Komatsu 960E-1 Dump Truck Operation & Maintenance Manual
187 pages · Publication CEAM015803
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- Models
- 960E-1
- Serial coverage
- A30003 - A30024
- Manual type
- Operation & Maintenance Manual
- Pages
- 187
- Publication
- CEAM015803
- Condition
- Brand new
What's inside
From the manual's own table of contents: 314 sections, 336 entries. See sample pages (PDF, 543 KB)
General1 topic
- TABLE OF CONTENTS INTRODUCTION
FOREWORD
TRUCK MODEL ILLUSTRATION
ABOUT THIS MANUAL
ALERTS PAGE
TORQUE TABLES AND CONVERSION CHARTS
SAFETY
GENERAL
Safety Rules
Safety Features
Fire Extinguishers And First Aid Kits
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 OPERATING THE TRUCK
Safety At The Work Site
Show all 315 sections
Fire Prevention
Ventilation In Enclosed Areas
Preparing For Operation
Mirrors, Windows, And Lights
In The Operator Cab (Before Starting The Engine)
PRECAUTIONS WHILE OPERATING THE TRUCK
When Starting The Engine
General Truck Operation
Ensuring Good Visibility
Traveling
Traveling In Reverse
Traveling On Slopes
Operating On Snow Or Ice1 topic
- TABLE OF CONTENTS (cont.) Avoid Damage To The Dump Body
Driving Near High Voltage Cables
When Dumping
When Loading
Working On Loose Ground
Parking The Truck
Towing
WORKING NEAR BATTERIES
Battery Hazard Prevention
Starting With Booster Cables
PRECAUTIONS BEFORE PERFORMING MAINTENANCE
Stopping The Engine
Warning Tag
Proper Tools
Securing The Dump Body
PRECAUTIONS WHILE PERFORMING SERVICE
Keep The Truck Clean
Attachments
Working Under The Truck
Rotating Fan And Belts
Waste Materials
Adding Fuel Or Oil
Radiator Coolant Level
Use Of Lighting
Precautions With The Battery
Handling High Pressure Hoses
Precautions With High Pressure Oil
Performing Maintenance Near High Temperature Or High Pressure
TIRES
Handling Tires
Storing Tires After Removal
PRECAUTIONS FOR PERFORMING REPAIRS
Engine Shutdown Procedure After AC Drive System Failure
PRECAUTIONS FOR WELDING ON THE TRUCK
CAPACITOR DISCHARGE SYSTEM
Necessary Tools
Warnings And Cautions
Manual DC Link Capacitor Discharge Procedure
Failure of the Discharge System
Manual Discharge of Capacitors
Short Isolated Capacitor Terminals1 topic
- TABLE OF CONTENTS (cont.) OPERATING INSTRUCTIONS
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
SUDDEN LOSS OF ENGINE POWER
FUEL DEPLETION
Special Wiring Harness
LOADING THE DUMP BODY
Overload Speed Limit Function
DUMPING A LOAD
Raising The Dump Body
LoweringThe Dump Body (On Flat Ground)
Lowering The Dump Body (Over A Berm Or Into A Crusher)
DISABLED TRUCK DUMPING PROCEDURE
Hookup
Raising the Body
Lowering the Body
SAFE PARKING PROCEDURE
NORMAL ENGINE SHUTDOWN PROCEDURE
OPERATOR CAB AND CONTROLS
STEERING WHEEL AND CONTROLS
Horn Button
Tilt/Telescope Lever
Multi-Function Turn Signal Switch
Turn Signal Operation
High Beam Headlight Operation
Windshield Wiper Operation
Retarder Control Lever
PEDALS
Retarder/Service Brake Pedal
Throttle/Accelerator Pedal1 topic
- TABLE OF CONTENTS (cont.) GRADE/SPEED CHART
OVERHEAD PANEL AND DISPLAYS
Speakers
Warning Alarm Buzzer
Radio/CD Player
Air Cleaner Restriction Gauges
CENTER CONSOLE
Direction Control Lever
Override/Fault Reset Switch
Engine Shutdown Switch
Window Control Switches
Hoist Control Lever
Retard Speed Control (RSC) Adjustment Dial
Retard Speed Control (RSC) Switch
Data Store Button
12V Auxiliary Power Outlets
DIAGNOSTIC PORTS
KOMTRAX Plus Diagnostic Port
Interface Module (IM) Diagnostic Port
Payload Meter Diagnostic Port
Truck Control Interface (TCI) Diagnostic Port
Propulsion System Controller (PSC) Diagnostic Port
Engine Diagnostic Port (CENSE)
Engine Diagnostic Port (QUANTUM)
OPERATOR’S SEAT
Seat Belts
Adjustment
PASSENGER SEAT
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
Retarding Grid Drier Switch
AC Drive System Rest Switch
Wheel Brake Lock Switch
Hazard Warning Lights1 topic
- TABLE OF CONTENTS (cont.) Fuel Level Gauge
Hydraulic Oil Temperature Gauge
Speedometer/Digital Display
Coolant Temperature Gauge
Drive System Temperature Gauge
Status Indicator Light Panel
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 LIGHTS
Body Up
Parking Brake Applied
Propulsion System Not Ready
No Propel
Engine Warming Up
Not Used
Grid Drier
Wheel Brake Lock Applied
Repair Monitor
Snapshot In Progress
Pantagraph Energized
Pantagraph 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
REAR AXLE LIGHT BAR
Backup Lights
Retard Lights
Brake Lights
Backup Alarm
KOMTRAX PLUS1 topic
- TABLE OF CONTENTS (cont.) Interface Module
Basic Precautions
KOMATSU WIRELESS BRIDGE (Optional)
General Information
Communication Setup
Switching to the KWB_SETUP Network
Setting the Computer Subnet Mask and IP Address
Properties
Setting Up the KWB
Adding Encryption
Final Computer Settings
Data Downloading
Resetting the KWB
KWB Lights
FUSES AND CIRCUIT BREAKERS
LUBRICATION AND SERVICE
960E-1 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
QUICK FILL SERVICE CENTER
TIE ROD INSPECTION AND TORQUE PROCEDURE
LUBRICATION CHART
HOUR (DAILY) INSPECTION
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE CHECKS
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE CHECKS
INITIAL 250 HOUR LUBRICATION AND MAINTENANCE CHECKS
HOUR LUBRICATION AND MAINTENANCE CHECKS1 topic
- TABLE OF CONTENTS (cont.) 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
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
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 Cab1 topic
- TABLE OF CONTENTS (cont.) Power Steering
Brake System
SPECIFICATIONS
Engine
AC Electric Drive System
Battery Electric System
Service Capacities
Hydraulic Systems
Service Brakes
Steering
Standard Dump Body Capacities And Dimensions
Weight Distribution
PAYLOAD METER III™
INTRODUCTION
COMPONENT DESCRIPTION
LOAD DISPLAY AND OPERATOR SWITCHES
PAYLOAD OPERATION & CALCULATION
SOURCES FOR PAYLOAD ERROR
HAUL CYCLE DATA
PDM SOFTWARE OVERVIEW
DOWNLOADING DATA
PLM III SYSTEM CONFIGURATION
DATA ANALYSIS
AM/FM RADIO / CD PLAYER
OPERATING INSTRUCTIONS
GENERAL RADIO RECEIVER FUNCTIONS
Turning On the Power
One-Hour Timer
Display
Setting a Default Display
Adjusting the Brightness of the Display
Auxiliary Mode
Adjusting the Receiver Settings
USING THE CLOCK
Setting the Clock1 topic
- TABLE OF CONTENTS (cont.) USING THE ALARM
Setting the Alarm
Turning the Alarm Off
Activating Snooze
Setting Alarm Volume
USING THE RADIO
Finding a Station
Setting the Presets
USING THE WEATHERBAND
USING THE COMPACT DISC PLAYER
Playing a Compact Disc
Button Functions
PLAYING AN MP3 DISC
MP3 Format Compatibility
Playing MP3 Files
TROUBLESHOOTING
TABLE13 topics
- TABLE 1 Standard Tightening Torque For Metric Cap screws and Nuts
- TABLE 2 Standard Tightening Torque For SAE Grade 5 & 8 Cap Screws and Nuts
- TABLE 3 Standard Tightening Torque 12-Pt, Grade 9, Cap Screws (SAE)
- TABLE 4 Tightening Torque for T-Bolt Type Hose Clamps
- TABLE 5 Standard Tightening Torque For Split Flange Clamp Bolts
- TABLE 6 Tightening Torque For Flared Tube And Hose Fittings
- TABLE 7 JIC 37° Swivel Nuts Torque Chart (SAE)
- TABLE 8 Pipe Thread Torque Chart (SAE)
- TABLE 9 O-Ring Boss Torque Chart (SAE)
- TABLE 10 O-Ring Face Seal Torque Chart (SAE)
- TABLE 11 Common Conversions Multipliers - Metric -to- English
- TABLE 12 Common Conversions Multipliers - English -to- Metric
- TABLE 13 Temperature Conversions
Inside this manual
Real pages from this operation & maintenance manual (187 pages). Open the sample pages (PDF, 541 KB)
- Specifications, page 50: Safety - Section 20
- Controls and operation, page 92: Operator Cab And Controls - Section 32
- Maintenance, page 132: Lubrication and Service - Section 40
- Color page, page 49: Safety - Section 20
- Color page, page 166: Payload Meter III - Section 60
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 960E-1 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Operation & Maintenance Manual CEAM015803$69.69
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This is an operator's manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
This manual
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 187 pages
Quantity one is the manual described above.
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Ships in 1 business day.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).