Komatsu 960E -1 Dump Truck Service Manual
1,004 pages · Publication CEBM021304
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- Models
- 960E -1
- Serial coverage
- A30003-A30024
- Manual type
- Service Manual
- Pages
- 1,004
- Publication
- CEBM021304
- Condition
- Brand new
What's inside
From the manual's own table of contents: 203 sections, 380 entries. See sample pages (PDF, 811 KB)
Composition of shop manual
Foreword
How to read the shop manual
General safety
Precautions before operating the truck
Precautions while operating the truck
Working near batteries
Precautions before performing service
Precautions while performing service
Tires
Precautions for performing repairs
Precautions for welding on the truck
Capacitor discharge system
Handling electrical equipment and hydraulic components
How to read electric wire code
Standard torque tables
Conversion tables
Preparing for operation
Engine start-up
After engine start-up
Emergency steering system
Precautions during truck operation
Operating on a haul road
Starting on a grade with a loaded truck
Show all 203 sections
Sudden loss of engine power
Fuel depletion
Towing
Loading the dump body
Dumping a load
Disabled truck dumping procedure
Safe parking procedure
Normal engine shutdown procedure
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants34 topics
- Steering circuit operation
- Steering circuit components
- Flow amplifier operation
- Steering/brake pump operation
- Steering cylinder wear data
- Hoist circuit operation
- Hoist circuit components
- Hoist pilot valve operation
- Hoist cylinder wear data
- General information
- Service brake circuit operation
- Secondary braking and auto apply
- Parking brake circuit operation
- Wheel brake lock circuit operation
- Brake warning circuit operation
- Brake assembly wear data
- Front suspension wear data
- Rear suspension wear data
- Battery supply system
- Auxiliary control cabinet components
- Relay boards
- Body-up switch
- Hoist limit switch
- Sensors
- Interface module inputs and outputs
- General system operation
- AC drive system components
- PSC software functions
- Alernator field control
- Event detection and processing
- Event logging and storage
- Serial data communications
- Abnormal conditions/overriding functions
- AC drive system component table
General information
Principles of refrigeration
Air conditioning system components
Air conditioning system electrical circuit
Operation
Remote tank fill system
Standard value table for truck
Special tools
General information on system checkout
Steering system checkout procedures
Steering system checkout data sheet
Brake cooling and hoist system checkout procedures
Brake cooling and hoist system checkout data sheet
Hydraulic system flushing procedure
Brake circuit checkout procedure
Brake system checkout data sheet
Brake piston leakage test
Brake seal pressure test
Wet disc brake bleeding procedure
Parking brake bleeding procedure
Brake disc wear inspection
Brake valve bench test and adjustment
Dual relay valve bench test and adjustment
Accumulator charging and storage
Accumulator leak testing
Suspension oiling and charging procedures
Suspension pressure test
KOMTRAX Plus and payload meter software
KOMTRAX Plus controller initial setting procedure
KOMTRAX Plus initialization check list
KOMTRAX Plus initialization form
Precautions for replacing KOMTRAX Plus controller
KOMTRAX Plus controller checkout procedure38 topics
- Payload meter initial setting procedure
- Interface module software
- Interface module checkout procedures
- Service tools and equipment
- Detecting leaks
- System performance test
- Checking system oil
- System flushing
- Installing the manifold gauge set
- Recovering and recycling refrigerant
- Evacuating the air conditioning system
- Charging the air conditioning system
- Fuse and circuit breaker locations
- DID panel fault code tables
- Fault Code A001: Left front suspension pressure sensor signal high
- Fault Code A002: Left front suspension pressure sensor signal low
- Fault Code A003: Right front suspension pressure sensor signal high
- Fault Code A004: Right front suspension pressure sensor signal low
- Fault Code A005: Left rear suspension pressure sensor signal high
- Fault Code A006: Left rear suspension pressure sensor signal low
- Fault Code A007: Right rear suspension pressure sensor signal high
- Fault Code A008: Right rear suspension pressure sensor signal low
- Fault Code A009: Incline sensor signal high
- Fault Code A010: Incline sensor signal low
- Fault Code A011: Payload meter speed sensor signal has failed
- Fault Code A013: Body up switch has failed
- Fault Code A014: Payload meter checksum computation has failed
- Fault Code A016: Payload meter write to flash memory has failed
- Fault Code A017: Payload meter flash memory read has failed
- Fault Code A018: Right rear flat suspension cylinder warning
- Fault Code A019: Left rear flat suspension cylinder warning
- Fault Code A022: Carryback load excessive
- Fault Code A100: An open circuit breaker has been detected on a relay board
- Fault Code A101: High pressure detected across an hydraulic pump filter
- Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level
- Fault Code A107: GE has generated a propel system caution
- Fault Code A108: GE has generated a propel system temperature caution
- Fault Code A109: GE has generated a propel system reduced level signal
Fault Code A111: Low steering pressure warning
Fault Code A115: Low steering precharge pressure detected
Fault Code A117: Low brake accumulator pressure warning
Fault Code A118: Brake pressure is low while in brake lock
Fault Code A123: GE has generated a reduced retarding caution
Fault Code A124: GE has generated a no propel / no retard warning
Fault Code A125: GE has generated a no propel warning
Fault Code A126: Oil level in the hydraulic tank is low
Fault Code A127: IM-furnished +5 volt output for sensors is low
Fault Code A128: IM-furnished +5 volt output for sensors is high
Fault Code A139: Low fuel warning
to advance level 1 for cooling of hydraulic oil
to advance level 2 for cooling of hydraulic oil
Fault Code A152: Starter failure
Fault Code A153: Battery voltage is low with the truck in operation
Fault Code A154: Battery charging voltage is excessive
Fault Code A155: Battery charging voltage is low
low fuel level
Fault Code A166: Left rear hydraulic oil temperature sensor is low
Fault Code A167: Right rear hydraulic oil temperature sensor is low
Fault Code A168: Left front hydraulic oil temperature sensor is low
Fault Code A169: Right front hydraulic oil temperature sensor is low
Fault Code A170: Left rear hydraulic oil temperature sensor is high
Fault Code A171: Right rear hydraulic oil temperature sensor is high
Fault Code A172: Left front hydraulic oil temperature sensor is high
Fault Code A173: Right front hydraulic oil temperature sensor is high
Fault Code A184: J1939 data link is not connected
Fault Code A190: Auto lube control has detected an incomplete lube cycle
Fault Code A194: Left front hydraulic oil temperature is high
Fault Code A195: Right front hydraulic oil temperature is high
Fault Code A196: Left rear hydraulic oil temperature is high
Fault Code A197: Right rear hydraulic oil temperature is high
Fault Code A198: Hoist pressure 1 sensor is high
Fault Code A199: Hoist pressure 2 sensor is high
Fault Code A200: Steering pressure sensor is high
Fault Code A201: Brake pressure sensor is high
Fault Code A202: Hoist pressure 1 sensor is low
Fault Code A203: Hoist pressure 2 sensor is low
Fault Code A204: Steering pressure sensor is low
Fault Code A205: Brake pressure sensor is low
Fault Code A206: Ambient temperature sensor is high
Fault Code A207: Ambient temperature sensor is low36 topics
- Fault Code A212: Bad truck speed signal
- Fault Code A213: Parking brake should have applied but is detected as not having applied
- not having released
- Fault Code A215: Brake auto apply valve circuit is defective
- command valve circuit
- has been attempted
- Fault Code A230: Parking brake has been requested while truck still moving
- Fault Code A231: The body is up with engine running and brakes not on
- Fault Code A235: Steering accumulator is in the process of being bled down
- Fault Code A236: The steering accumulator has not properly bled down after 90 seconds
- Fault Code A237: The CAN/RPC connection to the display is open
- Fault Code A240: The key switch input to the interface module is open
- Fault Code A242: Fuel gauge within the dash display panel is defective
- is defective
- Fault Code A246: Payload meter reports truck overload
- Fault Code A247: Low steering pressure warning
- Fault Code A248: Status module within the dash display panel is defective
- Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted
- Fault Code A250: Battery voltage is low with the truck parked
- shorted to ground
- Fault Code A252: Start enable output circuit is either open or shorted to ground
- Fault Code A253: Steering bleed circuit is not open while running
- Fault Code A256: Red warning lamp in the dash display (driven by IM) is open
- Fault Code A257: Payload CAN/RPC is not connected
- Fault Code A258: Steering accumulator bleed pressure switch circuit is defective
- Fault Code A260: Parking brake failure
- Fault Code A261: Low brake accumulator pressure warning
- Fault Code A262: Steering bleed valve circuit open during shutdown
- Fault Code A264: Parking brake relay circuit is defective
- Fault Code A265: Service brake failure
- Fault Code A266: Selector lever was not in park while attempting to crank engine
- Fault Code A267: Parking brake was not set while attempting to crank engine
- Fault Code A268: Secondary engine shutdown while cranking
- Fault Code A270: Brake lock switch power supply is not on when required
- Fault Code A271: Shifter not in gear
- Fault Code A272: Brake lock switch power supply is not off when required
pressure switch circuit
Fault Code A274: A brake setting fault has been detected
Fault Code A275: A starter has been detected as engaged without a cranking attempt
Fault Code A276: The drive system data link is not connected
Fault Code A277: Parking brake applied while loading
Fault Code A278: Service brake applied while loading
Fault Code A279: Low steering pressure switch is defective
Fault Code A280: Steering accumulator bleed down switch is defective
Fault Code A281: Brake lock degrade switch is defective
without the engine running has reached 7
was not set
shutdown switch was operated
Fault Code A285: The parking brake was not set when the key switch was turned off
Fault Code A286: A fault was detected in the shutdown delay relay circuit
key switch circuit is off
Fault Code A303: Shifter is defective
Fault Code A304: Auto lube grease level fault
Fault Code A305: Auto lube circuit is defective
Fault Code A307: Both GE inverters are disabled
Fault Code A309: No brakes applied when expected
Fault Code A310: Low fuel warning
Fault Code A311: Brake lock switch is on when it should not be
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings
Fault Code A315: DCDC converter 12 volt circuit is low
Fault Code A316: Starter engagement has been attempted with engine running
Fault Code A317: Operation of brake auto apply valve without a detected response
Fault Code A318: Unexpected power loss to interface module
wired input does not
Fault Code A323: Data link reports GE reduced retard level fault but wired input does not
Fault Code A324: Data link reports DC link voltage but wired input does not
Fault Code A325: Data link reports GE no propel/retard fault but wired input does not
Fault Code A326: Data link reports GE no propel fault but wired input does not
Fault Code A327: Data link reports GE at rest but wired input does not
Fault Code A328: Drive system not powered up
Fault Code A329: Data link reports the body is not down but wired input says it is36 topics
- wired input does not
- Fault Code A350: Overload on output 1B
- Fault Code A351: Overload on output 1E
- Fault Code A352: Overload on output 1H
- Fault Code A353: Overload on output 1J
- Fault Code A354: Overload on output 1K
- Fault Code A355: Overload on output 1L
- Fault Code A356: Overload on output 1M
- Fault Code A357: Overload on output 1N
- Fault Code A358: Overload on output 1P
- Fault Code A359: Overload on output 1R
- Fault Code A360: Overload on output 1S
- Fault Code A361: Overload on output 1T
- Fault Code A362: Overload on output 1U
- Fault Code A363: Overload on output 1X
- Fault Code A364: Overload on output 1Y
- Fault Code A365: Overload on output 1Z
- Preliminary checks
- Diagnosis of gauge readings and system performance
- Troubleshooting by manifold gauge set readings
- Pumping unit LED signals
- General information for tires and rims
- Removal and installation of front wheel
- Removal and installation of rear wheel
- Removal and installation of tires
- Removal and installation of front wheel hub and spindle
- Disassembly and assembly of front wheel hub and spindle
- Removal and installation of rear axle
- Removal and installation of anti-sway bar
- Removal and installation of pivot pin
- Pivot eye and bearing service
- Removal and installation of wheel motor
- Removal and installation of rear brake assembly
- Removal and installation of brake valve
- Disassembly and assembly of brake valve
- Removal and installation of dual relay valve
Disassembly and assembly of dual relay valve
Removal and installation of brake manifold
Disassembly and assembly of brake manifold
Removal and installation of brake accumulator
Disassembly and assembly of brake accumulator
Disassembly and assembly of wheel brake
Removal and installation of parking brake
Disassembly and assembly of parking brake
Removal and installation of steering control unit
Disassembly and assembly of steering control unit
Removal and installation of steering column
Removal and installation of steering wheel
Removal and installation of bleed down manifold
Removal and installation of flow amplifier
Disassembly and assembly of flow amplifier
Removal and installation of steering cylinders and tie rod
Disassembly and assembly of steering cylinders
Removal and installation of steering/brake pump
Disassembly and assembly of steering/brake pump
Removal and installation of steering accumulators
Disassembly and assembly of steering accumulators
Removal and installation of front suspension
Minor front suspension repairs (lower bearing and seals)
Major front suspension rebuild
Removal and installation of rear suspension
Disassembly and assembly of rear suspension
Removal and installation of hoist pump
Disassembly and assembly of hoist pump
Removal and installation of hoist valve
Disassembly and assembly of hoist valve
Overcenter valve manifold service
Removal and installation of hoist pilot valve
Disassembly and assembly of hoist pilot valve
Removal and installation of hoist cylinders
Disassembly and assembly of hoist cylinders
Removal and installation of operator cab
Removal and installation of cab door
Disassembly and assembly of cab door
Adjustment of cab door
Removal and installation of side window glass
Removal and installation of windshield and rear window glass
Removal and installation of windshield wiper motor33 topics
- Removal and installation of windshield wiper arm
- Removal and installation of windshield wiper linkage
- Removal and installation of operator seat
- Removal and installation of passenger seat
- Removal and installation of seat belts (standard seats)
- Removal and installation of seat belts (optional seats)
- Removal and installation of dump body
- Removal and installation of body pads
- Removal and installation of diagonal ladder/hood and grille assembly
- Removal and installation of right deck
- Removal and installation of left deck
- Removal and installation of fuel tank
- Removal and installation of fuel gauge sender
- Disassembly and assembly of fuel tank breather
- Removal and installation of hydraulic tank
- Replacement of air conditioning system components
- Diasassembly and assembly of compressor clutch
- Removal and installation of power module
- Removal and installation of alternator
- Removal and installation of engine
- Removal and installation of radiator
- Repairing the radiator
- Steering, hoist and brake cooling hydraulic circuit diagram
- Brake hydraulic circuit diagram
- Electrical circuit diagram - index & symbols
- Electrical circuit diagram - circuit locator sheet
- Electrical circuit diagram - battery box
- Electrical circuit diagram - 24V power distribution & circuit protection
- Electrical circuit diagram - engine control wiring
- Electrical circuit diagram - keyswitch, timed engine shutdown & auto lube system
- Electrical circuit diagram - engine start circuit
- Electrical circuit diagram - brake control wiring
- Electrical circuit diagram - steering & hoist pressure switch wiring
Electrical circuit diagram - operator drive system controls
Electrical circuit diagram - electronic dash panel
Electrical circuit diagram - operator cab light controls & horn
Electrical circuit diagram - operator cab windows & wipers
Electrical circuit diagram - operator cab radio & seat wiring
Electrical circuit diagram - clearance lights, fog lights & headlights
Electrical circuit diagram - hazard light wiring
Electrical circuit diagram - heater & air conditioning controls
Electrical circuit diagram - diagnostic ports - GE
Electrical circuit diagram - diagnostic ports - VHMS & GE
Electrical circuit diagram - modular mining interface
Electrical circuit diagram - interface module inputs & outputs
Electrical circuit diagram - payload meter III circuits
Connectors table and arrangement drawing
Inside this manual
Real pages from this service manual (1,004 pages). Open the sample pages (PDF, 810 KB)
- Specifications, page 43: 00 Index and foreword
- Troubleshooting, page 658: Fault Code A350: Overload on output 1B
- Diagram, page 973: XS5706-0 JUN 08
- Color page, page 46: 00 Index and foreword
- Color page, page 899: 50 Disassembly and assembly
- Foldout diagram, page 970: XS5703-1 APR 09
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 960E -1 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual CEBM021304$109.79
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,004 pages
Quantity one is the manual described above.
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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).