Komatsu 210M Dump Truck Shop Manual DG610 PDF

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Komatsu 210M Dump Truck Shop Manual DG610 – PDF DOWNLOAD

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Komatsu 210M Dump Truck Shop Manual DG610 – PDF DOWNLOAD 

Language : English
Pages : 481
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu 210M Dump Truck Shop Manual DG610 – PDF DOWNLOAD 

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.

TABLE OF CONTENTS:

Komatsu 210M Dump Truck Shop Manual DG610 – PDF DOWNLOAD 

MAIN MENU 0
COVER PAGE 1
TABLE OF CONTENTS 7
GENERAL INFORMATION 9
TRUCK COMPONENT DESCRIPTION AND 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 71
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 PAD 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
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 95
REMOVAL 95
INSTALLATION 95
MAIN FILTER ELEMENT CLEANING 97
PRECLEANER SECTION 98
CLEANING PRECLEANING TUBES 98
AIR INTAKE TROUBLESHOOTING 99
ENGINE COMPONENTS 101
THROTTLE CONTROL 101
THROTTLE CONTROL PEDAL 101
REMOVAL AND INSTALLATION 101
THROTTLE CONTROL LEVER 101
THROTTLE CONTROL ADJUSTMENT 103
ATEC THROTTLE POSITION SENSOR 104
THROTTLE POSITION SENSOR AND CABLE 104
REMOVAL 104
INSTALLATION 105
FAN 105
REMOVAL 105
INSTALLATION 105
FAN BELT ADJUSTMENT 105
ALTERNATOR BELT ADJUSTMENT 106
ELECTRIC SYSTEM (24 VDC NON-PROPULSION) 107
24 VDC ELECTRIC SUPPLY SYSTEM 109
ELECTRICAL SYSTEM DESCRIPTION 109
BATTERY 109
SERVICE 109
STORAGE 109
MAINTENANCE AND TROUBLESHOOTING 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
TROUBLESHOOTING 114
MONITOR 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
LIGHT CIRCUIT 122
CIRCUIT COMPONENTS 122
CIRCUIT CHECKOUT 123
HEATER AND AIR CONDITIONER CIRCUIT 123
CIRCUIT COMPONENTS 123
CIRCUIT CHECKOUT 123
24 VDC ELECTRIC START SYSTEM 124
24 VDC 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 TESTS 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 DIAGRAMS 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 135
SYSTEM DESCRIPTION 136
TRANSMISSION CONTROL CIRCUITS 137
BATTERY CHARGING CIRCUIT 137
CONTROL POWER AND MEMORY CIRCUITS 139
START CIRCUIT 139
CHECK TRANSMISSION WARNING LIGHT CIRCUIT 139
BACKUP HORN AND LIGHT CIRCUIT 139
HOIST INTERLOCK CIRCUIT 139
AUTO/MANUAL CIRCUIT 139
OVERSPEED RELAY CIRCUIT (NOT USED) 139
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 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 INSTALLATION ON RIM 162
FRONT TIRES AND RIMS 163
REMOVAL 163
INSTALLATION 163
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 ADJUSTMENT 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 ASSEMBLY 192
WHEEL HUB AND BEARINGS 192
REMOVAL 192
BEARING REPLACEMENT 192
INSTALLATION 193
HYDRAIR SUSPENSIONS 197
FRONT SUSPENSIONS 199
REMOVAL 199
INSTALLATION 200
DISASSEMBLY 201
INSPECTION 201
ASSEMBLY 202
REAR SUSPENSION 203
REAR SUSPENSIONS 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 CHART 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 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 237
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
REAR WET DISC BRAKE ASSEMBLY 251
REMOVAL 251
INSTALLATION 252
WET DISC BRAKE DISASSEMBLY 253
BRAKE PISTON DISASSEMBLY 256
BRAKE PISTON INSPECTION 256
BRAKE PISTON ASEMBLY 256
FLOATING RING SEAL INSTALLATION 257
WET DISC BRAKE ASSEMBLY 261
REAR WET DISC BRAKE ASSEMBLY 251
REAR WET DISC BRAKE BLEEDING PROCEDURE 263
REAR BRAKE DISC WEAR INDICATOR 264
REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER 264
PARK BRAKE 265
PARK BRAKE 265
REMOVAL/INSTALLATION 265
PARK BRAKE LINING ADJUSTMENT 265
PARK BRAKE LINKAGE ADJUSTMENT 265
PARK BRAKE ACTUATOR ASSEMBLY REPAIR 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 ASEMBLY 281
HYDRAULIC TANK 283
FILLING INSTRUCTIONS 283
REMOVAL 283
INSTALLATION 284
HYDRAULIC TANK BREATHERS 284
HYDRAULIC FILTERS 284
HYDRAULIC FILTERS 284
REMOVAL 285
INSTALLATION 285
DIFFERENTIAL PRESSURE SWITCH TESTING 286
TEST PROCEDURES 286
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
INSTALLATION 307
DISASSEMBLY 307
ASSEMBLY 313
PUMP SPECIFICATIONS CHART 321
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION 323
CIRCUIT OPERATION 323
HOIST VALVE 323
AUXILIARY MANIFOLD 324
COUNTER BALANCE VALVE 324
HOIST CYLINDERS 324
CHECK VALVES 324
HOIST CIRCUIT COMPONENT REPAIR 325
HOIST VALVE 325
REMOVAL 325
INSTALLATION 325
DISASSEMBLY 326
ASSEMBLY 327
HOIST CYLINDER 328
REMOVAL 328
INSTALLATION 328
DISASSEMBLY 330
CLEANING AND INSPECTION 330
ASSEMBLY 330
HOIST CYLINDER MOUNTING BEARING REPLACEMENT 330
HYDRAULIC CHECK-OUT PROCEDURE 331
GENERAL INFORMATION 331
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 331
INITIAL SYSTEM SET-UP 331
ACCUMULATOR AND PISTON PUMP CHECKS 331
STEERING VALVE LEAKAGE CHECK 333
STEERING CYLINDER LEAKAGE CHECK 333
TROUBLESHOOTING CHART (STEERING SYSTEM) 334
HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE 336
AUXILIARY VALVE 336
PRESSURE CHECK 336
LEAKAGE CHECK 336
CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE 337
CHECKING AND ADJUSTING “POWER DOWN” PRESSURE 337
TROUBLESHOOTING CHART (HOIST SYSTEM) 338
STEERING SYSTEM DATA SHEET 341
HOIST SYSTEM DATA SHEET 342
HYDRAULIC SYSTEM FLUSHING PROCEDURE 343
OPTIONS AND SPECIAL TOOLS 345
LINCOLN AUTOMATIC LUBRICATION SYSTEM 347
QUICK FUEL SYSTEMS 355
WIGGINS QUICK FILL FUEL SYSTEM 355
BUCKEYE QUICK FUEL SYSTEM 359
KIM “HOTSTART” SYSTEM 361
SPECIAL TOOLS 365
AIR CONDITIONING SYSTEM 383
PRINCIPLES OF REFRIGERATION 384
AIR CONDITIONER SYSTEM COMPONENTS 385
ELECTRICAL CIRCUIT 387
SYSTEM SERVICING 389
INSTALLING MANIFOLD GAUGE SET 393
SYSTEM STABILIZING 396
ADDING R-12 (PRIOR TO PERFORMANCE TEST) 396
SYSTEM PERFORMANCE TEST 398
DISCHARGING SYSTEM 399
FLUSHING AIR CONDITIONER COMPONENTS 399
SYSTEM REPAIR 400
HOSES, FITTINGS AND LINES 400
EXPANSION VALVE 400
RECEIVER DRIER 401
THERMOSTAT 401
CLUTCH 401
COMPRESSOR 401
CHECKING COMPRESSOR OIL LEVEL 402
EVACUATING THE SYSTEM 404
CHARGING THE SYSTEM 404
TROUBLESHOOTING 406
PREPARING FOR DIAGNOSIS 406
TROUBLESHOOTING CHART 407
AUTOMATIC POSITIVE LOCKING DIFFERENTIAL 411
RADIATOR SHUTTERS 413
OPERATOR’S CAB 415
TRUCK CAB 417
REMOVAL 417
INSTALLATION 420
OPERATOR COMFORT 423
OPERATOR SEAT 423
ADJUSTMENT 423
REMOVAL 423
INSTALLATION 423
DISASSEMBLY 424
INSPECTION 424
ASSEMBLY 424
HEATER/AIR CONDITIONER 426
WATER CONTROL VALVE 426
REMOVAL 426
INSTALLATION 428
DISASSEMBLY 429
INSPECTION 429
ASSEMBLY 429
OPERATOR CONTROLS AND INSTRUMENT PANEL 431
OPERATOR CONTROLS 431
INSTRUMENT PANEL 434
RETARDER OPERATION 438
INSTRUMENT PANEL (RIGHT SIDE) 439
HEATER/AIR CONDITIONER CONTROLS 442
THROTTLE PEDAL 443
REMOVAL 443
INSTALLATION 443
DISASSEMBLY 444
INSPECTION 445
ASSEMBLY 445
LUBRICATION AND SERVICE 447
LUBRICATION AND SERVICE 449
LUBRICATION AND SPECIFICATIONS CHARTS 449
SERVICE CAPACITIES 449
ANTI-FREEZE SPECIFICATIONS 449
OIL AND GREASE SPECIFICATIONS 450
10 HOUR LUBRICATION AND MAINTENANCE CHECKS 451
100 HOUR LUBRICATION AND MAINTENANCE CHECKS 453
250 HOUR LUBRICATION AND MAINTENANCE CHECKS 455
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS 457
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS 459
ALPHABETICAL INDEX 461
SYSTEM SCHEMATICS 465
ELECTRIC SCHEMATIC 467
HYDRAULIC SYSTEM SCHEMATIC 476
ALLISON TRANSMISSION 479

S.V 16/12/24