Komatsu 960E-2 DUMP TRUCK Shop Manual CEBM028701 PDF

Description

Komatsu 960E-2 DUMP TRUCK Shop Manual CEBM028701  – PDF DOWNLOAD

FILE DETAILS:

Komatsu 960E-2 DUMP TRUCK Shop Manual CEBM028701  – PDF DOWNLOAD

Language : English
Pages : 1106
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu 960E-2 DUMP TRUCK Shop Manual CEBM028701  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2 A30074 and up
• ENGINE 18V170

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 19
Foreword 23
How to read the shop manual 24
Composition of shop manual 24
Revision and distribution 24
Symbols 25
General safety 26
Safety rules 26
Safety features 26
Fire extinguisher and first aid kit 26
Clothing and personal items 26
Leaving the operator seat 27
Mounting and dismounting 27
Fire prevention for fuel and oil 27
Precautions with high temperature fluids 28
Asbestos dust hazard prevention 28
Prevention of injury by work equipment 28
Unauthorized modification 28
Precautions when using ROPS 28
Precautions for attachments 29
Precautions for starting the truck 29
Precautions before operating the truck 29
Safety at the worksite 29
Fire prevention 30
Ventilation in enclosed areas 30
Preparing for operation 30
Mirrors, windows and lights 30
In operator cab (before starting the engine) 30
Seat Belts 30
Precautions while operating the truck 31
When starting the engine 31
General truck operation 31
Ensuring good visibility 31
Traveling 32
Traveling in reverse 32
Traveling on slopes 32
Operating on snow or ice 32
Avoid damage to dump body 32
Driving near high voltage cables 33
When dumping 33
When loading 33
Working on loose ground 33
Parking the truck 33
Towing 33
Working near batteries 34
Battery hazard prevention 34
Starting with jumper cables 35
Jump starting with receptacles 35
Precautions before performing service 36
Warning tag 36
Stopping the engine 36
Proper tools 36
Use of Tie-Off Anchor During Maintenance and Repair 36
Securing the dump body 37
Jack point locations 38
Precautions while performing service 39
Keep the truck clean 39
Attachments 39
Working under the truck 39
Rotating fan and belts 39
Adding fuel or oil 39
Use of lighting 39
Radiator coolant level 40
Precautions with the battery 40
Precautions with high pressure oil 40
Handling high pressure hoses 40
Precautions when performing maintenance near high temperature or high pressure 40
Waste materials 40
Tires 41
Inspection 41
Maintenance 41
Storage 42
Handling 43
Precautions for performing repairs 44
Engine shutdown procedure after AC drive system failure 44
Precautions for welding on the truck 45
Capacitor discharge system 46
Necessary tools 46
Warnings and cautions 47
Manual DC link capacitor discharge procedure 48
Failure of the discharge system 50
Manual discharge of capacitors 51
Short isolated capacitor terminals 53
Handling electrical equipment and hydraulic components 54
Points to remember when handling electrical equipment 54
Points to remember when handling hydraulic equipment 60
Standard tightening torques 62
Effect of special lubricants on fasteners and standard torque values 62
Suggested sources for rust preventive grease 62
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 63
SAE grade 9 capscrews 64
Class 10 9 capscrews and class 10 nuts 64
Standard tightening torques for fittings 65
Standard tightening torques for clamps 67
Conversion tables 68
Common conversion multipliers 68
Operating instructions 73
Preparing for operation 75
Walk around inspection 75
Engine start-up 79
After engine start-up 80
Pre-shift brake check 80
Events 80
Operation 81
Description 81
Brake test exit criteria 81
Brake test setup 82
Service brake test 82
Parking brake test 83
Retard system test 84
Emergency steering system 84
Operation 84
Pre-operation testing 84
Precautions during truck operation 85
Operating on a haul road 86
Starting on a grade with a loaded truck 87
Sudden loss of engine power or loss of drive system function 87
Fuel depletion 88
Towing 88
Special Wiring Harness 89
Loading the dump body 91
Dumping a load 91
Raising the dump body 91
Lowering the dump body (on flat ground) 92
Lowering the dump body (over a berm or into a crusher) 93
Disabled truck dumping procedure 93
Hookup 93
Raising the body 94
Lowering the body 94
Safe parking procedure 94
Normal engine shutdown procedure 95
01 Specification 97
Specification and technical data 97
Specification drawing 99
Specifications 100
Weight table 102
Fuel, coolant and lubricants 103
Suspension cylinder oil and nitrogen specifications 104
10 Structure and functions 107
Steering circuit 107
Steering circuit operation 109
Steering circuit components 111
Steering control unit 111
High pressure filter 111
Steering accumulators 111
Bleeddown manifold 112
Steering accumulator bleeddown solenoid 114
Hoist up limit solenoid 114
Quick disconnect ports 114
Flow amplifier 114
Flow amplifier operation 115
No steer 116
Steering left 118
Steering right 120
No steer, external shock load 122
Steering/brake pump operation 125
Normal operation 125
Neutral position 127
Full pump volume 128
Half pump volume 128
Steering cylinder wear data 129
Hoist circuit 131
Hoist circuit operation 133
Hoist circuit components 134
Hydraulic tank 134
Hoist pump 134
High pressure filters 134
Hoist valve 134
Inlet sections 135
Tank ports (front) spool section 135
Work ports (rear) spool section 135
Hoist pilot valve 136
Bleeddown manifold 136
Hoist limit solenoid 136
Pilot operated check valve 136
Overcenter manifold 137
Hoist pilot valve operation 138
Float position with body down 138
Power up operation 140
Hold operation 142
Power down operation 144
Float operation 146
Hoist cylinder wear data 148
Brake circuits 151
General information 153
Service brake circuit operation 154
Secondary braking and auto apply 154
Parking brake circuit operation 156
Normal operation (key switch ON, engine on) 156
Wheel brake lock circuit operation 157
Brake warning circuit operation 157
Brake assembly wear data 159
Suspensions 161
General information 163
Front suspension wear data 163
Rear suspension wear data 164
Electrical system, 24 volt 167
Battery supply system 169
Batteries 169
24VDC Auxiliary Battery Receptacles 169
Battery Disconnect Switches 169
Engine starting system 170
Engine prelube pump 170
Prelube pressure switch 170
Engine start relays 170
Auxiliary control cabinet components 171
24VDC to 12VDC converter 171
Diode board – DB1 171
Power distribution terminals 171
Control power relay 171
Fuse blocks 171
Relay boards 173
Relay boards RB1, RB3, RB4, RB5 173
Relay boards RB6, RB7, RB8, RB9 175
Relay functions 175
Body-up switch 177
Hoist limit switch 178
Interface module (IM) 181
General information 183
Sensors 183
Temperature sensors 183
Pressure sensors 183
Interface module inputs and outputs 184
Electrical system, AC drive 191
General system operation 192
System components 194
Drive system controller (DSC) 194
Diagnostic information display (DID) panel 195
DSC software functions 195
Input processing 195
State machine 195
DC link state 198
Engine control 199
Alternator field control 200
Desired DC link voltage 200
Self-load 200
Propel torque control 200
Retard torque control 201
Wheel slide control 201
Resistor grid control 201
Chopper voltage control 201
Event detection and processing 202
Power-on tests 202
Initiated tests 203
Periodic tests 203
Event restrictions 203
Event logging and storage 203
Data packs 204
Event reset 204
Abnormal conditions/overriding functions 205
Engine shutdown/Engine not running 205
Limp home mode 205
AC drive system component table 206
Electronic accelerator and retarder pedals 213
Cab air conditioning 215
General information 217
Environmental impact of air conditioning 217
Air conditioning for off-highway vehicles 217
Principles of refrigeration 218
Air conditioning 218
Refrigeration – the act of cooling 218
The refrigeration cycle 218
Air conditioning system components 220
Relays 220
Fan motor and speed control 220
Cab air filter 220
Heater core 220
Actuators 220
Compressor (refrigerant pump) 222
Service valves 222
Condenser 222
Receiver-drier 222
Expansion valve 223
Accumulator 223
Evaporator core 223
Air conditioning system electrical circuit 224
Thermostat 224
Compressor clutch 224
Trinary™ switch 225
Reserve engine oil system 227
General information 229
Operation 230
LED monitor light 230
Remote tank fill system 231
20 Standard value table 233
Standard value table 233
Standard value table for truck 235
30 Testing and adjusting 241
General information 241
Special tool list 243
Steering, brake cooling and hoist hydraulic system 245
General information on system checkout 247
Steering system checkout procedures 247
Steering pump pressure control adjustments on steering pumps with a pressure compensator 248
Steering pump pressure control adjustments on steering pumps without a pressure compensator 249
Steering control valve and flow amplifier leakage test 250
Bleeddown manifold leakage test 251
Shock and suction valve pressure tests on steering pumps with a pressure compensator 252
Shock and suction valve pressure tests on steering pumps without a pressure compensator 254
Steering system checkout data sheet 256
Toe-in adjustment 257
Brake cooling and hoist system checkout procedures 258
Pressure gauge locations 258
Brake cooling circuit test 259
Power up relief pressure test 259
Power down relief pressure test 260
Counterbalance valve pressure check 261
Counterbalance valve adjustment 262
Brake cooling and hoist system checkout data sheet 263
Hoist cylinder leakage test 264
Hydraulic system flushing procedure 264
Brake system 273
General information on system checkout 275
Brake circuit checkout procedure 275
Initial system setup 277
Brake lock / secondary braking checkout 277
Parking brake checkout 278
Service brake checkout 279
Low brake accumulator pressure and auto apply checkout 279
Parking brake control logic checkout 281
Brake lock control logic checkout 283
Brake system checkout data sheet 285
Brake piston leakage test 289
Brake seal pressure test 289
Wet disc brake bleeding procedure 290
Parking brake bleeding procedure 290
Service brake disc wear inspection 291
Parking brake disc wear inspection 292
Brake valve bench test and adjustment 294
Test setup procedure 295
Brake valve output pressure adjustment 295
Final test and adjustment 296
Dual relay valve bench test and adjustment 297
Test setup procedure 298
Relay valve output pressure adjustment 298
Accumulators and suspensions 301
Accumulator charging and storage 302
Temperature during precharge 302
Bladder accumulator charging procedure 303
Precharge maintenance 305
Bladder accumulator storage procedure 306
Bladder storage 306
Installing a bladder accumulator from storage 306
Bladder accumulator leak testing 307
Piston accumulator charging procedure 307
Piston accumulator storage 310
Piston accumulator leak testing 311
Checking for improper suspension charge 312
Suspension oiling and charging procedures 313
Required equipment 313
Installing the charging kit 314
Removing the charging kit 314
Support blocks for oiling and charging dimensions 315
Front suspensions 316
Rear suspensions 319
Suspension pressure test 322
Payload meter IV 325
Payload meter IV software and tools 327
Payload meter IV system configuration 327
Connecting to the payload meter IV web server 327
Configuring a static IP address 327
Payload meter IV software installation 329
Payload meter IV checkout procedure 330
PLM IV system checkout data sheet 336
Downloading PLM IV data and possible errors 337
KOMTRAX Plus II 341
Required software and tools 343
Ethernet connection to KOMTRAX Plus II controller 343
KOMTRAX Plus II configuration 345
GPS connection test 347
Iridium satellite system opening 349
Data download over ethernet connection for KOMTRAX Plus II initialization 351
Interface module (IM) 355
Interface module software 357
Flashburn program installation 357
Interface module application code installation 358
Interface module realtime data monitor software installation 358
Interface module checkout procedures 359
Necessary equipment 359
Preliminary 360
Check digital inputs to the interface module 361
Check analog inputs to the interface module 364
Check serial interfaces to the interface module 365
Check outputs from the interface module 366
Electrical system, AC drive 369
General information 371
Test equipment 371
Circuit continuity and resistance checks 371
Megger test for grounds 372
Troubleshooting for grounds 375
Low voltage power supply checks 375
Drive System Controller (DSC) card checks 376
Propulsion system software installation 377
Software installation procedure 378
DSC manual test procedures 379
Accelerator pedal, retarder pedal, and retarder lever calibration and checks 381
Set truck ID number 386
Control cabinet pressure switch check 387
Checks prior to self load engine test (loadbox) 388
Verifying DSC Software Version 388
Resetting and erasing DSC event data 389
Engine running tests 390
Battery boost circuit verification 390
Selector switch check 393
Ground detection network tests 395
Self load engine test (loadbox) procedure 400
Diagnostic information display (DID) panel 402
DID panel display selection 402
DID modes display 404
Function key F1 – DID events or faults display 405
Function key F4 – DID menu display 408
DID self load engine test (loadbox) 409
DID link capacitance test 411
DID speedometer test 412
DID view software version 414
DID view overspeed setting 416
DID view data menu 417
DID inverter cutout menu 422
DID truck configuration menu 424
Language selection 431
Viewing event and statistical data 432
Viewing the DSC event summary, trigger data, and data packs 432
Viewing the statistical data 435
Logic screens 436
Datalogger function 438
Setting up the datalogger 438
Starting the datalogger 440
Uploading data 442
Consolidated truck data save 442
USB drive 443
Cab air conditioning 445
General information 447
Service tools and equipment 448
Recovery/recycle station 448
Leak detector 448
Manifold gauge set 449
Service valves 450
Vacuum pump 450
Detecting leaks 451
System performance test 452
Checking system oil 453
System flushing 454
Installing the manifold gauge set 455
Purging air from the service hoses 455
Recovering and recycling refrigerant 456
Draining oil from previous recovery cycle 457
Recovery cycle 457
Recycling procedure 457
Evacuating the air conditioning system 458
Charging the air conditioning system 459
Automatic lubrication (auto lube) system 461
Priming the system 463
Checkout procedure 464
Adjusting the lubrication cycle timing 465
40 Troubleshooting 467
Fuse and circuit breaker locations 467
Fuse and circuit breaker locations 469
AC drive system fault codes (DSC) 475
Fault code tables 477
Troubleshooting by fault code, Part 1 505
Fault Code A001: Left front suspension pressure sensor signal high 508
Related circuit diagram 508
Fault Code A002: Left front suspension pressure sensor signal low 509
Related circuit diagram 509
Fault Code A003: Right front suspension pressure sensor signal high 510
Related circuit diagram 510
Fault Code A004: Right front suspension pressure sensor signal low 511
Related circuit diagram 511
Fault Code A005: Left rear suspension pressure sensor signal high 512
Related circuit diagram 512
Fault Code A006: Left rear suspension pressure sensor signal low 513
Related circuit diagram 513
Fault Code A007: Right rear suspension pressure sensor signal high 514
Related circuit diagram 514
Fault Code A008: Right rear suspension pressure sensor signal low 515
Related circuit diagram 515
Fault Code A009: Incline sensor signal high 516
Related circuit diagram 516
Fault Code A010: Incline sensor signal low 517
Related circuit diagram 517
Fault Code A011: Payload meter speed sensor signal has failed 518
Related circuit diagram 518
Fault Code A013: Body up switch has failed 519
Related circuit diagram 519
Fault Code A014: Payload meter checksum computation has failed 520
Related circuit diagram 520
Fault Code A016: Payload meter write to flash memory has failed 521
Related circuit diagram 521
Fault Code A017: Payload meter flash memory read has failed 522
Related circuit diagram 522
Fault Code A018: Right rear flat suspension cylinder warning 523
Related circuit diagram 524
Fault Code A019: Left rear flat suspension cylinder warning 525
Related circuit diagram 526
Fault Code A022: Carryback load excessive 527
Related circuit diagram 528
Fault Code A100: An open circuit breaker has been detected on a relay board 529
Related circuit diagram 529
Fault Code A101: High pressure detected across an hydraulic pump filter 530
Related circuit diagram 532
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level 533
Related circuit diagram 534
Fault Code A107: GE has generated a propel system caution 535
Related circuit diagram 535
Fault Code A108: GE has generated a propel system temperature caution 536
Related circuit diagram 536
Fault Code A109: GE has generated a propel system reduced level signal 537
Related circuit diagram 537
Fault Code A111: Low steering pressure warning 538
Related circuit diagram 538
Fault Code A115: Low steering precharge pressure detected 539
Related circuit diagram 540
Fault Code A117: Low brake accumulator pressure warning 541
Related circuit diagram 541
Fault Code A118: Brake pressure is low while in brake lock 542
Related circuit diagram 543
Fault Code A123: GE has generated a reduced retarding caution 544
Related circuit diagram 544
Fault Code A124: GE has generated a no propel / no retard warning 545
Related circuit diagram 545
Fault Code A125: GE has generated a no propel warning 546
Related circuit diagram 546
Fault Code A126: Oil level in the hydraulic tank is low 547
Related circuit diagram 547
Fault Code A127: IM-furnished +5 volt output for sensors is low 548
Related circuit diagram 549
Fault Code A128: IM-furnished +5 volt output for sensors is high 550
Related circuit diagram 551
Fault Code A139: Low fuel warning 552
Related circuit diagram 553
Troubleshooting by fault code, Part 2 555
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil 558
Related circuit diagram 559
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil 560
Related circuit diagram 561
Fault Code A152: Starter failure 562
Related circuit diagram 563
Fault Code A153: Battery voltage is low with the truck in operation 564
Related circuit diagram 565
Fault Code A154: Battery charging voltage is excessive 566
Related circuit diagram 566
Fault Code A155: Battery charging voltage is low 567
Related circuit diagram 567
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level 568
Related circuit diagram 569
Fault Code A166: Left rear hydraulic oil temperature sensor is low 570
Related circuit diagram 571
Fault Code A167: Right rear hydraulic oil temperature sensor is low 572
Related circuit diagram 573
Fault Code A168: Left front hydraulic oil temperature sensor is low 574
Related circuit diagram 575
Fault Code A169: Right front hydraulic oil temperature sensor is low 576
Related circuit diagram 577
Fault Code A170: Left rear hydraulic oil temperature sensor is high 578
Related circuit diagram 578
Fault Code A171: Right rear hydraulic oil temperature sensor is high 579
Related circuit diagram 579
Fault Code A172: Left front hydraulic oil temperature sensor is high 580
Related circuit diagram 580
Fault Code A173: Right front hydraulic oil temperature sensor is high 581
Related circuit diagram 581
Fault Code A184: J1939 data link is not connected 582
Related circuit diagram 583
Fault Code A190: Auto lube control has detected an incomplete lube cycle 584
Related circuit diagram 585
Fault Code A194: Left front hydraulic oil temperature is high 586
Related circuit diagram 586
Fault Code A195: Right front hydraulic oil temperature is high 587
Related circuit diagram 587
Fault Code A196: Left rear hydraulic oil temperature is high 588
Related circuit diagram 588
Fault Code A197: Right rear hydraulic oil temperature is high 589
Related circuit diagram 589
Fault Code A198: Hoist pressure 1 sensor is high 590
Related circuit diagram 590
Fault Code A199: Hoist pressure 2 sensor is high 591
Related circuit diagram 591
Fault Code A200: Steering pressure sensor is high 592
Related circuit diagram 592
Fault Code A201: Brake pressure sensor is high 593
Related circuit diagram 593
Fault Code A202: Hoist pressure 1 sensor is low 594
Related circuit diagram 595
Fault Code A203: Hoist pressure 2 sensor is low 596
Related circuit diagram 597
Fault Code A204: Steering pressure sensor is low 598
Related circuit diagram 599
Fault Code A205: Brake pressure sensor is low 600
Related circuit diagram 601
Fault Code A206: Ambient temperature sensor is high 602
Related circuit diagram 602
Fault Code A207: Ambient temperature sensor is low 603
Related circuit diagram 603
Troubleshooting by fault code, Part 3 605
Fault Code A212: Bad truck speed signal 608
Related circuit diagram 609
Fault Code A213: Parking brake should have applied but is detected as not having applied 610
Related circuit diagram 612
Fault Code A214: Parking brake should have released but is detected as not having released 613
Related circuit diagram 615
Fault Code A215: Brake auto apply valve circuit is defective 616
Related circuit diagram 617
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit 618
Related circuit diagram 619
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted 620
Related circuit diagram 621
Fault Code A230: Parking brake has been requested while truck still moving 623
Related circuit diagram 624
Fault Code A231: The body is up while traveling or intending to travel 625
Related circuit diagram 627
Fault Code A235: Steering accumulator is in the process of being bled down 628
Related circuit diagram 629
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds 630
Related circuit diagram 631
Fault Code A237: The CAN/RPC connection to the display is open 632
Related circuit diagram 632
Fault Code A240: The key switch input to the interface module is open 633
Related circuit diagram 633
Fault Code A242: Fuel gauge within the dash display panel is defective 634
Related circuit diagram 634
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective 635
Related circuit diagram 635
Fault Code A244: Drive system temperature gauge within the dash display panel is defective 636
Related circuit diagram 636
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective 637
Related circuit diagram 637
Fault Code A246: Payload meter reports truck overload 638
Related circuit diagram 638
Fault Code A247: Low steering pressure warning 639
Related circuit diagram 640
Fault Code A248: Status module within the dash display panel is defective 641
Related circuit diagram 641
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted 642
Related circuit diagram 642
Fault Code A250: Battery voltage is low with the truck parked 643
Related circuit diagram 645
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground 646
Related circuit diagram 647
Fault Code A252: Start enable output circuit is either open or shorted to ground 648
Related circuit diagram 649
Fault Code A253: Steering bleed circuit is not open while running 650
Related circuit diagram 651
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open 652
Related circuit diagram 652
Fault Code A257: Payload CAN/RPC is not connected 653
Related circuit diagram 653
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective 654
Related circuit diagram 654
Troubleshooting by fault code, Part 4 657
Fault Code A260: Parking brake failure 660
Related circuit diagram 662
Fault Code A261: Low brake accumulator pressure warning 663
Related circuit diagram 664
Fault Code A262: Steering bleed valve circuit open during shutdown 665
Related circuit diagram 666
Fault Code A264: Parking brake relay circuit is defective 667
Related circuit diagram 668
Fault Code A265: Service brake failure 669
Related circuit diagram 670
Fault Code A266: Selector lever was not in park while attempting to crank engine 671
Related circuit diagram 671
Fault Code A267: Parking brake was not set while attempting to crank engine 672
Related circuit diagram 672
Fault Code A268: Secondary engine shutdown while cranking 673
Related circuit diagram 673
Fault Code A270: Brake lock switch power supply is not on when required 674
Related circuit diagram 676
Fault Code A271: Shifter not in gear 677
Related circuit diagram 678
Fault Code A272: Brake lock switch power supply is not off when required 679
Related circuit diagram 680
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit 681
Related circuit diagram 681
Fault Code A274: A brake setting fault has been detected 682
Related circuit diagram 682
Fault Code A275: A starter has been detected as engaged without a cranking attempt 683
Related circuit diagram 684
Fault Code A276: The drive system data link is not connected 685
Related circuit diagram 686
Fault Code A277: Parking brake applied while loading 687
Related circuit diagram 688
Fault Code A278: Service brake applied while loading 689
Related circuit diagram 690
Fault Code A279: Low steering pressure switch is defective 691
Related circuit diagram 691
Fault Code A280: Steering accumulator bleed down switch is defective 692
Related circuit diagram 692
Fault Code A281: Brake lock degrade switch is defective 693
Related circuit diagram 694
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 695
Related circuit diagram 696
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set 698
Related circuit diagram 699
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated 700
Related circuit diagram 701
Fault Code A285: The parking brake was not set when the key switch was turned off 702
Related circuit diagram 703
Fault Code A286: A fault was detected in the shutdown delay relay circuit 704
Related circuit diagram 705
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off 706
Related circuit diagram 707
Troubleshooting by fault code, Part 5 709
Fault Code A303: Shifter is defective 712
Related circuit diagram 713
Fault Code A304: Auto lube grease level fault 714
Related circuit diagram 714
Fault Code A305: Auto lube circuit is defective 715
Related circuit diagram 716
Fault Code A307: Both GE inverters are disabled 717
Related circuit diagram 717
Fault Code A309: No brakes applied when expected 718
Related circuit diagram 719
Fault Code A310: Low fuel warning 720
Related circuit diagram 721
Fault Code A311: Brake lock switch is on when it should not be 722
Related circuit diagram 723
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings 724
Related circuit diagram 724
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings 725
Related circuit diagram 725
Fault Code A315: DCDC converter 12 volt circuit is low 726
Related circuit diagram 727
Fault Code A316: Starter engagement has been attempted with engine running 728
Related circuit diagram 729
Fault Code A317: Operation of brake auto apply valve without a detected response 730
Related circuit diagram 731
Fault Code A318: Unexpected power loss to interface module 732
Related circuit diagram 732
Fault Code A320: Data link reports GE propel system caution fault but wired input does not 733
Related circuit diagram 734
Fault Code A321: Data link reports GE propel system temp caution fault but wired input does not 735
Related circuit diagram 736
Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not 737
Related circuit diagram 738
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not 739
Related circuit diagram 740
Fault Code A324: Data link reports DC link voltage but wired input does not 741
Related circuit diagram 742
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not 743
Related circuit diagram 744
Fault Code A326: Data link reports GE no propel fault but wired input does not 745
Related circuit diagram 746
Fault Code A327: Data link reports GE at rest but wired input does not 747
Related circuit diagram 748
Fault Code A328: Drive system not powered up 749
Related circuit diagram 749
Fault Code A329: Data link reports the body is not down but wired input says it is 751
Related circuit diagram 752
Fault Code A330: Data link reports dynamic retard operating state but wired input does not 753
Related circuit diagram 754
Fault Code A334: Selector switch not in park when propel was either not ready or at rest 755
Related circuit diagram 755
Fault Code A335: Manual/Auto Apply Pressure Fault 756
Troubleshooting by fault code, Part 6 759
Fault Code A350: Overload on output 1B 761
Related circuit diagram 761
Fault Code A351: Overload on output 1E 762
Related circuit diagram 763
Fault Code A352: Overload on output 1H 764
Related circuit diagram 764
Fault Code A353: Overload on output 1J 765
Related circuit diagram 765
Fault Code A354: Overload on output 1K 766
Related circuit diagram 767
Fault Code A355: Overload on output 1L 768
Related circuit diagram 768
Fault Code A356: Overload on output 1M 769
Related circuit diagram 769
Fault Code A357: Overload on output 1N 770
Related circuit diagram 770
Fault Code A358: Overload on output 1P 771
Related circuit diagram 771
Fault Code A359: Overload on output 1R 772
Related circuit diagram 772
Fault Code A360: Overload on output 1S 773
Related circuit diagram 773
Fault Code A361: Overload on output 1T 774
Related circuit diagram 775
Fault Code A362: Overload on output 1U 776
Related circuit diagram 776
Fault Code A363: Overload on output 1X 777
Related circuit diagram 778
Fault Code A364: Overload on output 1Y 779
Related circuit diagram 779
Fault Code A365: Overload on output 1Z 780
Related circuit diagram 780
Cab air conditioning 783
Preliminary checks 785
Diagnosis of gauge readings and system performance 785
Troubleshooting by manifold gauge set readings 786
Reserve engine oil system 793
Pumping unit LED signals 795
Circuit fuses 795
Automatic lubrication (auto lube) system 797
Autolube troubleshooting chart 799
Steering system 803
Steering circuit troubleshooting chart 805
Steering circuit troubleshooting guidelines 807
Basic hydraulic system checks 808
System leakage check 809
Steering pump troubleshooting guide 811
Pump pressure control checks 814
Pump fails to unload 815
Pump fails to develop pressure 815
Pump slow in developing pressure 816
Pump control valve inspection and trouble shooting 816
Pump case drain check 818
Setting pump pressure controls 818
50 Disassembly and assembly 821
General information 821
Special tool list 823
Wheels, spindles and rear axle 827
General information for tires and rims 829
Storage and handling 829
Wheel stud maintenance 830
Rim components 831
Removal and installation of front wheel 832
Removal 832
Installation 832
Removal and installation of rear wheel 834
Removal 834
Installation 835
Removal and installation of tires 836
Removal 836
Installation 837
Removal and installation of front wheel hub and spindle 838
Removal 839
Spindle removal (off the truck) 842
Installation 844
Disassembly and assembly of front wheel hub and spindle 845
Disassembly 845
Cleaning and inspection 845
Assembly 847
Wheel bearing adjustment 847
Seal assembly gap check and adjustment 848
Brake installation 849
Speed sensor installation and adjustment 849
Removal and installation of rear axle 850
Removal 850
Cleaning and inspection 851
Installation 851
Removal and installation of anti-sway bar 851
Removal 851
Installation 852
Removal and installation of pivot pin 853
Removal 853
Installation 853
Pivot eye and bearing service 854
Bearing removal 854
Bearing installation 854
Pivot eye repair 855
Removal and installation of wheel motor 856
Preparation 856
Removal 856
Cleaning and inspection 857
Installation 859
Removal and installation of rear brake assembly 863
Removal 863
Installation 863
Brake system 867
Removal and installation of brake valve 869
Removal 869
Installation 870
Disassembly and assembly of brake valve/pedal assembly 870
Disassembly 870
Assembly 871
Removal and installation of dual relay valve 873
Removal 873
Installation 874
Removal and installation of brake manifold 875
Removal 875
Installation 875
Disassembly and assembly of brake manifold 876
Disassembly 876
Assembly 876
Removal and installation of brake accumulator 877
Removal 877
Installation 877
Disassembly and assembly of brake accumulator 878
Disassembly 878
Cleaning and inspection 879
Assembly 880
Disassembly and assembly of wheel brake 881
Disassembly 882
Cleaning and inspection 885
Assembly 886
Floating ring seal assembly and installation 889
Removal and installation of parking brake 893
Removal 893
Installation 895
Disassembly and assembly of parking brake 895
Disassembly 895
Cleaning and inspection 896
Assembly 898
Cleaning and inspecting new discs 900
Steering system 903
Removal and installation of steering control unit 905
Removal 905
Installation 906
Disassembly and assembly of steering control unit 907
Disassembly 907
Assembly 909
Removal and installation of steering column 912
Removal 912
Inspection 912
Installation 913
Removal and installation of steering wheel 913
Removal 913
Installation 914
Removal and installation of bleeddown manifold 915
Removal 915
Installation 916
Removal and installation of flow amplifier 917
Removal 917
Installation 917
Disassembly and assembly of flow amplifier 917
Disassembly 917
Assembly 919
Removal and installation of steering cylinders and tie rod 920
Removal 920
Bearing replacement 920
Installation 920
Disassembly and assembly of steering cylinders 921
Disassembly 921
Assembly 922
Removal and installation of steering/brake pump 922
Removal 922
Installation 923
Disassembly and assembly of steering/brake pump 925
Disassembly 925
Inspection 928
Assembly 931
Driveshaft group 931
Rotating group 932
Removal and installation of bladder style steering accumulators 935
Removal 935
Installation 935
Disassembly and assembly of bladder style steering accumulators 936
Disassembly 936
Cleaning and Inspection 936
Bladder accumulator assembly 937
Removal and installation of piston style steering accumulators 939
Removal 939
Installation 940
Disassembly and Assembly of Piston Accumulators 941
Cleaning and Inspection 941
Assembly 942
Testing 942
Suspensions 945
Removal and installation of front suspension 947
Removal 947
Installation 948
Inspection 951
Minor front suspension repairs (lower bearing and seals) 954
Lower bearing retainer removal 954
Lower bearing retainer installation 954
Major front suspension rebuild 955
Disassembly 955
Assembly 956
Removal and installation of rear suspension 958
Removal 959
Installation 961
Disassembly and assembly of rear suspension 961
Disassembly 961
Cleaning and Inspection 962
Assembly 962
Hoist circuit 965
Removal and installation of hoist pump 967
Removal 967
Installation 968
Disassembly and assembly of hoist pump 969
Disassembly 969
Inspection 972
Assembly 972
Removal and installation of hoist valve 977
Removal 977
Installation 978
Disassembly and assembly of hoist valve 978
O-ring replacement 978
Disassembly of inlet section 979
Assembly of inlet section 980
Disassembly of rear spool section 980
Assembly of rear spool section 983
Disassembly of front spool section 984
Assembly of front spool section 985
Overcenter valve manifold service 985
Removal and installation of hoist pilot valve 986
Removal 986
Installation 986
Disassembly and assembly of hoist pilot valve 987
Disassembly 987
Cleaning and inspection 988
Assembly 988
Removal and installation of hoist cylinders 989
Removal 989
Installation 990
Disassembly and assembly of hoist cylinders 991
Disassembly 991
Cleaning and inspection 993
Installation of the quill 994
Assembly 996
Operator cab 999
Removal and installation of operator cab 1001
Removal 1002
Installation 1003
Removal and installation of cab door 1004
Removal 1004
Installation 1004
Disassembly and assembly of cab door 1004
Removing door panel 1004
Installing door panel 1005
Replacing the door window regulator 1005
Replacing door handle or latch assembly 1006
Replacing door assembly seal and door hinge seal 1007
Replacing door opening seal 1007
Removing door glass 1008
Installing door glass 1010
Adjustment of cab door 1011
Door jamb bolt adjustment 1011
Door handle plunger adjustment 1013
Removal and installation of side window glass 1014
Recommended tools and supplies 1014
Removal 1014
Installation 1014
Removal and installation of windshield and rear window glass 1015
Removal 1015
Installation 1015
Removal and installation of windshield wiper motor 1017
Removal 1017
Installation 1017
Removal and installation of windshield wiper arm 1018
Removal 1018
Installation 1018
Removal and installation of windshield wiper linkage 1018
Removal 1018
Installation 1019
Removal and installation of operator seat 1019
Inspection 1019
Removal 1019
Installation 1019
Replacing the seat compressor 1020
Removal and installation of passenger seat 1025
Removal 1025
Installation 1025
Removal and installation of seat belts (standard seats) 1026
Removal 1026
Installation 1026
Removal and installation of seat belts (optional seats) 1028
General 1028
Removal 1028
Installation 1030
Removal and installation of electronic accelerator and retard pedals 1032
Removal 1032
Installation 1032
Disassembly 1032
Assembly 1032
Body and structures 1035
Removal and installation of dump body 1037
Removal 1037
Inspection 1038
Installation 1039
Removal and installation of body pads 1040
Removal 1040
Installation 1040
Body pad shimming procedure 1041
Removal and installation of diagonal ladder/ hood and grille assembly 1042
Removal 1042
Installation 1042
Removal and installation of right deck 1044
Removal 1044
Installation 1044
Removal and installation of left deck 1046
Removal 1046
Installation 1046
Removal and installation of fuel tank 1048
Removal 1048
Cleaning and inspection 1048
Installation 1050
Removal and installation of fuel gauge sender 1051
Removal (earlier models) 1051
Installation (earlier models) 1051
Removal (later models) 1051
Installation (later models) 1051
Disassembly and assembly of fuel tank breather 1052
Disassembly 1052
Assembly 1052
Removal and installation of hydraulic tank 1053
Removal 1053
Installation 1053
Cab air conditioning 1055
Replacement of air conditioning system components 1057
Hoses and fittings 1057
Lines 1057
Expansion valve 1057
Receiver-drier 1057
Thermostat 1057
Compressor 1058
Accumulator 1058
Clutch 1058
Power module 1061
Removal and installation of power module 1063
General 1063
Preparation 1063
Removal 1064
Installation 1070
Exhaust tube installation 1072
Exhaust blanket installation 1072
Removal and installation of alternator 1073
Removal 1073
Installation 1075
Removal and installation of engine 1078
Removal 1078
Service 1078
Installation 1078
Removal and installation of radiator 1079
Removal 1079
Installation 1081
Repairing the radiator 1082
Internal inspection 1082
External cleaning 1082
Disassembly 1083
Cleaning and inspection 1084
Assembly 1084
Pressure testing 1085
90 Diagrams and drawings 1087
Hydraulic circuit diagrams 1087
Electrical circuit diagrams 1093

DESCRIPTION:

Komatsu 960E-2 DUMP TRUCK Shop Manual CEBM028701  – PDF DOWNLOAD

• SERIAL NUMBERS 960E-2 A30074 and up
• ENGINE 18V170

Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The
structure and function sub-section explains the structure and function of each component. It serves not
only to give an understanding of the structure, but also serves as reference material for troubleshooting.
The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table
This section explains the standard values for new machine and judgment criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting
and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgment criteria for testing and adjusting are
explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by
failure modes.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and weight of
components are also explained.
90. Diagrams and drawings
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most uptodate
information before you start any work.

G.B  21/12/24