Komatsu 960E-2 Dump Truck Operation & Maintenance Manual
211 pages · Publication CEAM026102
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- Models
- 960E-2
- Serial coverage
- A30027 - A30106
- Manual type
- Operation & Maintenance Manual
- Pages
- 211
- Publication
- CEAM026102
- Condition
- Brand new
What's inside
From the manual's own table of contents: 118 sections, 448 entries. See sample pages (PDF, 588 KB)
FOREWORD
ABOUT THIS MANUAL
WARNINGS1 topic
- California Proposition 65 Warnings
ALERTS
TRUCK MODEL ILLUSTRATION
PARTS IN CRITICAL SYSTEMS
GENERAL INFORMATION2 topics
- Effect Of Special Lubricants
- Suggested Sources For Rust Preventive Grease
STANDARD TIGHTENING TORQUES10 topics
- Class 10.9 Capscrews And Class 10 Nuts
- SAE Grade 5 And Grade 8 Capscrews
- SAE Grade 9 Capscrews
- T-Bolt Clamps
- Split Flange Clamps
- Flared Tube And Hose Fittings
- JIC 37° Swivel Nuts
- Pipe Thread Fittings
- O-Ring Boss Fittings
- O-Ring Face Seal Fittings
CONVERSION MULTIPLIERS3 topics
- Metric To English
- English To Metric
- Temperature Conversions
GENERAL SAFETY14 topics
- Safety Rules
- Truck Safety Features
- Clothing And Personal Items
- Unauthorized Modification
- Leaving The Operator’s Seat
- Mounting And Dismounting
- Fire Extinguishers And First Aid Kits
- Precautions For High Temperature Fluids
- Asbestos Dust Hazard Prevention
- Fire Prevention
- ROPS Precautions
- Preventing Injury From Work Equipment
- Precautions For Optional Attachments
- Precautions When Starting The Machine
PRECAUTIONS FOR TRUCK OPERATION8 topics
- Safety Is Thinking Ahead
- Safety At The Worksite
- Preparing For Operation
- Ventilation For Enclosed Areas
- Mirrors, Windows, And Lights
- Before Starting The Engine
- Seat Belts And Tethers
- Emergency Egress Ladders
OPERATING THE MACHINE14 topics
- General Information
- Starting The Engine
- Traveling In The Machine
- Traveling In Reverse
- Traveling On Slopes
- Traveling On Snow
- Traveling Near High Voltage Cables
- Traveling On Loose Ground
- Ensuring Good Visibility
- Avoid Damage To The Dump Body
- Safe Parking Of The Machine
- Loading The Machine
- Dumping The Machine
- Towing The Machine
EXTERIOR LIGHTING11 topics
- Fog Lights
- Headlights
- Ladder Lights and Deck Mounted Flood Lights
- Mirror Mounted Backup Lights
- Brake Light
- Retard Light
- Clearance/Turn Signal Lights
- Backup Lights
- Retard Lights
- Brake Lights
- Backup Alarm
PRECAUTIONS FOR MAINTENANCE
BEFORE PERFORMING MAINTENANCE1 topic
- Securing The Dump Body
DURING MAINTENANCE20 topics
- Warning Tag
- Proper Tools
- Attachments
- Working Under The Machine
- Keeping The Machine Clean
- Adding Fuel Or Oil To The Machine
- Radiator Coolant Level
- Use Of Lighting
- Handling High Pressure Hoses
- Precautions With High Pressure Oil
- Maintenance Near High Temperatures And High Pressures
- Rotating Fan And Belts
- Waste Materials
- Use Of Tie-Off Anchor During Maintenance
- Handling Tires
- Tire Maintenance
- Storing Tires After Removal
- Battery Hazard Prevention
- Jump Starting With Jumper Cables
- Jump Starting With Receptacles
WHEN REPAIRS ARE NECESSARY1 topic
- Observe The Following Precautions
SPECIAL PRECAUTIONS4 topics
- Preliminary Procedures Before Welding Or Performing Maintenance
- Engine Shutdown Procedure Before Welding or Performing Maintenance
- Before Welding On The Machine, Obey The Following Guidelines
- Discharging Control Cabinet Capacitors
PIN PLATE
GRADE SPEED CHART
MACHINE SAFETY
KEY SWITCH
OIL FILL AND CHECK
HIGH PRESSURES
Show all 118 sections
BATTERY AND ENGINE SHUTDOWN
HIGH VOLTAGE
WELDING
LIFTING POINTS
EMERGENCY DUMPING
ROPS/FOPS
TOWING
LUBRICATION CHART
PREPARING FOR OPERATION2 topics
- Safety Is Thinking Ahead
- Walk Around Inspection
RETRACTABLE LADDER SYSTEM (If Equipped)6 topics
- General Information
- Ladder System Description
- Ladder System Operation
- In-Cab Control Panel
- Ground Level Control Box
- Emergency Down Valve
BRAKE TEST5 topics
- OPERATION
- Service Brake Test
- Parking Brake Test
- Retard System Test
- Brake Test Exit Criteria
TRUCK OPERATION18 topics
- ENGINE START-UP SAFETY
- After Engine Has Started
- MACHINE OPERATION SAFETY PRECAUTIONS
- Machine Operation On The Haul Road
- Starting On A Grade With A Loaded Truck
- Retarding On A Grade
- Passing
- Loading
- Overload Speed Limit Function
- Dumping
- Lowering The Dump Body (When Dumping On Flat Ground)
- Lowering The Dump Body (When Dumping Over A Berm Or Into A Crusher)
- SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
- EMERGENCY STEERING SYSTEM
- Operation
- Pre-Operation Testing
- Additional Guidelines
- FUEL DEPLETION
SAFE PARKING PROCEDURES
NORMAL ENGINE SHUTDOWN PROCEDURE
DISABLED TRUCK CONNECTORS
HOIST SYSTEM2 topics
- Hookup
- Dumping Procedure
SPECIAL WIRING HARNESS
TOWING PROCEDURE
PAYLOAD METER III SYSTEM2 topics
- Data Summary
- Data Gathering
COMPONENT DESCRIPTION6 topics
- Operator Display
- Operator Switches
- Brake Lock Switch
- Payload Meter Module
- Communications Ports
- Load Lights
OPERATOR’S DISPLAY AND SWITCH5 topics
- Reading the Load Display
- Setting the Operator ID
- Load and Ton Counter
- Viewing Live Sensor Data
- Other Display Messages
HAUL CYCLE WARNING FLAGS2 topics
- Haul Cycle Data
- Haul Cycle Warning Flags
PC SOFTWARE OVERVIEW
SYSTEM CONFIGURATION13 topics
- Connecting to the Payload Meter
- Displayed Payload Units
- Connection Menu
- Configure the Payload Meter
- Setting the Date and Time
- Setting the Truck Type and Serial Number
- Setting the Gauge Display Units
- Setting the Carryback Alarm Threshold
- Setting the Truck Number
- Setting the Komatsu Distributor
- Setting the Komatsu Customer
- Clean Truck Tare Calibration
- Inclinometer Calibration
DOWNLOADING PAYLOAD DATA
UPLOADING DATA
DATA ANALYSIS10 topics
- Creating a Query
- Payload Detail Screen
- Creating Reports
- Creating Graphs
- Exporting Data
- Importing Data
- Deleting Haul Cycle Records
- Viewing Alarms
- Deleting Alarm Records
- Patent Acknowledgment
AUTOMATIC LUBRICATION SYSTEM19 topics
- GENERAL INFORMATION
- COMPONENT DESCRIPTION
- Filter
- Hydraulic Motor and Pump
- Grease Reservoir
- Pressure Reducing Valve
- Flow Control Valve
- Solenoid Valve
- Vent Valve
- Interface Module
- Injectors
- Grease Pressure Failure Switch
- Relief Valve (unloader valve)
- SYSTEM OPERATION
- Filling The Reservoir
- Priming The Automatic Lubrication System
- PREVENTIVE MAINTENANCE PROCEDURES
- Daily Lubrication System Inspection
- Hour Inspection
SYSTEM CHECKOUT2 topics
- General Checks
- Lubrication Cycle Operation
RESERVE ENGINE OIL SYSTEM3 topics
- Operation
- LED Monitor Light
- Changing Oil
CAB INTERIOR
STEERING WHEEL AND CONTROLS6 topics
- Horn Button
- Tilt / Telescope Lever
- Multi-Function Turn Signal Switch
- Turn Signal Operation
- High Beam Headlight Operation
- Windshield Wiper Operation
PEDALS AND RETARDER LEVER4 topics
- Dynamic Retarding
- Retarder Lever
- Brake/Retarder Pedal
- Accelerator Pedal
OVERHEAD PANEL AND DISPLAYS4 topics
- Radio Speakers
- Warning Alarm Buzzer
- Cab Radio
- Air Cleaner Vacuum Gauges
CENTER CONSOLE13 topics
- Directional Control Lever
- Override/Fault Reset Switch
- Engine Stop Switch
- Window Control Switches
- Hoist Control Lever
- Raising The Dump Body
- Lowering The Dump Body
- Retard Speed Control (RSC) Adjust Dial
- Retard Speed Control (RSC) Switch
- Data Store Button
- 12V Auxiliary Power Outlets
- Fire Suppression Control Outlet
- Communication Radio Outlet
DIAGNOSTIC PORTS6 topics
- KOMTRAX Plus
- Interface Module (IM)
- Truck Control Interface (TCI)
- Propulsion System Controller (PSC)
- Engine (CENSE)
- Engine (QUANTUM)
OPERATOR SEAT (Standard)2 topics
- Seat Belts And Tethers
- Adjustment
PASSENGER SEAT (Standard)
OPERATOR SEAT (Optional)
PASSENGER SEAT (Optional)
HEATER / AIR CONDITIONER CONTROLS4 topics
- Fan Speed Control Knob
- Temperature Control Knob
- Air Flow Directional Knob
- Heater/Air Conditioner Vents
INSTRUMENT PANEL21 topics
- CONTROL SYMBOLS
- Key Switch
- Engine Warming Switch
- AC Drive System Rest Switch
- Wheel Brake Lock Control Switch
- Hazard Warning Lights
- Fuel Level Gauge
- Hydraulic Oil Temperature Gauge
- Speedometer/Digital Display
- Coolant Temperature Gauge
- Drive System Temperature Gauge
- Status Indicator Light Panel
- Headlight/Panel Illumination Light Switch (3-Way)
- Ladder Light Switch
- Backup Light Switch
- Fog Light Switch
- Mode Switches
- Panel Illumination Light Dimmer Switch
- Right/Left Turn Signal Indicators
- Digital Display Contrast Buttons
- Warning Light
STATUS INDICATOR LIGHT PANEL17 topics
- STATUS INDICATOR LIGHT SYMBOLS
- Body Up
- Parking Brake
- Propel System Not Ready
- No Propel
- Engine Warm Up
- Engine Shutdown Delay
- Retarding Grid Drier
- Wheel Brake Lock
- Traction Control
- Repair Monitor
- Snapshot In Progress
- Pantograph Energized
- Pantograph Up
- Service Brake
- Dynamic Retarding
- No DC Link Voltage
OVERHEAD DASH PANEL2 topics
- Brake Test Switch (If Equipped)
- Brake Test Light (If Equipped)
DIGITAL DISPLAY OPERATION3 topics
- Toggling Through Main Level Screens
- Toggling Through Warning Screens
- Entering Payload Meter Data
KOMTRAX Plus19 topics
- KOMTRAX Plus OPERATION
- Basic Precautions
- Interface Module
- DOWNLOADING KOMTRAX Plus DATA
- General Information
- KOMTRAX Plus Downloading Procedure
- Location Of Downloaded Files
- UPLOADING KOMTRAX Plus DATA
- ORBCOMM
- KOMATSU WIRELESS BRIDGE (Optional)
- General Information
- Communication Setup
- Switching To The KWB_SETUP Network
- Setting The Computer Subnet Mask And IP Address
- Setting Up The KWB
- Adding Encryption
- Final Computer Settings
- Downloading Data
- Resetting The KWB
FUSES AND CIRCUIT BREAKERS4 topics
- FUSE BLOCK #1
- FUSE BLOCK #2
- FUSE BLOCK #3
- FUSE BLOCK #4
FUSE HOLDERS
CIRCUIT BREAKERS
HYDRAULIC SYSTEM SERVICE3 topics
- Hydraulic Tank
- Hydraulic Filters
- Hydraulic Pump Drive Shaft
WHEEL MOTOR SERVICE
COOLANT LEVEL SERVICE3 topics
- Radiator Filling Procedure
- Coolant Specifications
- Unacceptable Practices
RESERVE ENGINE OIL SERVICE2 topics
- Reserve Oil Tank Filling Procedure (Remote Fill)
- Inline Screen
CAB AIR FILTER SERVICE
FUEL SYSTEM SERVICE2 topics
- Fuel Tank Cleaning
- Fuel Filter Service
INTAKE AIR CLEANER SERVICE
QUICK FILL SERVICE CENTER
TIE ROD INSPECTION AND TORQUE PROCEDURE
EVERY 10 HOUR (DAILY) MAINTENANCE
INITIAL 50 HOUR LUBRICATION AND MAINTENANCE INSPECTION
INITIAL 100 HOUR LUBRICATION AND MAINTENANCE INSPECTION
EVERY 250 HOUR LUBRICATION AND MAINTENANCE
EVERY 500 HOUR LUBRICATION AND MAINTENANCE
EVERY 1000 HOURS LUBRICATION AND MAINTENANCE
EVERY 3000 HOUR LUBRICATION AND MAINTENANCE
EVERY 5000 HOUR MAINTENANCE
EVERY 18,000 HOUR MAINTENANCE
MAJOR COMPONENT DESCRIPTION
Truck and Engine
Traction Alternator
Main Control Cabinet
AC Induction Traction Motorized Wheels
Suspension
Operator's Cab
Power Steering
Dynamic Retarding Grid
Brake System
SPECIFICATIONS
Engine
AC Electric Drive System
Dynamic Retarding
Battery Electric System
Service Capacities
Hydraulic Systems
Service Brakes
Steering
Standard Dump Body Capacities and Dimensions3 topics
- Tires
- Weight Distribution
- Overall Truck Dimensions
RADIO OPERATION10 topics
- General Radio Receiver Functions
- Turning On The Power
- One-Hour Timer
- Finding A Station
- Setting The Presets
- Adjusting The Receiver Audio Settings
- Display
- Adjusting The Receiver Menu Settings
- Front Auxiliary Mode
- Rear Auxiliary Mode
CLOCK5 topics
- Clock/Alarm Button
- Setting The Clock
- Setting The Alarm
- Turning The Alarm Off
- Activating Snooze
CD PLAYER4 topics
- Playing A Compact Disc
- Playing An MP3 DISC
- CD Mode Displays
- Button Functions
MP3 PLAYER3 topics
- Playing MP3 Files
- MP3 Mode Displays
- Button Functions
iPod ®3 topics
- Playing An iPod ®
- iPod ® Mode Displays
- Button Functions
WEATHERBAND (USA Only)
TROUBLESHOOTING3 topics
- Tips About the Audio System
- Understanding Radio Reception
- Care Of The Compact Discs
Inside this manual
Real pages from this operation & maintenance manual (211 pages). Open the sample pages (PDF, 586 KB)
- Specifications, page 23: GENERAL INFORMATION
- Controls and operation, page 134: OPERATOR CAB AND CONTROLS
- Maintenance, page 188: LUBRICATION AND SERVICE
- Color page, page 173: GENERAL INFORMATION
- Color page, page 123: AUTOMATIC LUBRICATION SYSTEM
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 960E-2 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Operation & Maintenance Manual CEAM026102$69.91
Added to your cart. View cart
This is an operator's manual
Here's how it compares to the other manual types.
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.
This manual
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.
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, 211 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
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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).