................................................................137 Payload Meter.....................................................................137 Communications Ports..............................................................137 Key Switch Input..................................................................138 Payload Meter Power...............................................................138 Load Lights.......................................................................138 Wiring and Termination............................................................138 LOAD DISPLAY AND OPERATOR SWITCHES....................................................139 Setting the Operator ID...........................................................139 Total Ton and Total Load Counters.................................................139 Viewing Live Sensor Data..........................................................139 Other Display Messages............................................................140 PAYLOAD OPERATION & CALCULATION.......................................................140 Description of Haul Cycles........................................................140 Load Calculation..................................................................141 Carry Back........................................................................141 Measurement Accuracy..............................................................141 SOURCES FOR PAYLOAD ERROR.............................................................142 Suspensions.......................................................................142 Loading Conditions................................................................142 Pressure Sensors..................................................................142 Swingloads........................................................................142 Speed and Distance................................................................142 HAUL CYCLE DATA.......................................................................143 Haul Cycle Warning Flags..........................................................143 Frame Torque Data.................................................................144 Sprung Weight Data................................................................144 Maximum Speed Data................................................................144 Alarm Records.....................................................................146 PDM SOFTWARE OVERVIEW.................................................................147 System Configuration..............................................................147 Installing the PDM Software.......................................................147 DOWNLOADING DATA......................................................................147 PLM III SYSTEM CONFIGURATION..........................................................148 Starting Communications...........................................................148 Connection Menu...................................................................148 Connecting to the Payload Meter...................................................149 Configuring the Payload Meter.....................................................149 Setting the Date and Time.........................................................149 Setting the Truck Type............................................................150 Setting the Display Units.........................................................150 Setting the Frame Serial Number...................................................150 Setting the Truck Number..........................................................150 Setting the Komatsu Distributor...................................................150 Setting the Komatsu Customer......................................................150 Clean Truck Tare..................................................................151 Inclinometer Calibration..........................................................151 DATA ANALYSIS.........................................................................152 Creating a Query..................................................................152 Sorting on Truck Unit Number......................................................152 Sorting on Truck Type.............................................................152 Sorting on Date Range.............................................................153 Sorting on Time Range.............................................................153 Payload Detail Screen.............................................................154 Creating Reports..................................................................155 Creating Graphs...................................................................156 Exporting Data....................................................................156 Importing Data....................................................................158 Deleting Haul Cycle Records.......................................................158 Viewing Alarms....................................................................158 Deleting Alarm Records............................................................158 AM/FM RADIO / CD / MP3 / USB / iPOD™ / AUX PLAYER.........................................161 OPERATING INSTRUCTIONS................................................................161 GENERAL RADIO RECEIVER FUNCTIONS..................................................161 Turning On the Power..........................................................161 One-Hour Timer................................................................161 Adjusting the Volume..........................................................162 Display.......................................................................162 Radio Mode Displays...........................................................162 CD Mode Displays..............................................................162 MP3/USB/iPod Mode Displays....................................................162 AUX Input Displays............................................................163 CLOCK/ALARM Button............................................................163 Front Auxiliary Mode..........................................................163 Rear Auxiliary Mode...........................................................163 Adjusting the Receiver Audio Settings.........................................163 Adjusting the Receiver Menu Settings..........................................164 USING THE RADIO...................................................................165 Finding a Station.............................................................165 Setting the Presets...........................................................165 USING THE CLOCK...................................................................166 Setting the Clock.............................................................166 USING THE ALARM...................................................................166 Setting the Alarm.............................................................166 Turning the Alarm Off.........................................................167 Activating Snooze.............................................................167 USING THE WEATHERBAND (USA Only)..................................................167 USING THE COMPACT DISC PLAYER/USB.................................................168 Playing A Compact Disc........................................................168 Button Functions..............................................................168 PLAYING AN MP3 DISC/USB...........................................................169 Root Directory................................................................169 Empty Directory or Folder.....................................................169 No Folder.....................................................................169 File Name Display.............................................................169 PLAYING MP3 FILES.................................................................169 Button Functions..............................................................169 USING AN iPOD®....................................................................170 Playing an iPod...............................................................170 Button Functions..............................................................170 OPERATING TIPS....................................................................171 Tips About The Audio System...................................................171 Understanding Radio Reception.................................................171 Care of The Compact Discs.....................................................171 TROUBLESHOOTING...................................................................172

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