Komatsu 960E-1 Dump Truck Shop Manual CEBM021304 PDF

Description

Komatsu 960E-1 Dump Truck Shop Manual CEBM021304 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 960E-1 Dump Truck Shop Manual CEBM021304 – PDF DOWNLOAD 

Language : English
Pages : 1003
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 960E-1 Dump Truck Shop Manual CEBM021304 – PDF DOWNLOAD 

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 19
Foreword 22
How to read the shop manual 23
Composition of shop manual 23
Revision and distribution 23
Symbols 24
General safety 25
Safety rules 25
Safety features 25
Fire extinguisher and first aid kit 25
Clothing and personal items 25
Leaving the operator seat 26
Mounting and dismounting 26
Fire prevention for fuel and oil 26
Precautions with high temperature fluids 27
Asbestos dust hazard prevention 27
Prevention of injury by work equipment 27
Unauthorized modification 27
Precautions when using ROPS 27
Precautions for attachments 28
Precautions for starting the truck 28
Precautions before operating the truck 28
Safety at the worksite 28
Fire prevention 29
Ventilation in enclosed areas 29
Preparing for operation 29
Mirrors, windows and lights 29
In operator cab (before starting the engine) 29
Seat Belts 29
Precautions while operating the truck 30
When starting the engine 30
General truck operation 30
Ensuring good visibility 30
Traveling 31
Traveling in reverse 31
Traveling on slopes 31
Operating on snow or ice 31
Avoid damage to dump body 31
Driving near high voltage cables 32
When dumping 32
When loading 32
Working on loose ground 32
Parking the truck 32
Towing 32
Working near batteries 33
Battery hazard prevention 33
Starting with booster cables 34
Jump starting with receptacles 34
Precautions before performing service 35
Warning tag 35
Stopping the engine 35
Proper tools 35
Use of Tie-Off Anchor During Maintenance and Repair 35
Securing the dump body 36
Precautions while performing service 37
Keep the truck clean 37
Attachments 37
Working under the truck 37
Rotating fan and belts 37
Adding fuel or oil 37
Use of lighting 37
Radiator coolant level 38
Precautions with the battery 38
Precautions with high pressure oil 38
Handling high pressure hoses 38
Precautions when performing maintenance near high temperature or high pressure 38
Waste materials 38
Tires 39
Handling tires 39
Storing tires after removal 39
Precautions for performing repairs 40
Engine shutdown procedure after AC drive system failure 40
Precautions for welding on the truck 41
Capacitor discharge system 42
Necessary tools 42
Warnings and cautions 43
Manual DC link capacitor discharge procedure 44
Failure of the discharge system 46
Manual discharge of capacitors 47
Short isolated capacitor terminals 49
Handling electrical equipment and hydraulic components 50
Points to remember when handling electrical equipment 50
Points to remember when handling hydraulic equipment 56
How to read electric wire code 58
Standard torque tables 61
Effect of special lubricants on fasteners and standard torque values 61
Standard tightening torques for SAE hex head capscrew and nut assemblies 62
Standard assembly torques for 12-point, grade 9 capscrews (SAE) 63
Standard assembly torques for class 10 9 cap screws and class 10 nuts 63
Standard tightening torques for fittings 64
Conversion tables 66
Common conversion multipliers 66
Operating instructions 71
Preparing for operation 73
Walk around inspection 73
Engine start-up 77
After engine start-up 78
Emergency steering system 78
Operation 78
Pre-operation testing 78
Precautions during truck operation 79
Operating on a haul road 80
Starting on a grade with a loaded truck 81
Sudden loss of engine power 81
Fuel depletion 82
Towing 82
Special Wiring Harness 83
Loading the dump body 85
Dumping a load 85
Raising the dump body 85
Lowering the dump body (on flat ground) 86
Lowering the dump body (over a berm or into a crusher) 87
Disabled truck dumping procedure 87
Hookup 87
Raising the body 88
Lowering the body 88
Safe parking procedure 88
Normal engine shutdown procedure 89
01 Specification 91
Specification and technical data 91
Specification drawing 93
Specifications 94
Weight table 96
Fuel, coolant and lubricants 97
Suspension cylinder oil and nitrogen specifications 98
10 Structure, functions and maintenance standard 101
Steering circuit 101
Steering circuit operation 103
Steering circuit components 105
Steering control unit 105
High pressure filter 105
Steering accumulators 105
Bleed down manifold 106
Steering accumulator bleed down solenoid 108
Hoist up limit solenoid 108
Quick disconnect ports 108
Flow amplifier 108
Flow amplifier operation 109
No steer 110
Steering left 112
Steering right 114
No steer, external shock load 116
Steering/brake pump operation 119
Normal operation 119
Neutral position 120
Full pump volume 121
Half pump volume 121
Steering cylinder wear data 122
Hoist circuit 125
Hoist circuit operation 127
Hoist circuit components 128
Hydraulic tank 128
Hoist pump 128
High pressure filters 128
Hoist valve 128
Inlet sections 129
Tank ports (front) spool section 129
Work ports (rear) spool section 129
Hoist pilot valve 130
Bleed down manifold 130
Hoist limit solenoid 130
Pilot operated check valve 130
Overcenter manifold 131
Hoist pilot valve operation 132
Float position with body down 132
Power up operation 134
Hold operation 136
Power down operation 138
Float operation 140
Hoist cylinder wear data 142
Brake circuits 145
General information 147
Service brake circuit operation 148
Secondary braking and auto apply 148
Parking brake circuit operation 150
Normal operation (key switch ON, engine on) 150
Wheel brake lock circuit operation 151
Brake warning circuit operation 151
Brake assembly wear data 153
Suspensions 155
General information 157
Front suspension wear data 157
Rear suspension wear data 158
Electrical system, 24 volt 161
Battery supply system 163
Batteries 163
24VDC Auxiliary Battery Receptacles 164
Battery Disconnect Switches 164
Isolation Diode 164
Engine starting system 165
Engine prelube pump 165
Prelube pressure switch 165
Engine start relays 165
Auxiliary control cabinet components 166
24VDC to 12VDC converter 166
Diode board – DB1 166
Power distribution terminals 166
Control power relay 166
Fuse blocks 166
Relay boards 168
Relay boards RB1, RB3, RB4, RB5 168
Relay boards RB6, RB7, RB8, RB9 170
Relay functions 170
Body-up switch 172
Hoist limit switch 173
Interface module (IM) 175
General information 177
Sensors 177
Temperature sensors 177
Pressure sensors 177
Interface module inputs and outputs 178
Electrical system, AC drive 185
General system operation 187
AC drive system components 189
Propulsion system controller (PSC) 189
Truck control interface (TCI) 190
Diagnostic information display (DID) panel 190
PSC software functions 191
Input processing 191
State machine 191
DC link state 194
Engine control 195
Alternator field control 196
Desired three-phase voltage 196
Desired DC link voltage 196
Self-load 196
Propel torque control 196
Retard torque control 197
Wheel slide control 197
Resistor grid control 197
Chopper voltage control 197
Event detection and processing 198
Power-on tests 198
Initiated tests 199
Periodic tests 199
Event restrictions 199
Event logging and storage 199
Event history buffer 199
Data packs 200
Event reset 201
Serial data communications 201
PSC to TCI communications processing 201
PSC to PTU communications processing 201
Inverter communications processing 202
Output processing 202
Abnormal conditions/overriding functions 202
Fast start 202
Engine shutdown/Engine not running 202
Limp home mode 203
AC drive system component table 204
Cab air conditioning 213
General information 214
Environmental impact of air conditioning 214
Air conditioning for off-highway vehicles 214
Principles of refrigeration 215
Air conditioning 215
Refrigeration – the act of cooling 215
The refrigeration cycle 215
Air conditioning system components 217
Relays 217
Fan motor and speed control 217
Cab air filter 217
Heater core 217
Actuators 217
Compressor (refrigerant pump) 219
Service valves 219
Condenser 219
Receiver-drier 219
Expansion valve 220
Accumulator 220
Evaporator core 220
Air conditioning system electrical circuit 221
Thermostat 221
Compressor clutch 221
Trinary™ switch 222
Reserve engine oil system 225
General information 227
Operation 228
LED monitor light 228
Remote tank fill system 229
20 Standard value table 231
Standard value table 231
Standard value table for truck 233
30 Testing and adjusting 239
General information 239
Special tool list 241
Steering, brake cooling and hoist hydraulic system 243
General information on system checkout 245
Steering system checkout procedures 245
Steering pump pressure control adjustments 246
Steering control valve and flow amplifier leakage test 247
Bleed down manifold leakage test 248
Shock and suction valve pressure tests 249
Steering system checkout data sheet 251
Toe-in adjustment 252
Brake cooling and hoist system checkout procedures 253
Pressure gauge locations 253
Brake cooling circuit test 254
Power up relief pressure test 254
Power down relief pressure test 255
Counterbalance valve pressure check 256
Counterbalance valve adjustment 257
Brake cooling and hoist system checkout data sheet 258
Hoist cylinder leakage test 259
Hydraulic system flushing procedure 259
Brake system 267
General information on system checkout 269
Brake circuit checkout procedure 269
Initial system setup 271
Brake lock / secondary braking checkout 271
Parking brake checkout 272
Service brake checkout 273
Low brake accumulator pressure and auto apply checkout 273
Parking brake control logic checkout 275
Brake lock control logic checkout 277
Brake system checkout data sheet 279
Brake piston leakage test 283
Brake seal pressure test 283
Wet disc brake bleeding procedure 284
Parking brake bleeding procedure 284
Brake disc wear inspection 285
Brake valve bench test and adjustment 287
Test setup procedure 288
Brake valve output pressure adjustment 288
Final test and adjustment 289
Dual relay valve bench test and adjustment 290
Test setup procedure 291
Relay valve output pressure adjustment 291
Accumulators and suspensions 293
Accumulator charging and storage 295
Accumulator charging procedures 295
Precharge maintenance 298
Accumulator storage procedure 299
Bladder storage 299
Installing a bladder accumulator from storage 299
Accumulator leak testing 300
Suspension oiling and charging procedures 302
Equipment list 302
Installing the charging kit 302
Removing the charging kit 303
Support blocks for oiling and charging dimensions 303
Front suspension oiling 304
Front suspension nitrogen charging 305
Rear suspension oiling 306
Rear suspension nitrogen charging 308
Suspension pressure test 309
KOMTRAX Plus and payload meter 311
KOMTRAX Plus and payload meter software 313
VHMS Tool Box Installation 313
VHMS Setting Tool Installation 313
Installing the PDM software 313
KOMTRAX Plus controller initial setting procedure 314
KOMTRAX Plus controller setup procedure 314
KOMTRAX Plus snapshot procedure 317
KOMTRAX Plus download procedure 318
KOMTRAX Plus FTP upload procedure 319
KOMTRAX Plus initialization forms 320
KOMTRAX Plus initialization check list 321
KOMTRAX Plus initialization form 323
Precautions for replacing KOMTRAX Plus controller 324
KOMTRAX Plus controller checkout procedure 329
Necessary equipment 329
Preliminary 329
Checkout procedure 330
Payload meter initial setting procedure 332
Starting communications 332
Configure payload meter 332
Setting truck number 334
Clean truck tare 335
Inclinometer calibration 335
Interface module (IM) 337
Interface module software 339
Flashburn program installation 339
Interface module application code installation 340
Interface module realtime data monitor software installation 340
Interface module checkout procedures 341
Necessary equipment 341
Preliminary 342
Check digital inputs to the interface module 343
Check analog inputs to the interface module 346
Check serial interfaces to the interface module 346
Check outputs from the interface module 347
Cab air conditioning 349
General information 350
Service tools and equipment 351
Recovery/recycle station 351
Leak detector 351
Manifold gauge set 352
Service valves 353
Vacuum pump 353
Detecting leaks 354
System performance test 355
Checking system oil 356
System flushing 357
Installing the manifold gauge set 358
Purging air from the service hoses 358
Recovering and recycling refrigerant 359
Draining oil from previous recovery cycle 360
Recovery cycle 360
Recycling procedure 360
Evacuating the air conditioning system 361
Charging the air conditioning system 362
40 Troubleshooting 365
Fuse and circuit breaker locations 365
Fuse and circuit breaker locations 367
AC drive system fault codes 373
DID panel fault code tables 375
Troubleshooting by fault code, Part 1 395
Fault Code A001: Left front suspension pressure sensor signal high 397
Related circuit diagram 397
Fault Code A002: Left front suspension pressure sensor signal low 398
Related circuit diagram 398
Fault Code A003: Right front suspension pressure sensor signal high 399
Related circuit diagram 399
Fault Code A004: Right front suspension pressure sensor signal low 400
Related circuit diagram 400
Fault Code A005: Left rear suspension pressure sensor signal high 401
Related circuit diagram 401
Fault Code A006: Left rear suspension pressure sensor signal low 402
Related circuit diagram 402
Fault Code A007: Right rear suspension pressure sensor signal high 403
Related circuit diagram 403
Fault Code A008: Right rear suspension pressure sensor signal low 404
Related circuit diagram 404
Fault Code A009: Incline sensor signal high 405
Related circuit diagram 405
Fault Code A010: Incline sensor signal low 406
Related circuit diagram 406
Fault Code A011: Payload meter speed sensor signal has failed 407
Related circuit diagram 407
Fault Code A013: Body up switch has failed 408
Related circuit diagram 408
Fault Code A014: Payload meter checksum computation has failed 409
Related circuit diagram 409
Fault Code A016: Payload meter write to flash memory has failed 410
Related circuit diagram 410
Fault Code A017: Payload meter flash memory read has failed 411
Related circuit diagram 411
Fault Code A018: Right rear flat suspension cylinder warning 412
Related circuit diagram 413
Fault Code A019: Left rear flat suspension cylinder warning 414
Related circuit diagram 415
Fault Code A022: Carryback load excessive 416
Related circuit diagram 417
Fault Code A100: An open circuit breaker has been detected on a relay board 419
Related circuit diagram 419
Fault Code A101: High pressure detected across an hydraulic pump filter 420
Related circuit diagram 421
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 422
Related circuit diagram 423
Fault Code A107: GE has generated a propel system caution 424
Related circuit diagram 424
Fault Code A108: GE has generated a propel system temperature caution 425
Related circuit diagram 425
Fault Code A109: GE has generated a propel system reduced level signal 426
Related circuit diagram 426
Fault Code A111: Low steering pressure warning 427
Related circuit diagram 427
Fault Code A115: Low steering precharge pressure detected 428
Related circuit diagram 429
Fault Code A117: Low brake accumulator pressure warning 430
Related circuit diagram 430
Fault Code A118: Brake pressure is low while in brake lock 432
Related circuit diagram 433
Fault Code A123: GE has generated a reduced retarding caution 434
Related circuit diagram 434
Fault Code A124: GE has generated a no propel / no retard warning 435
Related circuit diagram 435
Fault Code A125: GE has generated a no propel warning 436
Related circuit diagram 436
Fault Code A126: Oil level in the hydraulic tank is low 437
Related circuit diagram 437
Fault Code A127: IM-furnished +5 volt output for sensors is low 438
Related circuit diagram 439
Fault Code A128: IM-furnished +5 volt output for sensors is high 440
Related circuit diagram 441
Fault Code A139: Low fuel warning 442
Related circuit diagram 443
Troubleshooting by fault code, Part 2 445
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 448
Related circuit diagram 449
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 450
Related circuit diagram 451
Fault Code A152: Starter failure 452
Related circuit diagram 453
Fault Code A153: Battery voltage is low with the truck in operation 454
Related circuit diagram 455
Fault Code A154: Battery charging voltage is excessive 456
Related circuit diagram 456
Fault Code A155: Battery charging voltage is low 457
Related circuit diagram 457
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 458
Related circuit diagram 459
Fault Code A166: Left rear hydraulic oil temperature sensor is low 460
Related circuit diagram 461
Fault Code A167: Right rear hydraulic oil temperature sensor is low 462
Related circuit diagram 463
Fault Code A168: Left front hydraulic oil temperature sensor is low 464
Related circuit diagram 465
Fault Code A169: Right front hydraulic oil temperature sensor is low 466
Related circuit diagram 467
Fault Code A170: Left rear hydraulic oil temperature sensor is high 468
Related circuit diagram 468
Fault Code A171: Right rear hydraulic oil temperature sensor is high 469
Related circuit diagram 469
Fault Code A172: Left front hydraulic oil temperature sensor is high 470
Related circuit diagram 470
Fault Code A173: Right front hydraulic oil temperature sensor is high 471
Related circuit diagram 471
Fault Code A184: J1939 data link is not connected 472
Related circuit diagram 473
Fault Code A190: Auto lube control has detected an incomplete lube cycle 474
Related circuit diagram 475
Fault Code A194: Left front hydraulic oil temperature is high 476
Related circuit diagram 476
Fault Code A195: Right front hydraulic oil temperature is high 477
Related circuit diagram 477
Fault Code A196: Left rear hydraulic oil temperature is high 478
Related circuit diagram 478
Fault Code A197: Right rear hydraulic oil temperature is high 479
Related circuit diagram 479
Fault Code A198: Hoist pressure 1 sensor is high 480
Related circuit diagram 480
Fault Code A199: Hoist pressure 2 sensor is high 481
Related circuit diagram 481
Fault Code A200: Steering pressure sensor is high 482
Related circuit diagram 482
Fault Code A201: Brake pressure sensor is high 483
Related circuit diagram 483
Fault Code A202: Hoist pressure 1 sensor is low 484
Related circuit diagram 485
Fault Code A203: Hoist pressure 2 sensor is low 486
Related circuit diagram 487
Fault Code A204: Steering pressure sensor is low 488
Related circuit diagram 489
Fault Code A205: Brake pressure sensor is low 490
Related circuit diagram 491
Fault Code A206: Ambient temperature sensor is high 492
Related circuit diagram 492
Fault Code A207: Ambient temperature sensor is low 493
Related circuit diagram 493
Troubleshooting by fault code, Part 3 495
Fault Code A212: Bad truck speed signal 498
Related circuit diagram 499
Fault Code A213: Parking brake should have applied but is detected as not having applied 500
Related circuit diagram 502
Fault Code A214: Parking brake should have released but is detected as not having released 504
Related circuit diagram 506
Fault Code A215: Brake auto apply valve circuit is defective 508
Related circuit diagram 509
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 510
Related circuit diagram 511
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 512
Related circuit diagram 513
Fault Code A230: Parking brake has been requested while truck still moving 516
Related circuit diagram 517
Fault Code A231: The body is up with engine running and brakes not on 518
Related circuit diagram 519
Fault Code A235: Steering accumulator is in the process of being bled down 520
Related circuit diagram 521
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 522
Related circuit diagram 523
Fault Code A237: The CAN/RPC connection to the display is open 524
Related circuit diagram 524
Fault Code A240: The key switch input to the interface module is open 525
Related circuit diagram 525
Fault Code A242: Fuel gauge within the dash display panel is defective 526
Related circuit diagram 526
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 527
Related circuit diagram 527
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 528
Related circuit diagram 528
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 529
Related circuit diagram 529
Fault Code A246: Payload meter reports truck overload 530
Related circuit diagram 530
Fault Code A247: Low steering pressure warning 532
Related circuit diagram 533
Fault Code A248: Status module within the dash display panel is defective 534
Related circuit diagram 534
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 535
Related circuit diagram 535
Fault Code A250: Battery voltage is low with the truck parked 536
Related circuit diagram 537
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 538
Related circuit diagram 539
Fault Code A252: Start enable output circuit is either open or shorted to ground 540
Related circuit diagram 541
Fault Code A253: Steering bleed circuit is not open while running 542
Related circuit diagram 543
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 544
Related circuit diagram 544
Fault Code A257: Payload CAN/RPC is not connected 545
Related circuit diagram 545
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 546
Related circuit diagram 546
Troubleshooting by fault code, Part 4 549
Fault Code A260: Parking brake failure 552
Related circuit diagram 553
Fault Code A261: Low brake accumulator pressure warning 554
Related circuit diagram 555
Fault Code A262: Steering bleed valve circuit open during shutdown 556
Related circuit diagram 557
Fault Code A264: Parking brake relay circuit is defective 558
Related circuit diagram 559
Fault Code A265: Service brake failure 560
Related circuit diagram 561
Fault Code A266: Selector lever was not in park while attempting to crank engine 562
Related circuit diagram 562
Fault Code A267: Parking brake was not set while attempting to crank engine 563
Related circuit diagram 563
Fault Code A268: Secondary engine shutdown while cranking 564
Related circuit diagram 564
Fault Code A270: Brake lock switch power supply is not on when required 566
Related circuit diagram 568
Fault Code A271: Shifter not in gear 570
Related circuit diagram 571
Fault Code A272: Brake lock switch power supply is not off when required 572
Related circuit diagram 574
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 575
Related circuit diagram 575
Fault Code A274: A brake setting fault has been detected 576
Related circuit diagram 577
Fault Code A275: A starter has been detected as engaged without a cranking attempt 578
Related circuit diagram 579
Fault Code A276: The drive system data link is not connected 580
Related circuit diagram 581
Fault Code A277: Parking brake applied while loading 582
Related circuit diagram 583
Fault Code A278: Service brake applied while loading 584
Related circuit diagram 585
Fault Code A279: Low steering pressure switch is defective 586
Related circuit diagram 586
Fault Code A280: Steering accumulator bleed down switch is defective 587
Related circuit diagram 587
Fault Code A281: Brake lock degrade switch is defective 588
Related circuit diagram 589
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 590
Related circuit diagram 591
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 594
Related circuit diagram 595
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 596
Related circuit diagram 597
Fault Code A285: The parking brake was not set when the key switch was turned off 598
Related circuit diagram 599
Fault Code A286: A fault was detected in the shutdown delay relay circuit 600
Related circuit diagram 601
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 602
Related circuit diagram 603
Troubleshooting by fault code, Part 5 605
Fault Code A303: Shifter is defective 608
Related circuit diagram 609
Fault Code A304: Auto lube grease level fault 610
Related circuit diagram 610
Fault Code A305: Auto lube circuit is defective 612
Related circuit diagram 613
Fault Code A307: Both GE inverters are disabled 614
Related circuit diagram 614
Fault Code A309: No brakes applied when expected 616
Related circuit diagram 617
Fault Code A310: Low fuel warning 618
Related circuit diagram 619
Fault Code A311: Brake lock switch is on when it should not be 620
Related circuit diagram 621
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings 622
Related circuit diagram 622
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings 623
Related circuit diagram 623
Fault Code A315: DCDC converter 12 volt circuit is low 624
Related circuit diagram 625
Fault Code A316: Starter engagement has been attempted with engine running 626
Related circuit diagram 627
Fault Code A317: Operation of brake auto apply valve without a detected response 628
Related circuit diagram 629
Fault Code A318: Unexpected power loss to interface module 630
Related circuit diagram 630
Fault Code A320: Data link reports GE propel system caution fault but wired input does not 632
Related circuit diagram 633
Fault Code A321: Data link reports GE propel system temp caution fault but wired input does not 634
Related circuit diagram 635
Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not 636
Related circuit diagram 637
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not 638
Related circuit diagram 639
Fault Code A324: Data link reports DC link voltage but wired input does not 640
Related circuit diagram 641
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not 642
Related circuit diagram 643
Fault Code A326: Data link reports GE no propel fault but wired input does not 644
Related circuit diagram 645
Fault Code A327: Data link reports GE at rest but wired input does not 646
Related circuit diagram 647
Fault Code A328: Drive system not powered up 648
Related circuit diagram 648
Fault Code A329: Data link reports the body is not down but wired input says it is 650
Related circuit diagram 651
Fault Code A330: Data link reports dynamic retard operating state but wired input does not 652
Related circuit diagram 653
Troubleshooting by fault code, Part 6 655
Fault Code A350: Overload on output 1B 657
Related circuit diagram 657
Fault Code A351: Overload on output 1E 658
Related circuit diagram 659
Fault Code A352: Overload on output 1H 660
Related circuit diagram 660
Fault Code A353: Overload on output 1J 661
Related circuit diagram 661
Fault Code A354: Overload on output 1K 662
Related circuit diagram 663
Fault Code A355: Overload on output 1L 664
Related circuit diagram 664
Fault Code A356: Overload on output 1M 665
Related circuit diagram 665
Fault Code A357: Overload on output 1N 666
Related circuit diagram 666
Fault Code A358: Overload on output 1P 667
Related circuit diagram 667
Fault Code A359: Overload on output 1R 668
Related circuit diagram 668
Fault Code A360: Overload on output 1S 669
Related circuit diagram 669
Fault Code A361: Overload on output 1T 670
Related circuit diagram 671
Fault Code A362: Overload on output 1U 672
Related circuit diagram 672
Fault Code A363: Overload on output 1X 674
Related circuit diagram 675
Fault Code A364: Overload on output 1Y 676
Related circuit diagram 676
Fault Code A365: Overload on output 1Z 677
Related circuit diagram 677
Cab air conditioning 679
Preliminary checks 681
Diagnosis of gauge readings and system performance 681
Troubleshooting by manifold gauge set readings 682
Reserve engine oil system 689
Pumping unit LED signals 691
Circuit fuses 691
50 Disassembly and assembly 693
General information 693
Special tool list 695
Wheels, spindles and rear axle 701
General information for tires and rims 703
Storage and handling 703
Wheel stud maintenance 704
Removal and installation of front wheel 704
Removal 704
Installation 705
Removal and installation of rear wheel 706
Removal 706
Installation 707
Removal and installation of tires 708
Removal 708
Installation 709
Removal and installation of front wheel hub and spindle 710
Removal 711
Spindle removal (off the truck) 714
Installation 716
Disassembly and assembly of front wheel hub and spindle 717
Disassembly 717
Cleaning and inspection 717
Assembly 719
Wheel bearing adjustment 719
Seal assembly gap check and adjustment 720
Brake installation 721
Speed sensor installation and adjustment 721
Removal and installation of rear axle 722
Removal 722
Cleaning and inspection 723
Installation 723
Removal and installation of anti-sway bar 724
Removal 724
Installation 724
Removal and installation of pivot pin 725
Removal 725
Installation 725
Pivot eye and bearing service 726
Bearing removal 726
Bearing installation 726
Pivot eye repair 727
Removal and installation of wheel motor 728
Preparation 728
Removal 728
Cleaning and inspection 729
Installation 731
Removal and installation of rear brake assembly 735
Removal 735
Installation 735
Brake system 739
Removal and installation of brake valve 741
Removal 741
Installation 742
Disassembly and assembly of brake valve 742
Disassembly 742
Cleaning and inspection 746
Assembly 746
Removal and installation of dual relay valve 749
Removal 749
Installation 750
Disassembly and assembly of dual relay valve 751
Disassembly 751
Cleaning and inspection 752
Assembly 752
Removal and installation of brake manifold 753
Removal 753
Installation 753
Disassembly and assembly of brake manifold 754
Disassembly 754
Assembly 754
Removal and installation of brake accumulator 755
Removal 755
Installation 755
Disassembly and assembly of brake accumulator 756
Disassembly 756
Cleaning and inspection 757
Assembly 758
Disassembly and assembly of wheel brake 759
Disassembly 760
Cleaning and inspection 763
Assembly 764
Floating ring seal assembly and installation 767
Removal and installation of parking brake 771
Removal 771
Installation 773
Disassembly and assembly of parking brake 773
Disassembly 773
Cleaning and inspection 774
Assembly 776
Cleaning and inspecting new discs 778
Steering system 781
Removal and installation of steering control unit 783
Removal 783
Installation 784
Disassembly and assembly of steering control unit 785
Disassembly 785
Assembly 787
Removal and installation of steering column 790
Removal 790
Inspection 790
Installation 791
Removal and installation of steering wheel 791
Removal 791
Installation 792
Removal and installation of bleed down manifold 793
Removal 793
Installation 794
Removal and installation of flow amplifier 795
Removal 795
Installation 795
Disassembly and assembly of flow amplifier 795
Disassembly 795
Assembly 797
Removal and installation of steering cylinders and tie rod 798
Removal 798
Bearing replacement 798
Installation 798
Disassembly and assembly of steering cylinders 800
Disassembly 800
Assembly 801
Removal and installation of steering/brake pump 801
Removal 801
Installation 802
Disassembly and assembly of steering/brake pump 804
Disassembly 804
Inspection 807
Assembly 810
Driveshaft group 811
Rotating group 811
Removal and installation of steering accumulators 813
Removal 813
Installation 814
Disassembly and assembly of steering accumulators 814
Disassembly 814
Cleaning and Inspection 815
Assembly 816
Suspensions 819
Removal and installation of front suspension 821
Removal 821
Installation 822
Inspection 825
Minor front suspension repairs (lower bearing and seals) 828
Lower bearing retainer removal 828
Lower bearing retainer installation 828
Major front suspension rebuild 829
Disassembly 829
Assembly 830
Removal and installation of rear suspension 832
Removal 833
Installation 835
Disassembly and assembly of rear suspension 835
Disassembly 835
Cleaning and Inspection 836
Assembly 836
Hoist circuit 839
Removal and installation of hoist pump 841
Removal 841
Installation 842
Disassembly and assembly of hoist pump 843
Disassembly 843
Inspection 846
Assembly 846
Removal and installation of hoist valve 851
Removal 851
Installation 852
Disassembly and assembly of hoist valve 852
O-ring replacement 852
Disassembly of inlet section 853
Assembly of inlet section 854
Disassembly of rear spool section 855
Assembly of rear spool section 857
Disassembly of front spool section 858
Assembly of front spool section 859
Overcenter valve manifold service 859
Removal and installation of hoist pilot valve 860
Removal 860
Installation 860
Disassembly and assembly of hoist pilot valve 861
Disassembly 861
Cleaning and inspection 862
Assembly 862
Removal and installation of hoist cylinders 863
Removal 863
Installation 864
Disassembly and assembly of hoist cylinders 865
Disassembly 865
Cleaning and inspection 867
Installation of the quill 868
Assembly 870
Operator cab 873
Removal and installation of operator cab 875
Removal 876
Installation 877
Removal and installation of cab door 878
Removal 878
Installation 878
Disassembly and assembly of cab door 878
Removing door panel 878
Installing door panel 879
Replacing door window regulator 879
Replacing door handle or latch assembly 880
Replacing door assembly seal and door hinge seal 881
Replacing door opening seal 881
Removing door glass 882
Installing door glass 883
Adjustment of cab door 885
Door jamb bolt adjustment 885
Door handle plunger adjustment 886
Removal and installation of side window glass 887
Recommended tools and supplies 887
Removal 888
Installation 888
Removal and installation of windshield and rear window glass 889
Removal 889
Installation 889
Removal and installation of windshield wiper motor 890
Removal 890
Installation 890
Removal and installation of windshield wiper arm 891
Removal 891
Installation 891
Removal and installation of windshield wiper linkage 892
Removal 892
Installation 892
Removal and installation of operator seat 893
Inspection 893
Removal 893
Installation 893
Removal and installation of passenger seat 894
Removal 894
Installation 894
Removal and installation of seat belts (standard seats) 895
Removal 895
Installation 895
Removal and installation of seat belts (optional seats) 897
General 897
Removal 897
Installation 899
Body and structures 903
Removal and installation of dump body 905
Removal 905
Inspection 906
Installation 907
Removal and installation of body pads 908
Removal 908
Installation 908
Body pad shimming procedure 909
Removal and installation of diagonal ladder/hood and grille assembly 910
Removal 910
Installation 910
Removal and installation of right deck 912
Removal 912
Installation 912
Removal and installation of left deck 914
Removal 914
Installation 914
Removal and installation of fuel tank 916
Removal 916
Cleaning and inspection 916
Installation 918
Removal and installation of fuel gauge sender 918
Removal 918
Installation 918
Disassembly and assembly of fuel tank breather 919
Disassembly 919
Assembly 919
Removal and installation of hydraulic tank 920
Removal 920
Installation 920
Cab air conditioning 923
Replacement of air conditioning system components 925
Hoses and fittings 925
Lines 925
Expansion valve 925
Receiver-drier 925
Thermostat 925
Compressor 926
Accumulator 926
Clutch 926
Diasassembly and assembly of compressor clutch 927
Removal of the clutch assembly 927
Removal of the pulley 929
Installation of the pulley 929
Installation of the clutch assembly 930
Power module 933
Removal and installation of power module 935
General 935
Preparation 935
Removal 936
Installation 942
Removal and installation of alternator 944
Removal 944
Installation 946
Removal and installation of engine 949
Removal 949
Service 949
Installation 949
Removal and installation of radiator 950
Removal 950
Installation 952
Repairing the radiator 953
Internal inspection 953
External cleaning 953
Disassembly 953
Cleaning and inspection 954
Assembly 955
Pressure testing 956
90 Diagrams and drawings 959
Hydraulic circuit diagrams 959
Hydraulic Schematic (EM7616) 961
Brake Schematic (EM7623) 962
Electrical circuit diagrams 965
XS5701-0 pdf 967
XS5702-1 pdf 968
XS5703-1 pdf 969
XS5704-0 pdf 970
XS5705-1 pdf 971
XS5706-0 pdf 972
XS5707-1 pdf 973
XS5708-0 pdf 974
XS5709-1 pdf 975
XS5710-0 pdf 976
XS5711-1 pdf 977
XS5712-1 pdf 979
XS5713-0 pdf 980
XS5714-1 pdf 981
XS5715-0 pdf 982
XS5716-2 pdf 983
XS5717-1 pdf 984
XS5718-0 pdf 985
XS5719-1 pdf 986
XS5720-1 pdf 987
XS5721-0 pdf 988
XS5722-0 pdf 989
XS5723-0 pdf 990
XS5724-1 pdf 991
XS5725-0 pdf 992
XS5726-0 pdf 993
XS5727-1 pdf 994
XS5728-0 pdf 995
XS5729-1 pdf 996
XS5730-0 pdf 997
XS5731-0 pdf 998
XS5732-2 pdf 999
XS5733-1 pdf 1000
HE487 1001

DESCRIPTION:

Komatsu 960E-1 Dump Truck Shop Manual CEBM021304 – PDF DOWNLOAD 

FOREWORD:

• This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
• The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs.
• The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model.
• This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”,
  “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have æ10% tolerance unless otherwise specified.
• A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
• The KOMATSU Truck Model designation consists of three numbers and one letter (i.e. 930E). The three numbers
  represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an
  Electrical propulsion system.
• The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
• The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.The vehicle design and application guidelines are sensitive to the total maximum Gross Vehicle Weight (GVW) and this means the total weight: the Empty Vehicle Weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants for proper level and fill fuel tank of empty truck (which
  includes all accessories, body liners, tailgates, etc.) and then weigh truck.Record this value and subtract from the GVW rating.

S.V 12/12/24