Komatsu 960E-2 Dump Truck Operation and Maintenance Manual (CEAM026102)

Out on a mine site, the 960E-2 spends its life hauling heavy loads on rough haul roads, so keeping it reliable is all about steady, planned care. This Operation and Maintenance Manual helps you set a sensible service rhythm, so you’re not waiting on breakdowns or guessing what to look at next. When a driver reports a vibration or a change in braking feel, this is the book I’d open to walk through the basic checks, trace simple issues, and decide if it’s safe to keep running or needs to be parked and inspected further.

Applications & Use Cases

Plan preventive maintenance so inspections, filter changes, and adjustments are grouped and done with minimal downtime.
Walk an operator through daily checks to spot leaks, loose hardware, or tire damage before a shift.
Verify service tasks after a shop visit, confirming nothing obvious was missed before sending the truck back to production.
Train new operators on proper warm-up, shutdown, and operating habits that reduce stress on components.
Align maintenance with site conditions, adjusting inspection focus for dust, extreme temps, or steep grades.

FAQ

Q: Can I keep this manual on a tablet in the service truck?

A: Yes, it’s well-suited for digital use so you can zoom in on diagrams and search procedures right at the machine.

Q: Is it worth printing sections of this manual?

A: I’d print the routine checklists and service schedules to keep in the cab and in the workshop for quick reference.

Safety Note

Always follow the manual’s lockout, tagging, and support instructions before working under or around the truck.

📘 Show Index

Komatsu 960E-2 Dump Truck Index:

1 INTRODUCTION
- FOREWORD
- ABOUT THIS MANUAL
- WARNINGS
  - California Proposition 65 Warnings
- ALERTS
- TRUCK MODEL ILLUSTRATION
- NON-OEM PARTS IN CRITICAL SYSTEMS
2 STANDARD CHARTS AND TABLES
- GENERAL INFORMATION
  - Effect Of Special Lubricants
  - Suggested Sources For Rust Preventive Grease
- STANDARD TIGHTENING TORQUES
  - 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 MULTIPLIERS
  - Metric To English
  - English To Metric
  - Temperature Conversions
3 GENERAL SAFETY
- GENERAL SAFETY
  - 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 OPERATION
  - 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 MACHINE
  - 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 LIGHTING
  - Fog Lights
  - Headlights
  - Ladder Lights and Deck Mounted Flood Lights
  - Mirror Mounted Backup Lights
  - Brake Light
  - Retard Light
  - Clearance/Turn Signal Lights
  - Backup Alarm
- PRECAUTIONS FOR MAINTENANCE
  - BEFORE PERFORMING MAINTENANCE
  - DURING MAINTENANCE
- WHEN REPAIRS ARE NECESSARY
  - Observe The Following Precautions
- SPECIAL PRECAUTIONS
  - Preliminary Procedures Before Welding Or Performing Maintenance
  - Engine Shutdown Procedure Before Welding or Performing Maintenan
  - Before Welding On The Machine, Obey The Following Guidelines:
  - Discharging Control Cabinet Capacitors
4 WARNING AND CAUTIONS
- GENERAL INFORMATION
- PIN PLATE
- GRADE SPEED CHART
- MACHINE SAFETY
- KEY SWITCH
- OIL FILL AND CHECK
- HIGH PRESSURES
- BATTERY AND ENGINE SHUTDOWN
- HIGH VOLTAGE
- WELDING
- LIFTING POINTS
- EMERGENCY DUMPING
- ROPS/FOPS
- TOWING
- LUBRICATION CHART
5 OPERATING INSTRUCTIONS
- PREPARING FOR OPERATION
  - Safety Is Thinking Ahead
  - Walk Around Inspection
- RETRACTABLE LADDER SYSTEM (If Equipped)
  - General Information
  - Ladder System Description
  - Ladder System Operation
  - In-Cab Control Panel
  - Ground Level Control Box
  - Emergency Down Valve
- PRE-SHIFT BRAKE TEST
  - OPERATION
  - Service Brake Test
  - Parking Brake Test
  - Retard System Test
  - Brake Test Exit Criteria
- TRUCK OPERATION
  - ENGINE START-UP SAFETY
  - MACHINE OPERATION SAFETY PRECAUTIONS
  - SUDDEN LOSS OF ENGINE POWER OR LOSS OF DRIVE SYSTEM FUNCTION
  - EMERGENCY STEERING SYSTEM
  - FUEL DEPLETION
  - SAFE PARKING PROCEDURES
  - NORMAL ENGINE SHUTDOWN PROCEDURE
- DISABLED TRUCK CONNECTORS
  - GENERAL INFORMATION
  - HOIST SYSTEM
- TOWING
  - SPECIAL WIRING HARNESS
  - TOWING PROCEDURE
- PAYLOAD METER III SYSTEM
  - GENERAL INFORMATION
  - COMPONENT DESCRIPTION
  - OPERATOR’S DISPLAY AND SWITCH
  - HAUL CYCLE WARNING FLAGS
  - PC SOFTWARE OVERVIEW
  - SYSTEM CONFIGURATION
  - DOWNLOADING PAYLOAD DATA
  - UPLOADING DATA
  - DATA ANALYSIS
- AUTOMATIC LUBRICATION SYSTEM
  - GENERAL INFORMATION
  - COMPONENT DESCRIPTION
  - SYSTEM OPERATION
  - PREVENTIVE MAINTENANCE PROCEDURES
- SYSTEM CHECKOUT
  - General Checks
  - Lubrication Cycle Operation
- RESERVE ENGINE OIL SYSTEM
  - Operation
  - LED Monitor Light
  - Changing Oil
6 OPERATOR CAB AND CONTROLS
- CAB INTERIOR
- STEERING WHEEL AND CONTROLS
  - Horn Button
  - Tilt / Telescope Lever
  - Multi-Function Turn Signal Switch
  - Turn Signal Operation
  - High Beam Headlight Operation
  - Windshield Wiper Operation
- PEDALS AND RETARDER LEVER
  - Dynamic Retarding
  - Retarder Lever
  - Brake/Retarder Pedal
  - Accelerator Pedal
- OVERHEAD PANEL AND DISPLAYS
  - Radio Speakers
  - Warning Alarm Buzzer
  - Cab Radio
  - Air Cleaner Vacuum Gauges
- CENTER CONSOLE
  - 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 PORTS
  - KOMTRAX Plus
  - Interface Module (IM)
  - Truck Control Interface (TCI)
  - Propulsion System Controller (PSC)
  - Engine (CENSE)
  - Engine (QUANTUM)
- OPERATOR SEAT (Standard)
  - Seat Belts And Tethers
  - Adjustment
- PASSENGER SEAT (Standard)
  - Seat Belts And Tethers
  - Adjustment
- OPERATOR SEAT (Optional)
  - Seat Belts And Tethers
  - Adjustment
- PASSENGER SEAT (Optional)
  - Seat Belts And Tethers
  - Adjustment
- HEATER / AIR CONDITIONER CONTROLS
  - Fan Speed Control Knob
  - Temperature Control Knob
  - Air Flow Directional Knob
  - Heater/Air Conditioner Vents
- INSTRUMENT PANEL
  - CONTROL SYMBOLS
  - Key Switch
  - Engine Warming Switch
  - AC Drive System Rest Switch
  - Wheel Brake Lock Control Switch
  - Hazard Warning Lights
  - Heater/Air Conditioner Vents
  - 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 PANEL
  - STATUS INDICATOR LIGHT SYMBOLS
- OVERHEAD DASH PANEL
  - Brake Test Switch (If Equipped)
  - Brake Test Light (If Equipped)
- DIGITAL DISPLAY OPERATION
  - Toggling Through Main Level Screens
  - Toggling Through Warning Screens
  - Entering Payload Meter Data
- KOMTRAX Plus
  - KOMTRAX Plus OPERATION
  - DOWNLOADING KOMTRAX Plus DATA
  - UPLOADING KOMTRAX Plus DATA
  - ORBCOMM
  - KOMATSU WIRELESS BRIDGE (Optional)
- FUSES AND CIRCUIT BREAKERS
  - FUSE BLOCK #1
  - FUSE BLOCK #2
  - FUSE BLOCK #3
  - FUSE BLOCK #4
  - FUSE HOLDERS
  - CIRCUIT BREAKERS
7 LUBRICATION AND SERVICE
- GENERAL INFORMATION
  - HYDRAULIC SYSTEM SERVICE
  - WHEEL MOTOR SERVICE
  - COOLANT LEVEL SERVICE
  - RESERVE ENGINE OIL SERVICE
  - CAB AIR FILTER SERVICE
  - FUEL SYSTEM SERVICE
  - INTAKE AIR CLEANER SERVICE
  - QUICK FILL SERVICE CENTER
  - TIE ROD INSPECTION AND TORQUE PROCEDURE
- LUBRICATION CHART
- 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
8 SPECIFICATIONS
- 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 Dimensions
  - Tires
  - Weight Distribution
  - Overall Truck Dimensions
9 RADIO
- RADIO OPERATION
  - 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
- CLOCK
  - Clock/Alarm Button
  - Setting The Clock
  - Setting The Alarm
  - Turning The Alarm Off
  - Activating Snooze
- CD PLAYER
  - Playing A Compact Disc
  - Playing An MP3 DISC
  - CD Mode Displays
  - Button Functions
- MP3 PLAYER
  - Playing MP3 Files
  - MP3 Mode Displays
  - Button Functions
- iPod®
  - Playing An iPod®
  - iPod® Mode Displays
  - Button Functions
- WEATHERBAND (USA Only)
- TROUBLESHOOTING
  - Tips About the Audio System
  - Understanding Radio Reception
  - Care Of The Compact Discs