Komatsu 960E-1 Dump Truck Operation and Maintenance Manual CEAM015803

Description

• Model List:
  • 960E-1 Dump Truck

• 1. COVER
• 2. INTRODUCTION
• 2.1. FOREWORD
• 2.2. TRUCK MODEL ILLUSTRATION
• 2.3. ABOUT THIS MANUAL
• 2.4. ALERTS PAGE
• 3. TABLE OF CONTENTS
• 4. TORQUE TABLES AND CONVERSION CHARTS
• 4.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 4.2. STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws Class 10 Nuts
• 4.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
• 4.4. STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws
• 5. SAFETY
• 5.1. General
• 5.2. Precautions before operating the truck
• 5.3. Precautions while operating the truck
• 5.4. Working near batteries
• 5.5. Precautions before performing service
• 5.6. Precautions while performing service
• 5.7. Tires
• 5.8. Precautions for performing repairs
• 5.9. Precautions for welding on the truck
• 5.10. Capacitor discharge system
• 6. WARNINGS AND CAUTIONS
• 6.1. GRADE/SPEED CHART
• 6.2. KEY SWITCH
• 6.3. ROPS/FOPS
• 6.4. BATTERIES
• 6.5. EMERGENCY SHUTDOWN
• 6.6. RADIATOR
• 6.7. CRUSHING HAZARD
• 6.8. CYLINDER PRESSURE
• 6.9. FILLING THE HYDRAULIC TANK
• 6.10. HYDRAULIC OIL PRESSURE
• 6.11. WHEEL MOTOR OIL LEVEL
• 6.12. EMERGENCY TOWING PROCEDURE
• 6.13. EMERGENCY DUMP PROCEDURE
• 6.14. ACCUMULATOR DRAIN VALVES
• 6.15. HOT EXHAUST
• 6.16. WELDING
• 6.17. INFORMATION DISPLAY
• 6.18. CAPACITORS
• 6.19. HIGH VOLTAGE
• 6.20. LIFTING INSTRUCTIONS
• 6.21. WIRELESS SIGNALS
• 6.22. PRODUCT IDENTIFICATION PLATE
• 6.23. LUBRICATION CHART
• 7. OPERATING INSTRUCTIONS
• 7.1. Preparing for operation
• 7.2. Walk around inspection
• 7.3. Engine startup
• 7.4. After engine startup
• 7.5. Emergency steering system
• 7.6. Precautions during truck operation
• 7.7. Operating on a haul road
• 7.8. Starting on a grade with a loaded truck
• 7.9. Sudden loss of engine power
• 7.10. Fuel depletion
• 7.11. Towing
• 7.12. Loading the dump body
• 7.13. Dumping a load
• 7.14. Disabled truck dumping procedure
• 7.15. Safe parking procedure
• 7.16. Normal engine shutdown procedure
• 8. OPERATOR CAB AND CONTROLS
• 8.1. STEERING WHEEL AND CONTROLS
• 8.2. PEDALS
• 8.3. GRADE/SPEED CHART
• 8.4. OVERHEAD PANEL AND DISPLAYS
• 8.5. CENTER CONSOLE
• 8.6. DIAGNOSTIC PORTS
• 8.7. OPERATORS SEAT
• 8.8. PASSENGER SEAT
• 8.9. HEATER / AIR CONDITIONER CONTROLS
• 8.10. INSTRUMENT PANEL
• 8.11. STATUS INDICATOR LIGHTS
• 8.12. DIGITAL DISPLAY OPERATION
• 8.13. REAR AXLE LIGHT BAR
• 8.14. KOMTRAX PLUS
• 8.15. KOMATSU WIRELESS BRIDGE (Optional)
• 8.16. FUSES AND CIRCUIT BREAKERS
• 9. LUBRICATION AND SERVICE
• 9.1. SERVICE CAPACITIES
• 9.2. HYDRAULIC TANK SERVICE
• 9.3. COOLING SYSTEM SERVICE
• 9.4. WHEEL MOTOR SERVICE
• 9.5. RESERVE OIL TANK SERVICE
• 9.6. AIR CLEANER SERVICE
• 9.7. QUICK FILL SERVICE CENTER
• 9.8. TIE ROD INSPECTION AND TORQUE PROCEDURE
• 9.9. LUBRICATION CHART
• 9.10. HOUR (DAILY) INSPECTION
• 9.11. INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.12. INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.13. INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.14. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.15. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.16. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.17. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 9.18. HOUR MAINTENANCE CHECKS
• 10. AUTOMATIC LUBRICATION SYSTEM
• 10.1. GENERAL DESCRIPTION
• 10.2. SYSTEM COMPONENTS
• 10.3. SYSTEM OPERATION
• 10.4. GENERAL INSTRUCTIONS
• 10.5. LUBRICANT PUMP
• 10.6. INJECTORS (SL1 Series H)
• 10.7. PREVENTIVE MAINTENANCE PROCEDURES
• 10.8. SYSTEM CHECKOUT
• 10.9. SYSTEM TROUBLESHOOTING CHART
• 11. COMPONENTS SPECIFICATIONS
• 11.1. MAJOR COMPONENT DESCRIPTIONS
• 11.2. SPECIFICATIONS
• 12. PAYLOAD METETR III
• 12.1. INTRODUCTION
• 12.2. COMPONENT DESCRIPTION
• 12.3. LOAD DISPLAY AND OPERATOR SWITCHES
• 12.4. PAYLOAD OPERATION CALCULATION
• 12.5. SOURCES FOR PAYLOAD ERROR
• 12.6. HAUL CYCLE DATA
• 12.7. PDM SOFTWARE OVERVIEW
• 12.8. DOWNLOADING DATA
• 12.9. PLM III SYSTEM CONFIGURATION
• 12.10. DATA ANALYSIS
• 13. AM/FM RADIO / CD PLAYER
• 13.1. GENERAL RADIO RECEIVER FUNCTIONS
• 13.2. USING THE CLOCK
• 13.3. USING THE ALARM
• 13.4. USING THE RADIO
• 13.5. USING THE WEATHERBAND
• 13.6. USING THE COMPACT DISC PLAYER
• 13.7. PLAYING AN MP3 DISC
• 13.8. TROUBLESHOOTING