Komatsu 960E-1 Dump Truck Operation and Maintenance Manual CEAM022901

Description

• Model List:
  • 960E-1 Dump Truck

• 1. INTRODUCTION
• 1.1. FOREWORD
• 1.2. TRUCK MODEL ILLUSTRATION
• 1.3. ABOUT THIS MANUAL
• 1.4. ALERTS PAGE
• 2. TABLE OF CONTENTS
• 3. TORQUE TABLES AND CONVERSION CHARTS
• 3.1. EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values
• 3.2. STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws Class 10 Nuts
• 3.3. STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws
• 3.4. STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws
• 4. SAFETY
• 4.1. General
• 4.2. Precautions before operating the truck
• 4.3. Precautions while operating the truck
• 4.4. Working near batteries
• 4.5. Precautions before performing service
• 4.6. Precautions while performing service
• 4.7. Tires
• 4.8. Precautions for performing repairs
• 4.9. Precautions for welding on the truck
• 4.10. Capacitor discharge system
• 5. WARNINGS AND CAUTIONS
• 5.1. GRADE/SPEED CHART
• 5.2. KEY SWITCH
• 5.3. ROPS/FOPS
• 5.4. BATTERIES
• 5.5. EMERGENCY SHUTDOWN
• 5.6. RADIATOR
• 5.7. CRUSHING HAZARD
• 5.8. CYLINDER PRESSURE
• 5.9. FILLING THE HYDRAULIC TANK
• 5.10. HYDRAULIC OIL PRESSURE
• 5.11. WHEEL MOTOR OIL LEVEL
• 5.12. EMERGENCY TOWING PROCEDURE
• 5.13. EMERGENCY DUMP PROCEDURE
• 5.14. ACCUMULATOR DRAIN VALVES
• 5.15. HOT EXHAUST
• 5.16. WELDING
• 5.17. INFORMATION DISPLAY
• 5.18. CAPACITORS
• 5.19. HIGH VOLTAGE
• 5.20. LIFTING INSTRUCTIONS
• 5.21. WIRELESS SIGNALS
• 5.22. PRODUCT IDENTIFICATION PLATE
• 5.23. LUBRICATION CHART
• 6. OPERATING INSTRUCTIONS
• 6.1. Preparing for operation
• 6.2. Walk around inspection
• 6.3. Engine startup
• 6.4. After engine startup
• 6.5. Emergency steering system
• 6.6. Precautions during truck operation
• 6.7. Operating on a haul road
• 6.8. Starting on a grade with a loaded truck
• 6.9. Sudden loss of engine power
• 6.10. Fuel depletion
• 6.11. Towing
• 6.12. Loading the dump body
• 6.13. Dumping a load
• 6.14. Disabled truck dumping procedure
• 6.15. Safe parking procedure
• 6.16. Normal engine shutdown procedure
• 7. OPERATOR CAB AND CONTROLS
• 7.1. STEERING WHEEL AND CONTROLS
• 7.2. PEDALS
• 7.3. GRADE/SPEED CHART
• 7.4. OVERHEAD PANEL AND DISPLAYS
• 7.5. CENTER CONSOLE
• 7.6. DIAGNOSTIC PORTS
• 7.7. OPERATORS SEAT
• 7.8. PASSENGER SEAT
• 7.9. HEATER / AIR CONDITIONER CONTROLS
• 7.10. INSTRUMENT PANEL
• 7.11. STATUS INDICATOR LIGHTS
• 7.12. DIGITAL DISPLAY OPERATION
• 7.13. REAR AXLE LIGHT BAR
• 7.14. KOMTRAX PLUS
• 7.15. KOMATSU WIRELESS BRIDGE (Optional)
• 7.16. FUSES AND CIRCUIT BREAKERS
• 8. LUBRICATION AND SERVICE
• 8.1. SERVICE CAPACITIES
• 8.2. HYDRAULIC TANK SERVICE
• 8.3. COOLING SYSTEM SERVICE
• 8.4. WHEEL MOTOR SERVICE
• 8.5. RESERVE OIL TANK SERVICE
• 8.6. AIR CLEANER SERVICE
• 8.7. QUICK FILL SERVICE CENTER
• 8.8. TIE ROD INSPECTION AND TORQUE PROCEDURE
• 8.9. LUBRICATION CHART
• 8.10. HOUR (DAILY) INSPECTION
• 8.11. INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.12. INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.13. INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.14. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.15. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.16. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.17. HOUR LUBRICATION AND MAINTENANCE CHECKS
• 8.18. HOUR MAINTENANCE CHECKS
• 9. AUTOMATIC LUBRICATION SYSTEM
• 9.1. GENERAL DESCRIPTION
• 9.2. SYSTEM COMPONENTS
• 9.3. SYSTEM OPERATION
• 9.4. GENERAL INSTRUCTIONS
• 9.5. LUBRICANT PUMP
• 9.6. INJECTORS (SL1 Series H)
• 9.7. PREVENTIVE MAINTENANCE PROCEDURES
• 9.8. SYSTEM CHECKOUT
• 9.9. SYSTEM TROUBLESHOOTING CHART
• 10. COMPONENTS SPECIFICATIONS
• 10.1. MAJOR COMPONENT DESCRIPTIONS
• 10.2. SPECIFICATIONS
• 11. PAYLOAD METER III
• 12. AM/FM RADIO / CD / MP3 / USB / iPOD / AUX PLAYER
• 12.1. OPERATING INSTRUCTIONS