Komatsu 960E-1 Dump Truck Service Repair Shop Manual (A30003 and up) - CEBM021300

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Dump Truck 960E-1 (SN: A30003 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu 960E-1 Dump Truck
Serial Numbers : A30003 and up and up


TABLE OF CONTENTS :

00 Index and foreword
01 Specification
10 Structure, functions and maintenance standard
20 Standard value table
30 Testing and adjusting
40 Troubleshooting
50 Disassembly and assembly
90 Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM021300
Total Pages : 906


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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Cover
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword, safety and general information
Foreword
How to read the shop manual
Composition of shop manual
Revision and distribution
Symbols
General safety
Safety rules
Safety features
Fire extinguisher and first aid kit
Clothing and personal items
Leaving the operator seat
Mounting and dismounting
Fire prevention for fuel and oil
Precautions with high temperature fluids
Asbestos dust hazard prevention
Prevention of injury by work equipment
Unauthorized modification
Precautions when using ROPS
Precautions for attachments
Precautions for starting the truck
Precautions before operating the truck
Safety at the worksite
Fire prevention
Ventilation in enclosed areas
Preparing for operation
Mirrors, windows and lights
In operator cab (before starting the engine)
Precautions while operating the truck
When starting the engine
General truck operation
Ensuring good visibility
Traveling
Traveling in reverse
Traveling on slopes
Operating on snow or ice
Avoid damage to dump body
Driving near high voltage cables
When dumping
When loading
Working on loose ground
Parking the truck
Towing
Working near batteries
Battery hazard prevention
Starting with booster cables
Precautions before performing service
Warning tag
Stopping the engine
Proper tools
Securing the dump body
Precautions while performing service
Keep the truck clean
Attachments
Working under the truck
Rotating fan and belts
Adding fuel or oil
Radiator coolant level
Use of lighting
Precautions with the battery
Handling high pressure hoses
Precautions when performing maintenance near high temperature or high pressure
Precautions with high pressure oil
Waste materials
Tires
Handling tires
Storing tires after removal
Precautions for performing repairs
Engine shutdown procedure after AC drive system failure
Precautions for welding on the truck
Handling electrical equipment and hydraulic components
Points to remember when handling electrical equipment
Points to remember when handling hydraulic equipment
How to read electric wire code
Standard torque tables
Effect of special lubricants on fasteners and standard torque values
Standard tightening torques for SAE hex head capscrew and nut assemblies
Standard assembly torques for 12-point, grade 9 capscrews (SAE)
Standard assembly torques for class 10.9 capscrews and class 10 nuts
Standard tightening torques for fittings
Conversion tables
Common conversion multipliers
Operating instructions
Preparing for operation
Walk-around inspection
Engine start-up
After engine start-up
Emergency steering system
Operation
Pre-operation testing
Precautions during truck operation
Operating on a haul road
Starting on a grade with a loaded truck
Sudden loss of engine power
Fuel depletion
Towing
Loading the dump body
Dumping a load
Raising the dump body
Lowering the dump body (on flat ground)
Lowering the dump body (over a berm or into a crusher)
Disabled truck dumping procedure
Hookup
Raising the body
Lowering the body
Safe parking procedure
Normal engine shutdown procedure

01 Specification
Specification and technical data
Specification drawing
Specifications
Weight table
Fuel, coolant and lubricants
Mixing rate of water and anti-freeze
Suspension cylinder oil and nitrogen specifications

10 Structure, functions and maintenance standard
Steering circuit
Steering circuit operation
Steering circuit components
Steering control unit
High pressure filter
Steering accumulators
Bleed down manifold
Steering accumulator bleed down solenoid
Hoist up limit solenoid
Quick disconnect ports
Flow amplifier
Flow amplifier operation
No steer
Steering left
Steering right
No steer, external shock load
Steering/brake pump operation
Normal operation
Neutral position
Full pump volume
Half pump volume
Steering cylinder wear data
Hoist circuit
Hoist circuit operation
Hoist circuit components
Hydraulic tank
Hoist pump
High pressure filters
Hoist valve
Inlet sections
Tank ports (front) spool section
Work ports (rear) spool section
Hoist pilot valve
Bleed down manifold
Hoist limit solenoid
Pilot operated check valve
Overcenter manifold
Hoist pilot valve operation
Float position with body down
Power up operation
Hold operation
Power down operation
Float operation
Hoist cylinder wear data
Brake circuits
General information
Service brake circuit operation
Secondary braking and auto apply
Parking brake circuit operation
Normal operation (key switch ON, engine on)
Wheel brake lock circuit operation
Brake warning circuit operation
Brake assembly wear data
Suspensions
General information
Front suspension wear data
Rear suspension wear data
Electrical system, 24 volt
Battery supply system
Auxiliary control cabinet components
24VDC to 12VDC converter
Diode board - DB1
Power distribution terminals
Pulse voltage modulator (PMV)
Control power relay
Fuse blocks
Relay boards
Relay boards RB1, RB3, RB4, RB5
Relay boards RB6, RB7, RB8, RB9
Relay functions
Body-up switch
Hoist limit switch
Interface module (IM)
General information
Sensors
Temperature sensors
Pressure sensors
Interface module inputs and outputs
Electrical system, AC drive
General system operation
AC drive system components
Propulsion system controller (PSC)
Truck control interface (TCI)
Diagnostic information display (DID) panel
PSC software functions
Input processing
State machine
DC link state
Engine control
Alernator field control
Desired three-phase voltage
Desired DC link voltage
Self-load
Propel torque control
Retard torque control
Wheel slide control
Resistor grid control
Chopper voltage control
Event detection and processing
Power-on tests
Initiated tests
Periodic tests
Event restrictions
Event logging and storage
Event history buffer
Data packs
Event reset
Serial data communications
PSC to TCI communications processing
PSC to PTU communications processing
Inverter communications processing
Output processing
Abnormal conditions/overriding functions
Fast start
Engine shutdown/Engine not running
Limp home mode
AC drive system component table
Cab air conditioning
General information
Environmental impact of air conditioning
Air conditioning for off-highway vehicles
Principles of refrigeration
Air conditioning
Refrigeration - the act of cooling
The refrigeration cycle
Air conditioning system components
Relays
Fan motor and speed control
Cab air filter
Heater core
Actuators
Compressor (refrigerant pump)
Service valves
Condenser
Receiver-drier
Expansion valve
Accumulator
Evaporator core
Air conditioning system electrical circuit
Thermostat
Compressor clutch
Trinary™ switch

20 Standard value table
Standard value table
Standard value table for truck

30 Testing and adjusting
General information
Special tool list
Steering, brake cooling and hoist hydraulic system
General information on system checkout
Steering system checkout procedures
Steering pump pressure control adjustments
Steering control valve and flow amplifier leakage test
Bleed down manifold leakage test
Shock and suction valve pressure tests
Steering system checkout data sheet
Toe-in adjustment
Brake cooling and hoist system checkout procedures
Pressure gauge locations
Brake cooling circuit test
Power up relief pressure test
Power down relief pressure test
Counterbalance valve pressure check
Counterbalance valve adjustment
Brake cooling and hoist system checkout data sheet
Hydraulic system flushing procedure
Preparation
Flushing procedure
Brake system
General information on system checkout
Brake circuit checkout procedure
Initial system setup
Brake lock / secondary braking checkout
Parking brake checkout
Service brake checkout
Low brake accumulator pressure and auto apply checkout
Parking brake control logic checkout
Brake lock control logic checkout
Brake system checkout data sheet
Brake piston leakage test
Wet disc brake bleeding procedure
Parking brake bleeding procedure
Brake valve bench test and adjustment
Test setup procedure
Brake valve output pressure adjustment
Final test and adjustment
Dual relay valve bench test and adjustment
Test setup procedure
Relay valve output pressure adjustment
Accumulators and suspensions
Accumulator charging and storage
Accumulator charging procedures
Precharge maintenance
Accumulator storage procedure
Bladder storage
Installing a bladder accumulator from storage
Accumulator leak testing
Suspension oiling and charging procedures
Equipment list
Installing the charging kit
Removing the charging kit
Support blocks for oiling and charging dimensions
Front suspension oiling
Front suspension nitrogen charging
Rear suspension oiling
Rear suspension nitrogen charging
Suspension pressure test
VHMS and payload meter
VHMS and payload meter software
VHMS Tool Box Installation
VHMS Setting Tool Installation
Installing the PDM software
VHMS controller initial setting procedure
VHMS controller setup procedure
VHMS snapshot procedure
VHMS download procedure
VHMS FTP upload procedure
VHMS initialization forms
VHMS initialization check list
VHMS initialization form
Precautions for replacing VHMS controller
VHMS controller checkout procedure
Necessary equipment
Preliminary
Checkout procedure
Payload meter initial setting procedure
Starting communications
Configure payload meter
Setting truck number
Clean truck tare
Inclinometer calibration
Interface module (IM)
Interface module software
Flashburn program installation
Interface module application code installation
Interface module realtime data monitor software installation
Interface module checkout procedures
Necessary equipment
Preliminary
Check digital inputs to the interface module
Check analog inputs to the interface module
Check serial interfaces to the interface module
Check outputs from the interface module
Cab air conditioning
General information
Service tools and equipment
Recovery/recycle station
Leak detector
Manifold gauge set
Service valves
Vacuum pump
Detecting leaks
System performance test
Checking system oil
System flushing
Installing the manifold gauge set
Purging air from the service hoses
Recovering and recycling refrigerant
Draining oil from previous recovery cycle
Recovery cycle
Recycling procedure
Evacuating the air conditioning system
Charging the air conditioning system
A/C drive belt checkout procedure
Pulley alignment
Belt tension check

40 Troubleshooting
Fault code table and fuse locations
Fault code table
Fuse and circuit breaker locations
AC drive system fault codes
DID panel fault code tables
Troubleshooting by fault code, Part 1
Fault Code A001: Left front suspension pressure sensor signal high
Related circuit diagram
Fault Code A002: Left front suspension pressure sensor signal low
Related circuit diagram
Fault Code A003: Right front suspension pressure sensor signal high
Related circuit diagram
Fault Code A004: Right front suspension pressure sensor signal low
Related circuit diagram
Fault Code A005: Left rear suspension pressure sensor signal high
Related circuit diagram
Fault Code A006: Left rear suspension pressure sensor signal low
Related circuit diagram
Fault Code A007: Right rear suspension pressure sensor signal high
Related circuit diagram
Fault Code A008: Right rear suspension pressure sensor signal low
Related circuit diagram
Fault Code A009: Incline sensor signal high
Related circuit diagram
Fault Code A010: Incline sensor signal low
Related circuit diagram
Fault Code A011: Payload meter speed sensor signal has failed
Related circuit diagram
Fault Code A013: Body up switch has failed
Related circuit diagram
Fault Code A014: Payload meter checksum computation has failed
Related circuit diagram
Fault Code A016: Payload meter write to flash memory has failed
Related circuit diagram
Fault Code A017: Payload meter flash memory read has failed
Related circuit diagram
Fault Code A018: Right rear flat suspension cylinder warning
Related circuit diagram
Fault Code A019: Left rear flat suspension cylinder warning
Related circuit diagram
Fault Code A022: Carryback load excessive
Related circuit diagram
Fault Code A100: An open circuit breaker has been detected on a relay board
Related circuit diagram
Fault Code A101: High pressure detected across an hydraulic pump filter
Related circuit diagram
Fault Code A105: Fuel level sensor shorted to ground, indicating a false high fuel level
Related circuit diagram
Fault Code A107: GE has generated a propel system caution
Related circuit diagram
Fault Code A108: GE has generated a propel system temperature caution
Related circuit diagram
Fault Code A109: GE has generated a propel system reduced level signal
Related circuit diagram
Fault Code A111: Low steering pressure warning
Related circuit diagram
Fault Code A115: Low steering precharge pressure detected
Related circuit diagram
Fault Code A117: Low brake accumulator pressure warning
Related circuit diagram
Fault Code A118: Brake pressure is low while in brake lock
Related circuit diagram
Fault Code A123: GE has generated a reduced retarding caution
Related circuit diagram
Fault Code A124: GE has generated a no propel / no retard warning
Related circuit diagram
Fault Code A125: GE has generated a no propel warning
Related circuit diagram
Fault Code A126: Oil level in the hydraulic tank is low
Related circuit diagram
Fault Code A127: IM-furnished +5 volt output for sensors is low
Related circuit diagram
Fault Code A128: IM-furnished +5 volt output for sensors is high
Related circuit diagram
Fault Code A139: Low fuel warning
Related circuit diagram
Troubleshooting by fault code, Part 2
Fault Code A145: Hydraulic temperature sensors cause advance of engine rpm to advance level 1 for cooling of hydraulic oil
Related circuit diagram
Fault Code A146: Hydraulic temperature sensors cause advance of engine rpm to advance level 2 for cooling of hydraulic oil
Related circuit diagram
Fault Code A152: Starter failure
Related circuit diagram
Fault Code A153: Battery voltage is low with the truck in operation
Related circuit diagram
Fault Code A154: Battery charging voltage is excessive
Related circuit diagram
Fault Code A155: Battery charging voltage is low
Related circuit diagram
Fault Code A158: Fuel level sensor is open or shorted high, indicating a false low fuel level
Related circuit diagram
Fault Code A166: Left rear hydraulic oil temperature sensor is low
Related circuit diagram
Fault Code A167: Right rear hydraulic oil temperature sensor is low
Related circuit diagram
Fault Code A168: Left front hydraulic oil temperature sensor is low
Related circuit diagram
Fault Code A169: Right front hydraulic oil temperature sensor is low
Related circuit diagram
Fault Code A170: Left rear hydraulic oil temperature sensor is high
Related circuit diagram
Fault Code A171: Right rear hydraulic oil temperature sensor is high
Related circuit diagram
Fault Code A172: Left front hydraulic oil temperature sensor is high
Related circuit diagram
Fault Code A173: Right front hydraulic oil temperature sensor is high
Related circuit diagram
Fault Code A184: J1939 data link is not connected
Related circuit diagram
Fault Code A190: Auto lube control has detected an incomplete lube cycle
Related circuit diagram
Fault Code A194: Left front hydraulic oil temperature is high
Related circuit diagram
Fault Code A195: Right front hydraulic oil temperature is high
Related circuit diagram
Fault Code A196: Left rear hydraulic oil temperature is high
Related circuit diagram
Fault Code A197: Right rear hydraulic oil temperature is high
Related circuit diagram
Fault Code A198: Hoist pressure 1 sensor is high
Related circuit diagram
Fault Code A199: Hoist pressure 2 sensor is high
Related circuit diagram
Fault Code A200: Steering pressure sensor is high
Related circuit diagram
Fault Code A201: Brake pressure sensor is high
Related circuit diagram
Fault Code A202: Hoist pressure 1 sensor is low
Related circuit diagram
Fault Code A203: Hoist pressure 2 sensor is low
Related circuit diagram
Fault Code A204: Steering pressure sensor is low
Related circuit diagram
Fault Code A205: Brake pressure sensor is low
Related circuit diagram
Fault Code A206: Ambient temperature sensor is high
Related circuit diagram
Fault Code A207: Ambient temperature sensor is low
Related circuit diagram
Troubleshooting by fault code, Part 3
Fault Code A212: Bad truck speed signal
Related circuit diagram
Fault Code A213: Parking brake should have applied but is detected as not having applied
Related circuit diagram
Fault Code A214: Parking brake should have released but is detected as not having released
Related circuit diagram
Fault Code A215: Brake auto apply valve circuit is defective
Related circuit diagram
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit
Related circuit diagram
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted
Related circuit diagram
Fault Code A230: Parking brake has been requested while truck still moving
Related circuit diagram
Fault Code A231: The body is up while traveling or with selector in forward or neutral
Related circuit diagram
Fault Code A235: Steering accumulator is in the process of being bled down
Related circuit diagram
Fault Code A236: The steering accumulator has not properly bled down after 90 seconds
Related circuit diagram
Fault Code A237: The CAN/RPC connection to the display is open
Related circuit diagram
Fault Code A240: The key switch input to the interface module is open
Related circuit diagram
Fault Code A242: Fuel gauge within the Actia display panel is defective
Related circuit diagram
Fault Code A243: Engine coolant temperature gauge within the Actia display panel is defective
Related circuit diagram
Fault Code A244: Drive system temperature gauge within the Actia display panel is defective
Related circuit diagram
Fault Code A245: Hydraulic oil temperature gauge within the Actia display panel is defective
Related circuit diagram
Fault Code A246: Payload meter reports truck overload
Related circuit diagram
Fault Code A247: Low steering pressure warning
Related circuit diagram
Fault Code A248: Status module within the Actia display panel is defective
Related circuit diagram
Fault Code A249: Red warning lamp within the Actia display (driven by IM) is shorted
Related circuit diagram
Fault Code A250: Battery voltage is low with the truck parked
Related circuit diagram
Fault Code A251: Sonalert used with the Actia display (driven by IM) is open or shorted to ground
Related circuit diagram
Fault Code A252: Start enable output circuit is either open or shorted to ground
Related circuit diagram
Fault Code A253: Steering bleed circuit is not open while running
Related circuit diagram
Fault Code A256: Red warning lamp in the Actia display (driven by IM) is open
Related circuit diagram
Fault Code A257: Payload CAN/RPC is not connected
Related circuit diagram
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective
Related circuit diagram
Troubleshooting by fault code, Part 4
Fault Code A260: Parking brake failure
Related circuit diagram
Fault Code A261: Low brake accumulator pressure warning
Related circuit diagram
Fault Code A262: Steering bleed valve circuit open during shutdown
Related circuit diagram
Fault Code A263: Steering bleed valve circuit shorted to ground
Related circuit diagram
Fault Code A264: Parking brake relay circuit is defective
Related circuit diagram
Fault Code A265: Service brake failure
Related circuit diagram
Fault Code A266: Selector lever was not in park while attempting to crank engine
Related circuit diagram
Fault Code A267: Parking brake was not set while attempting to crank engine
Related circuit diagram
Fault Code A268: Secondary engine shutdown while cranking
Related circuit diagram
Fault Code A270: Brake lock switch power supply is not on when required
Related circuit diagram
Fault Code A271: Shifter not in gear
Related circuit diagram
Fault Code A272: Brake lock switch power supply is not off when required
Related circuit diagram
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit
Related circuit diagram
Fault Code A274: A brake setting fault has been detected
Related circuit diagram
Fault Code A275: A starter has been detected as engaged without a cranking attempt
Related circuit diagram
Fault Code A276: The drive system data link is not connected
Related circuit diagram
Fault Code A277: Parking brake applied while loading
Related circuit diagram
Fault Code A278: Service brake applied while loading
Related circuit diagram
Fault Code A279: Low steering pressure switch is defective
Related circuit diagram
Fault Code A280: Steering accumulator bleed down switch is defective
Related circuit diagram
Fault Code A281: Brake lock degrade switch is defective
Related circuit diagram
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7
Related circuit diagram
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set
Related circuit diagram
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated
Related circuit diagram
Fault Code A285: The parking brake was not set when the key switch was turned off
Related circuit diagram
Fault Code A286: A fault was detected in the shutdown delay relay circuit
Related circuit diagram
Fault Code A292: The shutdown delay relay has remained on after the latched key switch circuit is off
Related circuit diagram
Troubleshooting by fault code, Part 5
Fault Code A303: Shifter is defective
Related circuit diagram
Fault Code A304: Auto lube grease level fault
Related circuit diagram
Fault Code A305: Auto lube circuit is defective
Related circuit diagram
Fault Code A307: Both GE inverters are disabled
Related circuit diagram
Fault Code A309: No brakes applied when expected
Related circuit diagram
Fault Code A310: Low fuel warning
Related circuit diagram
Fault Code A311: Brake lock switch is on when it should not be
Related circuit diagram
Fault Code A312: DCDC converter 12 volt circuit sensing is producing low readings
Related circuit diagram
Fault Code A313: DCDC converter 12 volt circuit sensing is producing high readings
Related circuit diagram
Fault Code A314: DCDC converter 12 volt circuit is high
Related circuit diagram
Fault Code A315: DCDC converter 12 volt circuit is low
Related circuit diagram
Fault Code A316: Starter engagement has been attempted with engine running
Related circuit diagram
Fault Code A317: Operation of brake auto apply valve without a detected response
Related circuit diagram
Fault Code A318: Unexpected power loss to interface module
Related circuit diagram
Fault Code A328: Drive system not powered up
Related circuit diagram
Fault Code A350: Overload on output 1B
Related circuit diagram
Fault Code A351: Overload on output 1E
Related circuit diagram
Fault Code A352: Overload on output 1H
Related circuit diagram
Fault Code A353: Overload on output 1J
Related circuit diagram
Fault Code A354: Overload on output 1K
Related circuit diagram
Fault Code A355: Overload on output 1L
Related circuit diagram
Fault Code A356: Overload on output 1M
Related circuit diagram
Fault Code A357: Overload on output 1N
Related circuit diagram
Fault Code A358: Overload on output 1P
Related circuit diagram
Fault Code A359: Overload on output 1R
Related circuit diagram
Fault Code A360: Overload on output 1S
Related circuit diagram
Fault Code A361: Overload on output 1T
Related circuit diagram
Fault Code A362: Overload on output 1U
Related circuit diagram
Fault Code A363: Overload on output 1X
Related circuit diagram
Fault Code A364: Overload on output 1Y
Related circuit diagram
Fault Code A365: Overload on output 1Z
Related circuit diagram
Cab air conditioning
Preliminary checks
Diagnosis of gauge readings and system performance
Troubleshooting by manifold gauge set readings

50 Disassembly and assembly
General information
Special tool list
Wheels, spindles and rear axle
General information for tires and rims
Storage and handling
Wheel stud maintenance
Removal and installation of front wheel
Removal
Installation
Removal and installation of rear wheel
Removal
Installation
Removal and installation of tires
Removal
Installation
Removal and installation of front wheel hub and spindle
Removal
Installation
Disassembly and assembly of front wheel hub and spindle
Disassembly
Cleaning and inspection
Assembly
Wheel bearing adjustment
Seal assembly gap check and adjustment
Brake installation
Speed sensor installation and adjustment
Removal and installation of rear axle
Removal
Cleaning and inspection
Installation
Removal and installation of anti-sway bar
Removal
Installation
Removal and installation of pivot pin
Removal
Installation
Pivot eye and bearing service
Bearing removal
Bearing installation
Pivot eye repair
Removal and installation of wheel motor
Preparation
Removal
Cleaning and inspection
Installation
Brake system
Removal and installation of brake valve
Removal
Installation
Disassembly and assembly of brake valve
Disassembly
Cleaning and inspection
Assembly
Removal and installation of dual relay valve
Removal
Installation
Disassembly and assembly of dual relay valve
Disassembly
Cleaning and inspection
Assembly
Removal and installation of brake manifold
Removal
Installation
Disassembly and assembly of brake manifold
Disassembly
Assembly
Removal and installation of brake accumulator
Removal
Installation
Disassembly and assembly of brake accumulator
Disassembly
Cleaning and inspection
Assembly
Disassembly and assembly of wheel brake
Disassembly
Cleaning and inspection
Assembly
Floating ring seal assembly and installation
Removal and installation of parking brake
Removal
Installation
Disassembly and assembly of parking brake
Disassembly
Cleaning and inspection
Assembly
Steering system
Removal and installation of steering control unit
Removal
Installation
Disassembly and assembly of steering control unit
Disassembly
Assembly
Removal and installation of steering column
Removal
Inspection
Installation
Removal and installation of steering wheel
Removal
Installation
Removal and installation of bleed down manifold
Removal
Installation
Removal and installation of flow amplifier
Removal
Installation
Disassembly and assembly of flow amplifier
Disassembly
Assembly
Removal and installation of steering cylinders and tie rod
Removal
Bearing replacement
Installation
Disassembly and assembly of steering cylinders
Disassembly
Assembly
Removal and installation of steering/brake pump
Removal
Installation
Disassembly and assembly of steering/brake pump
Disassembly
Inspection
Assembly
Driveshaft group
Rotating group
Removal and installation of steering accumulators
Removal
Installation
Disassembly and assembly of steering accumulators
Disassembly
Cleaning and Inspection
Assembly
Suspensions
Removal and installation of front suspension
Removal
Installation
Inspection
Minor front suspension repairs (lower bearing and seals)
Lower bearing retainer removal
Lower bearing retainer installation
Major front suspension rebuild
Disassembly
Assembly
Removal and installation of rear suspension
Removal
Installation
Disassembly and assembly of rear suspension
Disassembly
Cleaning and Inspection
Assembly
Hoist circuit
Removal and installation of hoist pump
Removal
Installation
Disassembly and assembly of hoist pump
Disassembly
Inspection
Assembly
Removal and installation of hoist valve
Removal
Installation
Disassembly and assembly of hoist valve
O-ring replacement
Disassembly of inlet section
Assembly of inlet section
Disassembly of rear spool section
Assembly of rear spool section
Disassembly of front spool section
Assembly of front spool section
Overcenter valve manifold service
Removal and installation of hoist pilot valve
Removal
Installation
Disassembly and assembly of hoist pilot valve
Disassembly
Cleaning and inspection
Assembly
Removal and installation of hoist cylinders
Removal
Installation
Disassembly and assembly of hoist cylinders
Disassembly
Cleaning and inspection
Installation of the quill
Assembly
Operator cab
Removal and installation of operator cab
Removal
Installation
Removal and installation of cab door
Removal
Installation
Disassembly and assembly of cab door
Removing door panel
Installing door panel
Replacing door window regulator
Replacing door handle or latch assembly
Replacing door assembly seal and door hinge seal
Replacing door opening seal
Removing door glass
Installing door glass
Adjustment of cab door
Door jamb bolt adjustment
Door handle plunger adjustment
Removal and installation of side window glass
Recommended tools and supplies
Removal
Installation
Removal and installation of windshield and rear window glass
Removal
Installation
Removal and installation of windshield wiper motor
Removal
Installation
Removal and installation of windshield wiper arm
Removal
Installation
Removal and installation of windshield wiper linkage
Removal
Installation
Removal and installation of seat
Removal
Installation
Body and structures
Removal and installation of dump body
Removal
Inspection
Installation
Removal and installation of body pads
Removal
Installation
Removal and installation of diagonal ladder/hood and grille assembly
Removal
Installation
Removal and installation of right deck
Removal
Installation
Removal and installation of left deck
Removal
Installation
Removal and installation of fuel tank
Removal
Cleaning and inspection
Installation
Removal and installation of fuel gauge sender
Removal
Installation
Disassembly and assembly of fuel tank breather
Disassembly
Assembly
Cab air conditioning
Replacement of air conditioning system components
Hoses and fittings
Lines
Expansion valve
Receiver-drier
Thermostat
Compressor
Accumulator
Clutch
Diasassembly and assembly of compressor clutch
Removal of the clutch assembly
Removal of the pulley
Installation of the pulley
Installation of the clutch assembly

90 Diagrams and drawings
Hydraulic circuit diagrams
Electrical circuit diagrams

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