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Komatsu 210M DG694 Service Repair Workshop Manual – PDF DOWNLOAD
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Komatsu 210M DG694 Service Repair Workshop Manual
MACHINE MODEL SERIAL SUFFIX :
210M BFA40BX THRU CZ
24361 THRU 24511
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Description
Komatsu 210M DG694 Service Repair Workshop Manual
TABLE OF CONTENTS:
Komatsu 210M DG694 Service Repair Workshop Manual
MAIN MENU.................................................................................................... 0 COVER........................................................................................................ 1 TABLE OF CONTENTS............................................................................................ 7 GENERAL INFORMATION.......................................................................................... 9 TRUCK COMPONENT DESCRIPTION & SPECIFICATIONS............................................................. 11 GENERAL SAFETY AND TRUCK OPERATION....................................................................... 15 WARNINGS AND CAUTIONS.................................................................................... 37 CHARTS AND TABLES........................................................................................ 43 STORAGE PROCEDURES....................................................................................... 49 STRUCTURES................................................................................................... 69 STRUCTURAL COMPONENTS.................................................................................... 71 COWL AND HOOD........................................................................................ 71 DECKS................................................................................................ 71 RIGHT DECK STRUCTURE................................................................................. 71 REMOVAL.......................................................................................... 71 INSTALLATION..................................................................................... 74 INSPECTION....................................................................................... 72 DUMP BODY................................................................................................ 73 DUMP BODY............................................................................................ 73 REMOVAL.......................................................................................... 73 INSTALLATION..................................................................................... 74 BODY PIVOT PINS AND SPACERS.......................................................................... 74 REMOVAL.......................................................................................... 74 INSTALLATION..................................................................................... 74 BODY-UP PIN.......................................................................................... 75 INSTALLATION..................................................................................... 75 BODY PADS............................................................................................ 75 ROCK EJECTORS........................................................................................ 76 INSPECTION....................................................................................... 76 BODY POSITION INDICATOR.............................................................................. 76 LINER PLATES/BODY REPAIR............................................................................. 76 BODY-UP LIMIT SWITCH................................................................................. 76 ADJUSTMENT....................................................................................... 76 MAINTENANCE...................................................................................... 78 FUEL TANK................................................................................................ 79 FUEL TANK............................................................................................ 79 REMOVAL.......................................................................................... 79 INSTALLATION..................................................................................... 80 CLEANING......................................................................................... 80 VENT................................................................................................. 80 GAUGE................................................................................................ 80 REMOVAL.......................................................................................... 80 INSTALLATION..................................................................................... 80 ENGINE, FUEL, COOLING AND AIR CLEANER........................................................................ 81 COOLING SYSTEM........................................................................................... 83 RADIATOR............................................................................................. 83 REMOVAL.......................................................................................... 83 INSTALLATION..................................................................................... 85 REPAIR........................................................................................... 86 HEAT EXCHANGER....................................................................................... 86 REMOVAL.......................................................................................... 86 INSTALLATION..................................................................................... 87 REPAIR........................................................................................... 87 ENGINE................................................................................................... 89 ENGINE............................................................................................... 89 REMOVAL.......................................................................................... 89 INSTALLATION..................................................................................... 91 REPAIR........................................................................................... 93 AIR FILTRATION SYSTEM.................................................................................... 95 AIR CLEANER.......................................................................................... 95 SERVICE CHECKS................................................................................... 95 FILTER ELEMENT REPLACEMENT....................................................................... 95 MAIN FILTER ELEMENT.................................................................................. 97 REMOVAL.......................................................................................... 95 INSTALLATION..................................................................................... 95 MAIN FILTER ELEMENT CLEANING..................................................................... 97 PRECLEANER SECTION............................................................................... 98 CLEANING PRECLEANER TUBES........................................................................ 98 AIR INTAKE TROUBLESHOOTING....................................................................... 99 ENGINE COMPONENTS........................................................................................101 THROTTLE CONTROL.....................................................................................101 THROTTLE CONTROL PEDAL...............................................................................101 REMOVAL/INSTALLATION.............................................................................101 THROTTLE CONTROL LEVER...............................................................................101 THROTTLE CONTROL ADJUSTMENT......................................................................103 ATEC THROTTLE POSITION SENSOR........................................................................104 THROTTLE POSITION SENSOR.........................................................................104 REMOVAL..........................................................................................104 INSTALLATION.....................................................................................105 FAN..................................................................................................105 REMOVAL..........................................................................................105 INSTALLATION.....................................................................................105 FAN BELT ADJUSTMENT..................................................................................105 ALTERNATOR BELT ADJUSTMENT...........................................................................106 ELECTRIC SYSTEM (24VDC. NON-PROPULSION)......................................................................107 24VDC ELECTRICAL SUPPLY SYSTEM...........................................................................109 ELECTRICAL SYSTEM DESCRIPTION........................................................................109 BATTERY..............................................................................................109 SERVICE..........................................................................................109 STORAGE..........................................................................................109 MAINTENANCE AND TROUBLE SHOOTING.................................................................110 SPILLAGE.........................................................................................111 BATTERY CHARGING ALTERNATOR..........................................................................111 OPERATION........................................................................................111 MAGNETIZING THE ROTOR............................................................................113 REGULATOR ADJUSTMENT.............................................................................113 CIRCUIT CHECKOUT.................................................................................113 BATTERY CHARGING CIRCUIT COMPONENTS..................................................................113 BATTERY EQUALIZER....................................................................................114 PURPOSE..........................................................................................114 CIRCUIT CHECKOUT.................................................................................115 ELECTRICAL SYSTEM COMPONENTS.............................................................................117 ELECTRICAL CIRCUIT CHECKOUT..........................................................................117 HORN, WINDSHIELD WIPER, AND WINDSHIELD WASHER CIRCUITS...............................................117 WINDSHIELD WASHER CIRCUIT............................................................................117 WINDSHIELD WIPER CIRCUIT CHECKOUT PROCEDURE......................................................117 BRAKE LOCK AND PARK BRAKE CIRCUITS...................................................................118 BRAKE LOCK SWITCH CIRCUIT........................................................................118 BRAKE LOCK CHECKOUT..............................................................................118 PARK BRAKE SWITCH AND CIRCUIT....................................................................118 PARK BRAKE CHECKOUT..............................................................................118 LOW BRAKE PRESSURE SWITCH AND CIRCUIT................................................................118 GAUGES AND CIRCUIT COMPONENTS........................................................................118 CIRCUIT COMPONENTS...............................................................................118 LOW BRAKE PRESSURE WARNING AND INDICATOR LIGHT CIRCUITS..............................................119 CIRCUIT COMPONENTS...............................................................................119 HOIST CONTROL CIRCUIT................................................................................121 HOIST CONTROL SWITCH CIRCUIT CHECKOUT............................................................121 BODY-UP LIMIT SWITCH.................................................................................121 BODY-UP LIMIT SWITCH CIRCUIT CHECKOUT............................................................121 STEERING BLEEDDOWN TIMER CIRCUIT.....................................................................121 CIRCUIT COMPONENTS...............................................................................122 STEERING BLEEDDOWN CIRCUIT CHECKOUT..............................................................122 ACCUMULATOR PRECHARGE CIRCUIT....................................................................122 ENGINE SHUTDOWN CIRCUIT..........................................................................122 LIGHT CIRCUIT........................................................................................122 CIRCUIT CHECKOUT.................................................................................123 HEATER AND AIR CONDITIONER CIRCUIT.......................................................................123 CIRCUIT COMPONENTS...................................................................................123 CIRCUIT CHECKOUT.....................................................................................123 24 VDC ELECTRICAL START SYSTEM...........................................................................124 24VDC ELECTRIC START SYSTEM..........................................................................124 OPERATION........................................................................................124 CRANKING MOTOR...................................................................................124 REMOVAL..........................................................................................124 INSTALLATION.....................................................................................124 CRANKING MOTOR TROUBLESHOOTING.......................................................................125 PRELIMINARY INSPECTION...........................................................................125 NO-LOAD TEST.....................................................................................125 INTERPRETING RESULTS OF TEST.....................................................................125 DISASSEMBLY......................................................................................126 CLEANING AND INSPECTION..........................................................................128 ARMATURE SERVICING...............................................................................128 FIELD COIL CHECKS................................................................................128 FIELD COIL REMOVAL...............................................................................128 SOLENOID CHECKS..................................................................................129 ASSEMBLY.........................................................................................130 PINION CLEARANCE.................................................................................130 MAGNETIC SWITCH..........................................................................................131 REMOVAL..............................................................................................131 INSTALLATION.........................................................................................131 COIL TEST............................................................................................131 ELECTRIC START SYSTEM WIRING DIAGRAM.....................................................................132 STARTER, ENGINE 24 VDC...................................................................................133 CIRCUIT CHECK-OUT....................................................................................133 ALLISON TRANSMISSION ELECTRONIC CONTROL (ATEC)...........................................................135 ATEC SYSTEM OPERATION................................................................................135 RANGE SELECTOR...................................................................................135 DO NOT SHIFT LIGHT...............................................................................135 CHECK TRANS LIGHT................................................................................136 SYSTEM DESCRIPTION...................................................................................136 TRANSMISSION CONTROL CIRCUITS........................................................................137 BATTERY CHARGING CIRCUIT.........................................................................137 CONTROL POWER AND MEMORY CIRCUITS................................................................138 START CIRCUIT....................................................................................138 CHECK TRANSMISSION WARNING LIGHT CIRCUIT.........................................................138 BACKUP HORN AND LIGHT CIRCUIT....................................................................138 HOIST INTERLOCK CIRCUIT..........................................................................138 AUTO/MANUAL CIRCUIT..............................................................................138 OVERSPEED RELAY CIRCUIT..........................................................................138 SPEEDOMETER CIRCUIT..............................................................................139 TRANSMISSION CIRCUIT COMPONENTS......................................................................140 CIRCUIT DESCRIPTION AND CHECKOUT.....................................................................141 ATEC DIAGNOSTIC CODES................................................................................144 TRANSMISSION AND PTO.........................................................................................145 TRANSMISSION.............................................................................................147 TRANSMISSION.........................................................................................147 TRANSMISSION REMOVAL.............................................................................147 TRANSMISSION INSTALLATION........................................................................148 TRANSMISSION FILL INSTRUCTIONS...................................................................149 TRANSMISSION FILTER..................................................................................150 SERVICE..........................................................................................150 TRANSMISSION OIL COOLER..................................................................................151 REMOVAL AND INSTALLATION.............................................................................151 REPAIR...............................................................................................151 POWER TAKE OFF (PTO).....................................................................................153 PTO GEARBOX..........................................................................................153 REMOVAL..........................................................................................153 INSTALLATION.....................................................................................153 DISASSEMBLY......................................................................................154 ASSEMBLY.........................................................................................155 DRIVELINES & U-JOINTS....................................................................................157 REMOVAL..............................................................................................157 INSTALLATION.........................................................................................157 DISASSEMBLY..........................................................................................157 ASSEMBLY.............................................................................................158 DRIVE AXLE, SPINDLES AND WHEELS..............................................................................159 TIRES AND RIMS...........................................................................................161 TIRES AND RIMS.......................................................................................161 GENERAL INFORMATION..............................................................................161 TIRE REMOVAL FROM RIM............................................................................162 TIRE INSTALATION ON RIM..........................................................................162 FRONT TIRE AND RIM...................................................................................163 REMOVAL..........................................................................................163 INSTALLATION.....................................................................................164 REAR TIRE AND RIM....................................................................................164 REMOVAL..........................................................................................164 INSTALLATION.....................................................................................164 TIRE MATCHING........................................................................................165 FRONT WHEEL HUB AND SPINDLES.............................................................................167 FRONT WHEEL HUB......................................................................................167 REMOVAL..........................................................................................167 FRONT WHEEL BEARING AND BRAKE DISC REPLACEMENT...................................................168 FRONT WHEEL HUB INSTALLATION AND BEARING ADJUSTMENT..............................................168 FRONT WHEEL SPINDLE REMOVAL......................................................................169 FRONT WHEEL SPINDLE INSTALLATION.................................................................170 STEERING LINKAGE REMOVAL.........................................................................171 STEERING LINKAGE BALL STUD AND BEARING REMOVAL...................................................171 FRONT WHEEL TOE-IN ADJUSTMENT....................................................................172 BIAS PLY TIRES...............................................................................172 RADIAL TIRES.................................................................................172 FINAL DRIVE ATTACHMENTS..................................................................................173 FINAL DRIVE ANCHOR...................................................................................173 PIN REMOVAL......................................................................................173 PIN INSTALLATION.................................................................................174 BEARING REMOVAL AND INSPECTION...................................................................174 BEARING INSTALLATION.............................................................................174 PANHARD ROD..........................................................................................174 REMOVAL..........................................................................................174 INSTALLATION.....................................................................................174 BEARING REPLACEMENT..............................................................................175 FINAL DRIVE ASSEMBLY.....................................................................................177 COMPLETE FINAL DRIVE ASSEMBLY........................................................................177 REMOVAL..........................................................................................177 INSTALLATION.....................................................................................178 DIFFERENTIAL CARRIER ASSEMBLY-SERVICE WITH COMPLETE FINAL DRIVE ASSEMBLY REMOVED FROM UNDER TRUCK....179 REMOVAL..........................................................................................179 INSTALLATION.....................................................................................180 DIFFERENTIAL CARRIER ASSEMBLY SERVICE WITH FINAL DRIVE IN PLACE UNDER TRUCK......................181 REMOVAL......................................................................................181 INSTALLATION.................................................................................182 DIFFERENTIAL CAGE REMOVAL....................................................................183 PINION REMOVAL...............................................................................183 DIFFERENTIAL CAGE DISASSEMBLY................................................................183 SPIDER GEAR BEARING REMOVAL..................................................................184 CLEANING AND INSPECTION......................................................................185 SPIDER GEAR BEARING INSTALLATION.............................................................185 DIFFERENTIAL CAGE ASSEMBLY...................................................................185 PINION INSTALLATION AND BEARING ADJSTMENT....................................................186 DIFFERENTIAL CAGE INSTALLATION...............................................................187 CARRIER BEARING AND BACKLASH ADJUSTMENT......................................................188 FINAL DRIVE PLANETARIES AND WHEEL HUBS...........................................................189 PLANETARY DRIVE..............................................................................189 PLANETARY DRIVE REMOVAL..................................................................189 PLANETARY REACTOR AND RING GEAR REMOVAL..................................................190 PLANETARY REACTOR AND RING GEAR INSTALLATION.............................................190 CLEANING AND INSPECTION..................................................................191 PLANETARY DRIVE INSTALLATION.............................................................191 PLANETARY CARRIER DISASSEMBLY............................................................191 PLANETARY CARRIER DISASSEMBLY............................................................192 WHEEL HUB AND BEARINGS.......................................................................192 REMOVAL..................................................................................192 BEARING REPLACEMENT......................................................................193 INSTALLATION.............................................................................193 HYDRAIR II SUSPENSIONS.......................................................................................197 FRONT SUSPENSIONS........................................................................................199 FRONT SUSPENSIONS....................................................................................199 REMOVAL..........................................................................................199 INSTALLATION.....................................................................................200 DISASSEMBLY......................................................................................201 INSPECTION.......................................................................................201 ASSEMBLY.........................................................................................202 REAR SUSPENSION..........................................................................................203 REAR SUSPENSION......................................................................................203 REMOVAL..........................................................................................203 INSTALLATION.....................................................................................204 DISASSEMBLY......................................................................................204 ASSEMBLY.........................................................................................205 REAR SUSPENSION SPHERICAL BEARING REPAIR.............................................................206 DISASSEMBLY......................................................................................206 INSPECTION.......................................................................................206 ASSEMBLY.........................................................................................206 OILING AND CHARGING PROCEDURES...........................................................................207 GENERAL..............................................................................................207 EQUIPMENT LIST.......................................................................................207 HYDRAIR SERVICE KIT..................................................................................207 INSTALLATION OF CHARGING KIT.....................................................................207 REMOVAL OF CHARGING KIT..........................................................................208 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS....................................................208 FRONT SUSPENSION.....................................................................................208 FRONT SUSPENSION OILING..........................................................................208 FRONT SUSPENSION NITROGEN CHARGING...............................................................209 REAR SUSPENSION......................................................................................210 REAR SUSPENSION OILING...........................................................................210 REAR SUSPENSION NITROGEN CHARGING................................................................211 OIL AND NITROGEN SPECIFICATIONS CHARTS...............................................................212 BRAKE CIRCUIT................................................................................................213 BRAKE CIRCUIT............................................................................................215 CIRCUIT OPERATION....................................................................................215 CHARGING.........................................................................................215 MANUAL APPLICATION...............................................................................216 HYDRAULIC OIL MANIFOLD...............................................................................216 BRAKE ACCUMULATORS...................................................................................216 ACCUMULATOR PRECHARGE................................................................................216 LOW-PRESSURE BRAKE DETECTION MODULE..................................................................216 LOW-PRESSURE SENSING SHUTTLE VALVE...............................................................216 BRAKE ACCUMULATOR PRESSURE CHECKS................................................................216 ACCUMULATOR SHUTTLE VALVE........................................................................217 ACCUMULATOR DISCHARGE VALVES (BLEEDDOWN VALVES)..................................................217 EMERGENCY APPLY VALVE............................................................................217 BRAKE PRESSURE WARNING SWITCH....................................................................217 BRAKE MANIFOLD.......................................................................................217 BRAKE LOCK SHUTTLE VALVE.........................................................................217 BRAKE LOCK SOLENOID VALVE........................................................................218 BRAKE MANIFOLD SHUTTLE VALVE.....................................................................218 STEERING BLEEDDOWN SOLENOID VALVE................................................................218 STEERING ACCUMULATOR PRESSURE CHECK..............................................................218 SERVICE BRAKE TREADLE VALVE..........................................................................218 RETARDER TREADLE VALVE...............................................................................218 SERVICE BRAKE/RETARDER SHUTTLE VALVE.................................................................219 STOP LIGHT MANIFOLD AND TEE..........................................................................219 REAR BRAKE SHUTTLE VALVE.............................................................................219 WET DISC BRAKE ASSEMBLY..............................................................................219 BRAKE CIRCUIT COMPONENT SERVICE..........................................................................221 LOW PRESSURE BRAKE DETECTION MODULE..................................................................221 BRAKE MANIFOLD.......................................................................................221 BRAKE ACCUMULATOR REPAIR.............................................................................222 SERVICE BRAKE TREADLE VALVE REPAIR...................................................................222 REMOVAL..........................................................................................222 INSTALLATION.....................................................................................223 DISASSEMBLY OF TREADLE VALVE ASSEMBLY............................................................223 REMOVAL OF BRAKE MANIFOLD....................................................................223 BRAKE VALVE DISASSEMBLY......................................................................225 ASSEMBLY OF TREADLE VALVE ASSEMBLY...............................................................225 BRAKE VALVE ASSEMBLY.........................................................................225 INSTALLATION OF BRAKE MANIFOLD...............................................................227 ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE.........................................................227 BRAKE PEDAL ADJUSTMENT...........................................................................229 SERVICE BRAKE TREADLE PEDAL..........................................................................230 PEDAL DISASSEMBLY................................................................................230 PEDAL ASSEMBLY...................................................................................230 RETARDER TREADLE VALVE...............................................................................231 REMOVAL..........................................................................................231 INSTALLATION.....................................................................................231 DISASSEMBLY......................................................................................231 ASSEMBLY.........................................................................................233 RETARDER TREADLE PEDAL DISASSEMBLY...............................................................234 RETARDER TREADLE PEDAL ASSEMBLY..................................................................234 BRAKE CIRCUIT CHECKOUT PROCEDURE.........................................................................235 CIRCUIT TRACKING.....................................................................................235 INITIAL SYSTEM SET-UP................................................................................236 CHECK OF BRAKE CIRCUIT SHUTTLE VALVES................................................................236 BRAKE SYSTEM CHECKOUT................................................................................237 FAILURE MODE CHECKOUT................................................................................238 BRAKE VALVE LEAKAGE..................................................................................236 TROUBLESHOOTING......................................................................................239 CHECKOUT DATA SHEET..................................................................................243 FRONT WHEEL SPEED DISC BRAKES............................................................................245 FRONT WHEEL SPEED DISC BRAKES........................................................................245 LINING REPLACEMENT ON TRUCK......................................................................245 BRAKE CALIPER REPAIR.................................................................................246 REMOVAL..........................................................................................246 INSTALLATION.....................................................................................246 PISTON AND SEAL REMOVAL..........................................................................246 PISTON AND SEAL INSTALLATION.....................................................................247 BRAKE CALIPER BENCH TEST.............................................................................247 FRONT BRAKE BLEEDING PROCEDURE.......................................................................248 FRONT SERVICE BRAKE BURNISHING PROCEDURE.............................................................248 REAR WET DISC BRAKE ASSEMBLY.............................................................................251 WET DISC BRAKE ASSEMBLY..............................................................................251 REMOVAL..........................................................................................251 INSTALLATION.....................................................................................252 WET DISC BRAKE DISASSEMBLY.......................................................................253 BRAKE PISTON DISASSEMBLY.........................................................................256 BRAKE PISTON INSPECTION..........................................................................256 BRAKE PISTON ASSEMBLY............................................................................256 FLOATING RING SEAL INSTALLATION..................................................................257 WET DISC BRAKE ASSEMBLY..........................................................................261 REAR WET DISC BRAKE BLEEDING PROCEDURE...............................................................263 REAR BRAKE DISC WEAR INDICATOR.......................................................................264 REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER...................................................264 PARKING BRAKE............................................................................................265 PARKING BRAKE........................................................................................265 REMOVAL/INSTALLATION.............................................................................265 PARK BRAKE LINING ADJUSTMENT.....................................................................265 PARK BRAKE LINKAGE ADJUSTMENT....................................................................265 PARK BRAKE ACTUATOR ASSEMBLY.........................................................................266 REMOVAL..........................................................................................266 INSTALLATION.....................................................................................266 DISASSEMBLY......................................................................................267 ASSEMBLY.........................................................................................267 ACTUATOR SPRING POD DISASSEMBLY..................................................................267 ACTUATOR SPRING POD ASSEMBLY.....................................................................268 PARK BRAKE BURNISHING................................................................................268 HYDRAULIC SYSTEM.............................................................................................269 HYDRAULIC SYSTEM.........................................................................................271 HYDRAULIC SYSTEM DESCRIPTION.........................................................................271 HYDRAULIC SYSTEM COMPONENT REPAIR........................................................................275 TANDEM HYDRAULIC PUMP................................................................................275 TANDEM HYDRAULIC PUMP............................................................................275 REMOVAL......................................................................................275 INSTALLATION.................................................................................275 PUMP DISASSEMBLY.................................................................................276 PUMP ASSEMBLY....................................................................................278 CARTRIDGE DISASSEMBLY............................................................................279 INSPECTION...................................................................................279 CARTRIDGE ASSEMBLY...............................................................................281 HYDRAULIC TANK.......................................................................................283 FILLING INSTRUCTIONS.............................................................................283 REMOVAL......................................................................................283 INSTALLATION.................................................................................284 HYDRAULIC TANK BREATHER..............................................................................285 HYDRAULIC FILTERS....................................................................................285 HYDRAULIC FILTER.................................................................................285 REMOVAL......................................................................................286 INSTALLATION.................................................................................286 DIFFERENTIAL PRESSURE SWITCH TESTING.............................................................287 TEST PROCEDURE...............................................................................287 STEERING CIRCUIT.........................................................................................289 STEERING CIRCUIT OPERATION...........................................................................289 STEERING CIRCUIT COMPONENT DESCRIPTION...............................................................289 STEERING CONTROL VALVE...................................................................................293 REMOVAL..............................................................................................293 INSTALLATION.........................................................................................293 DISASSEMBLY..........................................................................................294 CLEANING AND INSPECTION..............................................................................297 ASSEMBLY.............................................................................................297 ALTERNATE METHOD.....................................................................................297 STEERING CIRCUIT COMPONENT REPAIR........................................................................301 ACCUMULATORS.........................................................................................301 REMOVAL..........................................................................................301 INSTALLATION.....................................................................................302 DISASSEMBLY......................................................................................302 CLEANING AND INSPECTION..........................................................................302 ASSEMBLY.........................................................................................302 LOW PRESSURE ACCUMULATOR PRESSURE SWITCH.............................................................303 ACCUMULATOR CHARGING PROCEDURE.......................................................................304 INLINE FILTERS.......................................................................................305 SERVICE..........................................................................................305 STEERING CYLINDERS...................................................................................306 DISASSEMBLY......................................................................................306 ASSEMBLY.........................................................................................306 BRAKE/STEERING PUMP REPAIR...........................................................................307 REMOVAL..........................................................................................307 REMOVAL......................................................................................307 INSTALLATION.................................................................................307 SHAFT SEAL REPLACEMENT...........................................................................308 PUMP DISASSEMBLY.............................................................................310 PUMP ASSEMBLY................................................................................314 CONTROL (COMPENSATOR) VALVE......................................................................316 HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION........................................................319 CIRCUIT OPERATION....................................................................................319 HOIST VALVE......................................................................................319 AUXILIARY MANIFOLD...............................................................................320 COUNTER-BALANCE VALVE............................................................................320 HOIST CYLINDERS..................................................................................320 CHECK VALVES.....................................................................................320 HOIST CIRCUIT COMPONENT REPAIR...........................................................................321 HOIST VALVE..........................................................................................321 REMOVAL..........................................................................................321 INSTALLATION.....................................................................................321 DISASSEMBLY......................................................................................322 ASSEMBLY.........................................................................................323 HOIST CYLINDER.......................................................................................324 REMOVAL..........................................................................................324 INSTALLATION.....................................................................................324 DISASSEMBLY......................................................................................326 CLEANING AND INSPECTION..........................................................................326 ASSEMBLY.........................................................................................326 HOIST CYLINDER MOUNTING BEARING REPLACEMENT......................................................326 HYDRAULIC CHECK-OUT PROCEDURE............................................................................327 GENERAL INFORMATION..................................................................................327 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE....................................................327 INITIAL SYSTEM SET-UP................................................................................327 ACCUMULATOR AND BRAKE/STEERING PUMP CHECKS.......................................................327 STEERING VALVE LEAKAGE CHECK.....................................................................329 STEERING CYLINDER LEAKAGE CHECK..................................................................329 TROUBLESHOOTING CHART (STEERING SYSTEM)..............................................................330 HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE........................................................332 AUXILIARY VALVE..................................................................................332 PRESSURE CHECK...............................................................................332 LEAKAGE CHECK................................................................................332 CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE........................................333 CHECKING AND ADJUSTING "POWER DOWN" PRESSURE.....................................................333 TROUBLESHOOTING CHART FOR HOIST CIRCUIT..................................................................334 STEERING SYSTEM DATA SHEET...............................................................................337 HOIST SYSTEM DATA SHEET..................................................................................338 HYDRAULIC SYSTEM FLUSHING PROCEDURE......................................................................339 OPTIONS AND SPECIAL TOOLS....................................................................................341 LINCOLN AUTOMATIC LUBRICATION SYSTEM.....................................................................343 QUICK FUEL SYSTEMS.......................................................................................351 WIGGINS QUICK FUEL SYSTEM............................................................................351 BUCKEYE QUICK FUEL SYSTEM............................................................................355 KIM "HOTSTART" SYSTEM....................................................................................357 SPECIAL TOOLS............................................................................................361 AIR CONDITIONING SYSTEM..................................................................................379 PRINCIPLES OF REFRIGERATION..........................................................................380 AIR CONDITIONER SYSTEM COMPONENTS....................................................................381 ELECTRICAL CIRCUIT...................................................................................383 SYSTEM SERVICING.....................................................................................385 INSTALLING MANIFOLD GAUGE SET....................................................................389 SYSTEM STABILIZATION.............................................................................392 ADDING R-12 (PRIOR TO PERFORMANCE TEST)..........................................................392 SYSTEM PERFORMANCE TEST..........................................................................394 DISCHARGING SYSTEM...............................................................................393 FLUSHING AIR CONDITIONER COMPONENTS..............................................................395 SYSTEM REPAIR........................................................................................396 HOSES, FITTINGS, AND LINES.......................................................................396 EXPANSION VALVE..................................................................................396 RECEIVER-DRIER...................................................................................397 THERMOSTAT.......................................................................................397 CLUTCH...........................................................................................397 COMPRESSOR.......................................................................................397 CHECKING COMPRESSOR OIL LEVEL........................................................................398 EVACUATING THE SYSTEM................................................................................400 CHARGING THE SYSTEM..................................................................................393 TROUBLESHOOTING......................................................................................402 PREPARING FOR DIAGNOSIS..........................................................................402 TROUBLESHOOTING CHART................................................................................403 AUTOMATIC POSITIVE LOCKING DIFFERENTIAL..................................................................407 RADIATOR SHUTTERS........................................................................................409 OPERATOR'S CAB...............................................................................................411 TRUCK CAB................................................................................................413 REMOVAL..............................................................................................413 INSTALLATION.........................................................................................416 OPERATOR COMFORT.........................................................................................419 OPERATOR SEAT........................................................................................419 ADJUSTMENT.......................................................................................419 REMOVAL......................................................................................419 INSTALLATION.................................................................................419 DISASSEMBLY..................................................................................420 INSPECTION...................................................................................420 ASSEMBLY.....................................................................................420 HEATER/AIRCONDITIONER................................................................................422 WATER CONTROL VALVE..............................................................................422 HEATER/AIR CONDITIONER...........................................................................422 REMOVAL......................................................................................422 INSTALLATION.................................................................................424 DISASSEMBLY..................................................................................425 INSPECTION...................................................................................425 ASSEMBLY.....................................................................................425 OPERATOR CONTROLS AND INSTRUMENT PANEL...................................................................427 OPERATOR CONTROLS....................................................................................427 INSTRUMENT PANEL.....................................................................................430 RETARDER OPERATION...............................................................................434 INSTRUMENT PANEL - RIGHT SIDE........................................................................435 HEATER/AIR CONDITIONER CONTROLS......................................................................438 THROTTLE CONTROL PEDAL...............................................................................439 REMOVAL..........................................................................................439 INSTALLATION.....................................................................................439 DISASSEMBLY......................................................................................440 INSPECTION.......................................................................................441 ASSEMBLY.........................................................................................441 LUBRICATION AND SERVICE......................................................................................443 LUBRICATION AND SERVICE..................................................................................445 LUBRICATION SPECIFICATIONS CHART.........................................................................445 SERVICE CAPACITIES...................................................................................445 ANTI-FREEZE SPECIFICATIONS...........................................................................445 OIL AND GREASE SPECIFICATIONS........................................................................446 10 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................447 100 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................449 250 HOUR LUBRICATION AND MAINTENANCE CHECKS..............................................................451 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................453 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS.............................................................455 ALPHABETICAL INDEX...........................................................................................457 SYSTEM SCHEMATICS............................................................................................461 ELECTRICAL SCHEMATIC.....................................................................................463 HYDRAULIC SCHEMATIC......................................................................................472 ALLISON TRANSMISSION - HYDRAULIC SCHEMATIC...............................................................475
KOMATSU 210M DG694 SERVICE REPAIR WORKSHOP MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu 210M DG694 Service Repair Workshop Manual
FOREWORD:
This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general information. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque. All torque specifications have ± 10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The HAULPAK® Model designation consists of three numbers and one letter (i.e. 210M). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system. The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
