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Komatsu 960E -2 Dump Truck Service Manual

1,070 pages · Publication CEBM028700

$109.73
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Models
960E -2
Serial coverage
A30074 & up
Manual type
Service Manual
Pages
1,070
Publication
CEBM028700
Condition
Brand new
Komatsu 960E -2 Dump Truck Service Manual, publication CEBM028700

What's inside

From the manual's own table of contents: 192 sections, 366 entries. See sample pages (PDF, 1199 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
Pre-shift brake check
Emergency steering system
Precautions during truck operation
Operating on a haul road
Show all 192 sections
Starting on a grade with a loaded truck
Sudden loss of engine power or loss of drive system function
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 table35 topics
  • Fuel, coolant and lubricants
  • 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
  • Engine starting 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
  • Alternator 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
Toe-in adjustment
Brake cooling and hoist system checkout procedures
Brake cooling and hoist system checkout data sheet
Hoist cylinder leakage test
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 procedure36 topics
  • KOMTRAX Plus initialization check list
  • KOMTRAX Plus initialization form
  • Precautions for replacing KOMTRAX Plus controller
  • KOMTRAX Plus controller checkout procedure
  • Payload meter initial setting procedure
  • Interface module software
  • Interface module checkout procedures
  • Checks prior to self load engine test (loadbox)
  • Engine running tests
  • Diagnostic information display (DID) panel
  • Viewing event and statistical data
  • Logic screens
  • Datalogger function
  • Uploading data
  • 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 high37 topics
  • 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 low
  • Fault Code A212: Bad truck speed signal
  • Fault Code A213: Parking brake should have applied but is detected as not having applied
  • released
  • Fault Code A215: Brake auto apply valve circuit is defective
  • command valve circuit
  • 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
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
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 module32 topics
  • 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 is
  • 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 service34 topics
  • 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 motor
  • Removal and installation of windshield wiper arm
  • Removal and installation of windshield wiper linkage
  • Removal and installation of operator seat
  • Replacing the seat compressor
  • Removal and installation of seat belts (standard seats)
  • Removal and installation of seat belts (optional seats)
  • Removal and installation of electronic accelerator and retard pedals
  • 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
  • Removal and installation of power module
  • Removal and installation of alternator
  • Removal and installation of engine
  • Removal and installation of radiator
  • Repairing the radiator
  • Connectors table and arrangement drawing

Inside this manual

Real pages from this service manual (1,070 pages). Open the sample pages (PDF, 1197 KB)

Sample pages from the Komatsu 960E -2 Dump Truck Service Manual: Specifications, Diagram, Troubleshooting, Color page, Color page, Foldout diagram (color)
  • Specifications, page 45: 00 Index and foreword
  • Diagram, page 493: Fault Code A010: Incline sensor signal low
  • Troubleshooting, page 749: Fault Code A355: Overload on output 1L
  • Color page, page 44: 00 Index and foreword
  • Color page, page 355: 30 Testing and adjusting
  • Foldout diagram (color), page 1,061: ELECTRICAL SCHEMATIC

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: Service Manual CEBM028700$109.73
Other manuals for the 960E -2

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Details

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, 1,070 pages

Quantity one is the manual described above.

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Other editions and similar models

Komatsu 960E -1Service Manual · CEBM021304 · $109.79Komatsu 960E- 1Service Manual · CEBM023802 · $109.55

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