Komatsu 960E-1 - Install guide

CEBM023802
Shop
Manual
DUMP TRUCK
SERIAL NUMBERS A30025 -A30026
®

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1
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
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CEN00011-02 00 Index and foreword
2
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. denote the following:
: New module (to be filed additionally) : Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accordingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs CEBM023802 
00 Index and foreword
Index CEN00011-02 
Foreword, safety and general information CEN00002-04 
Operating instructions CEN00003-02 
01 Specification
Specification and technical data CEN01001-04 
10 Structure, function and maintenance standard
Steering circuit CEN10001-04 
Hoist circuit CEN10002-01
Brake circuits CEN10003-02
Suspensions CEN10004-01
Electrical system, 24 volt CEN10028-01 
Interface module (IM) CEN10006-01 
Electrical system, AC drive CEN10007-00
Cab air conditioning CEN10008-01
Reserve engine oil system CEN10022-00
20 Standard value table
Standard service value table CEN20001-00
30 Testing and adjusting
General information CEN30001-02 
Steering, brake cooling and hoist hydraulic system CEN30002-01
Brake system CEN30003-02 
Accumulators and suspensions CEN30004-02
KOMTRAX Plus and payload meter CEN30005-03 
Interface module (IM) CEN30006-03 
Cab air conditioning CEN30032-00 
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00 Index and foreword CEN00011-02
3
40 Troubleshooting
Fuse and circuit breaker locations CEN40001-01
AC drive system fault codes CEN40002-00
Troubleshooting by failure code, Part 1 CEN40003-02 
Troubleshooting by failure code, Part 2 CEN40004-02 
Troubleshooting by failure code, Part 3 CEN40005-03 
Troubleshooting by failure code, Part 4 CEN40006-03 
Troubleshooting by failure code, Part 5 CEN40007-02 
Troubleshooting by failure code, Part 6 CEN40016-00
Cab air conditioning CEN40008-01
Reserve engine oil system CEN40010-00
50 Disassembly and assembly
General information CEN50001-05 
Wheels, spindle and rear axle CEN50002-04 
Brake system CEN50003-05 
Steering system CEN50004-05 
Suspensions CEN50005-06 
Hoist circuit CEN50006-04 
Operator cab CEN50007-03 
Body and structures CEN50008-03 
Cab air conditioning CEN50009-02
Power module CEN50019-03 
90 Diagrams and drawings
Hydraulic circuit diagrams CEN90001-00
Electrical circuit diagrams CEN90002-01
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CEN00011-02 00 Index and foreword
4
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
Precautions before performing service....................................................................................16
Precautions while performing service......................................................................................17
Tires ........................................................................................................................................19
Precautions for performing repairs..........................................................................................20
Precautions for welding on the truck.......................................................................................21
Capacitor discharge system....................................................................................................22
Handling electrical equipment and hydraulic components ......................................................30
How to read electric wire code................................................................................................38
Standard torque tables............................................................................................................41
Conversion tables....................................................................................................................46
Operating instructions CEN00003-02
Preparing for operation..............................................................................................................3
Engine start-up..........................................................................................................................7
After engine start-up..................................................................................................................8
Emergency steering system......................................................................................................8
Precautions during truck operation............................................................................................9
Operating on a haul road.........................................................................................................10
Starting on a grade with a loaded truck...................................................................................11
Sudden loss of engine power..................................................................................................11
Fuel depletion..........................................................................................................................12
Towing.....................................................................................................................................12
Loading the dump body...........................................................................................................15
Dumping a load.......................................................................................................................15
Disabled truck dumping procedure..........................................................................................17
Safe parking procedure...........................................................................................................18
Normal engine shutdown procedure .......................................................................................19
01 Specification
Specification and technical data CEN01001-04
Specification drawing.................................................................................................................3
Specifications ............................................................................................................................4
Weight table ..............................................................................................................................6
Fuel, coolant and lubricants ......................................................................................................7
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00 Index and foreword CEN00011-02
5
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................................................................................................................3
Hoist circuit components...........................................................................................................4
Hoist pilot valve operation.........................................................................................................8
Hoist cylinder wear data..........................................................................................................18
Brake circuits CEN10003-02
General information...................................................................................................................3
Service brake circuit operation..................................................................................................4
Secondary braking and auto apply............................................................................................4
Parking brake circuit operation..................................................................................................6
Wheel brake lock circuit operation ............................................................................................7
Brake warning circuit operation.................................................................................................7
Brake assembly wear data........................................................................................................9
Suspensions CEN10004-01
General information...................................................................................................................3
Front suspension wear data......................................................................................................3
Rear suspension wear data ......................................................................................................4
Electrical system, 24V CEN10028-01
Battery supply system...............................................................................................................3
Engine starting system..............................................................................................................4
Auxiliary control cabinet components........................................................................................5
Relay boards.............................................................................................................................7
Body-up switch........................................................................................................................11
Hoist limit switch......................................................................................................................12
Interface module (IM) CEN10006-01
General information...................................................................................................................3
Sensors.....................................................................................................................................3
Interface module inputs and outputs.........................................................................................4
Electrical system, AC drive CEN10007-00
General system operation.........................................................................................................3
AC drive system components ...................................................................................................5
PSC software functions.............................................................................................................7
Alernator field control..............................................................................................................12
Event detection and processing..............................................................................................14
Event logging and storage ......................................................................................................15
Serial data communications....................................................................................................17
Abnormal conditions/overriding functions ...............................................................................18
AC drive system component table ..........................................................................................20
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CEN00011-02 00 Index and foreword
6
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
30 Testing and adjusting
General information CEN30001-02
Special tools..............................................................................................................................3
Steering, brake cooling and hoist hydraulic system CEN30002-01
General information on system checkout..................................................................................3
Steering system checkout procedures ......................................................................................3
Steering system checkout data sheet........................................................................................9
Brake cooling and hoist system checkout procedures............................................................11
Brake cooling and hoist system checkout data sheet .............................................................16
Hydraulic system flushing procedure ......................................................................................17
Brake system CEN30003-02
General information on system checkout..................................................................................3
Brake circuit checkout procedure..............................................................................................3
Brake system checkout data sheet .........................................................................................13
Brake piston leakage test........................................................................................................17
Brake seal pressure test..........................................................................................................17
Wet disc brake bleeding procedure.........................................................................................18
Parking brake bleeding procedure ..........................................................................................18
Brake disc wear inspection......................................................................................................19
Brake valve bench test and adjustment ..................................................................................21
Dual relay valve bench test and adjustment............................................................................24
Accumulators and suspensions CEN30004-02
Accumulator charging and storage............................................................................................3
Accumulator leak testing...........................................................................................................8
Suspension oiling and charging procedures ...........................................................................10
Suspension pressure test........................................................................................................17
KOMTRAX Plus and payload meter CEN30005-03
KOMTRAX Plus and payload meter software ...........................................................................3
KOMTRAX Plus controller initial setting procedure...................................................................4
KOMTRAX Plus initialization check list...................................................................................11
KOMTRAX Plus initialization form...........................................................................................13
Precautions for replacing KOMTRAX Plus controller..............................................................14
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00 Index and foreword CEN00011-02
7
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.....................................................................................................3
Detecting leaks..........................................................................................................................6
System performance test ..........................................................................................................7
Checking system oil ..................................................................................................................8
System flushing.........................................................................................................................9
Installing the manifold gauge set.............................................................................................10
Recovering and recycling refrigerant ......................................................................................11
Evacuating the air conditioning system...................................................................................13
Charging the air conditioning system......................................................................................14
40 Troubleshooting
Fuse and circuit breaker locations CEN40001-01
Fuse and circuit breaker locations ............................................................................................3
AC drive system fault codes CEN40002-00
DID panel fault code tables.......................................................................................................3
Troubleshooting by fault code, Part 1 CEN40003-02
Fault Code A001: Left front suspension pressure sensor signal high.......................................3
Fault Code A002: Left front suspension pressure sensor signal low ........................................4
Fault Code A003: Right front suspension pressure sensor signal high ....................................5
Fault Code A004: Right front suspension pressure sensor signal low......................................6
Fault Code A005: Left rear suspension pressure sensor signal high........................................7
Fault Code A006: Left rear suspension pressure sensor signal low.........................................8
Fault Code A007: Right rear suspension pressure sensor signal high .....................................9
Fault Code A008: Right rear suspension pressure sensor signal low.....................................10
Fault Code A009: Incline sensor signal high...........................................................................11
Fault Code A010: Incline sensor signal low ............................................................................12
Fault Code A011: Payload meter speed sensor signal has failed...........................................13
Fault Code A013: Body up switch has failed...........................................................................14
Fault Code A014: Payload meter checksum computation has failed......................................15
Fault Code A016: Payload meter write to flash memory has failed ........................................16
Fault Code A017: Payload meter flash memory read has failed.............................................17
Fault Code A018: Right rear flat suspension cylinder warning ...............................................18
Fault Code A019: Left rear flat suspension cylinder warning..................................................20
Fault Code A022: Carryback load excessive ..........................................................................22
Fault Code A100: An open circuit breaker has been detected on a relay board.....................25
Fault Code A101: High pressure detected across an hydraulic pump filter ............................26
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level.......28
Fault Code A107: GE has generated a propel system caution...............................................30
Fault Code A108: GE has generated a propel system temperature caution...........................31
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CEN00011-02 00 Index and foreword
8
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
Fault Code A125: GE has generated a no propel warning......................................................42
Fault Code A126: Oil level in the hydraulic tank is low............................................................43
Fault Code A127: IM-furnished +5 volt output for sensors is low............................................44
Fault Code A128: IM-furnished +5 volt output for sensors is high ..........................................46
Fault Code A139: Low fuel warning ........................................................................................48
Troubleshooting by fault code, Part 2 CEN40004-02
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm
to advance level 1 for cooling of hydraulic oil............................................................................4
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm
to advance level 2 for cooling of hydraulic oil............................................................................6
Fault Code A152: Starter failure................................................................................................8
Fault Code A153: Battery voltage is low with the truck in operation .......................................10
Fault Code A154: Battery charging voltage is excessive........................................................12
Fault Code A155: Battery charging voltage is low...................................................................13
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false
low fuel level............................................................................................................................14
Fault Code A166: Left rear hydraulic oil temperature sensor is low........................................16
Fault Code A167: Right rear hydraulic oil temperature sensor is low .....................................18
Fault Code A168: Left front hydraulic oil temperature sensor is low.......................................20
Fault Code A169: Right front hydraulic oil temperature sensor is low.....................................22
Fault Code A170: Left rear hydraulic oil temperature sensor is high ......................................24
Fault Code A171: Right rear hydraulic oil temperature sensor is high....................................25
Fault Code A172: Left front hydraulic oil temperature sensor is high......................................26
Fault Code A173: Right front hydraulic oil temperature sensor is high...................................27
Fault Code A184: J1939 data link is not connected................................................................28
Fault Code A190: Auto lube control has detected an incomplete lube cycle ..........................30
Fault Code A194: Left front hydraulic oil temperature is high .................................................32
Fault Code A195: Right front hydraulic oil temperature is high...............................................33
Fault Code A196: Left rear hydraulic oil temperature is high ..................................................34
Fault Code A197: Right rear hydraulic oil temperature is high................................................35
Fault Code A198: Hoist pressure 1 sensor is high..................................................................36
Fault Code A199: Hoist pressure 2 sensor is high..................................................................37
Fault Code A200: Steering pressure sensor is high................................................................38
Fault Code A201: Brake pressure sensor is high....................................................................39
Fault Code A202: Hoist pressure 1 sensor is low ...................................................................40
Fault Code A203: Hoist pressure 2 sensor is low ...................................................................42
Fault Code A204: Steering pressure sensor is low .................................................................44
Fault Code A205: Brake pressure sensor is low .....................................................................46
Fault Code A206: Ambient temperature sensor is high...........................................................48
Fault Code A207: Ambient temperature sensor is low............................................................49
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00 Index and foreword CEN00011-02
9
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 .................................................14
Fault Code A216: An open or short to ground has been detected in the parking brake command valve cir-
cuit...........................................................................................................................................16
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted18
Fault Code A230: Parking brake has been requested while truck still moving .......................22
Fault Code A231: The body is up with engine running and brakes not on..............................24
Fault Code A235: Steering accumulator is in the process of being bled down.......................26
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds...28
Fault Code A237: The CAN/RPC connection to the display is open.......................................30
Fault Code A240: The key switch input to the interface module is open ................................31
Fault Code A242: Fuel gauge within the dash display panel is defective ...............................32
Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective33
Fault Code A244: Drive system temperature gauge within the dash display panel is defective34
Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective35
Fault Code A246: Payload meter reports truck overload ........................................................36
Fault Code A247: Low steering pressure warning ..................................................................38
Fault Code A248: Status module within the dash display panel is defective...........................40
Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted .........41
Fault Code A250: Battery voltage is low with the truck parked...............................................42
Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground44
Fault Code A252: Start enable output circuit is either open or shorted to ground...................46
Fault Code A253: Steering bleed circuit is not open while running.........................................48
Fault Code A256: Red warning lamp in the dash display (driven by IM) is open....................50
Fault Code A257: Payload CAN/RPC is not connected..........................................................51
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective ................52
Troubleshooting by fault code, Part 4 CEN40006-03
Fault Code A260: Parking brake failure ....................................................................................4
Fault Code A261: Low brake accumulator pressure warning ...................................................6
Fault Code A262: Steering bleed valve circuit open during shutdown......................................8
Fault Code A264: Parking brake relay circuit is defective.......................................................10
Fault Code A265: Service brake failure ..................................................................................12
Fault Code A266: Selector lever was not in park while attempting to crank engine ...............14
Fault Code A267: Parking brake was not set while attempting to crank engine .....................15
Fault Code A268: Secondary engine shutdown while cranking..............................................16
Fault Code A270: Brake lock switch power supply is not on when required...........................18
Fault Code A271: Shifter not in gear.......................................................................................22
Fault Code A272: Brake lock switch power supply is not off when required...........................24
Fault Code A273: A fault has been detected in the hoist or steering pump filter
pressure switch circuit.............................................................................................................27
Fault Code A274: A brake setting fault has been detected.....................................................28
Fault Code A275: A starter has been detected as engaged without a cranking attempt........30
Fault Code A276: The drive system data link is not connected ..............................................32
Fault Code A277: Parking brake applied while loading...........................................................34

CEN00011-02 00 Index and foreword
10
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
was not set..............................................................................................................................46
Fault Code A284: An engine shutdown delay was aborted because the secondary
shutdown switch was operated ...............................................................................................48
Fault Code A285: The parking brake was not set when the key switch was turned off...........50
Fault Code A286: A fault was detected in the shutdown delay relay circuit............................52
Fault Code A292: The shutdown delay relay has remained on after the latched
key switch circuit is off.............................................................................................................54
Troubleshooting by fault code, Part 5 CEN40007-02
Fault Code A303: Shifter is defective........................................................................................4
Fault Code A304: Auto lube grease level fault..........................................................................6
Fault Code A305: Auto lube circuit is defective.........................................................................8
Fault Code A307: Both GE inverters are disabled ..................................................................10
Fault Code A309: No brakes applied when expected.............................................................12
Fault Code A310: Low fuel warning ........................................................................................14
Fault Code A311: Brake lock switch is on when it should not be ............................................16
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings............18
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings...........19
Fault Code A315: DCDC converter 12 volt circuit is low.........................................................20
Fault Code A316: Starter engagement has been attempted with engine running...................22
Fault Code A317: Operation of brake auto apply valve without a detected response.............24
Fault Code A318: Unexpected power loss to interface module ..............................................26
Fault Code A320: Data link reports GE propel system caution fault but
wired input does not................................................................................................................28
Fault Code A321: Data link reports GE propel system temp caution fault but
wired input does not................................................................................................................30
Fault Code A322: Data link reports GE propel system reduced level fault but
wired input does not................................................................................................................32
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not ...34
Fault Code A324: Data link reports DC link voltage but wired input does not.........................36
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not..........38
Fault Code A326: Data link reports GE no propel fault but wired input does not....................40
Fault Code A327: Data link reports GE at rest but wired input does not.................................42
Fault Code A328: Drive system not powered up.....................................................................44
Fault Code A329: Data link reports the body is not down but wired input says it is................46
Fault Code A330: Data link reports dynamic retard operating state but
wired input does not................................................................................................................48
Troubleshooting by fault code, Part 6 CEN40016-00
Fault Code A350: Overload on output 1B .................................................................................3
Fault Code A351: Overload on output 1E .................................................................................4
Fault Code A352: Overload on output 1H.................................................................................6

00 Index and foreword CEN00011-02
11
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 ...............................................................................13
Fault Code A359: Overload on output 1R...............................................................................14
Fault Code A360: Overload on output 1S ...............................................................................15
Fault Code A361: Overload on output 1T ...............................................................................16
Fault Code A362: Overload on output 1U...............................................................................18
Fault Code A363: Overload on output 1X ...............................................................................20
Fault Code A364: Overload on output 1Y ...............................................................................22
Fault Code A365: Overload on output 1Z ...............................................................................23
Cab air conditioning CEN40008-01
Preliminary checks....................................................................................................................3
Diagnosis of gauge readings and system performance............................................................3
Troubleshooting by manifold gauge set readings......................................................................4
Reserve engine oil system CEN40010-00
Pumping unit LED signals.........................................................................................................3
50 Disassembly and assembly
General information CEN50001-05
Special tools..............................................................................................................................3
Wheels, spindles and rear axles CEN50002-04
General information for tires and rims.......................................................................................3
Removal and installation of front wheel ....................................................................................4
Removal and installation of rear wheel .....................................................................................6
Removal and installation of tires ...............................................................................................8
Removal and installation of front wheel hub and spindle........................................................10
Disassembly and assembly of front wheel hub and spindle....................................................17
Removal and installation of rear axle......................................................................................22
Removal and installation of anti-sway bar...............................................................................24
Removal and installation of pivot pin.......................................................................................25
Pivot eye and bearing service.................................................................................................26
Removal and installation of wheel motor ................................................................................28
Removal and installation of rear brake assembly ...................................................................35
Brake system CEN50003-05
Removal and installation of brake valve....................................................................................3
Disassembly and assembly of brake valve ...............................................................................4
Removal and installation of dual relay valve...........................................................................11
Disassembly and assembly of dual relay valve.......................................................................13
Removal and installation of brake manifold ............................................................................15
Disassembly and assembly of brake manifold........................................................................16
Removal and installation of brake accumulator ......................................................................17
Disassembly and assembly of brake accumulator..................................................................18
Disassembly and assembly of wheel brake ............................................................................21

CEN00011-02 00 Index and foreword
12
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.............................................................................11
Removal and installation of bleed down manifold...................................................................13
Removal and installation of flow amplifier...............................................................................15
Disassembly and assembly of flow amplifier...........................................................................15
Removal and installation of steering cylinders and tie rod......................................................18
Disassembly and assembly of steering cylinders....................................................................20
Removal and installation of steering/brake pump ...................................................................21
Disassembly and assembly of steering/brake pump...............................................................24
Removal and installation of steering accumulators.................................................................33
Disassembly and assembly of steering accumulators.............................................................34
Suspensions CEN50005-06
Removal and installation of front suspension............................................................................3
Minor front suspension repairs (lower bearing and seals).......................................................10
Major front suspension rebuild ................................................................................................11
Removal and installation of rear suspension...........................................................................14
Disassembly and assembly of rear suspension......................................................................17
Hoist circuit CEN50006-04
Removal and installation of hoist pump.....................................................................................3
Disassembly and assembly of hoist pump................................................................................5
Removal and installation of hoist valve...................................................................................13
Disassembly and assembly of hoist valve...............................................................................14
Overcenter valve manifold service ..........................................................................................21
Removal and installation of hoist pilot valve............................................................................22
Disassembly and assembly of hoist pilot valve .......................................................................23
Removal and installation of hoist cylinders .............................................................................25
Disassembly and assembly of hoist cylinders.........................................................................27
Operator cab CEN50007-03
Removal and installation of operator cab..................................................................................3
Removal and installation of cab door........................................................................................6
Disassembly and assembly of cab door....................................................................................6
Adjustment of cab door ...........................................................................................................13
Removal and installation of side window glass.......................................................................15
Removal and installation of windshield and rear window glass...............................................17
Removal and installation of windshield wiper motor................................................................18
Removal and installation of windshield wiper arm...................................................................19
Removal and installation of windshield wiper linkage .............................................................20
Removal and installation of operator seat...............................................................................21
Removal and installation of passenger seat............................................................................22
Removal and installation of seat belts (standard seats)..........................................................23
Removal and installation of seat belts (optional seats) ...........................................................25

00 Index and foreword CEN00011-02
13
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.......................................................................................12
Removal and installation of fuel tank.......................................................................................14
Removal and installation of fuel gauge sender .......................................................................16
Disassembly and assembly of fuel tank breather....................................................................17
Removal and installation of hydraulic tank..............................................................................18
Cab air conditioning CEN50009-02
Replacement of air conditioning system components...............................................................3
Diasassembly and assembly of compressor clutch ..................................................................5
Power module, engine and alternator CEN50019-03
Removal and installation of power module ...............................................................................3
Removal and installation of alternator.....................................................................................12
Removal and installation of engine .........................................................................................17
Removal and installation of radiator........................................................................................18
Repairing the radiator..............................................................................................................21
90 Digrams and drawings
Hydraulic circuit diagrams CEN90001-00
Steering, hoist and brake cooling hydraulic circuit diagram .......................................... EM7616
Brake hydraulic circuit diagram..................................................................................... EM7623
Electrical circuit diagrams CEN90002-01
Electrical circuit diagram - index & symbols...................................................................XS5701
Electrical circuit diagram - circuit locator sheet..............................................................XS5702
Electrical circuit diagram - circuit locator sheet..............................................................XS5703
Electrical circuit diagram - battery box ...........................................................................XS5704
Electrical circuit diagram - 24V power distribution & circuit protection...........................XS5705
Electrical circuit diagram - 24V power distribution & circuit protection...........................XS5706
Electrical circuit diagram - engine control wiring............................................................XS5707
Electrical circuit diagram - engine control wiring............................................................XS5708
Electrical circuit diagram - engine control wiring............................................................XS5709
Electrical circuit diagram - engine control wiring............................................................XS5710
Electrical circuit diagram - keyswitch, timed engine shutdown & auto lube system....... XS5711
Electrical circuit diagram - engine start circuit................................................................XS5712
Electrical circuit diagram - brake control wiring..............................................................XS5713
Electrical circuit diagram - brake control wiring..............................................................XS5714
Electrical circuit diagram - steering & hoist pressure switch wiring................................XS5715
Electrical circuit diagram - operator drive system controls.............................................XS5716
Electrical circuit diagram - operator drive system controls.............................................XS5717
Electrical circuit diagram - electronic dash panel...........................................................XS5718
Electrical circuit diagram - operator cab light controls & horn........................................XS5719
Electrical circuit diagram - operator cab light controls & horn........................................XS5720
Electrical circuit diagram - operator cab windows & wipers ...........................................XS5721

CEN00011-02 00 Index and foreword
14
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............................................................XS5726
Electrical circuit diagram - diagnostic ports - VHMS & GE.............................................XS5727
Electrical circuit diagram - modular mining interface......................................................XS5728
Electrical circuit diagram - interface module inputs & outputs........................................XS5729
Electrical circuit diagram - interface module inputs & outputs........................................XS5730
Electrical circuit diagram - interface module inputs & outputs........................................XS5731
Electrical circuit diagram - interface module inputs & outputs........................................XS5732
Electrical circuit diagram - payload meter III circuits ......................................................XS5733
Connectors table and arrangement drawing....................................................................HE487

00 Index and foreword CEN00011-02
15
NOTES

16
CEN00011-02 00 Index and foreword
960E Dump truck
Form No. CEN00011-02
© 2011 KOMATSU
All Rights Reserved
Printed in USA 11-11

1
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............................................................................................................... 10
Precautions while operating the truck................................................................................................................. 12
Working near batteries........................................................................................................................................ 15
Precautions before performing service ............................................................................................................... 17
Precautions while performing service................................................................................................................. 19
Tires.................................................................................................................................................................... 21
Precautions for performing repairs...................................................................................................................... 22
Precautions for welding on the truck................................................................................................................... 23
Capacitor discharge system................................................................................................................................ 24
Handling electrical equipment and hydraulic components.................................................................................. 32
How to read electric wire code............................................................................................................................ 40
Standard torque tables........................................................................................................................................ 43
Conversion tables ............................................................................................................................................... 48

CEN00002-05 00 Index and foreword
2
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. The
Company reserves the right to make changes or
add improvements at any time without incurring
any obligation to install such changes on products
sold previously.
Because of continuous research and development,
periodic revisions may be made to this publication.
Customers should contact their local Komatsu dis-
tributor for information on the latest revision.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust, some of its constituents, and certain vehicle components contain or emit
chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
CALIFORNIA
Proposition 65 Warning
Battery posts, terminals and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and birth defects or other reproductive harm. Wash
hands after handling.
Unsafe use of this machine may cause serious injury or death. Operators and maintenance person-
nel must read and understand this manual before operating or maintaining this machine.
This manual should be kept in or near the machine for reference, and periodically reviewed by all
personnel who will come into contact with it.
CALIFORNIA
Proposition 65 Warning
Mercury and mercury compounds are known to the State of California to cause developmental prob-
lems. This machine may be equipped with optional HID lamps which contain mercury. There is no
risk of exposure unless the lamps are broken. However, the lamps must be reused, recycled or prop-
erly disposed of in accordance with Local, State and Federal Laws at the end of their useful lives.