Komatsu 960E-2KT Dump Truck Operation & Maintenance Manual
213 pages · Publication CEAM028202
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- Models
- 960E-2KT
- Serial coverage
- A50028 - A50088
- Manual type
- Operation & Maintenance Manual
- Pages
- 213
- Publication
- CEAM028202
- Condition
- Brand new
What's inside
From the manual's own table of contents: 114 sections, 459 entries. See sample pages (PDF, 617 KB)
FOREWORD
ABOUT THIS MANUAL
WARNINGS1 topic
- California Proposition 65 Warnings
ALERTS
TRUCK MODEL ILLUSTRATION
PARTS IN CRITICAL SYSTEMS
GENERAL INFORMATION2 topics
- Effect Of Special Lubricants
- Suggested Sources For Rust Preventive Grease
STANDARD TIGHTENING TORQUES10 topics
- Class 10.9 Capscrews And Class 10 Nuts
- SAE Grade 5 And Grade 8 Capscrews
- SAE Grade 9 Capscrews
- T-Bolt Clamps
- Split Flange Clamps
- Flared Tube And Hose Fittings
- JIC 37° Swivel Nuts
- Pipe Thread Fittings
- O-Ring Boss Fittings
- O-Ring Face Seal Fittings
CONVERSION MULTIPLIERS3 topics
- Metric To English
- English To Metric
- Temperature Conversions
GENERAL SAFETY14 topics
- Safety Rules
- Truck Safety Features
- Clothing And Personal Items
- Unauthorized Modification
- Leaving The Operator’s Seat
- Mounting And Dismounting
- Fire Extinguishers And First Aid Kits
- Precautions For High Temperature Fluids
- Asbestos Dust Hazard Prevention
- Fire Prevention
- ROPS Precautions
- Preventing Injury From Work Equipment
- Precautions For Optional Attachments
- Precautions When Starting The Machine
PRECAUTIONS FOR TRUCK OPERATION8 topics
- Safety Is Thinking Ahead
- Safety At The Worksite
- Preparing For Operation
- Ventilation For Enclosed Areas
- Mirrors, Windows, And Lights
- Before Starting The Engine
- Seat Belts And Tethers
- Emergency Egress Ladders
OPERATING THE MACHINE14 topics
- General Information
- Starting The Engine
- Traveling In The Machine
- Traveling In Reverse
- Traveling On Slopes
- Traveling On Snow
- Traveling Near High Voltage Cables
- Traveling On Loose Ground
- Ensuring Good Visibility
- Avoid Damage To The Dump Body
- Safe Parking Of The Machine
- Loading The Machine
- Dumping The Machine
- Towing The Machine
EXTERIOR LIGHTING11 topics
- Fog Lights
- Headlights
- Ladder Lights and Deck Mounted Flood Lights
- Mirror Mounted Backup Lights
- Brake Light
- Retard Light
- Clearance/Turn Signal Lights
- Retard Lights
- Brake Lights
- Backup Alarm
- HID Backup Lights
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE1 topic
- Securing The Dump Body
DURING MAINTENANCE17 topics
- Warning Tag
- Proper Tools
- Attachments
- Working Under The Machine
- Keeping The Machine Clean
- Adding Fuel Or Oil To The Machine
- Radiator Coolant Level
- Use Of Lighting
- Handling High Pressure Hoses
- Precautions With High Pressure Oil
- Maintenance Near High Temperatures And High Pressures
- Rotating Fan And Belts
- Waste Materials
- Use Of Tie-Off Anchor During Maintenance
- Handling Tires
- Tire Maintenance
- Storing Tires After Removal
Battery Hazard Prevention2 topics
- Jump Starting With Jumper Cables
- Jump Starting With Receptacles
WHEN REPAIRS ARE NECESSARY1 topic
- Observe The Following Precautions
SPECIAL PRECAUTIONS3 topics
- Preliminary Procedures Before Welding Or Performing Maintenance
- Engine Shutdown Procedure Before Welding or Performing Maintenance
- Before Welding On The Machine, Obey The Following Guidelines
PIN PLATE
GRADE SPEED CHART
GREASE POINTS
MACHINE SAFETY
KEY SWITCH
Show all 114 sections
OIL FILL AND CHECK
HIGH PRESSURES
BATTERIES
HIGH VOLTAGE
WELDING
EMERGENCY DUMPING
AUTOMATIC LUBRICATION FILL
ROPS/FOPS
TOWING
LUBRICATION CHART
PREPARING FOR OPERATION2 topics
- Safety Is Thinking Ahead
- Walk Around Inspection
TRUCK OPERATION30 topics
- ENGINE START-UP SAFETY
- After Engine Has Started
- MACHINE OPERATION SAFETY PRECAUTIONS
- Machine Operation On The Haul Road
- Starting On A Grade With A Loaded Truck
- Passing
- Loading
- Overload Speed Limit Function
- Dumping
- Lowering The Dump Body (When Dumping On Flat Ground)
- Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)
- TROLLEY OPERATING INSTRUCTIONS
- Operating in Trolley Line Mode
- Getting on Line
- Operating on Trolley
- Getting off Line
- Line Status Signals
- Trolley Disconnect
- Traffic Consideration for Trolley Line Operation
- Approaching Slow Moving Vehicles in a Trolley Assisted Truck
- Operating Slow Moving Vehicles on Trolley Assist Ramps
- Truck Failure While on Trolley
- SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
- EMERGENCY STEERING SYSTEM
- Operation
- Pre-Operation Testing
- Additional Guidelines
- FUEL DEPLETION
- SAFE PARKING PROCEDURES
- NORMAL ENGINE SHUTDOWN PROCEDURE
DISABLED TRUCK CONNECTORS
STEERING AND BRAKE SYSTEM2 topics
- Components Required
- Hookup
HOIST SYSTEM1 topic
- Dumping Procedure
SPECIAL WIRING HARNESS
TOWING PROCEDURE
PAYLOAD METER III SYSTEM2 topics
- Data Summary
- Data Gathering
COMPONENT DESCRIPTION6 topics
- Operator Display
- Operator Switches
- Brake Lock Switch
- Payload Meter Module
- Communications Ports
- Load Lights
OPERATOR’S DISPLAY AND SWITCH5 topics
- Reading the Load Display
- Setting the Operator ID
- Load and Ton Counter
- Viewing Live Sensor Data
- Other Display Messages
HAUL CYCLE WARNING FLAGS2 topics
- Haul Cycle Data
- Haul Cycle Warning Flags
PC SOFTWARE OVERVIEW
SYSTEM CONFIGURATION13 topics
- Connecting to the Payload Meter
- Displayed Payload Units
- Connection Menu
- Configure the Payload Meter
- Setting the Date and Time
- Setting the Truck Type and Serial Number
- Setting the Gauge Display Units
- Setting the Carryback Alarm Threshold
- Setting the Truck Number
- Setting the Komatsu Distributor
- Setting the Komatsu Customer
- Clean Truck Tare Calibration
- Inclinometer Calibration
DOWNLOADING PAYLOAD DATA
Uploading Data3 topics
- Creating a Query
- Detailed Multi-Page Report
- Creating Graphs
DATA ANALYSIS9 topics
- Payload Detail Screen
- Creating Reports
- Creating Graphs
- Exporting Data
- Importing Data
- Deleting Haul Cycle Records
- Viewing Alarms
- Deleting Alarm Records
- Patent Acknowledgment
AUTOMATIC LUBRICATION SYSTEM22 topics
- GENERAL INFORMATION
- COMPONENT DESCRIPTION
- Filter
- Hydraulic Motor and Pump
- Grease Reservoir
- Pressure Reducing Valve
- Flow Control Valve
- Solenoid Valve
- Vent Valve
- Interface Module
- Injectors
- Grease Pressure Failure Switch
- Relief Valve (unloader valve)
- SYSTEM OPERATION
- Filling The Reservoir
- Priming The Automatic Lubrication System
- PREVENTIVE MAINTENANCE PROCEDURES
- Daily Lubrication System Inspection
- Hour Inspection
- SYSTEM CHECKOUT
- General Checks
- Lubrication Cycle Operation
RESERVE ENGINE OIL SYSTEM3 topics
- Operation
- LED Monitor Light
- Changing Oil
CAB INTERIOR
STEERING WHEEL AND CONTROLS7 topics
- Horn Button
- Tilt / Telescope Lever
- Multi-Function Turn Signal Switch
- Speed Control Lever
- Turn Signal Operation
- High Beam Headlight Operation
- Windshield Wiper Operation
PEDALS3 topics
- DYNAMIC RETARDING
- Dynamic Retarder/Service Brake Pedal
- ACCELERATOR PEDAL
OVERHEAD PANEL AND DISPLAYS4 topics
- Radio Speakers
- Warning Alarm Buzzer
- Cab Radio
- Air Cleaner Vacuum Gauges
CENTER CONSOLE11 topics
- DIRECTIONAL CONTROL LEVER
- OVERRIDE/FAULT RESET SWITCH
- ENGINE STOP SWITCH
- WINDOW CONTROL SWITCHES
- HOIST CONTROL LEVER
- Raising The Dump Body
- Lowering The Dump Body
- ASHTRAY
- LIGHTER
- DATA STORE BUTTON
- 12V AUXILIARY POWER OUTLETS
DIAGNOSTIC PORTS7 topics
- DRIVE SYSTEM #1
- ENGINE (QUANTUM)
- DRIVE SYSTEM #3
- ENGINE (CENSE)
- INTERFACE MODULE (IM)
- KOMTRAX Plus
- PAYLOAD METER
OPERATOR SEAT (Standard)2 topics
- Seat Belts And Tethers
- Adjustment
PASSENGER SEAT (Standard)
OPERATOR SEAT (Optional)
PASSENGER SEAT (Optional)
HEATER / AIR CONDITIONER CONTROLS4 topics
- Fan Speed Control Knob
- Temperature Control Knob
- Air Flow Directional Knob
- Heater/Air Conditioner Vents
INSTRUMENT PANEL24 topics
- CONTROL SYMBOLS
- Key Switch
- Speed Control Switch
- Traction Control Switch
- Retarding Grid Drier Switch
- AC Drive System Rest Switch
- Wheel Brake Lock Switch
- Pantograph Switch
- Hazard Light Switch
- Drive System Temperature Gauge
- Fuel Level Gauge
- Speedometer/Digital Display
- Coolant Temperature Gauge
- Hydraulic Oil Temperature Gauge
- Status Indicator Light Panel
- Headlight/Panel Illumination Light Switch
- Ladder Light Switch
- Backup Light Switch
- Fog Light Switch
- Mode Switches
- Panel Lights Dimmer Switch
- Turn Signal Indicators
- Digital Display Contrast Buttons
- Warning Light
STATUS INDICATOR LIGHT PANEL18 topics
- STATUS INDICATOR LIGHT SYMBOLS
- Body Up
- Parking Brake
- Propel System Not Ready
- No Propel
- Engine Warm Up
- Engine Shutdown Delay
- Retarding Grid Drier
- Wheel Brake Lock
- Traction Control
- Repair Monitor
- Retractable Ladder Down
- Snapshot In Progress
- Pantograph Energized
- Pantograph Up
- Service Brake
- Dynamic Retarding
- No DC Link Voltage
DIGITAL DISPLAY OPERATION3 topics
- Toggling Through Main Level Screens
- Toggling Through Warning Screens
- Entering Payload Meter Data
KOMTRAX Plus19 topics
- KOMTRAX Plus OPERATION
- Basic Precautions
- Interface Module
- DOWNLOADING KOMTRAX Plus DATA
- General Information
- KOMTRAX Plus Downloading Procedure
- Location Of Downloaded Files
- UPLOADING KOMTRAX Plus DATA
- ORBCOMM
- KOMATSU WIRELESS BRIDGE (Optional)
- General Information
- Communication Setup
- Switching To The KWB_SETUP Network
- Setting The Computer Subnet Mask And IP Address
- Setting Up The KWB
- Adding Encryption
- Final Computer Settings
- Downloading Data
- Resetting The KWB
FUSES AND CIRCUIT BREAKERS1 topic
- FUSE BLOCK #1
FUSE BLOCK #2
FUSE BLOCK #3
FUSE HOLDERS
CIRCUIT BREAKERS
HYDRAULIC SYSTEM SERVICE3 topics
- Hydraulic Tank
- Hydraulic Filters
- Hydraulic Pump Drive Shaft
WHEEL MOTOR SERVICE
WHEEL MOUNTING
COOLANT LEVEL SERVICE3 topics
- Radiator Filling Procedure
- Coolant Specifications
- Unacceptable Practices
IGBT COOLANT SERVICE
RESERVE ENGINE OIL SERVICE2 topics
- Reserve Oil Tank Filling Procedure (Remote Fill)
- Inline Screen
CAB AIR FILTER SERVICE
FUEL SYSTEM SERVICE2 topics
- Fuel Tank Cleaning
- Fuel Filter Service
INTAKE AIR CLEANER SERVICE
FRONT ENGINE MOUNT TRUNNION SERVICE
QUICK FILL SERVICE CENTER
TIE ROD INSPECTION AND TORQUE PROCEDURE
EVERY 10 HOUR (DAILY) MAINTENANCE
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 250 HOUR LUBRICATION AND MAINTENANCE
EVERY 500 HOUR LUBRICATION AND MAINTENANCE
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
EVERY 1500 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 2000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 3000 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 4000 HOUR MAINTENANCE
EVERY 5000 HOUR MAINTENANCE
EVERY 6000 HOUR MAINTENANCE
EVERY 12,000 HOUR MAINTENANCE
EVERY 18,000 HOUR MAINTENANCE
EVERY 24,000 HOUR MAINTENANCE
25,000 HOUR LUBRICATION AND MAINTENANCE CHECKS
30,000 HOUR LUBRICATION AND MAINTENANCE CHECKS
MAJOR COMPONENT DESCRIPTION
Truck and Engine
Traction Alternator
Main Control Cabinet
AC Induction Traction Motorized Wheels5 topics
- Suspension
- Operator's Cab
- Power Steering
- Dynamic Retarding Grid
- Brake System
SPECIFICATIONS12 topics
- Engine
- AC Electric Drive System
- Dynamic Retarding
- Battery Electric System
- Service Capacities
- Hydraulic Systems
- Service Brakes
- Steering
- Standard Dump Body Capacities and Dimensions
- Tires
- Weight Distribution
- Overall Truck Dimensions
RADIO OPERATION10 topics
- General Radio Receiver Functions
- Turning On The Power
- One-Hour Timer
- Finding A Station
- Setting The Presets
- Adjusting The Receiver Audio Settings
- Display
- Adjusting The Receiver Menu Settings
- Front Auxiliary Mode
- Rear Auxiliary Mode
CLOCK5 topics
- Clock/Alarm Button
- Setting The Clock
- Setting The Alarm
- Turning The Alarm Off
- Activating Snooze
CD PLAYER4 topics
- Playing A Compact Disc
- Playing An MP3 DISC
- CD Mode Displays
- Button Functions
MP3 PLAYER3 topics
- Playing MP3 Files
- MP3 Mode Displays
- Button Functions
iPod ®3 topics
- Playing An iPod ®
- iPod ® Mode Displays
- Button Functions
WEATHERBAND (USA Only)
TROUBLESHOOTING3 topics
- Tips About the Audio System
- Understanding Radio Reception
- Care Of The Compact Discs
Inside this manual
Real pages from this operation & maintenance manual (213 pages). Open the sample pages (PDF, 616 KB)
- Specifications, page 23: GENERAL INFORMATION
- Controls and operation, page 137: INSTRUMENT PANEL
- Maintenance, page 185: EVERY 3000 HOUR LUBRICATION AND
- Color page, page 168: LUBRICATION AND SERVICE
- Color page, page 115: AUTOMATIC LUBRICATION SYSTEM
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 960E-2KT 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 CEAM028202$69.91
Added to your cart. View cart
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, 213 pages
Quantity one is the manual described above.
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Ships in 1 business day.
60-day returns
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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).