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Komatsu 960E-1 Shop Manual
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Komatsu 960E-1 Shop Manual

Dump truck
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CEBM023802
Shop
Manual
DUMP TRUCK
A30025 - A30026
SERIAL NUMBERS
®

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Summary of Contents for Komatsu 960E-1

  • Page 1 CEBM023802 Shop Manual DUMP TRUCK A30025 - A30026 SERIAL NUMBERS ®...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 CEN00011-02 DUMP TRUCK 1SHOP MANUAL 960E Machine model Serial number 960E-1 A30025 - A30026 00 Index and foreword Index Composition of shop manual ..........................2 Table of contents..............................4 Find manuals at https://best-manuals.com...
  • Page 4 CEN00011-02 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
  • Page 5 00 Index and foreword CEN00011-02 40 Troubleshooting Fuse and circuit breaker locations CEN40001-01 AC drive system fault codes CEN40002-00 CEN40003-02  Troubleshooting by failure code, Part 1 CEN40004-02  Troubleshooting by failure code, Part 2 CEN40005-03  Troubleshooting by failure code, Part 3 CEN40006-03 ...
  • Page 6 CEN00011-02 00 Index and foreword Table of contents 00 Index and foreword Index CEN00011-02 Composition of shop manual ....................2 Table of contents ........................4 Foreword, safety and general information CEN00002-04 Foreword ...........................4 How to read the shop manual ....................5 General safety ...........................7 Precautions before operating the truck ...................10 Precautions while operating the truck ..................12 Working near batteries ......................15...
  • Page 7 00 Index and foreword CEN00011-02 10 Structure, function and maintenance standard Steering circuit CEN10001-04 Steering circuit operation......................3 Steering circuit components ...................... 5 Flow amplifier operation ......................9 Steering/brake pump operation ....................19 Steering cylinder wear data ..................... 22 Hoist circuit CEN10002-01 Hoist circuit operation........................
  • Page 8 CEN00011-02 00 Index and foreword Cab air conditioning CEN10008-01 General information........................2 Principles of refrigeration......................3 Air conditioning system components..................5 Air conditioning system electrical circuit..................9 Reserve engine oil system CEN10022-00 General information........................3 Operation...........................4 Remote tank fill system ......................5 20 Standard value table Standard value table CEN20001-00 Standard value table for truck....................3...
  • Page 9 00 Index and foreword CEN00011-02 KOMTRAX Plus controller checkout procedure ..............19 Payload meter initial setting procedure ................... 22 Infterface module (IM) CEN30006-03 Interface module software ......................3 Interface module checkout procedures ..................5 Cab air conditioning CEN30032-00 General information........................2 Service tools and equipment.....................
  • Page 10 CEN00011-02 00 Index and foreword Fault Code A109: GE has generated a propel system reduced level signal ......32 Fault Code A111: Low steering pressure warning ..............33 Fault Code A115: Low steering precharge pressure detected ..........34 Fault Code A117: Low brake accumulator pressure warning ..........36 Fault Code A118: Brake pressure is low while in brake lock ...........38 Fault Code A123: GE has generated a reduced retarding caution .........40 Fault Code A124: GE has generated a no propel / no retard warning ........41...
  • Page 11 00 Index and foreword CEN00011-02 Troubleshooting by fault code, Part 3 CEN40005-03 Fault Code A212: Bad truck speed signal................. 4 Fault Code A213: Parking brake should have applied but is detected as not having applied... 6 Fault Code A214: Parking brake should have released but is detected as not having released10 Fault Code A215: Brake auto apply valve circuit is defective ..........
  • Page 12 CEN00011-02 00 Index and foreword Fault Code A278: Service brake applied while loading ............36 Fault Code A279: Low steering pressure switch is defective ..........38 Fault Code A280: Steering accumulator bleed down switch is defective ........39 Fault Code A281: Brake lock degrade switch is defective ............40 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7 ................42 Fault Code A283: An engine shutdown delay was aborted because the parking brake...
  • Page 13 00 Index and foreword CEN00011-02 Fault Code A353: Overload on output 1J.................. 7 Fault Code A354: Overload on output 1K ................. 8 Fault Code A355: Overload on output 1L................10 Fault Code A356: Overload on output 1M................11 Fault Code A357: Overload on output 1N ................12 Fault Code A358: Overload on output 1P ................
  • Page 14 CEN00011-02 00 Index and foreword Removal and installation of parking brake ................33 Disassembly and assembly of parking brake ................35 Steering system CEN50004-05 Removal and installation of steering control unit...............3 Disassembly and assembly of steering control unit ..............5 Removal and installation of steering column................10 Removal and installation of steering wheel ................
  • Page 15 00 Index and foreword CEN00011-02 Body and structures CEN50008-03 Removal and installation of dump body ..................3 Removal and installation of body pads..................6 Removal and installation of diagonal ladder/hood and grille assembly........8 Removal and installation of right deck ..................10 Removal and installation of left deck..................
  • Page 16 CEN00011-02 00 Index and foreword Electrical circuit diagram - operator cab radio & seat wiring .......... XS5722 Electrical circuit diagram - clearance lights, fog lights & headlights ....... XS5723 Electrical circuit diagram - hazard light wiring ..............XS5724 Electrical circuit diagram - heater & air conditioning controls......... XS5725 Electrical circuit diagram - diagnostic ports - GE............
  • Page 17 00 Index and foreword CEN00011-02 NOTES...
  • Page 18 CEN00011-02 00 Index and foreword 960E Dump truck Form No. CEN00011-02 © 2011 KOMATSU All Rights Reserved Printed in USA 11-11...

  • Page 19: Machine Model

    CEN00002-05 DUMP TRUCK 1SHOP MANUAL 960E Machine model Serial number 960E-1 A30003 - A30026 960E-2 A30027 and up 00 Index and foreword Foreword, safety and general information Foreword................................4 How to read the shop manual ..........................5 General safety............................... 7 Precautions before operating the truck .......................
  • Page 20 CEN00002-05 00 Index and foreword This material is proprietary to Komatsu America Corp (KAC), and is not to be reproduced, used, or disclosed except in accordance with written autho- rization from KAC. It is the policy of the Company to improve products whenever it is possible and practical to do so.
  • Page 21 Komatsu is also aware of repair companies that will rework or modify an OEM part for reuse in critical systems. Komatsu does not generally authorize such repairs or modifications for the same reasons as noted above.
  • Page 22 Vehicle Weight) rating. and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance The KOMATSU truck model designation consists of personnel should read understand three numbers and one letter (i.e.
  • Page 23 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 up- to-date information before you start any work.
  • Page 24 CEN00002-05 00 Index and foreword Symbols This “ALERT” symbol is used with the signal words, “DANGER”, “WARNING”, and “CAUTION” in this manual to alert the reader to hazards arising from improper operating and maintenance practices. “DANGER” identifies a specific potential hazard WHICH WILL RESULT IN EITHER INJURY OR DEATH if proper precautions are not taken.

  • Page 25: General Safety

    00 Index and foreword CEN00002-05 General safety Fire extinguisher and first aid kit Safety records from most organizations will show that • Make sure that fire extinguishers are accessible and proper usage techniques are known. the greatest percentage of accidents are caused by unsafe acts performed by people.
  • Page 26 CEN00002-05 00 Index and foreword Leaving the operator seat Fire prevention for fuel and oil When preparing to leave the operator's seat, do not • Fuel, oil, and antifreeze can be ignited by a flame. Fuel is extremely flammable and can be touch any control lever that is not locked.
  • Page 27 If before removing the cap. it is modified or repaired without authorization from Komatsu, or if it is damaged when the truck rolls over, the strength of the structure will be compromised and will not be able to fulfill its Asbestos dust hazard prevention intended purpose.
  • Page 28 In addition, know the proper use and care of all the safety equipment on the truck. Only • Do not use attachments that are not authorized by Komatsu America Corp. or the authorized qualified operators or technicians should attempt to regional Komatsu distributor. Use of unauthorized operate or maintain a Komatsu machine.
  • Page 29 00 Index and foreword CEN00002-05 Fire prevention Mirrors, windows and lights • Remove wood chips, leaves, paper, and other • Remove any dirt from the surface of the flammable items that have accumulated in the windshield, cab windows, mirrors and lights. engine compartment.
  • Page 30 CEN00002-05 00 Index and foreword Precautions while operating the truck When starting the engine • Never attempt to start the engine by shorting across cranking motor terminals. This may cause The tire and rim assembly may explode if a fire, or serious injury or death to anyone in subjected to excessive heat.
  • Page 31 00 Index and foreword CEN00002-05 Traveling Traveling on slopes • When traveling on rough ground, travel at low • Traveling on slopes could result in the truck speeds. When changing direction, avoid turning tipping over or slipping. suddenly. • Do not change direction on slopes. To ensure •...
  • Page 32 CEN00002-05 00 Index and foreword Driving near high voltage cables Working on loose ground Driving near high voltage cables can cause electric • Avoid operating the truck near cliffs, overhangs and deep ditches. If these areas collapse, the shock. Always maintain safe distances between the truck could fall or tip over and result in serious truck and the high voltage cable as listed below.
  • Page 33 00 Index and foreword CEN00002-05 Working near batteries • Batteries generate hydrogen gas. Hydrogen gas is very explosive and can easily be ignited with a Battery hazard prevention small spark or flame. • Before working with batteries, stop the engine •...
  • Page 34 CEN00002-05 00 Index and foreword Starting with booster cables • If any tool touches between the positive (+) terminal and the chassis, it will cause sparks. • Always wear safety glasses or goggles when Always use caution when using tools near the starting the machine with booster cables.
  • Page 35 Attach additional warning tags around the truck as necessary. These tags are available from your Komatsu distributor. Warning tag part number: 09963-03001 Use of Tie-Off Anchor During Maintenance and...
  • Page 36 The Komatsu body-up safety sling can only be used with a Komatsu body. Non-OEM body may not accommodate the Komatsu body-up safety sling. The end user must ensure that a proper cable/sling is used.
  • Page 37 00 Index and foreword CEN00002-05 Precautions while performing service Working under the truck NOTE: Only authorized personnel should service and • Always lower all movable work equipment to the ground or to their lowest position before repair the truck. performing service or repairs under the truck. Keep the truck clean •...
  • Page 38 CEN00002-05 00 Index and foreword Radiator coolant level Handling high pressure hoses If it is necessary to add coolant to the radiator, stop • Do not bend high pressure hoses or hit them with hard objects. Do not use any bent or cracked the engine and allow the engine and radiator to cool piping, tubes or hoses.
  • Page 39 When performing such maintenance, consult your authorized regional Komatsu distributor or the tire manufacturer. Mounted tires stored as spares must be inflated to the minimum inflation pressure necessary to keep the tire beads properly seated. Maximum inflation pressure of the stored tire must, in no instance,...
  • Page 40 AC drive system. • Many components on the Komatsu truck are large and heavy. Ensure that lifting equipment 1. Before shutting down the engine, verify the (hoists, slings, chains, and lifting eyes) are of status of all the drive system warning lights.
  • Page 41 The metal panels on the back of the cabinet are NOTE: Before welding or repairing an AC drive truck, part of capacitors and cannot be heated. notify a Komatsu service representative. Only • Do not weld on the retarding grid exhaust qualified personnel, specifically trained for servicing louvers! They are made of stainless steel.
  • Page 42 • Grounding stick pair (Figure 00-3) capacitors can remain in a charged state even (Komatsu p/n PC3299) though the capacitor charge lights are off. (HVR Advanced Power Components MAS- 000039 Ground Stick Pair or equivalent)
  • Page 43 00 Index and foreword CEN00002-05 Warnings and cautions All applicable local mine, government, and industry rules for working with high voltage must be followed. Required personal protective equipment, including but not limited to safety shoes, high voltage gloves, Hazardous voltages are present in this equip- and safety glasses must be worn.
  • Page 44 CEN00002-05 00 Index and foreword Manual DC link capacitor discharge procedure Follow any and all local and site specific procedures and requirements for working on off-highway mining equipment. Verify that: • The engine is off and the parking brake is on. FIGURE 00-4.
  • Page 45 00 Index and foreword CEN00002-05 2. Observe both capacitor charge lights (CCL1, CCL2). CCL1 is on the outside of the contactor box. CCL2 is on the switch panel inside the low voltage area. The lights will stay illuminated as long as the voltage on the DC link is greater than 50 VDC.
  • Page 46 CEN00002-05 00 Index and foreword Failure of the discharge system 1. Open the high voltage area doors. 2. With a suitable high voltage meter rated for at If the capacitor charge lights remain illuminated, a least 2000 VDC, such as PC3186 or equivalent, failure of the normal (fast) capacitor discharge plus suitable protective equipment, measure the system (RP discharge path) has likely occurred.
  • Page 47 00 Index and foreword CEN00002-05 Manual discharge of capacitors 3. Discharge the relevant capacitors. Open the door(s) and place one grounding stick on one of If the voltage is greater than 1V on any of the capaci- the positive (+) capacitor terminals and the other tors, the capacitor must be manually discharged.
  • Page 48 CEN00002-05 00 Index and foreword 4. Measure voltage on all capacitors as described in “Failure of the discharge system” on page 28. Discharge any capacitors that show voltage. 5. If all capacitors read discharged, verify that the meter is functioning correctly using site- Voltages in excess of 1500 VDC may be present.
  • Page 49 00 Index and foreword CEN00002-05 Short isolated capacitor terminals Any capacitor that is isolated from the DC link and confirmed discharged must have its terminals electri- cally shorted together to prevent static charge build up. Use bare wire to jumper all four terminals on the capacitor.
  • Page 50 CEN00002-05 00 Index and foreword Handling electrical equipment and hydraulic components To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

A30025A30026