Komatsu 960E-1 Dump Truck Shop Manual CEBM021300 – Full PDF Download

Description

Komatsu 960E-1 Dump Truck Shop Manual – Form No. CEBM021300

This is the complete Komatsu 960E-1 Dump Truck Shop Manual, published under Form No. CEBM021300, covering machine serial numbers A30003 and up. It is the same comprehensive workshop reference used by Komatsu service technicians, written for the 960E-1 electric drive haul truck. Inside you will find the full structure, function and maintenance standard chapters, testing and adjusting procedures, troubleshooting by fault code, disassembly and assembly instructions, plus hydraulic and electrical circuit diagrams.

File Details

• Manual type: Shop Manual (Service / Workshop)
• Brand: Komatsu
• Model: 960E-1 Dump Truck
• Form / Document No.: CEBM021300
• Serial numbers covered: A30003 and up
• Language: English
• File format: PDF
• Page count: 906 pages

Chapters Covered

• 00 Index and foreword
• 01 Specification
• 10 Structure, function and maintenance standard
• 20 Standard value table
• 30 Testing and adjusting
• 40 Troubleshooting
• 50 Disassembly and assembly
• 90 Diagrams and drawings

00 – Index and Foreword

The opening section covers the shop manual composition, how to read the manual, general safety, precautions before and during operation, working near batteries, precautions before and during service, tire handling, welding precautions, handling electrical and hydraulic components, how to read electric wire code, standard torque tables and conversion tables. It also includes the operating instructions section with engine start-up, emergency steering system, haul road operation, towing, loading, dumping and safe parking procedures.

01 – Specification

Contains the specification drawing, full specifications, weight table and the fuel, coolant and lubricants charts. Detailed specifications for the 960E-1 include the KOMATSU SSDA18V170 engine rated at 2,611 kW (3,500 hp) @ 1,900 rpm, maximum torque of 13,771 Nm (10,157 ft lb), 18 cylinders with 170 mm x 190 mm bore and stroke, 78 L displacement, maximum travel speed of 64.5 kph (40 mph), dump body capacity of 191 m³ (250 yd³) and 239 m³ (313 yd³), and 56/80 R63 tires with 600 kPa (87 psi) minimum pressure.

10 – Structure, Function and Maintenance Standard

This is the technical heart of the manual and is divided into distinct system chapters:

• Steering circuit – Steering circuit operation, components, flow amplifier operation, steering/brake pump operation and steering cylinder wear data.
• Hoist circuit – Hoist circuit operation, components, hoist pilot valve operation and hoist cylinder wear data.
• Brake circuits – General information, service brake circuit operation, secondary braking and auto apply, parking brake circuit, wheel brake lock circuit, brake warning circuit and brake assembly wear data.
• Suspensions – Front and rear suspension wear data and general information.
• Electrical system, 24V – Battery supply system, auxiliary control cabinet components, relay boards, body-up switch and hoist limit switch.
• Interface module (IM) – General information, sensors and the interface module inputs and outputs tables.
• Electrical system, AC drive – General system operation, AC drive system components, PSC software functions, alternator field control, event detection and processing, event logging and storage, serial data communications, abnormal conditions/overriding functions and the AC drive system component table.
• Cab air conditioning – General information, air conditioning system components and electrical circuit.

20 – Standard Value Table

The standard value table for the truck provides the reference values for new and permissible wear limits, including travel speed, engine speed, steering wheel operating force, accelerator and brake pedal operating force and stroke, suspension cylinder installed length and nitrogen pressure, accumulator pressure, oil pressure values, relief pressures, and body lifting and lowering speeds.

30 – Testing and Adjusting

Contains the special tool list and detailed checkout procedures grouped by system:

• Steering, brake cooling and hoist hydraulic system – system checkout procedures, data sheets and hydraulic system flushing procedure.
• Brake system – brake circuit checkout, brake piston leakage test, wet disc brake bleeding, parking brake bleeding, brake valve bench test and adjustment, and dual relay valve bench test and adjustment.
• Accumulators and suspensions – accumulator charging and storage, leak testing, suspension oiling and charging, and suspension pressure test.
• VHMS and payload meter – software, controller initial setting, initialization check list and form, controller replacement precautions, controller checkout and payload meter initial setting.
• Interface module (IM) – software and checkout procedures.
• Cab air conditioning – general information, service tools, leak detection, system performance test, oil check, flushing, manifold gauge installation, refrigerant recovery and recycling, evacuation, charging and A/C drive belt checkout.

40 – Troubleshooting

One of the most valuable sections of the manual. It includes the fault code table and fuse and circuit breaker locations, AC drive system fault codes (DID panel fault code tables), and troubleshooting by fault code in five parts. Fault codes are covered in detail from A001 through A365, covering suspension pressure sensors, incline sensor, payload meter, body-up switch, steering pressure, brake accumulator pressure, hoist pressure sensors, fuel level sensor, hydraulic oil temperature sensors, J1939 data link, parking brake, brake auto apply, starter failure, battery voltage, relay board circuit breakers, output overloads and many more. Each fault code entry gives the fault description, fault conditions, operator alerting system response, resulting problems, related information and expected parameter states.

50 – Disassembly and Assembly

Step-by-step removal, installation, disassembly and assembly procedures for the major components of the 960E-1, including:

• Wheels, spindles and rear axles – front and rear wheel removal and installation, tire removal and installation, front wheel hub and spindle, rear axle, anti-sway bar, pivot pin, pivot eye and bearing service, and wheel motor removal and installation.
• Brake system – brake valve, dual relay valve, brake manifold, brake accumulator, wheel brake and parking brake.
• Steering system – steering control unit, steering column, steering wheel, bleed down manifold, flow amplifier, steering cylinders and tie rod, steering/brake pump and steering accumulators.
• Suspensions – front and rear suspension removal and installation, minor front suspension repairs and major front suspension rebuild.
• Hoist circuit – hoist pump, hoist valve, overcenter valve manifold, hoist pilot valve and hoist cylinders.
• Operator cab – cab, cab door, window glass, windshield wiper motor, wiper arm, wiper linkage and seat.
• Body and structures – dump body, body pads, diagonal ladder/hood and grille assembly, right and left deck, fuel tank, fuel gauge sender and fuel tank breather.
• Cab air conditioning – replacement of system components and compressor clutch disassembly and assembly.

90 – Diagrams and Drawings

The final section provides the hydraulic circuit diagrams (steering, hoist and brake cooling hydraulic circuit diagram EM7616, brake hydraulic circuit diagram EM7623) and the complete electrical circuit diagrams, including index and symbols, circuit locator sheets, battery box, 24V power distribution and circuit protection, engine control wiring, keyswitch and timed engine shutdown and auto lube system, engine start circuit, brake control wiring, steering and hoist pressure switch wiring, operator drive system controls, electronic dash panel, operator cab light controls and horn, cab windows and wipers, radio and seat wiring, clearance lights, fog lights and headlights, hazard light wiring, heater and air conditioning controls, diagnostic ports (GE and VHMS), modular mining interface, interface module inputs and outputs, payload meter III circuits, and a connectors table and arrangement drawing.

Why This Komatsu 960E-1 Shop Manual Matters

The 960E-1 is a 576,062 kg (1,270,000 lbs) gross vehicle weight electric drive haul truck, and it demands correct procedures, correct torque values and correct fault diagnosis. Whether you are performing a scheduled brake circuit checkout, troubleshooting a fault code on the DID panel, rebuilding a hoist cylinder, charging a suspension accumulator to the correct nitrogen precharge, checking the AC drive system or overhauling a wheel motor, this manual gives you the manufacturer’s procedures, wear limits, standard values and torque specifications.

Having the Komatsu 960E-1 Dump Truck Shop Manual on hand means you can identify the correct fault code, follow the correct disassembly sequence, apply the correct torque and keep the truck running safely and efficiently. It is an essential reference for any service technician, maintenance planner or fleet workshop responsible for the 960E-1.

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Instant PDF Delivery

This Komatsu 960E-1 Shop Manual is delivered as an instant PDF download after payment. There is no shipping, no waiting and no physical media. You can open it on any device – laptop, tablet or smartphone – and print the pages you need for the workshop. Keep the complete manual on hand in the service truck, the office or the maintenance bay and search through the sections you need whenever a repair or diagnosis is required.