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Komatsu 960E-1 Dump Truck Shop Manual A30025-A30026 – PDF DOWNLOAD
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Komatsu 960E-1 Dump Truck Shop Manual
SERIAL NUMBERS : A30025 – A30026
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Description
Komatsu 960E-1 Dump Truck Shop Manual
FILE DETAILS:
Komatsu 960E-1 Dump Truck Shop Manual
Language : English
Pages : 1004
Downloadable : Yes
File Type : PDF
Size: 31.7 MB
Book Code: CEBM023802
DESCRIPTION:
Komatsu 960E-1 Dump Truck Shop Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance andlor operational checks on the truck- All safety notices, warnings, and cautions should be understood and followed when operating the truck or perfomiing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general infonnation. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is cfiscussed as a unit. The same is true of the engine and engine accessories, and so on through the entire nechanical detafl of the truck.
- Disassembly should be canied only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear’ are made with respect to the operator‘s normal seated position unless specifically stated otherwise.
- When ammbly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N-m (100 ft lb). All torque specifications have 210% tolerance unless otherwise specified.
TABLE OF CONTENTS:
Komatsu 960E-1 Dump Truck Shop Manual
Cover................................................................................................................................. 1 00 Index and foreword................................................................................................................. 3 Index............................................................................................................................. 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 Foreword, safety and general information.......................................................................................... 19 Foreword...................................................................................................................... 22 How to read the shop manual................................................................................................... 23 Composition of shop manual................................................................................................ 23 Revision and distribution................................................................................................. 23 Symbols................................................................................................................... 24 General safety................................................................................................................ 25 Safety rules.............................................................................................................. 25 Safety features........................................................................................................... 25 Fire extinguisher and first aid kit....................................................................................... 25 Clothing and personal items............................................................................................... 25 Leaving the operator seat................................................................................................. 26 Mounting and dismounting.................................................................................................. 26 Fire prevention for fuel and oil.......................................................................................... 26 Precautions with high temperature fluids.................................................................................. 27 Asbestos dust hazard prevention........................................................................................... 27 Prevention of injury by work equipment.................................................................................... 27 Unauthorized modification................................................................................................. 27 Precautions when using ROPS............................................................................................... 27 Precautions for attachments............................................................................................... 28 Precautions for starting the truck........................................................................................ 28 Precautions before operating the truck........................................................................................ 28 Safety at the worksite.................................................................................................... 28 Fire prevention........................................................................................................... 29 Ventilation in enclosed areas............................................................................................. 29 Preparing for operation................................................................................................... 29 Mirrors, windows and lights............................................................................................... 29 In operator cab (before starting the engine).............................................................................. 29 Seat Belts................................................................................................................ 29 Precautions while operating the truck......................................................................................... 30 When starting the engine.................................................................................................. 30 General truck operation................................................................................................... 30 Ensuring good visibility.................................................................................................. 30 Traveling................................................................................................................. 31 Traveling in reverse...................................................................................................... 31 Traveling on slopes....................................................................................................... 31 Operating on snow or ice.................................................................................................. 31 Avoid damage to dump body................................................................................................. 31 Driving near high voltage cables.......................................................................................... 32 When dumping.............................................................................................................. 32 When loading.............................................................................................................. 32 Working on loose ground................................................................................................... 32 Parking the truck......................................................................................................... 32 Towing.................................................................................................................... 32 Working near batteries........................................................................................................ 33 Battery hazard prevention................................................................................................. 33 Starting with booster cables.............................................................................................. 34 Jump starting with receptacles............................................................................................ 34 Precautions before performing service......................................................................................... 35 Warning tag............................................................................................................... 35 Stopping the engine....................................................................................................... 35 Proper tools.............................................................................................................. 35 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 35 Securing the dump body.................................................................................................... 36 Precautions while performing service.......................................................................................... 37 Keep the truck clean...................................................................................................... 37 Attachments............................................................................................................... 37 Working under the truck................................................................................................... 37 Rotating fan and belts.................................................................................................... 37 Adding fuel or oil........................................................................................................ 37 Use of lighting........................................................................................................... 37 Radiator coolant level.................................................................................................... 38 Precautions with the battery.............................................................................................. 38 Precautions with high pressure oil........................................................................................ 38 Handling high pressure hoses.............................................................................................. 38 Precautions when performing maintenance near high temperature or high pressure............................................ 38 Waste materials........................................................................................................... 38 Tires......................................................................................................................... 39 Handling tires............................................................................................................ 39 Storing tires after removal............................................................................................... 39 Precautions for performing repairs............................................................................................ 40 Engine shutdown procedure after AC drive system failure................................................................... 40 Precautions for welding on the truck.......................................................................................... 41 Capacitor discharge system.................................................................................................... 42 Necessary tools........................................................................................................... 42 Warnings and cautions..................................................................................................... 43 Manual DC link capacitor discharge procedure.............................................................................. 44 Failure of the discharge system........................................................................................... 46 Manual discharge of capacitors............................................................................................ 47 Short isolated capacitor terminals........................................................................................ 49 Handling electrical equipment and hydraulic components........................................................................ 50 Points to remember when handling electrical equipment..................................................................... 50 Points to remember when handling hydraulic equipment...................................................................... 56 How to read electric wire code................................................................................................ 58 Standard torque tables........................................................................................................ 61 Effect of special lubricants on fasteners and standard torque values...................................................... 61 Standard tightening torques for SAE hex head capscrew and nut assemblies.................................................. 62 Standard assembly torques for 12-point, grade 9 capscrews (SAE)........................................................... 63 Standard assembly torques for class 10.9 cap screws and class 10 nuts..................................................... 63 Standard tightening torques for fittings.................................................................................. 64 Conversion tables............................................................................................................. 66 Common conversion multipliers............................................................................................. 66 Operating instructions............................................................................................................ 71 Preparing for operation....................................................................................................... 73 Walk around inspection.................................................................................................... 73 Engine start-up............................................................................................................... 77 After engine start-up......................................................................................................... 78 Emergency steering system..................................................................................................... 78 Operation................................................................................................................. 78 Pre-operation testing..................................................................................................... 78 Precautions during truck operation............................................................................................ 79 Operating on a haul road...................................................................................................... 80 Starting on a grade with a loaded truck....................................................................................... 81 Sudden loss of engine power................................................................................................... 81 Fuel depletion................................................................................................................ 82 Towing........................................................................................................................ 82 Special Wiring Harness.................................................................................................... 83 Loading the dump body......................................................................................................... 85 Dumping a load................................................................................................................ 85 Raising the dump body..................................................................................................... 85 Lowering the dump body (on flat ground)................................................................................... 86 Lowering the dump body (over a berm or into a crusher).................................................................... 87 Disabled truck dumping procedure.............................................................................................. 87 Hookup.................................................................................................................... 87 Raising the body.......................................................................................................... 88 Lowering the body......................................................................................................... 88 Safe parking procedure........................................................................................................ 88 Normal engine shutdown procedure.............................................................................................. 89 01 Specification...................................................................................................................... 91 Specification and technical data.................................................................................................. 91 Specification drawing......................................................................................................... 93 Specifications................................................................................................................ 94 Weight table.................................................................................................................. 96 Fuel, coolant and lubricants.................................................................................................. 97 Suspension cylinder oil and nitrogen specifications....................................................................... 98 10 Structure, functions and maintenance standard......................................................................................101 Steering circuit..................................................................................................................101 Steering circuit operation....................................................................................................103 Steering circuit components...................................................................................................105 Steering control unit.....................................................................................................105 High pressure filter......................................................................................................105 Steering accumulators.....................................................................................................105 Bleed down manifold.......................................................................................................106 Steering accumulator bleed down solenoid..................................................................................108 Hoist up limit solenoid...................................................................................................108 Quick disconnect ports....................................................................................................108 Flow amplifier............................................................................................................108 Flow amplifier operation......................................................................................................109 No steer..................................................................................................................110 Steering left.............................................................................................................112 Steering right............................................................................................................114 No steer, external shock load.............................................................................................116 Steering/brake pump operation.................................................................................................119 Normal operation..........................................................................................................119 Neutral position..........................................................................................................120 Full pump volume..........................................................................................................121 Half pump volume..........................................................................................................121 Steering cylinder wear data...................................................................................................122 Hoist circuit.....................................................................................................................125 Hoist circuit operation.......................................................................................................127 Hoist circuit components......................................................................................................128 Hydraulic tank............................................................................................................128 Hoist pump................................................................................................................128 High pressure filters.....................................................................................................128 Hoist valve...............................................................................................................128 Inlet sections............................................................................................................129 Tank ports (front) spool section..........................................................................................129 Work ports (rear) spool section...........................................................................................129 Hoist pilot valve.........................................................................................................130 Bleed down manifold.......................................................................................................130 Hoist limit solenoid......................................................................................................130 Pilot operated check valve................................................................................................130 Overcenter manifold.......................................................................................................131 Hoist pilot valve operation...................................................................................................132 Float position with body down.............................................................................................132 Power up operation........................................................................................................134 Hold operation............................................................................................................136 Power down operation......................................................................................................138 Float operation...........................................................................................................140 Hoist cylinder wear data......................................................................................................142 Brake circuits....................................................................................................................145 General information...........................................................................................................147 Service brake circuit operation...............................................................................................148 Secondary braking and auto apply..............................................................................................148 Parking brake circuit operation...............................................................................................150 Normal operation (key switch ON, engine on)...............................................................................150 Wheel brake lock circuit operation............................................................................................151 Brake warning circuit operation...............................................................................................151 Brake assembly wear data......................................................................................................153 Suspensions.......................................................................................................................155 General information...........................................................................................................157 Front suspension wear data....................................................................................................157 Rear suspension wear data.....................................................................................................158 Electrical system, 24 volt........................................................................................................161 Battery supply system.........................................................................................................163 Batteries.................................................................................................................163 24VDC Auxiliary Battery Receptacles.......................................................................................163 Battery Disconnect Switches...............................................................................................163 Engine starting system........................................................................................................164 Engine prelube pump.......................................................................................................164 Prelube pressure switch...................................................................................................164 Engine start relays.......................................................................................................164 Auxiliary control cabinet components..........................................................................................165 24VDC to 12VDC converter..................................................................................................165 Diode board - DB1.........................................................................................................165 Power distribution terminals..............................................................................................165 Control power relay.......................................................................................................165 Fuse blocks...............................................................................................................165 Relay boards..................................................................................................................167 Relay boards RB1, RB3, RB4, RB5...........................................................................................167 Relay boards RB6, RB7, RB8, RB9...........................................................................................169 Relay functions...........................................................................................................169 Body-up switch................................................................................................................171 Hoist limit switch............................................................................................................172 Interface module (IM).............................................................................................................175 General information...........................................................................................................177 Sensors.......................................................................................................................177 Temperature sensors.......................................................................................................177 Pressure sensors..........................................................................................................177 Interface module inputs and outputs...........................................................................................178 Electrical system, AC drive.......................................................................................................185 General system operation......................................................................................................187 AC drive system components....................................................................................................189 Propulsion system controller (PSC)........................................................................................189 Truck control interface (TCI).............................................................................................190 Diagnostic information display (DID) panel................................................................................190 PSC software functions........................................................................................................191 Input processing..........................................................................................................191 State machine.............................................................................................................191 DC link state.............................................................................................................194 Engine control............................................................................................................195 Alternator field control......................................................................................................196 Desired three-phase voltage...............................................................................................196 Desired DC link voltage...................................................................................................196 Self-load.................................................................................................................196 Propel torque control.....................................................................................................196 Retard torque control.....................................................................................................197 Wheel slide control.......................................................................................................197 Resistor grid control.....................................................................................................197 Chopper voltage control...................................................................................................197 Event detection and processing................................................................................................198 Power-on tests............................................................................................................198 Initiated tests...........................................................................................................199 Periodic tests............................................................................................................199 Event restrictions........................................................................................................199 Event logging and storage.....................................................................................................199 Event history buffer......................................................................................................199 Data packs................................................................................................................200 Event reset...............................................................................................................201 Serial data communications....................................................................................................201 PSC to TCI communications processing......................................................................................201 PSC to PTU communications processing......................................................................................201 Inverter communications processing........................................................................................202 Output processing.........................................................................................................202 Abnormal conditions/overriding functions......................................................................................202 Fast start................................................................................................................202 Engine shutdown/Engine not running........................................................................................202 Limp home mode............................................................................................................203 AC drive system component table...............................................................................................204 Cab air conditioning..............................................................................................................213 General information...........................................................................................................214 Environmental impact of air conditioning..................................................................................214 Air conditioning for off-highway vehicles.................................................................................214 Principles of refrigeration...................................................................................................215 Air conditioning..........................................................................................................215 Refrigeration - the act of cooling........................................................................................215 The refrigeration cycle...................................................................................................215 Air conditioning system components............................................................................................217 Relays....................................................................................................................217 Fan motor and speed control...............................................................................................217 Cab air filter............................................................................................................217 Heater core...............................................................................................................217 Actuators.................................................................................................................217 Compressor (refrigerant pump).............................................................................................219 Service valves............................................................................................................219 Condenser.................................................................................................................219 Receiver-drier............................................................................................................219 Expansion valve...........................................................................................................220 Accumulator...............................................................................................................220 Evaporator core...........................................................................................................220 Air conditioning system electrical circuit....................................................................................221 Thermostat................................................................................................................221 Compressor clutch.........................................................................................................221 Trinary™ switch...........................................................................................................222 Reserve engine oil system.........................................................................................................225 General information...........................................................................................................227 Operation.....................................................................................................................228 LED monitor light.........................................................................................................228 Remote tank fill system.......................................................................................................229 20 Standard value table...............................................................................................................231 Standard value table..............................................................................................................231 Standard value table for truck................................................................................................233 30 Testing and adjusting..............................................................................................................239 General information...............................................................................................................239 Special tool list.............................................................................................................241 Steering, brake cooling and hoist hydraulic system................................................................................243 General information on system checkout........................................................................................245 Steering system checkout procedures...........................................................................................245 Steering pump pressure control adjustments................................................................................246 Steering control valve and flow amplifier leakage test....................................................................247 Bleed down manifold leakage test..........................................................................................248 Shock and suction valve pressure tests....................................................................................249 Steering system checkout data sheet...........................................................................................251 Toe-in adjustment.............................................................................................................252 Brake cooling and hoist system checkout procedures............................................................................253 Pressure gauge locations..................................................................................................253 Brake cooling circuit test................................................................................................254 Power up relief pressure test.............................................................................................254 Power down relief pressure test...........................................................................................255 Counterbalance valve pressure check.......................................................................................256 Counterbalance valve adjustment...........................................................................................257 Brake cooling and hoist system checkout data sheet............................................................................258 Hoist cylinder leakage test...................................................................................................259 Hydraulic system flushing procedure...........................................................................................259 Brake system......................................................................................................................267 General information on system checkout........................................................................................269 Brake circuit checkout procedure..............................................................................................269 Initial system setup......................................................................................................271 Brake lock / secondary braking checkout...................................................................................271 Parking brake checkout....................................................................................................272 Service brake checkout....................................................................................................273 Low brake accumulator pressure and auto apply checkout....................................................................273 Parking brake control logic checkout......................................................................................275 Brake lock control logic checkout.........................................................................................277 Brake system checkout data sheet..............................................................................................279 Brake piston leakage test.....................................................................................................283 Brake seal pressure test......................................................................................................283 Wet disc brake bleeding procedure.............................................................................................284 Parking brake bleeding procedure..............................................................................................284 Brake disc wear inspection....................................................................................................285 Brake valve bench test and adjustment.........................................................................................287 Test setup procedure......................................................................................................288 Brake valve output pressure adjustment....................................................................................288 Final test and adjustment.................................................................................................289 Dual relay valve bench test and adjustment....................................................................................290 Test setup procedure......................................................................................................291 Relay valve output pressure adjustment....................................................................................291 Accumulators and suspensions......................................................................................................293 Accumulator charging and storage..............................................................................................295 Accumulator charging procedures...........................................................................................295 Precharge maintenance.....................................................................................................298 Accumulator storage procedure.............................................................................................299 Bladder storage...........................................................................................................299 Installing a bladder accumulator from storage.............................................................................299 Accumulator leak testing......................................................................................................300 Suspension oiling and charging procedures.....................................................................................302 Equipment list............................................................................................................302 Installing the charging kit...............................................................................................302 Removing the charging kit.................................................................................................303 Support blocks for oiling and charging dimensions.........................................................................303 Front suspension oiling...................................................................................................304 Front suspension nitrogen charging........................................................................................305 Rear suspension oiling....................................................................................................306 Rear suspension nitrogen charging.........................................................................................308 Suspension pressure test......................................................................................................309 KOMTRAX Plus and payload meter....................................................................................................311 KOMTRAX Plus and payload meter software.......................................................................................313 VHMS Tool Box Installation................................................................................................313 VHMS Setting Tool Installation............................................................................................313 Installing the PDM software...............................................................................................313 KOMTRAX Plus controller initial setting procedure.............................................................................314 KOMTRAX Plus controller setup procedure...................................................................................314 KOMTRAX Plus snapshot procedure...........................................................................................317 KOMTRAX Plus download procedure...........................................................................................318 KOMTRAX Plus FTP upload procedure.........................................................................................319 KOMTRAX Plus initialization forms.........................................................................................320 KOMTRAX Plus initialization check list........................................................................................321 KOMTRAX Plus initialization form..............................................................................................323 Precautions for replacing KOMTRAX Plus controller.............................................................................324 KOMTRAX Plus controller checkout procedure....................................................................................329 Necessary equipment.......................................................................................................329 Preliminary...............................................................................................................329 Checkout procedure........................................................................................................330 Payload meter initial setting procedure.......................................................................................332 Starting communications...................................................................................................332 Configure payload meter...................................................................................................332 Setting truck number......................................................................................................334 Clean truck tare..........................................................................................................335 Inclinometer calibration..................................................................................................335 Interface module (IM).............................................................................................................337 Interface module software.....................................................................................................339 Flashburn program installation............................................................................................339 Interface module application code installation............................................................................340 Interface module realtime data monitor software installation..............................................................340 Interface module checkout procedures..........................................................................................341 Necessary equipment.......................................................................................................341 Preliminary...............................................................................................................342 Check digital inputs to the interface module..............................................................................343 Check analog inputs to the interface module...............................................................................346 Check serial interfaces to the interface module...........................................................................346 Check outputs from the interface module...................................................................................347 Cab air conditioning..............................................................................................................349 General information...........................................................................................................350 Service tools and equipment...................................................................................................351 Recovery/recycle station..................................................................................................351 Leak detector.............................................................................................................351 Manifold gauge set........................................................................................................352 Service valves............................................................................................................353 Vacuum pump...............................................................................................................353 Detecting leaks...............................................................................................................354 System performance test.......................................................................................................355 Checking system oil...........................................................................................................356 System flushing...............................................................................................................357 Installing the manifold gauge set.............................................................................................358 Purging air from the service hoses........................................................................................358 Recovering and recycling refrigerant..........................................................................................359 Draining oil from previous recovery cycle.................................................................................360 Recovery cycle............................................................................................................360 Recycling procedure.......................................................................................................360 Evacuating the air conditioning system........................................................................................361 Charging the air conditioning system..........................................................................................362 40 Troubleshooting....................................................................................................................365 Fuse and circuit breaker locations................................................................................................365 Fuse and circuit breaker locations............................................................................................367 AC drive system fault codes.......................................................................................................373 DID panel fault code tables...................................................................................................375 Troubleshooting by fault code, Part 1.............................................................................................395 Fault Code A001: Left front suspension pressure sensor signal high............................................................397 Related circuit diagram...................................................................................................397 Fault Code A002: Left front suspension pressure sensor signal low.............................................................398 Related circuit diagram...................................................................................................398 Fault Code A003: Right front suspension pressure sensor signal high...........................................................399 Related circuit diagram...................................................................................................399 Fault Code A004: Right front suspension pressure sensor signal low............................................................400 Related circuit diagram...................................................................................................400 Fault Code A005: Left rear suspension pressure sensor signal high.............................................................401 Related circuit diagram...................................................................................................401 Fault Code A006: Left rear suspension pressure sensor signal low..............................................................402 Related circuit diagram...................................................................................................402 Fault Code A007: Right rear suspension pressure sensor signal high............................................................403 Related circuit diagram...................................................................................................403 Fault Code A008: Right rear suspension pressure sensor signal low.............................................................404 Related circuit diagram...................................................................................................404 Fault Code A009: Incline sensor signal high...................................................................................405 Related circuit diagram...................................................................................................405 Fault Code A010: Incline sensor signal low....................................................................................406 Related circuit diagram...................................................................................................406 Fault Code A011: Payload meter speed sensor signal has failed.................................................................407 Related circuit diagram...................................................................................................407 Fault Code A013: Body up switch has failed....................................................................................408 Related circuit diagram...................................................................................................408 Fault Code A014: Payload meter checksum computation has failed................................................................409 Related circuit diagram...................................................................................................409 Fault Code A016: Payload meter write to flash memory has failed...............................................................410 Related circuit diagram...................................................................................................410 Fault Code A017: Payload meter flash memory read has failed...................................................................411 Related circuit diagram...................................................................................................411 Fault Code A018: Right rear flat suspension cylinder warning..................................................................412 Related circuit diagram...................................................................................................413 Fault Code A019: Left rear flat suspension cylinder warning...................................................................414 Related circuit diagram...................................................................................................415 Fault Code A022: Carryback load excessive.....................................................................................416 Related circuit diagram...................................................................................................417 Fault Code A100: An open circuit breaker has been detected on a relay board...................................................419 Related circuit diagram...................................................................................................419 Fault Code A101: High pressure detected across an hydraulic pump filter.......................................................420 Related circuit diagram...................................................................................................421 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level......................................422 Related circuit diagram...................................................................................................423 Fault Code A107: GE has generated a propel system caution.....................................................................424 Related circuit diagram...................................................................................................424 Fault Code A108: GE has generated a propel system temperature caution.........................................................425 Related circuit diagram...................................................................................................425 Fault Code A109: GE has generated a propel system reduced level signal........................................................426 Related circuit diagram...................................................................................................426 Fault Code A111: Low steering pressure warning................................................................................427 Related circuit diagram...................................................................................................427 Fault Code A115: Low steering precharge pressure detected.....................................................................428 Related circuit diagram...................................................................................................429 Fault Code A117: Low brake accumulator pressure warning.......................................................................430 Related circuit diagram...................................................................................................430 Fault Code A118: Brake pressure is low while in brake lock....................................................................432 Related circuit diagram...................................................................................................433 Fault Code A123: GE has generated a reduced retarding caution.................................................................434 Related circuit diagram...................................................................................................434 Fault Code A124: GE has generated a no propel / no retard warning.............................................................435 Related circuit diagram...................................................................................................435 Fault Code A125: GE has generated a no propel warning.........................................................................436 Related circuit diagram...................................................................................................436 Fault Code A126: Oil level in the hydraulic tank is low.......................................................................437 Related circuit diagram...................................................................................................437 Fault Code A127: IM-furnished +5 volt output for sensors is low...............................................................438 Related circuit diagram...................................................................................................439 Fault Code A128: IM-furnished +5 volt output for sensors is high..............................................................440 Related circuit diagram...................................................................................................441 Fault Code A139: Low fuel warning.............................................................................................442 Related circuit diagram...................................................................................................443 Troubleshooting by fault code, Part 2.............................................................................................445 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil....448 Related circuit diagram...................................................................................................449 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil....450 Related circuit diagram...................................................................................................451 Fault Code A152: Starter failure..............................................................................................452 Related circuit diagram...................................................................................................453 Fault Code A153: Battery voltage is low with the truck in operation...........................................................454 Related circuit diagram...................................................................................................455 Fault Code A154: Battery charging voltage is excessive........................................................................456 Related circuit diagram...................................................................................................456 Fault Code A155: Battery charging voltage is low..............................................................................457 Related circuit diagram...................................................................................................457 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level.................................458 Related circuit diagram...................................................................................................459 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................460 Related circuit diagram...................................................................................................461 Fault Code A167: Right rear hydraulic oil temperature sensor is low...........................................................462 Related circuit diagram...................................................................................................463 Fault Code A168: Left front hydraulic oil temperature sensor is low...........................................................464 Related circuit diagram...................................................................................................465 Fault Code A169: Right front hydraulic oil temperature sensor is low..........................................................466 Related circuit diagram...................................................................................................467 Fault Code A170: Left rear hydraulic oil temperature sensor is high...........................................................468 Related circuit diagram...................................................................................................468 Fault Code A171: Right rear hydraulic oil temperature sensor is high..........................................................469 Related circuit diagram...................................................................................................469 Fault Code A172: Left front hydraulic oil temperature sensor is high..........................................................470 Related circuit diagram...................................................................................................470 Fault Code A173: Right front hydraulic oil temperature sensor is high.........................................................471 Related circuit diagram...................................................................................................471 Fault Code A184: J1939 data link is not connected.............................................................................472 Related circuit diagram...................................................................................................473 Fault Code A190: Auto lube control has detected an incomplete lube cycle......................................................474 Related circuit diagram...................................................................................................475 Fault Code A194: Left front hydraulic oil temperature is high.................................................................476 Related circuit diagram...................................................................................................476 Fault Code A195: Right front hydraulic oil temperature is high................................................................477 Related circuit diagram...................................................................................................477 Fault Code A196: Left rear hydraulic oil temperature is high..................................................................478 Related circuit diagram...................................................................................................478 Fault Code A197: Right rear hydraulic oil temperature is high.................................................................479 Related circuit diagram...................................................................................................479 Fault Code A198: Hoist pressure 1 sensor is high..............................................................................480 Related circuit diagram...................................................................................................480 Fault Code A199: Hoist pressure 2 sensor is high..............................................................................481 Related circuit diagram...................................................................................................481 Fault Code A200: Steering pressure sensor is high.............................................................................482 Related circuit diagram...................................................................................................482 Fault Code A201: Brake pressure sensor is high................................................................................483 Related circuit diagram...................................................................................................483 Fault Code A202: Hoist pressure 1 sensor is low...............................................................................484 Related circuit diagram...................................................................................................485 Fault Code A203: Hoist pressure 2 sensor is low...............................................................................486 Related circuit diagram...................................................................................................487 Fault Code A204: Steering pressure sensor is low..............................................................................488 Related circuit diagram...................................................................................................489 Fault Code A205: Brake pressure sensor is low.................................................................................490 Related circuit diagram...................................................................................................491 Fault Code A206: Ambient temperature sensor is high...........................................................................492 Related circuit diagram...................................................................................................492 Fault Code A207: Ambient temperature sensor is low............................................................................493 Related circuit diagram...................................................................................................493 Troubleshooting by fault code, Part 3.............................................................................................495 Fault Code A212: Bad truck speed signal.......................................................................................498 Related circuit diagram...................................................................................................499 Fault Code A213: Parking brake should have applied but is detected as not having applied......................................500 Related circuit diagram...................................................................................................502 Fault Code A214: Parking brake should have released but is detected as not having released....................................504 Related circuit diagram...................................................................................................506 Fault Code A215: Brake auto apply valve circuit is defective..................................................................508 Related circuit diagram...................................................................................................509 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit......................510 Related circuit diagram...................................................................................................511 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted....................................512 Related circuit diagram...................................................................................................513 Fault Code A230: Parking brake has been requested while truck still moving....................................................516 Related circuit diagram...................................................................................................517 Fault Code A231: The body is up with engine running and brakes not on.........................................................518 Related circuit diagram...................................................................................................519 Fault Code A235: Steering accumulator is in the process of being bled down....................................................520 Related circuit diagram...................................................................................................521 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds.........................................522 Related circuit diagram...................................................................................................523 Fault Code A237: The CAN/RPC connection to the display is open................................................................524 Related circuit diagram...................................................................................................524 Fault Code A240: The key switch input to the interface module is open.........................................................525 Related circuit diagram...................................................................................................525 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................526 Related circuit diagram...................................................................................................526 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective..................................527 Related circuit diagram...................................................................................................527 Fault Code A244: Drive system temperature gauge within the dash display panel is defective....................................528 Related circuit diagram...................................................................................................528 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective...................................529 Related circuit diagram...................................................................................................529 Fault Code A246: Payload meter reports truck overload.........................................................................530 Related circuit diagram...................................................................................................530 Fault Code A247: Low steering pressure warning................................................................................532 Related circuit diagram...................................................................................................533 Fault Code A248: Status module within the dash display panel is defective.....................................................534 Related circuit diagram...................................................................................................534 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted...........................................535 Related circuit diagram...................................................................................................535 Fault Code A250: Battery voltage is low with the truck parked.................................................................536 Related circuit diagram...................................................................................................537 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground..............................538 Related circuit diagram...................................................................................................539 Fault Code A252: Start enable output circuit is either open or shorted to ground..............................................540 Related circuit diagram...................................................................................................541 Fault Code A253: Steering bleed circuit is not open while running.............................................................542 Related circuit diagram...................................................................................................543 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open..................................................544 Related circuit diagram...................................................................................................544 Fault Code A257: Payload CAN/RPC is not connected.............................................................................545 Related circuit diagram...................................................................................................545 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective..............................................546 Related circuit diagram...................................................................................................546 Troubleshooting by fault code, Part 4.............................................................................................549 Fault Code A260: Parking brake failure........................................................................................552 Related circuit diagram...................................................................................................553 Fault Code A261: Low brake accumulator pressure warning.......................................................................554 Related circuit diagram...................................................................................................555 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................556 Related circuit diagram...................................................................................................557 Fault Code A264: Parking brake relay circuit is defective.....................................................................558 Related circuit diagram...................................................................................................559 Fault Code A265: Service brake failure........................................................................................560 Related circuit diagram...................................................................................................561 Fault Code A266: Selector lever was not in park while attempting to crank engine..............................................562 Related circuit diagram...................................................................................................562 Fault Code A267: Parking brake was not set while attempting to crank engine...................................................563 Related circuit diagram...................................................................................................563 Fault Code A268: Secondary engine shutdown while cranking.....................................................................564 Related circuit diagram...................................................................................................564 Fault Code A270: Brake lock switch power supply is not on when required.......................................................566 Related circuit diagram...................................................................................................568 Fault Code A271: Shifter not in gear..........................................................................................570 Related circuit diagram...................................................................................................571 Fault Code A272: Brake lock switch power supply is not off when required......................................................572 Related circuit diagram...................................................................................................574 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit.......................575 Related circuit diagram...................................................................................................575 Fault Code A274: A brake setting fault has been detected......................................................................576 Related circuit diagram...................................................................................................577 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................578 Related circuit diagram...................................................................................................579 Fault Code A276: The drive system data link is not connected..................................................................580 Related circuit diagram...................................................................................................581 Fault Code A277: Parking brake applied while loading..........................................................................582 Related circuit diagram...................................................................................................583 Fault Code A278: Service brake applied while loading..........................................................................584 Related circuit diagram...................................................................................................585 Fault Code A279: Low steering pressure switch is defective....................................................................586 Related circuit diagram...................................................................................................586 Fault Code A280: Steering accumulator bleed down switch is defective..........................................................587 Related circuit diagram...................................................................................................587 Fault Code A281: Brake lock degrade switch is defective.......................................................................588 Related circuit diagram...................................................................................................589 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7.............590 Related circuit diagram...................................................................................................591 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set...................................594 Related circuit diagram...................................................................................................595 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated......................596 Related circuit diagram...................................................................................................597 Fault Code A285: The parking brake was not set when the key switch was turned off.............................................598 Related circuit diagram...................................................................................................599 Fault Code A286: A fault was detected in the shutdown delay relay circuit.....................................................600 Related circuit diagram...................................................................................................601 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off.........................602 Related circuit diagram...................................................................................................603 Troubleshooting by fault code, Part 5.............................................................................................605 Fault Code A303: Shifter is defective.........................................................................................608 Related circuit diagram...................................................................................................609 Fault Code A304: Auto lube grease level fault.................................................................................610 Related circuit diagram...................................................................................................610 Fault Code A305: Auto lube circuit is defective...............................................................................612 Related circuit diagram...................................................................................................613 Fault Code A307: Both GE inverters are disabled...............................................................................614 Related circuit diagram...................................................................................................614 Fault Code A309: No brakes applied when expected..............................................................................616 Related circuit diagram...................................................................................................617 Fault Code A310: Low fuel warning.............................................................................................618 Related circuit diagram...................................................................................................619 Fault Code A311: Brake lock switch is on when it should not be................................................................620 Related circuit diagram...................................................................................................621 Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings.............................................622 Related circuit diagram...................................................................................................622 Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings............................................623 Related circuit diagram...................................................................................................623 Fault Code A315: DCDC converter 12 volt circuit is low........................................................................624 Related circuit diagram...................................................................................................625 Fault Code A316: Starter engagement has been attempted with engine running....................................................626 Related circuit diagram...................................................................................................627 Fault Code A317: Operation of brake auto apply valve without a detected response..............................................628 Related circuit diagram...................................................................................................629 Fault Code A318: Unexpected power loss to interface module....................................................................630 Related circuit diagram...................................................................................................630 Fault Code A320: Data link reports GE propel system caution fault but wired input does not....................................632 Related circuit diagram...................................................................................................633 Fault Code A321: Data link reports GE propel system temp caution fault but wired input does not...............................634 Related circuit diagram...................................................................................................635 Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not..............................636 Related circuit diagram...................................................................................................637 Fault Code A323: Data link reports GE reduced retard level fault but wired input does not.....................................638 Related circuit diagram...................................................................................................639 Fault Code A324: Data link reports DC link voltage but wired input does not...................................................640 Related circuit diagram...................................................................................................641 Fault Code A325: Data link reports GE no propel/retard fault but wired input does not.........................................642 Related circuit diagram...................................................................................................643 Fault Code A326: Data link reports GE no propel fault but wired input does not................................................644 Related circuit diagram...................................................................................................645 Fault Code A327: Data link reports GE at rest but wired input does not........................................................646 Related circuit diagram...................................................................................................647 Fault Code A328: Drive system not powered up..................................................................................648 Related circuit diagram...................................................................................................648 Fault Code A329: Data link reports the body is not down but wired input says it is............................................650 Related circuit diagram...................................................................................................651 Fault Code A330: Data link reports dynamic retard operating state but wired input does not....................................652 Related circuit diagram...................................................................................................653 Troubleshooting by fault code, Part 6.............................................................................................655 Fault Code A350: Overload on output 1B........................................................................................657 Related circuit diagram...................................................................................................657 Fault Code A351: Overload on output 1E........................................................................................658 Related circuit diagram...................................................................................................659 Fault Code A352: Overload on output 1H........................................................................................660 Related circuit diagram...................................................................................................660 Fault Code A353: Overload on output 1J........................................................................................661 Related circuit diagram...................................................................................................661 Fault Code A354: Overload on output 1K........................................................................................662 Related circuit diagram...................................................................................................663 Fault Code A355: Overload on output 1L........................................................................................664 Related circuit diagram...................................................................................................664 Fault Code A356: Overload on output 1M........................................................................................665 Related circuit diagram...................................................................................................665 Fault Code A357: Overload on output 1N........................................................................................666 Related circuit diagram...................................................................................................666 Fault Code A358: Overload on output 1P........................................................................................667 Related circuit diagram...................................................................................................667 Fault Code A359: Overload on output 1R........................................................................................668 Related circuit diagram...................................................................................................668 Fault Code A360: Overload on output 1S........................................................................................669 Related circuit diagram...................................................................................................669 Fault Code A361: Overload on output 1T........................................................................................670 Related circuit diagram...................................................................................................671 Fault Code A362: Overload on output 1U........................................................................................672 Related circuit diagram...................................................................................................672 Fault Code A363: Overload on output 1X........................................................................................674 Related circuit diagram...................................................................................................675 Fault Code A364: Overload on output 1Y........................................................................................676 Related circuit diagram...................................................................................................676 Fault Code A365: Overload on output 1Z........................................................................................677 Related circuit diagram...................................................................................................677 Cab air conditioning..............................................................................................................679 Preliminary checks............................................................................................................681 Diagnosis of gauge readings and system performance............................................................................681 Troubleshooting by manifold gauge set readings................................................................................682 Reserve engine oil system.........................................................................................................689 Pumping unit LED signals......................................................................................................691 Circuit fuses.............................................................................................................691 50 Disassembly and assembly...........................................................................................................693 General information...............................................................................................................693 Special tool list.............................................................................................................695 Wheels, spindles and rear axle....................................................................................................701 General information for tires and rims........................................................................................703 Storage and handling......................................................................................................703 Wheel stud maintenance....................................................................................................704 Removal and installation of front wheel.......................................................................................704 Removal...................................................................................................................704 Installation..............................................................................................................705 Removal and installation of rear wheel........................................................................................706 Removal...................................................................................................................706 Installation..............................................................................................................707 Removal and installation of tires.............................................................................................708 Removal...................................................................................................................708 Installation..............................................................................................................709 Removal and installation of front wheel hub and spindle.......................................................................710 Removal...................................................................................................................711 Spindle removal (off the truck)...........................................................................................714 Installation..............................................................................................................716 Disassembly and assembly of front wheel hub and spindle.......................................................................717 Disassembly...............................................................................................................717 Cleaning and inspection...................................................................................................717 Assembly..................................................................................................................719 Wheel bearing adjustment..................................................................................................719 Seal assembly gap check and adjustment....................................................................................720 Brake installation........................................................................................................721 Speed sensor installation and adjustment..................................................................................721 Removal and installation of rear axle.........................................................................................722 Removal...................................................................................................................722 Cleaning and inspection...................................................................................................723 Installation..............................................................................................................723 Removal and installation of anti-sway bar.....................................................................................724 Removal...................................................................................................................724 Installation..............................................................................................................724 Removal and installation of pivot pin.........................................................................................725 Removal...................................................................................................................725 Installation..............................................................................................................725 Pivot eye and bearing service.................................................................................................726 Bearing removal...........................................................................................................726 Bearing installation......................................................................................................726 Pivot eye repair..........................................................................................................727 Removal and installation of wheel motor.......................................................................................728 Preparation...............................................................................................................728 Removal...................................................................................................................728 Cleaning and inspection...................................................................................................729 Installation..............................................................................................................731 Removal and installation of rear brake assembly...............................................................................735 Removal...................................................................................................................735 Installation..............................................................................................................735 Brake system......................................................................................................................739 Removal and installation of brake valve.......................................................................................741 Removal...................................................................................................................741 Installation..............................................................................................................742 Disassembly and assembly of brake valve.......................................................................................742 Disassembly...............................................................................................................742 Cleaning and inspection...................................................................................................746 Assembly..................................................................................................................746 Removal and installation of dual relay valve..................................................................................749 Removal...................................................................................................................749 Installation..............................................................................................................750 Disassembly and assembly of dual relay valve..................................................................................751 Disassembly...............................................................................................................751 Cleaning and inspection...................................................................................................752 Assembly..................................................................................................................752 Removal and installation of brake manifold....................................................................................753 Removal...................................................................................................................753 Installation..............................................................................................................753 Disassembly and assembly of brake manifold....................................................................................754 Disassembly...............................................................................................................754 Assembly..................................................................................................................754 Removal and installation of brake accumulator.................................................................................755 Removal...................................................................................................................755 Installation..............................................................................................................755 Disassembly and assembly of brake accumulator.................................................................................756 Disassembly...............................................................................................................756 Cleaning and inspection...................................................................................................757 Assembly..................................................................................................................758 Disassembly and assembly of wheel brake.......................................................................................759 Disassembly...............................................................................................................760 Cleaning and inspection...................................................................................................763 Assembly..................................................................................................................764 Floating ring seal assembly and installation..............................................................................767 Removal and installation of parking brake.....................................................................................771 Removal...................................................................................................................771 Installation..............................................................................................................773 Disassembly and assembly of parking brake.....................................................................................773 Disassembly...............................................................................................................773 Cleaning and inspection...................................................................................................774 Assembly..................................................................................................................776 Cleaning and inspecting new discs.........................................................................................778 Steering system...................................................................................................................781 Removal and installation of steering control unit.............................................................................783 Removal...................................................................................................................783 Installation..............................................................................................................784 Disassembly and assembly of steering control unit.............................................................................785 Disassembly...............................................................................................................785 Assembly..................................................................................................................787 Removal and installation of steering column...................................................................................790 Removal...................................................................................................................790 Inspection................................................................................................................790 Installation..............................................................................................................791 Removal and installation of steering wheel....................................................................................791 Removal...................................................................................................................791 Installation..............................................................................................................792 Removal and installation of bleed down manifold...............................................................................793 Removal...................................................................................................................793 Installation..............................................................................................................794 Removal and installation of flow amplifier....................................................................................795 Removal...................................................................................................................795 Installation..............................................................................................................795 Disassembly and assembly of flow amplifier....................................................................................795 Disassembly...............................................................................................................795 Assembly..................................................................................................................797 Removal and installation of steering cylinders and tie rod....................................................................798 Removal...................................................................................................................798 Bearing replacement.......................................................................................................798 Installation..............................................................................................................798 Disassembly and assembly of steering cylinders................................................................................800 Disassembly...............................................................................................................800 Assembly..................................................................................................................801 Removal and installation of steering/brake pump...............................................................................801 Removal...................................................................................................................801 Installation..............................................................................................................802 Disassembly and assembly of steering/brake pump...............................................................................804 Disassembly...............................................................................................................804 Inspection................................................................................................................807 Assembly..................................................................................................................810 Driveshaft group..........................................................................................................811 Rotating group............................................................................................................811 Removal and installation of steering accumulators.............................................................................813 Removal...................................................................................................................813 Installation..............................................................................................................814 Disassembly and assembly of steering accumulators.............................................................................814 Disassembly...............................................................................................................814 Cleaning and Inspection...................................................................................................815 Assembly..................................................................................................................816 Suspensions.......................................................................................................................819 Removal and installation of front suspension..................................................................................821 Removal...................................................................................................................821 Installation..............................................................................................................822 Inspection................................................................................................................825 Minor front suspension repairs (lower bearing and seals)......................................................................828 Lower bearing retainer removal............................................................................................828 Lower bearing retainer installation.......................................................................................828 Major front suspension rebuild................................................................................................829 Disassembly...............................................................................................................829 Assembly..................................................................................................................830 Removal and installation of rear suspension...................................................................................832 Removal...................................................................................................................833 Installation..............................................................................................................835 Disassembly and assembly of rear suspension...................................................................................835 Disassembly...............................................................................................................835 Cleaning and Inspection...................................................................................................836 Assembly..................................................................................................................836 Hoist circuit.....................................................................................................................839 Removal and installation of hoist pump........................................................................................841 Removal...................................................................................................................841 Installation..............................................................................................................842 Disassembly and assembly of hoist pump........................................................................................843 Disassembly...............................................................................................................843 Inspection................................................................................................................846 Assembly..................................................................................................................846 Removal and installation of hoist valve.......................................................................................851 Removal...................................................................................................................851 Installation..............................................................................................................852 Disassembly and assembly of hoist valve.......................................................................................852 O-ring replacement........................................................................................................852 Disassembly of inlet section..............................................................................................853 Assembly of inlet section.................................................................................................854 Disassembly of rear spool section.........................................................................................855 Assembly of rear spool section............................................................................................857 Disassembly of front spool section........................................................................................858 Assembly of front spool section...........................................................................................859 Overcenter valve manifold service.............................................................................................859 Removal and installation of hoist pilot valve.................................................................................860 Removal...................................................................................................................860 Installation..............................................................................................................860 Disassembly and assembly of hoist pilot valve.................................................................................861 Disassembly...............................................................................................................861 Cleaning and inspection...................................................................................................862 Assembly..................................................................................................................862 Removal and installation of hoist cylinders...................................................................................863 Removal...................................................................................................................863 Installation..............................................................................................................864 Disassembly and assembly of hoist cylinders...................................................................................865 Disassembly...............................................................................................................865 Cleaning and inspection...................................................................................................867 Installation of the quill.................................................................................................868 Assembly..................................................................................................................870 Operator cab......................................................................................................................873 Removal and installation of operator cab......................................................................................875 Removal...................................................................................................................876 Installation..............................................................................................................877 Removal and installation of cab door..........................................................................................878 Removal...................................................................................................................878 Installation..............................................................................................................878 Disassembly and assembly of cab door..........................................................................................878 Removing door panel.......................................................................................................878 Installing door panel.....................................................................................................879 Replacing door window regulator...........................................................................................879 Replacing door handle or latch assembly...................................................................................880 Replacing door assembly seal and door hinge seal..........................................................................881 Replacing door opening seal...............................................................................................881 Removing door glass.......................................................................................................882 Installing door glass.....................................................................................................883 Adjustment of cab door........................................................................................................885 Door jamb bolt adjustment.................................................................................................885 Door handle plunger adjustment............................................................................................886 Removal and installation of side window glass.................................................................................887 Recommended tools and supplies............................................................................................887 Removal...................................................................................................................888 Installation..............................................................................................................888 Removal and installation of windshield and rear window glass..................................................................889 Removal...................................................................................................................889 Installation..............................................................................................................889 Removal and installation of windshield wiper motor............................................................................890 Removal...................................................................................................................890 Installation..............................................................................................................890 Removal and installation of windshield wiper arm..............................................................................891 Removal...................................................................................................................891 Installation..............................................................................................................891 Removal and installation of windshield wiper linkage..........................................................................892 Removal...................................................................................................................892 Installation..............................................................................................................892 Removal and installation of operator seat.....................................................................................893 Inspection................................................................................................................893 Removal...................................................................................................................893 Installation..............................................................................................................893 Removal and installation of passenger seat....................................................................................894 Removal...................................................................................................................894 Installation..............................................................................................................894 Removal and installation of seat belts (standard seats).......................................................................895 Removal...................................................................................................................895 Installation..............................................................................................................895 Removal and installation of seat belts (optional seats).......................................................................897 General...................................................................................................................897 Removal...................................................................................................................897 Installation..............................................................................................................899 Body and structures...............................................................................................................903 Removal and installation of dump body.........................................................................................905 Removal...................................................................................................................905 Inspection................................................................................................................906 Installation..............................................................................................................907 Removal and installation of body pads.........................................................................................908 Removal...................................................................................................................908 Installation..............................................................................................................908 Body pad shimming procedure...............................................................................................909 Removal and installation of diagonal ladder/hood and grille assembly..........................................................910 Removal...................................................................................................................910 Installation..............................................................................................................910 Removal and installation of right deck........................................................................................912 Removal...................................................................................................................912 Installation..............................................................................................................912 Removal and installation of left deck.........................................................................................914 Removal...................................................................................................................914 Installation..............................................................................................................914 Removal and installation of fuel tank.........................................................................................916 Removal...................................................................................................................916 Cleaning and inspection...................................................................................................916 Installation..............................................................................................................918 Removal and installation of fuel gauge sender.................................................................................918 Removal...................................................................................................................918 Installation..............................................................................................................918 Disassembly and assembly of fuel tank breather................................................................................919 Disassembly...............................................................................................................919 Assembly..................................................................................................................919 Removal and installation of hydraulic tank....................................................................................920 Removal...................................................................................................................920 Installation..............................................................................................................920 Cab air conditioning..............................................................................................................923 Replacement of air conditioning system components.............................................................................925 Hoses and fittings........................................................................................................925 Lines.....................................................................................................................925 Expansion valve...........................................................................................................925 Receiver-drier............................................................................................................925 Thermostat................................................................................................................925 Compressor................................................................................................................926 Accumulator...............................................................................................................926 Clutch....................................................................................................................926 Diasassembly and assembly of compressor clutch................................................................................927 Removal of the clutch assembly............................................................................................927 Removal of the pulley.....................................................................................................929 Installation of the pulley................................................................................................929 Installation of the clutch assembly.......................................................................................930 Power module......................................................................................................................933 Removal and installation of power module......................................................................................935 General...................................................................................................................935 Preparation...............................................................................................................935 Removal...................................................................................................................936 Installation..............................................................................................................942 Removal and installation of alternator........................................................................................944 Removal...................................................................................................................944 Installation..............................................................................................................946 Removal and installation of engine............................................................................................949 Removal...................................................................................................................949 Service...................................................................................................................949 Installation..............................................................................................................949 Removal and installation of radiator..........................................................................................950 Removal...................................................................................................................950 Installation..............................................................................................................952 Repairing the radiator........................................................................................................953 Internal inspection.......................................................................................................953 External cleaning.........................................................................................................953 Disassembly...............................................................................................................953 Cleaning and inspection...................................................................................................954 Assembly..................................................................................................................955 Pressure testing..........................................................................................................956 90 Diagrams and drawings..............................................................................................................959 Hydraulic circuit diagrams........................................................................................................959 Electrical circuit diagrams.......................................................................................................965
KOMATSU 960E-1 DUMP TRUCK SHOP MANUAL A30025-A30026 – PDF DOWNLOAD:
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