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Komatsu 960E-2K Dump Truck Service Manual

1,745 pages · Publication CEBM026301

$179.61
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Models
960E-2K
Serial coverage
A50011 & up
Manual type
Service Manual
Pages
1,745
Publication
CEBM026301
Condition
Brand new
Komatsu 960E-2K Dump Truck Service Manual, publication CEBM026301

What's inside

From the manual's own table of contents: 364 sections, 700 entries. See sample pages (PDF, 1026 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
While performing maintenance
Tires
Precautions for performing repairs
Precautions for welding on the truck
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
Loading the dump body
Show all 364 sections
Dumping a load
Using the speed control feature
Safe parking procedure
Normal engine shutdown procedure
Sudden loss of engine power
Fuel depletion
Towing
Disabled truck operation
Disabled truck dumping procedure
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants36 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 position switches (With proximity switch and magnet)
  • Sensors
  • Interface module inputs and outputs
  • SR rectifier module
  • ST module (auxiliary voltage inverter)
  • SD phase modules
  • SR/ST/SD module removal
  • Inverter cabinet layout
  • Inverter cabinet water flow
  • Field regulator
  • Field regulator (discharge resistor)
  • Gate unit power supply
  • Gate unit power supply (diode)
  • Gate unit power supply (tuning resistor)
  • Control power filter
Filter for TCU
Terminal block bus bar
Fuses (analog sensor voltage)
Fuses (fuse holder for field regulator)
Fuses (control power and trolley box contactor)
Diode modules
Support capacitors
3-Phase capacitor bank (for ST module output voltage)
Air-cooled inductors (for ST module)
3-Phase transformer (for ST module)
Diagnostics box
Diagnostic and system monitoring panel
Current transducers
Current transducers (for ST module output)
Voltage transducers
Voltage transducers (for ST module output)
Voltage transducers (SiBAS® 24V DC bus monitoring)
Analog inclinometer
DC link capacitors
Ground tie capacitor
Low-inductance bus bar assembly
Free-wheeling diode for low-inductance bus bars
Contactor (grid box and main blower motor)
Contactor (control power)
Contactor (DC contactors)
Contactor (crowbar bypass)
Temperature probes (PT100 style)
Coolant inlet temperature sensor
Coolant outlet temperature sensor (external pad style)
IGBT module heat sink temperature sensor
Coolant outlet temperature sensor (internal style)
Circuit breakers
Inner circulating blower fan
Coolant pump
Motor for coolant pump
Coolant pressure sensor
Inner radiator
Ground voltage monitoring resistors
Protection thyristor assembly (crowbar)
Discharge reactor
Main blower motor
Grid box
Grid box blower motor
Grid box blower motor grease fittings
Main alternator40 topics
  • Main alternator circuit diagram
  • IGBT – inverter/chopper phase module
  • Troubleshooting information
  • Main input rectifier module
  • Internal circuit diagram
  • Upper ground tie resistor
  • Lower ground tie resistor
  • Troubleshooting
  • Speed sensor, alternator
  • Speed sensors, wheel motors
  • Traction motor
  • Grid box
  • Principles of refrigeration
  • Air conditioning system components
  • Air conditioning system electrical circuit
  • Operation
  • Remote tank fill system
  • SIBAS® 32 Traction Control Unit (TCU)
  • Overview of the SIBAS® 32 systems
  • Removing and installing the SIBAS® 32 cards
  • SIBAS® 32 card device names
  • Structure of SIBAS® 32 card part number
  • SIBAS® 32 card interchangeability
  • SIBAS® 32 card interactions
  • SIBAS® 32 card detailed information
  • Blower subassembly
  • CPU card
  • DSP card
  • I/O card
  • TRACO card (optional)
  • Input voltage/frequency card
  • I/O analog card
  • Output pulse amplifier card
  • Input temperature sensor card
  • UWS card
  • Digital input card
  • Power start-up unit card
  • Binary output contactor drive card
  • 24V / 24V power supply
  • 24V / 15V power supply
24V / 5V power supply
Structure
Maintenance standard
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
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 system43 topics
  • Charging the air conditioning system
  • Interface module software
  • Interface module checkout procedures
  • Abbreviations
  • Precautions
  • Qualified person
  • Customer monitor for SIBAS® 32 control units
  • Installing and calling the customer monitor
  • Environment variables
  • Communication with the SIBAS® 32 control unit
  • Calling up the customer monitor
  • Monitor prompt
  • Notes on operation of the customer monitor
  • Command buffer
  • Structure of the monitor windows
  • Window menu
  • Set Menu
  • Applic. Menu
  • Hardw. Menu
  • Hardware-Oriented Access via the Customer Monitor
  • Graphic Menu
  • Traco Menu
  • HW-Traco
  • SW-Traco
  • DAC_Traco
  • Events Menu
  • STatistics
  • History
  • LEL:Last EvL
  • LES:Last EvS
  • DLL:DC,LastL
  • DLS:DC,LastS
  • DAL:DC,All L
  • DAS:DC,All S
  • ML:Memory L
  • MS:Memory S
  • CN:Clear Norm
  • CA:Clear All
  • Test-Code
  • DS:Diag-Strc
  • User Menu
  • DAC_IO
  • Operat.Data
Energy Usage data
Mileage indicator
Operating cycles
Service Brake on data
Temperature data
Motor torque data
Engine speed data
Gear test
Acc test
Engine_Test
X_Test_Inx
STate intern
ST inverter status
Vehicle status
Pedal calib
Language
OFFline-test
Variables
IV:Vehic-ID
Commands
Settings
Parameters
Temp_prot
Appendix
Background commands
Monitor commands for the central processing unit
Monitor commands for the signal processing unit
Monitor Program – Loading software into the SIBAS®
Loading software into the DSP procedure
Loading a DSP program Inverter A
Loading a DSP program Inverter B
Loading software into the CPU procedure
Loading ZR software Prog. jumpers Reset
Setting the system up After loading a new pgm
Loading the proper pgm file
Fuse and circuit breaker locations
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 high42 topics
  • 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 A111: Low steering pressure warning for storage by KOMTRAX Plus
  • Fault Code A115: Low steering precharge pressure detected
  • Fault Code A118: Brake pressure is low while in brake lock
  • 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 for storage by KOMTRAX Plus and for use by A310
  • advance level 1 for cooling of hydraulic oil
  • 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
  • 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 low
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 while traveling or with selector in forward or neutral
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 keyswitch input to the Interface Module is open
Fault Code A242: Fuel gauge within the dash display panel is defective
defective
Fault Code A246: Payload meter reports truck overload
Fault Code A247: Low steering pressure warning for display to operator
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
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 defective40 topics
  • Fault Code A260: Parking brake failure
  • Fault Code A261: Low brake accumulator pressure warning for display to operator
  • 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 switch 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 A275: A starter has been detected as engaged without a cranking attempt
  • 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 bleeddown switch is defective
  • Fault Code A281: Brake lock degrade switch is defective
  • the engine running has been reached
  • was not set
  • operated
  • Fault Code A285: The parking brake was not set when the keyswitch was turned off
  • Fault Code A286: A fault was detected in the shutdown delay relay circuit
  • keyswitch 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 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
  • Fault Code A328: Drive system not powered up
  • 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
Summary
EVENT CLASSIFICATION
L3C SYS: Time slice overflow CPU T1
L3C SYS: Time slice overflow CPU T2
L3C SYS: Time slice overflow CPU T3
L3C SYS: Time slice overflow CPU T4
L3C SYS: Time slice overflow CPU T5
L3C SYS: Time slice overflow CPU T6
L3C SYS: Time slice overflow CPU T7
L3C SYS: Time slice overflow CPU T8
L2A SYS: Pulse inhibit/asa inhibit PSU–ONLINE
L3D SYS: Pulse inhibit/asa inhibit PSU–Start-up
L1A SYS: SIBAS® blower fault
L1B SYS: Undervoltage in SIBAS® battery for BRAM
L3C SYS: SIBAS® power supply failure 24V for pulse amplifier
L3C SYS: SIBAS® power supply failure +5V
L3C SYS: SIBAS® power supply failure +15V
L3C SYS: SIBAS® power supply failure –15V
L3C SYS: SIBAS® power supply failure +24V
L3C SYS: SIBAS® power supply failure –24V
L3C SYS: FPGA clock missing for PSU
L3C SYS: Pulse inhibit by reset in PSU from CPU
L3C SYS: General protection error (G10)
L3C SYS: Total block
L1B SYS: Permanent inhibit fault active
L1B SYS: Regular inhibit fault active
L1A SYS: GW Test stopped by A/D converter faulty
L3C DSP A: Initialization fault detected by DSP
L3C DSP A: SW-WatchdoG
L3C DSP A: Initialization fault detected by CPU
L1B DSP A: SW-Traco triggered
L1B DSP A: SW-Traco full45 topics
  • L3C DSP A: Time slice overflow T1
  • L3C DSP A: Time slice overflow T2
  • L3C DSP A: Time slice overflow T3
  • L3C DSP A: Time slice overflow T4
  • L1A DSP A: Communication HSCX data from DSP B missing
  • L1A DSP A: Communication HSCX data from DSP T missing
  • L3C DSP A: Current offset during pulse block
  • L3C DSP A: Current offset during no pulse block
  • L3A DSP A: Overcurrent fault
  • L3C DSP A: Current transducer defective phase U
  • L3C DSP A: Current transducer defective phase W
  • L1A DSP A: Modulation software fault
  • L3A DSP A: Active current controller at limit
  • L3A DSP A: Active current reference at limit
  • L1A DSP A: Braking chopper controller at limit
  • L3C DSP A: Phase unbalance too large
  • L3A DSP A: Pulse block by DSP software
  • L3C DSP A: U/F Card defective
  • L3C DSP A: Difference in current of phase U over limit
  • L3C DSP A: Difference in current of phase W over limit
  • L3C DSP B: Initialization fault detected by DSP
  • L3C DSP B: SW-Watchdog
  • L3C DSP B: Initialization fault detected by CPU
  • L1B DSP B: SW-Traco triggered
  • L1B DSP B: SW-Traco full
  • L3C DSP B: Time slice overflow T1
  • L3C DSP B: Time slice overflow T2
  • L3C DSP B: Time slice overflow T3
  • L3C DSP B: Time slice overflow T4
  • L1A DSP B: Communication HSCX data from DSP A missing
  • L1A DSP B: Communication HSCX data from DSP T missing
  • L3C DSP B: Current offset during pulse block
  • L3C DSP B: Current offset during no pulse block
  • L3A DSP B: Overcurrent fault
  • L3C DSP B: Current transducer defective phase V
  • L3C DSP B: Current transducer defective phase W
  • L1A DSP B: Modulation software fault
  • L3A DSP B: Active current controller at limit
  • L3A DSP B: Active current reference at limit
  • L1A DSP B: Braking chopper controller at limit
  • L3C DSP B: Phase unbalance too large
  • L3A DSP B: Pulse block by DSP software
  • L3C DSP B: U/F Card defective
  • L3C DSP B: Difference in current of phase V over limit
  • L3C DSP B: Difference in current of phase W over limit
L3C DSP T: Initialization fault detected by DSP
L3C DSP T: SW-Watchdog
L3C DSP T: Initialization fault detected by CPU
L1B DSP T: SW-Traco triggered
L1B DSP T: SW-Traco full
L3C DSP T: Time slice overflow T1
L3C DSP T: Time slice overflow T2
L3C DSP T: Time slice overflow T3
L3C DSP T: Time slice overflow T4
L1A DSP T: Communication HSCX data from DSP A missing
L1A DSP T: Communication HSCX data from DSP B missing
L3C DSP T: Current offset during pulse block
L3C DSP T: Current offset during no pulse block
L3A DSP T: Overcurrent fault
L3C DSP T: Current transducer defective phase U
L3C DSP T: Current transducer defective phase V
L3C DSP T: Current transducer defective phase W
L3C DSP T: Sum of output current not equal zero
L1A DSP T: Modulation software fault
L1A DSP T: Voltage controller at limit
L3C DSP T: Phase unbalance too large
L3A DSP T: Pulse block by DSP software
L3C DSP T: U/F Card defective
L3C DSP T: Crowbar fired by DSP T
L1C DSP T: Voltage transducer U34 not ok
L3C IO: Supervision bus clock
L3C IO: Supervision I/O clock
L3C IO: Incorrect FPGA version identifier
L3C IO: Incorrect FPGA application version identifier
L3C IO: Incorrect module version identifier
L3C/L1A IO: AD Converter faulty
L3C IO: GW Comparator faulty during start-up test
L3C IO: Test voltage not equal zero
L1A IO: SIBAS® Temperature out of range
L3C IO: Incorrect EBIN card identifier
L3C IO: Front plug monitoring
L3C IO: CPU Watchdog triggered
L3C IO: DSP A Watchdog triggereD
L3C IO: DSP B Watchdog triggered
L3C IO: CPU Reset triggered
L1B IO: CPU Traco triggered
L3A IO: Pulse block from I/O
L3A IO: DC link voltage A level 1 exceeded
L3A IO: DC link voltage B level 1 exceeded
L3C IO: Trolley line overvoltage45 topics
  • L3B IO: Trolley line overcurrent
  • L2B IO: Trolley line current transducer faulty
  • L2B IO: Trolley line voltage transducer faulty
  • L3A IO: Throttle pedal out of range
  • L3A IO: Retard pedal out of range
  • L1A IO: Cruise speed control module out of range
  • L3C UWSA1: Supervision bus clock
  • L3C UWSA1: Supervision module clock
  • L3C UWSA1: Incorrect FPGA version identifier
  • L3C UWSA1: Incorrect FPGA project identifier
  • L3C UWSA1: GW Comparator faulty during start-up test
  • L1A UWSA1: ADC Faulty
  • L3C UWSA1: Configuration failure
  • L1A UWSA1: Hardware failure counter / processor
  • L3A UWSA1: Peak current protection active
  • L3D UWSA1: Peak current protection pulse start
  • L3D UWSA1: Number of peak current protection >limit
  • L3D UWSA1: Supervision switching frequency
  • L1A UWSA1: Overvoltage level 1 exceeded
  • L3D UWSA1: Limit 5 overcurrent phase U
  • L3D UWSA1: Limit 5 overcurrent phase V
  • L3D UWSA1: Limit 5 overcurrent phase W
  • L3D UWSA1: Limit 5 overvoltage DC bus
  • L3D UWSA1: Checkback INVA1 L1U faulty
  • L3D UWSA1: Checkback INVA1 L1L faulty
  • L3D UWSA1: Checkback INVA1 L2U faulty
  • L3D UWSA1: Checkback INVA1 L2L faulty
  • L3D UWSA1: Checkback INVA1 L3U faulty
  • L3D UWSA1: Checkback INVA1 L3L faulty
  • L3D UWSA1: Checkback chopper A faulty
  • L3C UWSB1: Supervision bus clock
  • L3C UWSB1: Supervision module clock
  • L3C UWSB1: Incorrect FPGA version identifier
  • L3C UWSB1: Incorrect FPGA project identifier
  • L3C UWSB1: GW Comparator faulty during start-up test
  • L1A UWSB1: ADC Faulty
  • L3C UWSB1: Configuration failure
  • L1A UWSB1: Hardware failure counter / processor
  • L3A UWSB1: Peak current protection active
  • L3D UWSB1: Peak current protection pulse start
  • L3D UWSB1: Number of peak current protection >limit
  • L3D UWSB1: Supervision switching frequency
  • L1A UWSB1: Overvoltage level 1 exceeded
  • L3D UWSB1: Limit 5 overcurrent phase V
  • L3D UWSB1: Limit 5 overcurrent phase U
L3D UWSB1: Limit 5 overcurrent phase W
L3D UWSB1: Limit 5 overvoltage DC bus
L3D UWSB1: Checkback INVB1 L1U Faulty
L3D UWSB1: Checkback INVB1 L1L Faulty
L3D UWSB1: Checkback INVB1 L2U Faulty
L3D UWSB1: Checkback INVB1 L2L Faulty
L3D UWSB1: Checkback INVB1 L3U Faulty
L3D UWSB1: Checkback INVB1 L3L Faulty
L3D UWSB1: Checkback chopper B Faulty
L3C UWSA2: Supervision bus clock
L3C UWSA2: Supervision module clock
L3C UWSA2: Incorrect FPGA version identifier
L3C UWSA2: Incorrect FPGA project identifier
L3C UWSA2: GW Comparator faulty during start-up test
L1A UWSA2: ADC Faulty
L3C UWSA2: Configuration failure
L1A UWSA2: Hardware failure counter / processor
L3A UWSA2: Peak current protection active
L3D UWSA2: Peak current protection pulse start
L3D UWSA2: Number of peak current protection >limit
L3D UWSA2: Supervision switching frequency
L1A UWSA2: Overvoltage level 1 exceeded
L3D UWSA2: Limit 5 overcurrent phase U1
L3D UWSA2: Limit 5 overcurrent phase V1
L3D UWSA2: Limit 5 overcurrent phase W1
L3D UWSA2: Limit 5 overvoltage DC bus
L3D UWSA2: Checkback INVA2 L1U faulty
L3D UWSA2: Checkback INVA2 L1L faulty
L3D UWSA2: Checkback INVA2 L2U faulty
L3D UWSA2: Checkback INVA2 L2L faulty
L3D UWSA2: Checkback INVA2 L3U faulty
L3D UWSA2: Checkback INVA2 L3L faulty
L3D UWSA2: Checkback chopper C faulty
L3C UWSB2: Supervision bus clock
L3C UWSB2: Supervision module clock
L3C UWSB2: Incorrect FPGA version identifier
L3C UWSB2: Incorrect FPGA project identifier
L3C UWSB2: GW Comparator faulty during start-up test
L1A UWSB2: ADC Faulty
L3C UWSB2: Configuration failure
L1A UWSB2: Hardware failure counter / processor
L3A UWSB2: Peak current protection active
L3D UWSB2: Peak current protection pulse start
L3D UWSB2: Number of peak current protection >limit
L3D UWSB2: Supervision switching frequency
L1A UWSB2: Overvoltage level 1 exceeded45 topics
  • L3D UWSB2: Limit 5 overcurrent phase V1
  • L3D UWSB2: Limit 5 overcurrent phase U1
  • L3D UWSB2: Limit 5 overcurrent phase W1
  • L3D UWSB2: Limit 5 overvoltage DC bus
  • L3D UWSB2: Checkback INVB2 L1U Faulty
  • L3D UWSB2: Checkback INVB2 L1L Faulty
  • L3D UWSB2: Checkback INVB2 L2U Faulty
  • L3D UWSB2: Checkback INVB2 L2L Faulty
  • L3D UWSB2: Checkback INVB2 L3U Faulty
  • L3D UWSB2: Checkback INVB2 L3L Faulty
  • L3D UWSB2: Checkback chopper D Faulty
  • L3C UWSST: Supervision bus clock
  • L3C UWSST: Supervision module clock
  • L3C UWSST: Incorrect FPGA version identifier
  • L3C UWSST: Incorrect FPGA project identifieR
  • L3C UWSST: GW Comparator faulty during start-up test
  • L1A UWSST: ADC Faulty
  • L3C UWSST: Configuration failure
  • L1A UWSST: Hardware failure counter / processor
  • L3A UWSST: Peak current protection active
  • L3D UWSST: Number of peak current protection >limit
  • L3D UWSST: Supervision switching frequency
  • L3C UWSST: Crowbar is fired without command
  • L3D UWSST: Limit 5 overcurrent phase U
  • L3D UWSST: Limit 5 overcurrent phase V
  • L3D UWSST: Limit 5 overcurrent phase W
  • L3D UWSST: Limit 5 overvoltage DC bus
  • L3D UWSST: Checkback INVST L1U Faulty
  • L3D UWSST: Checkback INVST L1L Faulty
  • L3D UWSST: Checkback INVST L2U Faulty
  • L3D UWSST: Checkback INVST L2L Faulty
  • L3D UWSST: Checkback INVST L3U Faulty
  • L3D UWSST: Checkback INVST L3L Faulty
  • L3C UWSST: Checkback crowbar faulty
  • L1A BUS: CAN Communication failure
  • L1A BUS: Serial link communication failure
  • L1A BUS: Truck is over loaded
  • L1B TR: Transient traco is triggered
  • L1B TR: Transient traco is full
  • L1A ETM: ADC Failure for ETM1
  • L1A ETM: ADC Failure for ETM2
  • L1A ETM: ADC Failure for ETM3
  • L1A ETM: ADC Failure for ETM4
  • L1A MEFA: ADC Failure
  • L3C HL: Gate unit power supply A defective
L3C HL: Gate unit power supply B defective
L1A DRZ: LIMP Mode A active
L1A DRZ: Limp mode B active
L1A DRZ: Low battery voltage
L1B BUS: Engine floor input increasing minimum engine speed
L1B DM: Data store switch pressed
L1B DM: Diagnosis memory configuration failure
L1B DM: Diagnosis memory occupation > 75%
L1B DM: Diagnosis memory full
L1B DM: Test event
L2A EXT: Main blower air flow supervision
L2A EXT: Minimum engine speed supervision
L1A EXT: Main blower pressure switch malfunction
L1A EXT: Shift lever supervision
L2A EXT: Engine derate protection active
L1A EXT: Truck external plug monitoring
L1A EXT: Grid dry mode active
L3A EXT: DC Power off mod request (rest switch on)
L1A EXT: Steering encoder defective
L1A EXT: Doppler sensor defective
L1A EXT: Auto lube control defective
L1A EXT: Service brake pressed at high speeD
L1A EXT: Service brake on above speed limit
L1A EXT: Anti-roll control malfunction
L3B BEF: CB301 Circuit breaker defective
L3B BEF: K303/K304 Contactor defective
L3B BEF: K103 Feedback defective
L3B BEF: K105 Feedback defective
L1A BEF: K107 Feedback defective
L1A BEF: K109 Feedback defective
L1A BEF: K111 Feedback defective
L1A BEF: Limp mode selector defective
L2B BEF: CB113 Tripped
L3D IUW: Output current supervision INV A
L3D IUW: Output current supervision INV B
L3B IUW: Precharge supervision 1

Inside this manual

Real pages from this service manual (1,745 pages). Open the sample pages (PDF, 1025 KB)

Sample pages from the Komatsu 960E-2K Dump Truck Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page, Foldout diagram
  • Specifications, page 207: 10 Structure and Function
  • Troubleshooting, page 801: Fault Code A352: Overload on output 1H
  • Diagram, page 1,665: XS6914-0 APR 09
  • Color page, page 1,630: 50 Disassembly and assembly
  • Color page, page 240: 10 Structure and Function
  • Foldout diagram, page 1,688: Auxilliary control cabinet

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 960E-2K 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 CEBM026301$179.61
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Operator's manuals

Details
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, 1,745 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

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.

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).