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Komatsu 960E-2 Dump Truck Shop Manual CEBM025901 – PDF DOWNLOAD
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Komatsu 960E-2 Dump Truck Shop Manual
SERIAL NUMBERS : A30027 & UP
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Description
Komatsu 960E-2 Dump Truck Shop Manual
FILE DETAILS:
Komatsu 960E-2 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: 960E-2
Serial Number: A30027 & UP
Book Code: CEBM025901
Language: English
Pages: 978
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu 960E-2 Dump Truck Shop Manual
How to read the shop manual:
Composition of shop manual:
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword:
• This section includes the index, foreword, safety and basic information.
01. Specification:
• This section explains the specifications of the machine.
10. Structure and function:
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting:
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting:
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly:
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard:
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix:
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings:
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu 960E-2 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.......................................................................................... 17 Foreword...................................................................................................................... 20 How to read the shop manual................................................................................................... 21 Composition of shop manual................................................................................................ 21 Revision and distribution................................................................................................. 21 Symbols................................................................................................................... 22 General safety................................................................................................................ 23 Safety rules.............................................................................................................. 23 Safety features........................................................................................................... 23 Fire extinguisher and first aid kit....................................................................................... 23 Clothing and personal items............................................................................................... 23 Leaving the operator seat................................................................................................. 24 Mounting and dismounting.................................................................................................. 24 Fire prevention for fuel and oil.......................................................................................... 24 Precautions with high temperature fluids.................................................................................. 25 Asbestos dust hazard prevention........................................................................................... 25 Prevention of injury by work equipment.................................................................................... 25 Unauthorized modification................................................................................................. 25 Precautions when using ROPS............................................................................................... 25 Precautions for attachments............................................................................................... 26 Precautions for starting the truck........................................................................................ 26 Precautions before operating the truck........................................................................................ 26 Safety at the worksite.................................................................................................... 26 Fire prevention........................................................................................................... 27 Ventilation in enclosed areas............................................................................................. 27 Preparing for operation................................................................................................... 27 Mirrors, windows and lights............................................................................................... 27 In operator cab (before starting the engine).............................................................................. 27 Seat Belts................................................................................................................ 27 Precautions while operating the truck......................................................................................... 28 When starting the engine.................................................................................................. 28 General truck operation................................................................................................... 28 Ensuring good visibility.................................................................................................. 28 Traveling................................................................................................................. 29 Traveling in reverse...................................................................................................... 29 Traveling on slopes....................................................................................................... 29 Operating on snow or ice.................................................................................................. 29 Avoid damage to dump body................................................................................................. 29 Driving near high voltage cables.......................................................................................... 30 When dumping.............................................................................................................. 30 When loading.............................................................................................................. 30 Working on loose ground................................................................................................... 30 Parking the truck......................................................................................................... 30 Towing.................................................................................................................... 30 Working near batteries........................................................................................................ 31 Battery hazard prevention................................................................................................. 31 Starting with booster cables.............................................................................................. 32 Jump starting with receptacles............................................................................................ 32 Precautions before performing service......................................................................................... 33 Warning tag............................................................................................................... 33 Stopping the engine....................................................................................................... 33 Proper tools.............................................................................................................. 33 Use of Tie-Off Anchor During Maintenance and Repair....................................................................... 33 Securing the dump body.................................................................................................... 34 Precautions while performing service.......................................................................................... 35 Keep the truck clean...................................................................................................... 35 Attachments............................................................................................................... 35 Working under the truck................................................................................................... 35 Rotating fan and belts.................................................................................................... 35 Adding fuel or oil........................................................................................................ 35 Use of lighting........................................................................................................... 35 Radiator coolant level.................................................................................................... 36 Precautions with the battery.............................................................................................. 36 Precautions with high pressure oil........................................................................................ 36 Handling high pressure hoses.............................................................................................. 36 Precautions when performing maintenance near high temperature or high pressure............................................ 36 Waste materials........................................................................................................... 36 Tires......................................................................................................................... 37 Handling tires............................................................................................................ 37 Storing tires after removal............................................................................................... 37 Precautions for performing repairs............................................................................................ 38 Engine shutdown procedure after AC drive system failure................................................................... 38 Precautions for welding on the truck.......................................................................................... 39 Capacitor discharge system.................................................................................................... 40 Necessary tools........................................................................................................... 40 Warnings and cautions..................................................................................................... 41 Manual DC link capacitor discharge procedure.............................................................................. 42 Failure of the discharge system........................................................................................... 44 Manual discharge of capacitors............................................................................................ 45 Short isolated capacitor terminals........................................................................................ 47 Handling electrical equipment and hydraulic components........................................................................ 48 Points to remember when handling electrical equipment..................................................................... 48 Points to remember when handling hydraulic equipment...................................................................... 54 How to read electric wire code................................................................................................ 56 Standard torque tables........................................................................................................ 59 Effect of special lubricants on fasteners and standard torque values...................................................... 59 Standard tightening torques for SAE hex head capscrew and nut assemblies.................................................. 60 Standard assembly torques for 12-point, grade 9 capscrews (SAE)........................................................... 61 Standard assembly torques for class 10.9 cap screws and class 10 nuts..................................................... 61 Standard tightening torques for fittings.................................................................................. 62 Conversion tables............................................................................................................. 64 Common conversion multipliers............................................................................................. 64 Operating instructions............................................................................................................ 69 Preparing for operation....................................................................................................... 71 Walk around inspection.................................................................................................... 71 Engine start-up............................................................................................................... 75 After engine start-up......................................................................................................... 76 Pre-shift brake check......................................................................................................... 76 Events.................................................................................................................... 76 Operation................................................................................................................. 77 Description............................................................................................................... 77 Brake test exit criteria.................................................................................................. 77 Brake test setup.......................................................................................................... 78 Service brake test........................................................................................................ 78 Parking brake test........................................................................................................ 79 Retard system test........................................................................................................ 80 Emergency steering system..................................................................................................... 80 Operation................................................................................................................. 80 Pre-operation testing..................................................................................................... 80 Precautions during truck operation............................................................................................ 81 Operating on a haul road...................................................................................................... 82 Starting on a grade with a loaded truck....................................................................................... 83 Sudden loss of engine power................................................................................................... 83 Fuel depletion................................................................................................................ 84 Towing........................................................................................................................ 84 Special Wiring Harness.................................................................................................... 85 Loading the dump body......................................................................................................... 87 Dumping a load................................................................................................................ 87 Raising the dump body..................................................................................................... 87 Lowering the dump body (on flat ground)................................................................................... 88 Lowering the dump body (over a berm or into a crusher).................................................................... 89 Disabled truck dumping procedure.............................................................................................. 89 Hookup.................................................................................................................... 89 Raising the body.......................................................................................................... 90 Lowering the body......................................................................................................... 90 Safe parking procedure........................................................................................................ 90 Normal engine shutdown procedure.............................................................................................. 91 01 Specification...................................................................................................................... 93 Specification and technical data.................................................................................................. 93 Specification drawing......................................................................................................... 95 Specifications................................................................................................................ 96 Weight table.................................................................................................................. 98 Fuel, coolant and lubricants.................................................................................................. 99 Suspension cylinder oil and nitrogen specifications.......................................................................100 10 Structure, functions and maintenance standard......................................................................................103 Steering circuit..................................................................................................................103 Steering circuit operation....................................................................................................105 Steering circuit components...................................................................................................107 Steering control unit.....................................................................................................107 High pressure filter......................................................................................................107 Steering accumulators.....................................................................................................107 Bleed down manifold.......................................................................................................108 Steering accumulator bleed down solenoid..................................................................................110 Hoist up limit solenoid...................................................................................................110 Quick disconnect ports....................................................................................................110 Flow amplifier............................................................................................................110 Flow amplifier operation......................................................................................................111 No steer..................................................................................................................112 Steering left.............................................................................................................114 Steering right............................................................................................................116 No steer, external shock load.............................................................................................118 Steering/brake pump operation.................................................................................................121 Normal operation..........................................................................................................121 Neutral position..........................................................................................................122 Full pump volume..........................................................................................................123 Half pump volume..........................................................................................................123 Steering cylinder wear data...................................................................................................124 Hoist circuit.....................................................................................................................127 Hoist circuit operation.......................................................................................................129 Hoist circuit components......................................................................................................130 Hydraulic tank............................................................................................................130 Hoist pump................................................................................................................130 High pressure filters.....................................................................................................130 Hoist valve...............................................................................................................130 Inlet sections............................................................................................................131 Tank ports (front) spool section..........................................................................................131 Work ports (rear) spool section...........................................................................................131 Hoist pilot valve.........................................................................................................132 Bleed down manifold.......................................................................................................132 Hoist limit solenoid......................................................................................................132 Pilot operated check valve................................................................................................132 Overcenter manifold.......................................................................................................133 Hoist pilot valve operation...................................................................................................134 Float position with body down.............................................................................................134 Power up operation........................................................................................................136 Hold operation............................................................................................................138 Power down operation......................................................................................................140 Float operation...........................................................................................................142 Hoist cylinder wear data......................................................................................................144 Brake circuits....................................................................................................................147 General information...........................................................................................................149 Service brake circuit operation...............................................................................................150 Secondary braking and auto apply..............................................................................................150 Parking brake circuit operation...............................................................................................152 Normal operation (key switch ON, engine on)...............................................................................152 Wheel brake lock circuit operation............................................................................................153 Brake warning circuit operation...............................................................................................153 Brake assembly wear data......................................................................................................155 Suspensions.......................................................................................................................157 General information...........................................................................................................159 Front suspension wear data....................................................................................................159 Rear suspension wear data.....................................................................................................160 Electrical system, 24 volt........................................................................................................163 Battery supply system.........................................................................................................165 Batteries.................................................................................................................165 24VDC Auxiliary Battery Receptacles.......................................................................................165 Battery Disconnect Switches...............................................................................................165 Engine starting system........................................................................................................166 Engine prelube pump.......................................................................................................166 Prelube pressure switch...................................................................................................166 Engine start relays.......................................................................................................166 Auxiliary control cabinet components..........................................................................................167 24VDC to 12VDC converter..................................................................................................167 Diode board - DB1.........................................................................................................167 Power distribution terminals..............................................................................................167 Control power relay.......................................................................................................167 Fuse blocks...............................................................................................................167 Relay boards..................................................................................................................169 Relay boards RB1, RB3, RB4, RB5...........................................................................................169 Relay boards RB6, RB7, RB8, RB9...........................................................................................171 Relay functions...........................................................................................................171 Body-up switch................................................................................................................173 Hoist limit switch............................................................................................................174 Interface module (IM).............................................................................................................177 General information...........................................................................................................179 Sensors.......................................................................................................................179 Temperature sensors.......................................................................................................179 Pressure sensors..........................................................................................................179 Interface module inputs and outputs...........................................................................................180 Electrical system, AC drive.......................................................................................................187 General system operation......................................................................................................189 AC drive system components....................................................................................................191 Propulsion system controller (PSC)........................................................................................191 Truck control interface (TCI).............................................................................................192 Diagnostic information display (DID) panel................................................................................192 PSC software functions........................................................................................................193 Input processing..........................................................................................................193 State machine.............................................................................................................193 DC link state.............................................................................................................196 Engine control............................................................................................................197 Alternator field control......................................................................................................198 Desired three-phase voltage...............................................................................................198 Desired DC link voltage...................................................................................................198 Self-load.................................................................................................................198 Propel torque control.....................................................................................................198 Retard torque control.....................................................................................................199 Wheel slide control.......................................................................................................199 Resistor grid control.....................................................................................................199 Chopper voltage control...................................................................................................199 Event detection and processing................................................................................................200 Power-on tests............................................................................................................200 Initiated tests...........................................................................................................201 Periodic tests............................................................................................................201 Event restrictions........................................................................................................201 Event logging and storage.....................................................................................................201 Event history buffer......................................................................................................201 Data packs................................................................................................................202 Event reset...............................................................................................................203 Serial data communications....................................................................................................203 PSC to TCI communications processing......................................................................................203 PSC to PTU communications processing......................................................................................203 Inverter communications processing........................................................................................204 Output processing.........................................................................................................204 Abnormal conditions/overriding functions......................................................................................204 Fast start................................................................................................................204 Engine shutdown/Engine not running........................................................................................204 Limp home mode............................................................................................................205 AC drive system component table...............................................................................................206 Cab air conditioning..............................................................................................................215 General information...........................................................................................................216 Environmental impact of air conditioning..................................................................................216 Air conditioning for off-highway vehicles.................................................................................216 Principles of refrigeration...................................................................................................217 Air conditioning..........................................................................................................217 Refrigeration - the act of cooling........................................................................................217 The refrigeration cycle...................................................................................................217 Air conditioning system components............................................................................................219 Relays....................................................................................................................219 Fan motor and speed control...............................................................................................219 Cab air filter............................................................................................................219 Heater core...............................................................................................................219 Actuators.................................................................................................................219 Compressor (refrigerant pump).............................................................................................221 Service valves............................................................................................................221 Condenser.................................................................................................................221 Receiver-drier............................................................................................................221 Expansion valve...........................................................................................................222 Accumulator...............................................................................................................222 Evaporator core...........................................................................................................222 Air conditioning system electrical circuit....................................................................................223 Thermostat................................................................................................................223 Compressor clutch.........................................................................................................223 Trinary™ switch...........................................................................................................224 Reserve engine oil system.........................................................................................................227 General information...........................................................................................................229 Operation.....................................................................................................................230 LED monitor light.........................................................................................................230 Remote tank fill system.......................................................................................................231 20 Standard value table...............................................................................................................233 Standard value table..............................................................................................................233 Standard value table for truck................................................................................................235 30 Testing and adjusting..............................................................................................................241 General information...............................................................................................................241 Special tool list.............................................................................................................243 Steering, brake cooling and hoist hydraulic system................................................................................245 General information on system checkout........................................................................................247 Steering system checkout procedures...........................................................................................247 Steering pump pressure control adjustments................................................................................248 Steering control valve and flow amplifier leakage test....................................................................249 Bleed down manifold leakage test..........................................................................................250 Shock and suction valve pressure tests....................................................................................251 Steering system checkout data sheet...........................................................................................253 Toe-in adjustment.............................................................................................................254 Brake cooling and hoist system checkout procedures............................................................................255 Pressure gauge locations..................................................................................................255 Brake cooling circuit test................................................................................................256 Power up relief pressure test.............................................................................................256 Power down relief pressure test...........................................................................................257 Counterbalance valve pressure check.......................................................................................258 Counterbalance valve adjustment...........................................................................................259 Brake cooling and hoist system checkout data sheet............................................................................260 Hoist cylinder leakage test...................................................................................................261 Hydraulic system flushing procedure...........................................................................................261 Brake system......................................................................................................................269 General information on system checkout........................................................................................271 Brake circuit checkout procedure..............................................................................................271 Initial system setup......................................................................................................273 Brake lock / secondary braking checkout...................................................................................273 Parking brake checkout....................................................................................................274 Service brake checkout....................................................................................................275 Low brake accumulator pressure and auto apply checkout....................................................................275 Parking brake control logic checkout......................................................................................277 Brake lock control logic checkout.........................................................................................279 Brake system checkout data sheet..............................................................................................281 Brake piston leakage test.....................................................................................................285 Brake seal pressure test......................................................................................................285 Wet disc brake bleeding procedure.............................................................................................286 Parking brake bleeding procedure..............................................................................................286 Brake disc wear inspection....................................................................................................287 Brake valve bench test and adjustment.........................................................................................289 Test setup procedure......................................................................................................290 Brake valve output pressure adjustment....................................................................................290 Final test and adjustment.................................................................................................291 Dual relay valve bench test and adjustment....................................................................................292 Test setup procedure......................................................................................................293 Relay valve output pressure adjustment....................................................................................293 Accumulators and suspensions......................................................................................................295 Accumulator charging and storage..............................................................................................297 Accumulator charging procedures...........................................................................................297 Precharge maintenance.....................................................................................................300 Accumulator storage procedure.............................................................................................301 Bladder storage...........................................................................................................301 Installing a bladder accumulator from storage.............................................................................301 Accumulator leak testing......................................................................................................302 Suspension oiling and charging procedures.....................................................................................304 Equipment list............................................................................................................304 Installing the charging kit...............................................................................................304 Removing the charging kit.................................................................................................305 Support blocks for oiling and charging dimensions.........................................................................305 Front suspension oiling...................................................................................................306 Front suspension nitrogen charging........................................................................................307 Rear suspension oiling....................................................................................................308 Rear suspension nitrogen charging.........................................................................................310 Suspension pressure test......................................................................................................311 KOMTRAX Plus and payload meter....................................................................................................313 KOMTRAX Plus and payload meter software.......................................................................................315 VHMS Tool Box Installation................................................................................................315 VHMS Setting Tool Installation............................................................................................315 Installing the PDM software...............................................................................................315 KOMTRAX Plus controller initial setting procedure.............................................................................316 KOMTRAX Plus controller setup procedure...................................................................................316 KOMTRAX Plus snapshot procedure...........................................................................................319 KOMTRAX Plus download procedure...........................................................................................320 KOMTRAX Plus FTP upload procedure.........................................................................................321 KOMTRAX Plus initialization forms.........................................................................................322 KOMTRAX Plus initialization check list........................................................................................323 KOMTRAX Plus initialization form..............................................................................................325 Precautions for replacing KOMTRAX Plus controller.............................................................................326 KOMTRAX Plus controller checkout procedure....................................................................................331 Necessary equipment.......................................................................................................331 Preliminary...............................................................................................................331 Checkout procedure........................................................................................................332 Payload meter initial setting procedure.......................................................................................334 Starting communications...................................................................................................334 Configure payload meter...................................................................................................334 Setting truck number......................................................................................................336 Clean truck tare..........................................................................................................337 Inclinometer calibration..................................................................................................337 Interface module (IM).............................................................................................................339 Interface module software.....................................................................................................341 Flashburn program installation............................................................................................341 Interface module application code installation............................................................................342 Interface module realtime data monitor software installation..............................................................342 Interface module checkout procedures..........................................................................................343 Necessary equipment.......................................................................................................343 Preliminary...............................................................................................................344 Check digital inputs to the interface module..............................................................................345 Check analog inputs to the interface module...............................................................................348 Check serial interfaces to the interface module...........................................................................348 Check outputs from the interface module...................................................................................349 Cab air conditioning..............................................................................................................351 General information...........................................................................................................352 Service tools and equipment...................................................................................................353 Recovery/recycle station..................................................................................................353 Leak detector.............................................................................................................353 Manifold gauge set........................................................................................................354 Service valves............................................................................................................355 Vacuum pump...............................................................................................................355 Detecting leaks...............................................................................................................356 System performance test.......................................................................................................357 Checking system oil...........................................................................................................358 System flushing...............................................................................................................359 Installing the manifold gauge set.............................................................................................360 Purging air from the service hoses........................................................................................360 Recovering and recycling refrigerant..........................................................................................361 Draining oil from previous recovery cycle.................................................................................362 Recovery cycle............................................................................................................362 Recycling procedure.......................................................................................................362 Evacuating the air conditioning system........................................................................................363 Charging the air conditioning system..........................................................................................364 40 Troubleshooting....................................................................................................................367 Fuse and circuit breaker locations................................................................................................367 Fuse and circuit breaker locations............................................................................................369 AC drive system fault codes.......................................................................................................375 DID panel fault code tables...................................................................................................377 Troubleshooting by fault code, Part 1.............................................................................................397 Fault Code A001: Left front suspension pressure sensor signal high............................................................399 Related circuit diagram...................................................................................................399 Fault Code A002: Left front suspension pressure sensor signal low.............................................................400 Related circuit diagram...................................................................................................400 Fault Code A003: Right front suspension pressure sensor signal high...........................................................401 Related circuit diagram...................................................................................................401 Fault Code A004: Right front suspension pressure sensor signal low............................................................402 Related circuit diagram...................................................................................................402 Fault Code A005: Left rear suspension pressure sensor signal high.............................................................403 Related circuit diagram...................................................................................................403 Fault Code A006: Left rear suspension pressure sensor signal low..............................................................404 Related circuit diagram...................................................................................................404 Fault Code A007: Right rear suspension pressure sensor signal high............................................................405 Related circuit diagram...................................................................................................405 Fault Code A008: Right rear suspension pressure sensor signal low.............................................................406 Related circuit diagram...................................................................................................406 Fault Code A009: Incline sensor signal high...................................................................................407 Related circuit diagram...................................................................................................407 Fault Code A010: Incline sensor signal low....................................................................................408 Related circuit diagram...................................................................................................408 Fault Code A011: Payload meter speed sensor signal has failed.................................................................409 Related circuit diagram...................................................................................................409 Fault Code A013: Body up switch has failed....................................................................................410 Related circuit diagram...................................................................................................410 Fault Code A014: Payload meter checksum computation has failed................................................................411 Related circuit diagram...................................................................................................411 Fault Code A016: Payload meter write to flash memory has failed...............................................................412 Related circuit diagram...................................................................................................412 Fault Code A017: Payload meter flash memory read has failed...................................................................413 Related circuit diagram...................................................................................................413 Fault Code A018: Right rear flat suspension cylinder warning..................................................................414 Related circuit diagram...................................................................................................415 Fault Code A019: Left rear flat suspension cylinder warning...................................................................416 Related circuit diagram...................................................................................................417 Fault Code A022: Carryback load excessive.....................................................................................418 Related circuit diagram...................................................................................................419 Fault Code A100: An open circuit breaker has been detected on a relay board...................................................421 Related circuit diagram...................................................................................................421 Fault Code A101: High pressure detected across an hydraulic pump filter.......................................................422 Related circuit diagram...................................................................................................423 Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level......................................424 Related circuit diagram...................................................................................................425 Fault Code A107: GE has generated a propel system caution.....................................................................426 Related circuit diagram...................................................................................................426 Fault Code A108: GE has generated a propel system temperature caution.........................................................427 Related circuit diagram...................................................................................................427 Fault Code A109: GE has generated a propel system reduced level signal........................................................428 Related circuit diagram...................................................................................................428 Fault Code A111: Low steering pressure warning................................................................................429 Related circuit diagram...................................................................................................429 Fault Code A115: Low steering precharge pressure detected.....................................................................430 Related circuit diagram...................................................................................................431 Fault Code A117: Low brake accumulator pressure warning.......................................................................432 Related circuit diagram...................................................................................................432 Fault Code A118: Brake pressure is low while in brake lock....................................................................434 Related circuit diagram...................................................................................................435 Fault Code A123: GE has generated a reduced retarding caution.................................................................436 Related circuit diagram...................................................................................................436 Fault Code A124: GE has generated a no propel / no retard warning.............................................................437 Related circuit diagram...................................................................................................437 Fault Code A125: GE has generated a no propel warning.........................................................................438 Related circuit diagram...................................................................................................438 Fault Code A126: Oil level in the hydraulic tank is low.......................................................................439 Related circuit diagram...................................................................................................439 Fault Code A127: IM-furnished +5 volt output for sensors is low...............................................................440 Related circuit diagram...................................................................................................441 Fault Code A128: IM-furnished +5 volt output for sensors is high..............................................................442 Related circuit diagram...................................................................................................443 Fault Code A139: Low fuel warning.............................................................................................444 Related circuit diagram...................................................................................................445 Troubleshooting by fault code, Part 2.............................................................................................447 Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil....450 Related circuit diagram...................................................................................................451 Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil....452 Related circuit diagram...................................................................................................453 Fault Code A152: Starter failure..............................................................................................454 Related circuit diagram...................................................................................................455 Fault Code A153: Battery voltage is low with the truck in operation...........................................................456 Related circuit diagram...................................................................................................457 Fault Code A154: Battery charging voltage is excessive........................................................................458 Related circuit diagram...................................................................................................458 Fault Code A155: Battery charging voltage is low..............................................................................459 Related circuit diagram...................................................................................................459 Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level.................................460 Related circuit diagram...................................................................................................461 Fault Code A166: Left rear hydraulic oil temperature sensor is low............................................................462 Related circuit diagram...................................................................................................463 Fault Code A167: Right rear hydraulic oil temperature sensor is low...........................................................464 Related circuit diagram...................................................................................................465 Fault Code A168: Left front hydraulic oil temperature sensor is low...........................................................466 Related circuit diagram...................................................................................................467 Fault Code A169: Right front hydraulic oil temperature sensor is low..........................................................468 Related circuit diagram...................................................................................................469 Fault Code A170: Left rear hydraulic oil temperature sensor is high...........................................................470 Related circuit diagram...................................................................................................470 Fault Code A171: Right rear hydraulic oil temperature sensor is high..........................................................471 Related circuit diagram...................................................................................................471 Fault Code A172: Left front hydraulic oil temperature sensor is high..........................................................472 Related circuit diagram...................................................................................................472 Fault Code A173: Right front hydraulic oil temperature sensor is high.........................................................473 Related circuit diagram...................................................................................................473 Fault Code A184: J1939 data link is not connected.............................................................................474 Related circuit diagram...................................................................................................475 Fault Code A190: Auto lube control has detected an incomplete lube cycle......................................................476 Related circuit diagram...................................................................................................477 Fault Code A194: Left front hydraulic oil temperature is high.................................................................478 Related circuit diagram...................................................................................................478 Fault Code A195: Right front hydraulic oil temperature is high................................................................479 Related circuit diagram...................................................................................................479 Fault Code A196: Left rear hydraulic oil temperature is high..................................................................480 Related circuit diagram...................................................................................................480 Fault Code A197: Right rear hydraulic oil temperature is high.................................................................481 Related circuit diagram...................................................................................................481 Fault Code A198: Hoist pressure 1 sensor is high..............................................................................482 Related circuit diagram...................................................................................................482 Fault Code A199: Hoist pressure 2 sensor is high..............................................................................483 Related circuit diagram...................................................................................................483 Fault Code A200: Steering pressure sensor is high.............................................................................484 Related circuit diagram...................................................................................................484 Fault Code A201: Brake pressure sensor is high................................................................................485 Related circuit diagram...................................................................................................485 Fault Code A202: Hoist pressure 1 sensor is low...............................................................................486 Related circuit diagram...................................................................................................487 Fault Code A203: Hoist pressure 2 sensor is low...............................................................................488 Related circuit diagram...................................................................................................489 Fault Code A204: Steering pressure sensor is low..............................................................................490 Related circuit diagram...................................................................................................491 Fault Code A205: Brake pressure sensor is low.................................................................................492 Related circuit diagram...................................................................................................493 Fault Code A206: Ambient temperature sensor is high...........................................................................494 Related circuit diagram...................................................................................................494 Fault Code A207: Ambient temperature sensor is low............................................................................495 Related circuit diagram...................................................................................................495 Troubleshooting by fault code, Part 3.............................................................................................497 Fault Code A212: Bad truck speed signal.......................................................................................500 Related circuit diagram...................................................................................................501 Fault Code A213: Parking brake should have applied but is detected as not having applied......................................502 Related circuit diagram...................................................................................................504 Fault Code A214: Parking brake should have released but is detected as not having released....................................506 Related circuit diagram...................................................................................................508 Fault Code A215: Brake auto apply valve circuit is defective..................................................................510 Related circuit diagram...................................................................................................511 Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit......................512 Related circuit diagram...................................................................................................513 Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted....................................514 Related circuit diagram...................................................................................................515 Fault Code A230: Parking brake has been requested while truck still moving....................................................518 Related circuit diagram...................................................................................................519 Fault Code A231: The body is up with engine running and brakes not on.........................................................520 Related circuit diagram...................................................................................................521 Fault Code A235: Steering accumulator is in the process of being bled down....................................................522 Related circuit diagram...................................................................................................523 Fault Code A236: The steering accumulator has not properly bled down after 90 seconds.........................................524 Related circuit diagram...................................................................................................525 Fault Code A237: The CAN/RPC connection to the display is open................................................................526 Related circuit diagram...................................................................................................526 Fault Code A240: The key switch input to the interface module is open.........................................................527 Related circuit diagram...................................................................................................527 Fault Code A242: Fuel gauge within the dash display panel is defective........................................................528 Related circuit diagram...................................................................................................528 Fault Code A243: Engine coolant temperature gauge within the dash display panel is defective..................................529 Related circuit diagram...................................................................................................529 Fault Code A244: Drive system temperature gauge within the dash display panel is defective....................................530 Related circuit diagram...................................................................................................530 Fault Code A245: Hydraulic oil temperature gauge within the dash display panel is defective...................................531 Related circuit diagram...................................................................................................531 Fault Code A246: Payload meter reports truck overload.........................................................................532 Related circuit diagram...................................................................................................532 Fault Code A247: Low steering pressure warning................................................................................534 Related circuit diagram...................................................................................................535 Fault Code A248: Status module within the dash display panel is defective.....................................................536 Related circuit diagram...................................................................................................536 Fault Code A249: Red warning lamp within the dash display (driven by IM) is shorted...........................................537 Related circuit diagram...................................................................................................537 Fault Code A250: Battery voltage is low with the truck parked.................................................................538 Related circuit diagram...................................................................................................539 Fault Code A251: Sonalert used with the dash display (driven by IM) is open or shorted to ground..............................540 Related circuit diagram...................................................................................................541 Fault Code A252: Start enable output circuit is either open or shorted to ground..............................................542 Related circuit diagram...................................................................................................543 Fault Code A253: Steering bleed circuit is not open while running.............................................................544 Related circuit diagram...................................................................................................545 Fault Code A256: Red warning lamp in the dash display (driven by IM) is open..................................................546 Related circuit diagram...................................................................................................546 Fault Code A257: Payload CAN/RPC is not connected.............................................................................547 Related circuit diagram...................................................................................................547 Fault Code A258: Steering accumulator bleed pressure switch circuit is defective..............................................548 Related circuit diagram...................................................................................................548 Troubleshooting by fault code, Part 4.............................................................................................551 Fault Code A260: Parking brake failure........................................................................................554 Related circuit diagram...................................................................................................555 Fault Code A261: Low brake accumulator pressure warning.......................................................................556 Related circuit diagram...................................................................................................557 Fault Code A262: Steering bleed valve circuit open during shutdown............................................................558 Related circuit diagram...................................................................................................559 Fault Code A264: Parking brake relay circuit is defective.....................................................................560 Related circuit diagram...................................................................................................561 Fault Code A265: Service brake failure........................................................................................562 Related circuit diagram...................................................................................................563 Fault Code A266: Selector lever was not in park while attempting to crank engine..............................................564 Related circuit diagram...................................................................................................564 Fault Code A267: Parking brake was not set while attempting to crank engine...................................................565 Related circuit diagram...................................................................................................565 Fault Code A268: Secondary engine shutdown while cranking.....................................................................566 Related circuit diagram...................................................................................................566 Fault Code A270: Brake lock switch power supply is not on when required.......................................................568 Related circuit diagram...................................................................................................570 Fault Code A271: Shifter not in gear..........................................................................................572 Related circuit diagram...................................................................................................573 Fault Code A272: Brake lock switch power supply is not off when required......................................................574 Related circuit diagram...................................................................................................576 Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit.......................577 Related circuit diagram...................................................................................................577 Fault Code A274: A brake setting fault has been detected......................................................................578 Related circuit diagram...................................................................................................579 Fault Code A275: A starter has been detected as engaged without a cranking attempt............................................580 Related circuit diagram...................................................................................................581 Fault Code A276: The drive system data link is not connected..................................................................582 Related circuit diagram...................................................................................................583 Fault Code A277: Parking brake applied while loading..........................................................................584 Related circuit diagram...................................................................................................585 Fault Code A278: Service brake applied while loading..........................................................................586 Related circuit diagram...................................................................................................587 Fault Code A279: Low steering pressure switch is defective....................................................................588 Related circuit diagram...................................................................................................588 Fault Code A280: Steering accumulator bleed down switch is defective..........................................................589 Related circuit diagram...................................................................................................589 Fault Code A281: Brake lock degrade switch is defective.......................................................................590 Related circuit diagram...................................................................................................591 Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7.............592 Related circuit diagram...................................................................................................593 Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set...................................596 Related circuit diagram...................................................................................................597 Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated......................598 Related circuit diagram...................................................................................................599 Fault Code A285: The parking brake was not set when the key switch was turned off.............................................600 Related circuit diagram...................................................................................................601 Fault Code A286: A fault was detected in the shutdown delay relay circuit.....................................................602 Related circuit diagram...................................................................................................603 Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off.........................604 Related circuit diagram...................................................................................................605 Troubleshooting by fault code, Part 5.............................................................................................607 Fault Code A303: Shifter is defective.........................................................................................610 Related circuit diagram...................................................................................................611 Fault Code A304: Auto lube grease level fault.................................................................................612 Related circuit diagram...................................................................................................612 Fault Code A305: Auto lube circuit is defective...............................................................................614 Related circuit diagram...................................................................................................615 Fault Code A307: Both GE inverters are disabled...............................................................................616 Related circuit diagram...................................................................................................616 Fault Code A309: No brakes applied when expected..............................................................................618 Related circuit diagram...................................................................................................619 Fault Code A310: Low fuel warning.............................................................................................620 Related circuit diagram...................................................................................................621 Fault Code A311: Brake lock switch is on when it should not be................................................................622 Related circuit diagram...................................................................................................623 Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings.............................................624 Related circuit diagram...................................................................................................624 Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings............................................625 Related circuit diagram...................................................................................................625 Fault Code A315: DCDC converter 12 volt circuit is low........................................................................626 Related circuit diagram...................................................................................................627 Fault Code A316: Starter engagement has been attempted with engine running....................................................628 Related circuit diagram...................................................................................................629 Fault Code A317: Operation of brake auto apply valve without a detected response..............................................630 Related circuit diagram...................................................................................................631 Fault Code A318: Unexpected power loss to interface module....................................................................632 Related circuit diagram...................................................................................................632 Fault Code A320: Data link reports GE propel system caution fault but wired input does not....................................634 Related circuit diagram...................................................................................................635 Fault Code A321: Data link reports GE propel system temp caution fault but wired input does not...............................636 Related circuit diagram...................................................................................................637 Fault Code A322: Data link reports GE propel system reduced level fault but wired input does not..............................638 Related circuit diagram...................................................................................................639 Fault Code A323: Data link reports GE reduced retard level fault but wired input does not.....................................640 Related circuit diagram...................................................................................................641 Fault Code A324: Data link reports DC link voltage but wired input does not...................................................642 Related circuit diagram...................................................................................................643 Fault Code A325: Data link reports GE no propel/retard fault but wired input does not.........................................644 Related circuit diagram...................................................................................................645 Fault Code A326: Data link reports GE no propel fault but wired input does not................................................646 Related circuit diagram...................................................................................................647 Fault Code A327: Data link reports GE at rest but wired input does not........................................................648 Related circuit diagram...................................................................................................649 Fault Code A328: Drive system not powered up..................................................................................650 Related circuit diagram...................................................................................................650 Fault Code A329: Data link reports the body is not down but wired input says it is............................................652 Related circuit diagram...................................................................................................653 Fault Code A330: Data link reports dynamic retard operating state but wired input does not....................................654 Related circuit diagram...................................................................................................655 Troubleshooting by fault code, Part 6.............................................................................................657 Fault Code A350: Overload on output 1B........................................................................................659 Related circuit diagram...................................................................................................659 Fault Code A351: Overload on output 1E........................................................................................660 Related circuit diagram...................................................................................................661 Fault Code A352: Overload on output 1H........................................................................................662 Related circuit diagram...................................................................................................662 Fault Code A353: Overload on output 1J........................................................................................663 Related circuit diagram...................................................................................................663 Fault Code A354: Overload on output 1K........................................................................................664 Related circuit diagram...................................................................................................665 Fault Code A355: Overload on output 1L........................................................................................666 Related circuit diagram...................................................................................................666 Fault Code A356: Overload on output 1M........................................................................................667 Related circuit diagram...................................................................................................667 Fault Code A357: Overload on output 1N........................................................................................668 Related circuit diagram...................................................................................................668 Fault Code A358: Overload on output 1P........................................................................................669 Related circuit diagram...................................................................................................669 Fault Code A359: Overload on output 1R........................................................................................670 Related circuit diagram...................................................................................................670 Fault Code A360: Overload on output 1S........................................................................................671 Related circuit diagram...................................................................................................671 Fault Code A361: Overload on output 1T........................................................................................672 Related circuit diagram...................................................................................................673 Fault Code A362: Overload on output 1U........................................................................................674 Related circuit diagram...................................................................................................674 Fault Code A363: Overload on output 1X........................................................................................676 Related circuit diagram...................................................................................................677 Fault Code A364: Overload on output 1Y........................................................................................678 Related circuit diagram...................................................................................................678 Fault Code A365: Overload on output 1Z........................................................................................679 Related circuit diagram...................................................................................................679 Cab air conditioning..............................................................................................................681 Preliminary checks............................................................................................................683 Diagnosis of gauge readings and system performance............................................................................683 Troubleshooting by manifold gauge set readings................................................................................684 Reserve engine oil system.........................................................................................................691 Pumping unit LED signals......................................................................................................693 Circuit fuses.............................................................................................................693 50 Disassembly and assembly...........................................................................................................695 General information...............................................................................................................695 Special tool list.............................................................................................................697 Wheels, spindles and rear axle....................................................................................................703 General information for tires and rims........................................................................................705 Storage and handling......................................................................................................705 Wheel stud maintenance....................................................................................................706 Removal and installation of front wheel.......................................................................................706 Removal...................................................................................................................706 Installation..............................................................................................................707 Removal and installation of rear wheel........................................................................................708 Removal...................................................................................................................708 Installation..............................................................................................................709 Removal and installation of tires.............................................................................................710 Removal...................................................................................................................710 Installation..............................................................................................................711 Removal and installation of front wheel hub and spindle.......................................................................712 Removal...................................................................................................................713 Spindle removal (off the truck)...........................................................................................716 Installation..............................................................................................................718 Disassembly and assembly of front wheel hub and spindle.......................................................................719 Disassembly...............................................................................................................719 Cleaning and inspection...................................................................................................719 Assembly..................................................................................................................721 Wheel bearing adjustment..................................................................................................721 Seal assembly gap check and adjustment....................................................................................722 Brake installation........................................................................................................723 Speed sensor installation and adjustment..................................................................................723 Removal and installation of rear axle.........................................................................................724 Removal...................................................................................................................724 Cleaning and inspection...................................................................................................725 Installation..............................................................................................................725 Removal and installation of anti-sway bar.....................................................................................726 Removal...................................................................................................................726 Installation..............................................................................................................726 Removal and installation of pivot pin.........................................................................................727 Removal...................................................................................................................727 Installation..............................................................................................................727 Pivot eye and bearing service.................................................................................................728 Bearing removal...........................................................................................................728 Bearing installation......................................................................................................728 Pivot eye repair..........................................................................................................729 Removal and installation of wheel motor.......................................................................................730 Preparation...............................................................................................................730 Removal...................................................................................................................730 Cleaning and inspection...................................................................................................731 Installation..............................................................................................................733 Removal and installation of rear brake assembly...............................................................................737 Removal...................................................................................................................737 Installation..............................................................................................................737 Brake system......................................................................................................................741 Removal and installation of brake valve.......................................................................................743 Removal...................................................................................................................743 Installation..............................................................................................................744 Disassembly and assembly of brake valve.......................................................................................744 Disassembly...............................................................................................................744 Cleaning and inspection...................................................................................................748 Assembly..................................................................................................................748 Removal and installation of dual relay valve..................................................................................751 Removal...................................................................................................................751 Installation..............................................................................................................752 Disassembly and assembly of dual relay valve..................................................................................753 Disassembly...............................................................................................................753 Cleaning and inspection...................................................................................................754 Assembly..................................................................................................................754 Removal and installation of brake manifold....................................................................................755 Removal...................................................................................................................755 Installation..............................................................................................................755 Disassembly and assembly of brake manifold....................................................................................756 Disassembly...............................................................................................................756 Assembly..................................................................................................................756 Removal and installation of brake accumulator.................................................................................757 Removal...................................................................................................................757 Installation..............................................................................................................757 Disassembly and assembly of brake accumulator.................................................................................758 Disassembly...............................................................................................................758 Cleaning and inspection...................................................................................................759 Assembly..................................................................................................................760 Disassembly and assembly of wheel brake.......................................................................................761 Disassembly...............................................................................................................762 Cleaning and inspection...................................................................................................765 Assembly..................................................................................................................766 Floating ring seal assembly and installation..............................................................................769 Removal and installation of parking brake.....................................................................................773 Removal...................................................................................................................773 Installation..............................................................................................................775 Disassembly and assembly of parking brake.....................................................................................775 Disassembly...............................................................................................................775 Cleaning and inspection...................................................................................................776 Assembly..................................................................................................................778 Cleaning and inspecting new discs.........................................................................................780 Steering system...................................................................................................................783 Removal and installation of steering control unit.............................................................................785 Removal...................................................................................................................785 Installation..............................................................................................................786 Disassembly and assembly of steering control unit.............................................................................787 Disassembly...............................................................................................................787 Assembly..................................................................................................................789 Removal and installation of steering column...................................................................................792 Removal...................................................................................................................792 Inspection................................................................................................................792 Installation..............................................................................................................793 Removal and installation of steering wheel....................................................................................793 Removal...................................................................................................................793 Installation..............................................................................................................794 Removal and installation of bleed down manifold...............................................................................795 Removal...................................................................................................................795 Installation..............................................................................................................796 Removal and installation of flow amplifier....................................................................................797 Removal...................................................................................................................797 Installation..............................................................................................................797 Disassembly and assembly of flow amplifier....................................................................................797 Disassembly...............................................................................................................797 Assembly..................................................................................................................799 Removal and installation of steering cylinders and tie rod....................................................................800 Removal...................................................................................................................800 Bearing replacement.......................................................................................................800 Installation..............................................................................................................800 Disassembly and assembly of steering cylinders................................................................................801 Disassembly...............................................................................................................801 Assembly..................................................................................................................802 Removal and installation of steering/brake pump...............................................................................802 Removal...................................................................................................................802 Installation..............................................................................................................803 Disassembly and assembly of steering/brake pump...............................................................................805 Disassembly...............................................................................................................805 Inspection................................................................................................................808 Assembly..................................................................................................................811 Driveshaft group..........................................................................................................812 Rotating group............................................................................................................812 Removal and installation of steering accumulators.............................................................................814 Removal...................................................................................................................814 Installation..............................................................................................................815 Disassembly and assembly of steering accumulators.............................................................................815 Disassembly...............................................................................................................815 Cleaning and Inspection...................................................................................................816 Assembly..................................................................................................................817 Suspensions.......................................................................................................................821 Removal and installation of front suspension..................................................................................823 Removal...................................................................................................................823 Installation..............................................................................................................824 Inspection................................................................................................................827 Minor front suspension repairs (lower bearing and seals)......................................................................830 Lower bearing retainer removal............................................................................................830 Lower bearing retainer installation.......................................................................................830 Major front suspension rebuild................................................................................................831 Disassembly...............................................................................................................831 Assembly..................................................................................................................832 Removal and installation of rear suspension...................................................................................834 Removal...................................................................................................................835 Installation..............................................................................................................837 Disassembly and assembly of rear suspension...................................................................................837 Disassembly...............................................................................................................837 Cleaning and Inspection...................................................................................................838 Assembly..................................................................................................................838 Hoist circuit.....................................................................................................................841 Removal and installation of hoist pump........................................................................................843 Removal...................................................................................................................843 Installation..............................................................................................................844 Disassembly and assembly of hoist pump........................................................................................845 Disassembly...............................................................................................................845 Inspection................................................................................................................848 Assembly..................................................................................................................848 Removal and installation of hoist valve.......................................................................................853 Removal...................................................................................................................853 Installation..............................................................................................................854 Disassembly and assembly of hoist valve.......................................................................................854 O-ring replacement........................................................................................................854 Disassembly of inlet section..............................................................................................855 Assembly of inlet section.................................................................................................856 Disassembly of rear spool section.........................................................................................857 Assembly of rear spool section............................................................................................859 Disassembly of front spool section........................................................................................860 Assembly of front spool section...........................................................................................861 Overcenter valve manifold service.............................................................................................861 Removal and installation of hoist pilot valve.................................................................................862 Removal...................................................................................................................862 Installation..............................................................................................................862 Disassembly and assembly of hoist pilot valve.................................................................................863 Disassembly...............................................................................................................863 Cleaning and inspection...................................................................................................864 Assembly..................................................................................................................864 Removal and installation of hoist cylinders...................................................................................865 Removal...................................................................................................................865 Installation..............................................................................................................866 Disassembly and assembly of hoist cylinders...................................................................................867 Disassembly...............................................................................................................867 Cleaning and inspection...................................................................................................869 Installation of the quill.................................................................................................870 Assembly..................................................................................................................872 Operator cab......................................................................................................................875 Removal and installation of operator cab......................................................................................877 Removal...................................................................................................................878 Installation..............................................................................................................879 Removal and installation of cab door..........................................................................................880 Removal...................................................................................................................880 Installation..............................................................................................................880 Disassembly and assembly of cab door..........................................................................................880 Removing door panel.......................................................................................................880 Installing door panel.....................................................................................................881 Replacing door window regulator...........................................................................................881 Replacing door handle or latch assembly...................................................................................882 Replacing door assembly seal and door hinge seal..........................................................................883 Replacing door opening seal...............................................................................................883 Removing door glass.......................................................................................................884 Installing door glass.....................................................................................................885 Adjustment of cab door........................................................................................................887 Door jamb bolt adjustment.................................................................................................887 Door handle plunger adjustment............................................................................................888 Removal and installation of side window glass.................................................................................889 Recommended tools and supplies............................................................................................889 Removal...................................................................................................................890 Installation..............................................................................................................890 Removal and installation of windshield and rear window glass..................................................................891 Removal...................................................................................................................891 Installation..............................................................................................................891 Removal and installation of windshield wiper motor............................................................................892 Removal...................................................................................................................892 Installation..............................................................................................................892 Removal and installation of windshield wiper arm..............................................................................893 Removal...................................................................................................................893 Installation..............................................................................................................893 Removal and installation of windshield wiper linkage..........................................................................894 Removal...................................................................................................................894 Installation..............................................................................................................894 Removal and installation of operator seat.....................................................................................895 Inspection................................................................................................................895 Removal...................................................................................................................895 Installation..............................................................................................................895 Removal and installation of passenger seat....................................................................................896 Removal...................................................................................................................896 Installation..............................................................................................................896 Removal and installation of seat belts (standard seats).......................................................................897 Removal...................................................................................................................897 Installation..............................................................................................................897 Removal and installation of seat belts (optional seats).......................................................................899 General...................................................................................................................899 Removal...................................................................................................................899 Installation..............................................................................................................901 Body and structures...............................................................................................................905 Removal and installation of dump body.........................................................................................907 Removal...................................................................................................................907 Inspection................................................................................................................908 Installation..............................................................................................................909 Removal and installation of body pads.........................................................................................910 Removal...................................................................................................................910 Installation..............................................................................................................910 Body pad shimming procedure...............................................................................................911 Removal and installation of diagonal ladder/hood and grille assembly..........................................................912 Removal...................................................................................................................912 Installation..............................................................................................................912 Removal and installation of right deck........................................................................................914 Removal...................................................................................................................914 Installation..............................................................................................................914 Removal and installation of left deck.........................................................................................916 Removal...................................................................................................................916 Installation..............................................................................................................916 Removal and installation of fuel tank.........................................................................................918 Removal...................................................................................................................918 Cleaning and inspection...................................................................................................918 Installation..............................................................................................................920 Removal and installation of fuel gauge sender.................................................................................920 Removal...................................................................................................................920 Installation..............................................................................................................920 Disassembly and assembly of fuel tank breather................................................................................921 Disassembly...............................................................................................................921 Assembly..................................................................................................................921 Removal and installation of hydraulic tank....................................................................................922 Removal...................................................................................................................922 Installation..............................................................................................................922 Cab air conditioning..............................................................................................................925 Replacement of air conditioning system components.............................................................................927 Hoses and fittings........................................................................................................927 Lines.....................................................................................................................927 Expansion valve...........................................................................................................927 Receiver-drier............................................................................................................927 Thermostat................................................................................................................927 Compressor................................................................................................................928 Accumulator...............................................................................................................928 Clutch....................................................................................................................928 Power module......................................................................................................................931 Removal and installation of power module......................................................................................933 General...................................................................................................................933 Preparation...............................................................................................................933 Removal...................................................................................................................934 Installation..............................................................................................................940 Removal and installation of alternator........................................................................................942 Removal...................................................................................................................942 Installation..............................................................................................................944 Removal and installation of engine............................................................................................947 Removal...................................................................................................................947 Service...................................................................................................................947 Installation..............................................................................................................947 Removal and installation of radiator..........................................................................................948 Removal...................................................................................................................948 Installation..............................................................................................................950 Repairing the radiator........................................................................................................951 Internal inspection.......................................................................................................951 External cleaning.........................................................................................................951 Disassembly...............................................................................................................951 Cleaning and inspection...................................................................................................952 Assembly..................................................................................................................953 Pressure testing..........................................................................................................954 90 Diagrams and drawings..............................................................................................................957 Hydraulic circuit diagrams........................................................................................................957 Steering, hoist and brake cooling hydraulic schematic.........................................................................959 Brake hydraulic schematic.....................................................................................................960 Electrical circuit diagrams.......................................................................................................963 Electrical schematics.........................................................................................................965 Connectors table and arrangement..............................................................................................974
KOMATSU 960E-2 DUMP TRUCK SHOP MANUAL CEBM025901 – PDF DOWNLOAD:
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