Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM033407 – PDF DOWNLOAD

Description

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM033407 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM033407 – PDF DOWNLOAD

Language : English
Pages :1334
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM033407 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50002 – A50021
ENGINE 16V159

Foreword

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
• All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing 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 typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout.
• All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise. When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
• A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating. The KOMATSU truck model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model.
• The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW.
• The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck components.

TABLE OF CONTENTS:’

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM033407 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50002 – A50021
ENGINE 16V159

Cover 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 21
Foreword 24
How to read the shop manual 25
Composition of shop manual 25
Revision and distribution 25
Symbols 26
General safety 27
Safety rules 27
Safety features 27
Fire extinguisher and first aid kit 27
Clothing and personal items 27
Leaving the operator seat 28
Mounting and dismounting 28
Fire prevention for fuel and oil 28
Precautions with high temperature fluids 29
Asbestos dust hazard prevention 29
Prevention of injury by work equipment 29
Unauthorized modification 29
Precautions when using ROPS 29
Precautions for attachments 30
Precautions for starting the truck 30
Precautions before operating the truck 30
Safety at the worksite 30
Fire prevention 31
Ventilation in enclosed areas 31
Preparing for operation 31
Mirrors, windows and lights 31
In operator cab (before starting the engine) 31
Seat Belts 31
Precautions while operating the truck 32
When starting the engine 32
General truck operation 32
Ensuring good visibility 32
Traveling 33
Traveling in reverse 33
Traveling on slopes 33
Operating on snow or ice 33
Avoid damage to dump body 33
Driving near high voltage cables 34
When dumping 34
When loading 34
Working on loose ground 34
Parking the truck 34
Towing 34
Working near batteries 35
Battery hazard prevention 35
Starting with jumper cables 36
Jump starting with receptacles 36
Precautions before performing service 37
Warning tag 37
Stopping the engine 37
Proper tools 37
Use of tie-off anchor during maintenance and repair 38
Tie-off anchor installation 38
Securing the dump body 39
Jack point locations 40
Precautions while performing service 41
Keep the truck clean 41
Attachments 41
Working under the truck 41
Rotating fan and belts 41
Adding fuel or oil 41
Use of lighting 41
Radiator coolant level 42
Precautions with the battery 42
Precautions with high pressure oil 42
Handling high pressure hoses 42
Precautions when performing maintenance near high temperature or high pressure 42
Waste materials 42
Tires 43
Inspection 43
Maintenance 43
Storage 44
Handling 45
Precautions for performing repairs 46
Engine shutdown procedure after AC drive system failure 46
Precautions for welding on the truck 47
Control cabinet capacitor discharge system 48
Handling electrical equipment and hydraulic components 50
Points to remember when handling electrical equipment 50
Points to remember when handling hydraulic equipment 56
Actions taken to meet exhaust gas regulations 58
About DEF 58
Precautions for diesel exhaust fluid (DEF) 59
About DEF 59
Precautions for handling DEF 59
Precautions for storing DEF 59
Precautions for disposing of DEF 60
Crystallization management 60
Precautions for cold weather operation 60
Standard tightening torques 61
Effect of special lubricants on fasteners and standard torque values 61
Suggested sources for rust preventive grease 61
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 62
SAE grade 9 capscrews 63
Class 109 capscrews and class 10 nuts 63
Standard tightening torques for fittings 64
Standard tightening torques for clamps 66
Conversion tables 67
Common conversion multipliers 67
01 Specification 71
Specification and technical data 71
Specification drawing 73
Specifications 74
Weight table 76
Fuel, coolant and lubricants 77
Suspension cylinder oil and nitrogen specifications 78
Wheel motor oil specifications 78
10 Structure and functions 81
Steering circuit 81
Steering circuit operation 83
Steering circuit components 85
Steering control unit 85
High pressure filter 85
Steering accumulators 85
Bleeddown manifold 88
Steering accumulator bleeddown solenoid 88
Quick disconnect ports 88
Flow amplifier 88
Steering/brake pump operation 89
High altitude operation 89
Neutral position 90
Full pump volume 91
Half pump volume 91
Flow amplifier operation 92
No steer 92
Steering left 94
Steering right 96
No steer, external shock load 98
Hoist circuit 101
Hoist circuit operation 103
Hoist circuit components 103
Hydraulic tank 103
Hoist pump 103
High pressure filters 103
Hoist valve 105
Overcenter manifold 106
Hoist pilot valve 107
Hoist limit solenoid 107
Pilot operated check valve 107
Hoist pilot valve operation 108
Float position with body coming down 108
Power up operation 110
Hold operation 112
Power down operation 114
Float operation 116
Brake circuits 119
General information 121
Service brake circuit operation 121
Secondary braking and auto apply 123
Parking brake circuit operation 123
Normal operation (engine start switch ON, engine on) 123
Wheel brake lock circuit operation 124
Brake warning circuit operation 124
Electrical system, 24 volt 127
Battery supply system 129
Batteries 129
24VDC auxiliary battery receptacles 129
Isolation box 130
Ground level shutdown switch 130
Battery disconnect switches 130
Propel lockout lever 130
System busy light 130
LED lights 130
Engine starting system with prelube 131
Prelube operation 131
Auxiliary control cabinet components 132
VEC blocks 133
24VDC to 12VDC converter 133
Circuit breakers 133
Engine service light timer 133
Ground terminals 133
24VDC power terminals 133
Relays 134
Body-up switch 135
Hoist limit switch 136
Heating/air conditioning (HVAC) system 139
Basic air conditioning system operation 141
HVAC components 143
Control panel 143
Water valve 143
Expansion valve 143
Actuators 143
Blower 143
Heater core 143
Evaporator core 143
Cab air temperature sensor 143
ECU module 143
Air filters 145
Compressor (refrigerant pump) 145
Compressor clutch 145
Trinary™ switch 146
Receiver-drier 146
Condenser 146
Accumulator 146
Automatic lubrication (auto lube) system 149
General information 151
System operation 152
Engine emissions aftertreatment system 155
About emissions aftertreatment 159
DEF injection system 159
DEF heating system 159
Sensors 159
Exhaust system cleaning 160
Propel lockout precaution 160
Inducement strategy 160
20 Standard value table 163
Standard value table 163
Standard value table for truck 165
30 Testing and adjusting 171
Steering, hoist and auxiliary hydraulic systems 171
Hydraulic system bleeddown procedure 173
General information on system checkout 175
Hydraulic system checkout procedures 175
Required equipment 175
Preliminary steps 176
Hydraulic system flushing procedure 176
Flow amplifier adjustment 179
Steering pump unloader valve adjustment 180
Auxiliary accumulator pressure verification 181
System diagnostics 182
Hoist pilot valve adjustment 185
Hoist counterbalance valve adjustment 185
Final steps 186
Oil cleanliness check 187
Hydraulic system checkout data sheet 188
Toe-in adjustment 192
Hoist cylinder leakage test 193
Steering cylinder leakage test 193
Brake system 195
Brake circuit checkout procedure 197
General information 197
Required equipment 197
Preliminary steps 197
Initial startup and service brake checkout 199
Brake lock system checkout 200
Parking brake checkout 200
Low brake pressure and auto apply 201
Parking brake control logic checkout 203
Brake lock control logic checkout 204
Brake system checkout data sheet 207
Service brake conditioning (burnishing) 218
Front brake conditioning 219
Rear brake conditioning 220
Brake bleeding procedure 221
Service brake 221
Parking brake (rear brake calipers only) 221
Piston assembly return spring force and built-in clearance (BIC) 223
Piston assembly adjuster grip force 224
Adjuster force 226
Piston return spring 227
Brake valve bench test and adjustment 229
Test setup procedure 230
Brake valve output pressure adjustment 230
Final test and adjustment 231
Installing brake pedal actuator to brake valve 233
Installing retard pedal to brake pedal 233
Accumulators and suspensions 235
Accumulator charging and storage 237
Temperature during precharge 237
Bladder accumulator charging procedure 238
Precharge maintenance 240
Bladder accumulator storage procedure 240
Bladder storage 240
Installing a bladder accumulator from storage 241
Bladder accumulator leak testing 241
Piston accumulator charging procedure 242
Piston accumulator storage 245
Piston accumulator leak testing 246
Checking for improper suspension charge on operating trucks 247
Suspension oil change recommendations 248
Suspension oiling and charging procedures 249
Required equipment 249
Installing the charging kit 250
Removing the charging kit 250
Support blocks for oiling and charging dimensions 251
Front suspensions 254
TOP FILL METHOD 255
PRESSURE FILL METHOD 255
Rear suspensions 257
TOP FILL METHOD 259
PRESSURE FILL METHOD 259
Suspension pressure test 262
Electrical systems 265
General information on system checkout 267
Truck shutdown procedure 268
Required software and tools 268
Electrical system checkout procedures 270
Visual inspection 270
Resistance checks 270
Voltage checks 271
Truck function checks 274
Interface module (IM) checks 275
KOMTRAX Plus II checks 275
Payload meter (PLM) checks 275
Drive system checks 276
Engine delayed shutdown Smart Timer check 277
Body hoist limit switch check 277
Electrical checkout sheet 278
Interface module (IM) 283
Required software and tools 285
Interface module checkout procedures 286
Initial startup 286
Checking digital inputs to the IM 286
Checking analog inputs to the IM 288
Checking serial communication to the IM 288
Checking outputs from the IM 288
IM checkout sheet 289
Interface module 2 (IM2) 293
Required tools 295
Programming the IM2 295
Updating the software 295
Configuring the IM2 296
Viewing IM2 real-time data 296
Interface module checkout procedures 297
Checking for IM fault codes 297
Checking digital inputs to the IM 297
Checking analog inputs to the IM 300
Checking serial communication to the IM 300
Checking outputs from the IM 301
IM checkout sheet 302
Payload meter IV 307
Payload meter IV software and tools 309
Payload meter IV system configuration 309
Connecting to the payload meter IV web server 309
Configuring a static IP address 309
Payload meter IV software installation 311
Inclinometer calibration and clean truck tare 312
Payload meter IV checkout procedure 312
PLM IV system checkout data sheet 318
Downloading PLM IV data and possible errors 319
KOMTRAX Plus II 323
Required software and tools 325
Ethernet connection to KOMTRAX Plus II controller 325
KOMTRAX Plus II configuration 327
GPS connection test 329
Iridium satellite system opening 331
Data download over ethernet connection for KOMTRAX Plus II initialization 334
Komatsu wireless bridge (KWB) 337
General information 339
Required software and tools 339
Download tools, firmware and scripts 339
Configure Mikrotik radio 340
Verify KWB_Connect bridge configuration 342
Verify KWB_Connect access point configuration 342
Verify 0002KPLUS access point configuration 342
Verify 0002KPLUS bridge configuration 342
Cab air conditioning 345
General information 347
Service tools and equipment 348
Recovery/recycle station 348
Leak detector 348
Manifold gauge set 349
Service valves 350
Vacuum pump 350
Detecting leaks 351
System performance test 352
Checking system oil 353
System flushing 354
Installing the manifold gauge set 355
Purging air from the service hoses 355
Recovering and recycling refrigerant 356
Draining oil from previous recovery cycle 357
Recovery cycle 357
Recycling procedure 357
Evacuating the air conditioning system 358
Charging the air conditioning system 359
Automatic lubrication (auto lube) system 361
Priming the system 363
Checkout procedure 365
Adjusting the lubrication cycle timing 366
Trucks with Interface Module 1 366
Trucks with Interface Module 2 366
KomVision 369
Requirements 371
Initial setup 372
Checkout data sheet 379
Calibration sheets 384
Layout and assemblage 384
Unfolding a calibration sheet 387
Folding a calibration sheet 388
Placement of calibration sheets 389
Camera calibration procedures 391
Automatic 6 camera calibration 391
Manual 6 camera calibration 395
1 camera calibration 398
Radar setting procedure 401
Tire monitoring system 405
Tire monitoring system software and tools 407
Tire monitoring system configuration 407
Connecting to the tire monitoring system web server 407
Configuring a static IP address 407
Tire monitoring system software installation 409
Tire monitoring system checkout procedure 410
Field Troubleshooting 410
Ethernet troubleshooting 410
Tire monitoring system configuration 411
CAN RPC Troubleshooting 411
Resetting the tire monitoring system 411
Tire monitoring system checkout data sheet 412
40 Troubleshooting 415
Fuse, diode and relay locations 415
Vehicle Electrical Center (VEC-89) 416
Vehicle Electrical Center (VEC-90) 418
Vehicle Electrical Center (VEC-91) 420
Vehicle Electrical Center (VEC-92) 422
Rear Terminal Mini-fuse and Relay (RTMR3) 423
Rear Terminal Mini-fuse and Relay (RTMR4) 424
Circuit breakers 424
Troubleshooting by fault code, Part 1 427
Fault Code A001 430
Fault Code A002 431
Fault Code A003 432
Fault Code A004 433
Fault Code A005 434
Fault Code A006 435
Fault Code A007 436
Fault Code A008 437
Fault Code A009 438
Related circuit diagram 438
Fault Code A010 439
Related circuit diagram 439
Fault Code A011 440
Fault Code A013 441
Fault Code A014 442
Fault Code A016 443
Fault Code A017 444
Fault Code A018 445
Fault Code A019 446
Fault Code A022 447
Fault Code A100 448
Related circuit diagram 448
Fault Code A101 449
Fault Code A103 450
Fault Code A104 451
Fault Code A105 452
Fault Code A109 453
Fault Code A111 454
Fault Code A115 455
Fault Code A117 456
Fault Code A118 457
Fault Code A123 458
Fault Code A124 459
Fault Code A125 460
Fault Code A126 461
Fault Code A127 462
Fault Code A128 463
Fault Code A139 464
Troubleshooting by fault code, Part 2 467
Fault Code A145 470
Fault Code A146 471
Fault Code A152 472
Fault Code A153 473
Fault Code A154 474
Fault Code A155 475
Fault Code A158 476
Fault Code A166 477
Fault Code A167 478
Fault Code A168 479
Fault Code A169 480
Fault Code A170 481
Fault Code A171 482
Fault Code A172 483
Fault Code A173 484
Fault Code A184 485
Fault Code A190 486
Fault Code A193 487
Fault Code A194 488
Fault Code A195 489
Fault Code A196 490
Fault Code A197 491
Fault Code A198 492
Fault Code A199 493
Fault Code A200 494
Fault Code A201 495
Fault Code A202 496
Fault Code A203 497
Fault Code A204 498
Fault Code A205 499
Fault Code A206 500
Fault Code A207 501
Fault Code A213 502
Fault Code A214 503
Fault Code A215 504
Fault Code A216 505
Fault Code A223 506
Fault Code A230 507
Fault Code A231 508
Fault Code A233 509
Fault Code A235 510
Fault Code A236 511
Fault Code A237 512
Fault Code A238 513
Fault Code A239 515
Related circuit diagram 516
Fault Code A240 517
Fault Code A242 518
Fault Code A243 519
Fault Code A244 520
Fault Code A245 521
Fault Code A246 522
Troubleshooting by fault code, Part 3 525
Fault Code A247 527
Fault Code A248 528
Fault Code A249 529
Fault Code A250 530
Fault Code A251 531
Fault Code A252 532
Fault Code A253 533
Fault Code A256 534
Fault Code A257 535
Fault Code A258 536
Fault Code A260 537
Fault Code A261 538
Fault Code A262 539
Fault Code A264 540
Fault Code A265 541
Fault Code A266 542
Fault Code A267 543
Fault Code A268 544
Fault Code A270 545
Fault Code A271 546
Related circuit diagram 547
Fault Code A272 548
Fault Code A273 549
Fault Code A274 550
Fault Code A275 551
Fault Code A277 552
Fault Code A278 553
Fault Code A279 554
Fault Code A280 555
Fault Code A281 556
Fault Code A282 557
Fault Code A283 558
Fault Code A284 559
Fault Code A285 560
Fault Code A286 561
Fault Code A292 562
Troubleshooting by fault code, Part 4 565
Fault Code A303 568
Fault Code A304 569
Fault Code A305 570
Fault Code A307 571
Fault Code A309 572
Fault Code A310 573
Fault Code A311 574
Fault Code A312 575
Fault Code A313 576
Fault Code A315 577
Fault Code A316 578
Fault Code A317 579
Fault Code A318 580
Fault Code A328 581
Fault Code A332 582
Fault Code A333 583
Fault Code A334 584
Fault Code A335 585
Fault Code A337 586
Fault Code A338 587
Fault Code A339 588
Fault Code A340 589
Fault Code A341 590
Fault Code A342 591
Fault Code A343 592
Fault Code A344 593
Fault Code A345 594
Fault Code A346 595
Fault Code A347 596
Fault Code A348 597
Fault Code A349 598
Fault Code A350 599
Fault Code A351 600
Fault Code A352 601
Fault Code A353 602
Fault Code A354 603
Fault Code A355 604
Fault Code A356 605
Fault Code A357 606
Fault Code A358 607
Fault Code A359 608
Fault Code A360 609
Fault Code A361 610
Fault Code A362 611
Fault Code A363 612
Fault Code A364 613
Fault Code A365 614
Fault Code A366 615
Troubleshooting by fault code, Part 5 617
Fault Code A400 620
Fault Code A401 621
Fault Code A402 622
Fault Code A403 623
Fault Code A404 624
Fault Code A405 625
Fault Code A406 626
Fault Code A407 627
Fault Code A408 628
Fault Code A409 629
Fault Code A410 630
Fault Code A411 631
Fault Code A412 632
Fault Code A413 633
Fault Code A414 634
Fault Code A415 635
Fault Code A416 636
Fault Code A417 637
Fault Code A418 638
Fault Code A419 639
Fault Code A420 640
Fault Code A421 641
Fault Code A422 642
Fault Code A423 643
Fault Code A424 644
Fault Code A425 645
Fault Code A426 646
Fault Code A427 647
Fault Code A428 648
Fault Code A429 649
Fault Code A430 650
Fault Code A431 651
Fault Code A432 652
Fault Code A433 653
Fault Code A434 654
Fault Code A435 655
Fault Code A436 656
Fault Code A437 657
Fault Code A438 658
Fault Code A439 659
Fault Code A440 660
Fault Code A441 661
Fault Code A442 662
Fault Code A443 663
Fault Code A444 664
Fault Code A445 665
Fault Code A446 666
Fault Code A447 667
Fault Code A510 668
Aftertreatment system fault codes 671
Fault Code CA256 675
Fault Code CA1677 677
Fault Code CA1678 679
Fault Code CA1682 682
Fault Code CA1683 689
Fault Code CA1684 691
Fault Code CA1685 693
Fault Code CA1686 695
Fault Code CA1712 697
Fault Code CA1713 699
Fault Code CA1714 701
Fault Code CA1715 702
Fault Code CA1887 704
Fault Code CA2771 705
Fault Code CA3142 709
Fault Code CA3143 711
Fault Code CA3146 713
Fault Code CA3147 715
Fault Code CA3232 717
Fault Code CA3497 720
Fault Code CA3498 721
Fault Code CA3547 722
Fault Code CA3558 723
Fault Code CA3559 725
Fault Code CA3562 727
Fault Code CA3563 729
Fault Code CA3567 731
Fault Code CA3571 733
Fault Code CA3572 735
Fault Code CA3573 738
Fault Code CA3574 740
Fault Code CA3575 742
Fault Code CA3712 744
Fault Code CA3713 745
Fault Code CA3714 748
Fault Code CA3867 749
Fault Code CA3868 750
Fault Code CA3878 753
Fault Code CA3988 754
Fault Code CA3995 758
Fault Code CA4113 760
Fault Code CA4114 762
Fault Code CA4119 764
Fault Code CA4121 766
Fault Code CA4152 768
Fault Code CA4164 772
Fault Code CA4165 774
Fault Code CA4166 777
Fault Code CA4168 779
Fault Code CA4169 781
Fault Code CA4174 783
Fault Code CA4175 785
Fault Code CA4233 788
Fault Code CA4234 789
Fault Code CA4243 790
Fault Code CA4277 791
Fault Code CA4457 793
Fault Code CA4458 795
Fault Code CA4459 798
Fault Code CA4461 800
Fault Code CA4462 802
Fault Code CA4464 804
Fault Code CA4465 806
Fault Code CA4466 809
Fault Code CA4467 816
Fault Code CA4474 818
Fault Code CA4475 820
Fault Code CA4572 823
Fault Code CA4677 827
Fault Code CA4679 831
Fault Code CA4682 832
Fault Code CA4731 833
Fault Code CA4732 834
Fault Code CA4736 835
Fault Code CA4737 836
Fault Code CA4738 837
Fault Code CA4739 838
Fault Code CA4745 839
Fault Code CA4768 840
Fault Code CA4769 842
Fault Code CA4842 844
Fault Code CA4863 845
Fault Code CA4947 846
Fault Code CA5115 847
Fault Code CA5116 850
Fault Code CA5117 853
Fault Code CA5247 856
Fault Code CA5653 858
Fault Code CA5654 861
Fault Code CA5725 863
Fault Code CA5727 868
Fault Code CA5728 871
Fault Code CA5729 874
Fault Code CA5748 876
Fault Code CA5749 878
Fault Code CA5751 880
Fault Code CA5753 882
Fault Code CA5755 885
Fault Code CA5756 890
Fault Code CA5758 892
Fault Code CA5768 894
Fault Code CA5769 896
Fault Code CA5771 899
Fault Code CA5772 901
Fault Code CA5773 904
Fault Code CA5774 907
Fault Code CA5775 909
Fault Code CA5776 914
Fault Code CA5778 916
Fault Code CA5779 918
Fault Code CA5887 920
Fault Code CA5888 921
Fault Code CA5889 922
Fault Code CA5891 923
Fault Code CA5892 924
Fault Code CA5893 925
Fault Code CA6692 926
Fault Code CA6693 928
Fault Code CA6694 930
Fault Code CA6695 932
Fault Code CA6696 934
Fault Code CA6697 936
Fault Code CA6855 938
Fault Code CA6856 941
Steering system 945
Steering circuit troubleshooting chart 947
Steering circuit troubleshooting guidelines 949
Basic hydraulic system checks 950
System leakage check 951
Steering pump troubleshooting guide 953
Pump pressure control checks 956
Pump fails to unload 957
Pump fails to develop pressure 957
Pump slow in developing pressure 958
Pump control valve inspection 958
Pump case drain check 959
Setting pump pressure controls 960
Steering pump adjustment 961
KomVision 963
KomVision fault codes 965
Automatic lubrication (auto lube) system 975
Autolube troubleshooting chart 977
Heating/air conditioning (HVAC) system 981
Control panel configurations 983
Diagnostics mode 984
Error codes 984
Advanced diagnostics 984
Firmware version 985
Additional HVAC troubleshooting chart 985
Voltage levels 987
50 Disassembly and assembly 989
Service tools 989
Special tool group 991
Additional service tools 992
KomVision calibration tools 992
Locally made tools 992
Wheels, spindles and rear axle 995
General precautions for tires and rims 997
Rim components 998
Smart rim component layout 998
Wheel stud maintenance 999
Rear outer wheel stud installation1000
Removal and installation of front wheel1001
Removal1001
Installation1002
Removal and installation of rear wheel1003
Removal1003
Installation1004
Rim and tire service1006
Lubricants1006
Tire inflation1006
Removal (5-piece standard rim)1006
Preparation before assembly1010
Installation (5-piece standard rim)1010
Removal and installation of front wheel hub and spindle1012
Removal1012
Spindle removal (off the truck)1017
Installation1019
Disassembly and assembly of front wheel hub and spindle1020
Cross Section View1020
Disassembly1021
Cleaning and inspection1025
Assembly1026
Wheel bearing adjustment1030
Speed sensor installation and adjustment1032
Floating ring seal assembly and installation1033
Floating seal test procedure1041
Removal and installation of rear axle1043
Removal1043
Cleaning and inspection1044
Installation1045
Removal and installation of anti-sway bar1046
Removal1046
Installation1048
Removal and installation of pivot pin1049
Removal1049
Installation1050
Pivot eye and bearing service1051
Bearing replacement1051
Pivot eye repair1052
Removal of wheel motor1053
Preparation1053
Removal1053
Installation of wheel motor1055
Cleaning and inspection1055
Installation1056
Brake system1061
Removal and installation of brake valve1063
Removal1063
Disassembly and assembly of brake valve/pedal assembly1066
Disassembly1066
Assembly1067
Removal and installation of brake manifold1069
Removal1069
Installation1070
Disassembly and assembly of brake manifold1071
Disassembly1071
Assembly1071
Installation of pressure reducing valve1072
Disassembly and assembly of brake accumulator1073
Cleaning and inspection1074
Assembly1075
Removal and installation of front brake caliper1077
Removal1077
Inspection1078
Installation1078
Disassembly and assembly of front brake caliper1079
Disassembly1079
Cleaning and inspection1079
Brake lining replacement1082
Assembly1082
Removal and installation of rear brake caliper1082
Removal1082
Inspection1085
Installation1085
Disassembly and assembly of rear brake caliper1088
Disassembly1088
Piston subassembly1091
Cleaning and inspection1092
Assembly1094
Piston subassembly1094
Brake caliper1095
Steering system1103
Removal and installation of steering control unit1105
Removal1105
Installation1107
Disassembly and assembly of steering control unit1108
Disassembly1108
Assembly1110
Removal and installation of steering column1113
Removal1113
Installation1114
Removal and installation of steering wheel1115
Removal1115
Installation1115
Removal and installation of bleeddown manifold1116
Removal1116
Installation1117
Removal and installation of flow amplifier1118
Removal1118
Installation1118
Removal and installation of steering cylinders and tie rod1119
Removal1119
Installation1119
Disassembly and assembly of steering cylinders1121
Disassembly1121
Cleaning and inspection1123
Assembly1124
Removal and installation of steering/brake pump1124
Removal1124
Installation1126
Removal and installation of piston steering accumulator1126
Removal1126
Installation1128
Disassembly and assembly of piston steering accumulator1129
Disassembly1129
Cleaning and inspection1131
Piston seal replacement1131
Assembly1132
Suspensions1135
General information1137
Removal and installation of front suspension1137
Preparation1137
Removal1137
Cleaning and Inspection1139
Installation1140
Disassembly and assembly of front suspension1146
Disassembly1146
Cleaning and inspection1148
Assembly1149
Removal and installation of rear suspension1151
General information1151
Removal1151
Installation1154
Disassembly and assembly of rear suspension1155
Disassembly1155
Cleaning and inspection1157
Assembly1158
Hoist circuit1161
Removal and installation of hoist pump1163
Removal1163
Installation1167
Disassembly and assembly of hoist pump1168
Disassembly1168
Inspection1173
Assembly1174
Removal and installation of hoist valve1177
Removal1177
Installation1179
Disassembly and assembly of hoist valve1179
O-ring replacement1179
Disassembly of inlet section1181
Assembly of inlet section1182
Disassembly of spool section1183
Assembly of spool section1185
Overcenter manifold service1186
Removal and installation of hoist pilot valve1187
Removal1187
Installation1187
Disassembly and assembly of hoist pilot valve1189
Disassembly1189
Cleaning and inspection1190
Assembly1190
Removal and installation of hoist cylinders1191
Removal1191
Installation1193
Disassembly and assembly of hoist cylinders1194
Disassembly1194
Cleaning and inspection1198
Installation of the quill1199
Assembly1201
Body and structures1207
Removal and installation of dump body1209
Removal1209
Inspection1210
Installation1211
Removal and installation of body pads1212
Removal1212
Installation1212
Body pad shimming procedure1213
Removal and installation of diagonal ladder/ hood and grille assembly1214
Removal1214
Installation1214
Removal and installation of RH deck1216
Removal1216
Installation1216
Removal and installation of LH deck1218
Removal1218
Installation1218
Removal and installation of fuel tank1220
Removal1220
Cleaning and inspection1222
Installation1222
Removal and installation of fuel gauge sender1223
Removal1223
Installation1223
Removal and installation of hydraulic tank1224
Removal1224
Installation1226
Removal and installation of hydraulic tank strainers1226
Removal1226
Cleaning and inspection1227
Installation1227
Operator cab1229
Removal and installation of operator cab1231
Removal1231
Installation1234
Removal and installation of cab door1234
Removal1234
Installation1235
Disassembly and assembly of cab door1236
Removing the window regulator1236
Installing the window regulator1237
Removing the door glass1238
Installing the door glass1239
Replacing the inner door seal1240
Replacing the outer door seal1240
Removing the interior door handle and door latch1241
Installing the interior door handle and door latch1243
Adjustment of cab door1244
Door jamb bolt adjustment1244
Exterior door handle release button adjustment1246
Removal and installation of side window glass1247
Recommended tools and supplies1247
Removal1247
Installation1248
Removal and installation of windshield and rear window glass1249
Removal1249
Installation1249
Removal and installation of windshield wiper components1250
Removing the windshield wiper motor1250
Installing the windshield wiper motor1250
Removing the windshield wiper arm and linkage1251
Installing the windshield wiper arm and linkage1252
Removal and installation of cab seats1252
Removal1252
Servicing the seat1253
Installation1253
Removal and installation of seat belts1254
Removal1254
Installation1255
Power module1257
Removal and installation of power module1259
General1259
Removal1260
Installation1268
Exhaust tube installation1272
Exhaust blanket installation1272
Removal and installation of alternator1273
Removal1273
Installation1276
Removal and installation of radiator1286
Removal1286
Installation1290
Repairing the radiator1291
Internal inspection1291
External cleaning1291
Disassembly1292
Cleaning and inspection1293
Assembly1293
Pressure testing1294
Removal and installation of engine1295
Removal1295
Service1296
Installation1296
90 Diagrams and drawings1299
Hydraulic circuit diagrams1299
Electrical circuit diagrams1306

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24