Komatsu 730E-10 Dump Truck Shop Manual CEBM035404 – PDF DOWNLOAD

Description

Komatsu 730E-10 Dump Truck Shop Manual CEBM035404 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E-10 Dump Truck Shop Manual CEBM035404 – PDF DOWNLOAD

Language : English
Pages :1043
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E-10 Dump Truck Shop Manual CEBM035404 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50022, A50024 – A50025

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 Nm (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 CEBM035404 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50022, A50024 – A50025

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 19
Foreword 22
How to read the shop manual 23
Composition of shop manual 23
Revision and distribution 23
Symbols 24
General safety 25
Safety rules 25
Safety features 25
Fire extinguisher and first aid kit 25
Clothing and personal items 25
Leaving the operator seat 26
Mounting and dismounting 26
Fire prevention for fuel and oil 26
Precautions with high temperature fluids 27
Asbestos dust hazard prevention 27
Prevention of injury by work equipment 27
Unauthorized modification 27
Precautions when using ROPS 27
Precautions for attachments 28
Precautions for starting the truck 28
Precautions before operating the truck 28
Safety at the worksite 28
Fire prevention 29
Ventilation in enclosed areas 29
Preparing for operation 29
Mirrors, windows and lights 29
In operator cab (before starting the engine) 29
Seat Belts 29
Precautions while operating the truck 30
When starting the engine 30
General truck operation 30
Ensuring good visibility 30
Traveling 31
Traveling in reverse 31
Traveling on slopes 31
Operating on snow or ice 31
Avoid damage to dump body 31
Driving near high voltage cables 32
When dumping 32
When loading 32
Working on loose ground 32
Parking the truck 32
Towing 32
Working near batteries 33
Battery hazard prevention 33
Starting with jumper cables 34
Jump starting with receptacles 34
Precautions before performing service 35
Warning tag 35
Stopping the engine 35
Proper tools 35
Use of tie-off anchor during maintenance and repair 36
Tie-off anchor installation 36
Securing the dump body 37
Jack point locations 38
Precautions while performing service 39
Keep the truck clean 39
Attachments 39
Working under the truck 39
Rotating fan and belts 39
Adding fuel or oil 39
Use of lighting 39
Radiator coolant level 40
Precautions with the battery 40
Precautions with high pressure oil 40
Handling high pressure hoses 40
Precautions when performing maintenance near high temperature or high pressure 40
Waste materials 40
Tires 41
Inspection 41
Maintenance 41
Storage 42
Handling 43
Precautions for performing repairs 44
Engine shutdown procedure after AC drive system failure 44
Precautions for welding on the truck 45
Control cabinet capacitor discharge system 46
Handling electrical equipment and hydraulic components 48
Points to remember when handling electrical equipment 48
Points to remember when handling hydraulic equipment 54
Standard tightening torques 56
Effect of special lubricants on fasteners and standard torque values 56
Suggested sources for rust preventive grease 56
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 57
SAE grade 9 capscrews 58
Class 109 capscrews and class 10 nuts 58
Standard tightening torques for fittings 59
Standard tightening torques for clamps 61
Conversion tables 62
Common conversion multipliers 62
01 Specification 67
Specification and technical data 67
Specification drawing 69
Specifications 70
Weight table 72
Fuel, coolant and lubricants 73
Suspension cylinder oil and nitrogen specifications 74
Wheel motor oil specifications 74
10 Structure and functions 77
Steering circuit 77
Steering circuit operation 79
Steering circuit components 81
Steering control unit 81
High pressure filter 81
Steering accumulators 81
Bleeddown manifold 84
Steering accumulator bleeddown solenoid 84
Quick disconnect ports 84
Flow amplifier 84
Steering/brake pump operation 85
High altitude operation 85
Neutral position 86
Full pump volume 87
Half pump volume 87
Flow amplifier operation 88
No steer 88
Steering left 90
Steering right 92
No steer, external shock load 94
Hoist circuit 97
Hoist circuit operation 99
Hoist circuit components 99
Hydraulic tank 99
Hoist pump 99
High pressure filters 99
Hoist valve 101
Overcenter manifold 102
Hoist pilot valve 103
Hoist limit solenoid 103
Pilot operated check valve 103
Hoist pilot valve operation 104
Float position with body coming down 104
Power up operation 106
Hold operation 108
Power down operation 110
Float operation 112
Brake circuits 115
General information 117
Service brake circuit operation 117
Secondary braking and auto apply 119
Parking brake circuit operation 119
Normal operation (engine start switch ON, engine on) 119
Wheel brake lock circuit operation 120
Brake warning circuit operation 120
Electrical system, 24 volt 123
Battery supply system 125
Batteries 125
24VDC auxiliary battery receptacles 125
Isolation box 126
Ground level shutdown switch 126
Battery disconnect switches 126
Propel lockout lever 126
System busy light 126
LED lights 126
Engine starting system with prelube 127
Prelube operation 127
Cranking operation 128
Auxiliary control cabinet components 129
VEC blocks 130
24VDC to 12VDC converter 130
Circuit breakers 130
Engine service light timer 130
Ground terminals 130
24VDC power terminals 130
Relays 131
Body-up switch 132
Hoist limit switch 133
Heating/air conditioning (HVAC) system 135
Basic air conditioning system operation 137
HVAC components 139
Control panel 139
Water valve 139
Expansion valve 139
Actuators 139
Blower 139
Heater core 139
Evaporator core 139
Cab air temperature sensor 139
ECU module 139
Air filters 141
Compressor (refrigerant pump) 141
Compressor clutch 141
Trinary™ switch 142
Receiver-drier 142
Condenser 142
Accumulator 142
Automatic lubrication (auto lube) system 145
General information 147
System operation 148
20 Standard value table 151
Standard value table 151
Standard value table for truck 153
30 Testing and adjusting 159
Steering, hoist and auxiliary hydraulic systems 159
Hydraulic system bleeddown procedure 161
General information on system checkout 163
Hydraulic system checkout procedures 163
Required equipment 163
Preliminary steps 164
Hydraulic system flushing procedure 164
Flow amplifier adjustment 167
Steering pump unloader valve adjustment 168
Auxiliary accumulator pressure verification 169
System diagnostics 170
Hoist pilot valve adjustment 173
Hoist counterbalance valve adjustment 173
Final steps 174
Oil cleanliness check 175
Hydraulic system checkout data sheet 176
Toe-in adjustment 180
Hoist cylinder leakage test 181
Steering cylinder leakage test 181
Brake system 183
Brake circuit checkout procedure 185
General information 185
Required equipment 185
Preliminary steps 185
Initial startup and service brake checkout 187
Brake lock system checkout 188
Parking brake checkout 188
Low brake pressure and auto apply 189
Parking brake control logic checkout 191
Brake lock control logic checkout 192
Brake system checkout data sheet 195
Service brake conditioning (burnishing) 206
Front brake conditioning 207
Rear brake conditioning 208
Brake bleeding procedure 209
Service brake 209
Parking brake (rear brake calipers only) 209
Piston assembly return spring force and built-in clearance (BIC) 211
Piston assembly adjuster grip force 212
Adjuster force 214
Piston return spring 215
Brake valve bench test and adjustment 217
Test setup procedure 218
Brake valve output pressure adjustment 218
Final test and adjustment 219
Installing brake pedal actuator to brake valve 221
Installing retard pedal to brake pedal 221
Accumulators and suspensions 223
Accumulator charging and storage 225
Temperature during precharge 225
Bladder accumulator charging procedure 226
Precharge maintenance 228
Bladder accumulator storage procedure 228
Bladder storage 228
Installing a bladder accumulator from storage 229
Bladder accumulator leak testing 229
Piston accumulator charging procedure 230
Piston accumulator storage 233
Piston accumulator leak testing 234
Checking for improper suspension charge on operating trucks 235
Suspension oil change recommendations 236
Suspension oiling and charging procedures 237
Required equipment 237
Installing the charging kit 238
Removing the charging kit 238
Support blocks for oiling and charging dimensions 239
Front suspensions 242
TOP FILL METHOD 243
PRESSURE FILL METHOD 243
Rear suspensions 245
TOP FILL METHOD 247
PRESSURE FILL METHOD 247
Suspension pressure test 249
Electrical systems 251
General information on system checkout 253
Truck shutdown procedure 254
Required software and tools 254
Electrical system checkout procedures 256
Visual inspection 256
Resistance checks 256
Voltage checks 256
Truck function checks 257
Interface module (IM) checks 258
Payload meter (PLM) checks 258
Drive system checks 259
Engine delayed shutdown Smart Timer check 259
Body hoist limit switch check 259
Electrical checkout sheet 260
Interface module 2 (IM2) 265
Required tools 267
Programming the IM2 267
Updating the software 267
Configuring the IM2 268
Viewing IM2 real-time data 268
Interface module checkout procedures 269
Checking for IM fault codes 269
Checking digital inputs to the IM 269
Checking analog inputs to the IM 272
Checking serial communication to the IM 272
Checking outputs from the IM 273
IM checkout sheet 274
KOMTRAX Plus II 279
Required software and tools 281
Ethernet connection to KOMTRAX Plus II controller 281
KOMTRAX Plus II configuration 283
Data download over ethernet connection for KOMTRAX Plus II initialization 285
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
Komatsu wireless bridge (KWB) 305
General information 307
Required software and tools 307
Download tools, firmware and scripts 307
Configure Mikrotik radio 308
Verify KWB_Connect bridge configuration 310
Verify KWB_Connect access point configuration 310
Verify 0002KPLUS access point configuration 310
Verify 0002KPLUS bridge configuration 310
Cab air conditioning 313
General information 315
Service tools and equipment 316
Recovery/recycle station 316
Leak detector 316
Manifold gauge set 317
Service valves 318
Vacuum pump 318
Detecting leaks 319
System performance test 320
Checking system oil 321
System flushing 322
Installing the manifold gauge set 323
Purging air from the service hoses 324
Recovering and recycling refrigerant 325
Draining oil from previous recovery cycle 326
Recovery cycle 326
Recycling procedure 326
Evacuating the air conditioning system 327
Charging the air conditioning system 328
Automatic lubrication (auto lube) system 331
Priming the system 333
Checkout procedure 335
Adjusting the lubrication cycle timing 336
Trucks with Interface Module 1 336
Trucks with Interface Module 2 336
KomVision 339
Requirements 341
Initial setup 342
Checkout data sheet 351
Calibration sheets 356
Layout and assemblage 356
Unfolding a calibration sheet 359
Folding a calibration sheet 360
Placement of calibration sheets 361
Camera calibration procedures 363
Automatic 6 camera calibration 363
Manual 6 camera calibration 367
1 camera calibration 370
Radar setting procedure 373
Tire monitoring system 377
Tire monitoring system software and tools 379
Tire monitoring system configuration 379
Connecting to the tire monitoring system web server 379
Configuring a static IP address 379
Tire monitoring system software installation 381
Tire monitoring system checkout procedure 382
Field Troubleshooting 382
Ethernet troubleshooting 382
Tire monitoring system configuration 383
CAN RPC Troubleshooting 383
Resetting the tire monitoring system 383
Tire monitoring system checkout data sheet 384
40 Troubleshooting 387
Fuse, diode and relay locations 387
Vehicle Electrical Center (VEC-89) 388
Vehicle Electrical Center (VEC-90) 390
Vehicle Electrical Center (VEC-91) 392
Vehicle Electrical Center (VEC-92) 394
Rear Terminal Mini-fuse and Relay (RTMR3) 395
Rear Terminal Mini-fuse and Relay (RTMR4) 396
Circuit breakers 396
Troubleshooting by fault code, Part 1 399
Fault Code A001 402
Fault Code A002 403
Fault Code A003 404
Fault Code A004 405
Fault Code A005 406
Fault Code A006 407
Fault Code A007 408
Fault Code A008 409
Fault Code A009 410
Related circuit diagram 410
Fault Code A010 411
Related circuit diagram 411
Fault Code A011 412
Fault Code A013 413
Fault Code A014 414
Fault Code A016 415
Fault Code A017 416
Fault Code A018 417
Fault Code A019 418
Fault Code A022 419
Fault Code A100 420
Related circuit diagram 420
Fault Code A101 421
Fault Code A103 422
Fault Code A104 423
Fault Code A105 424
Fault Code A109 425
Fault Code A111 426
Fault Code A115 427
Fault Code A117 428
Fault Code A118 429
Fault Code A123 430
Fault Code A124 431
Fault Code A125 432
Fault Code A126 433
Fault Code A127 434
Fault Code A128 435
Fault Code A139 436
Troubleshooting by fault code, Part 2 439
Fault Code A145 442
Fault Code A146 443
Fault Code A152 444
Fault Code A153 445
Fault Code A154 446
Fault Code A155 447
Fault Code A158 448
Fault Code A166 449
Fault Code A167 450
Fault Code A168 451
Fault Code A169 452
Fault Code A170 453
Fault Code A171 454
Fault Code A172 455
Fault Code A173 456
Fault Code A184 457
Fault Code A190 458
Fault Code A193 459
Fault Code A194 460
Fault Code A195 461
Fault Code A196 462
Fault Code A197 463
Fault Code A198 464
Fault Code A199 465
Fault Code A200 466
Fault Code A201 467
Fault Code A202 468
Fault Code A203 469
Fault Code A204 470
Fault Code A205 471
Fault Code A206 472
Fault Code A207 473
Fault Code A213 474
Fault Code A214 475
Fault Code A215 476
Fault Code A216 477
Fault Code A223 478
Fault Code A230 479
Fault Code A231 480
Fault Code A233 481
Fault Code A235 482
Fault Code A236 483
Fault Code A237 484
Fault Code A238 485
Fault Code A239 487
Related circuit diagram 488
Fault Code A240 489
Fault Code A242 490
Fault Code A243 491
Fault Code A244 492
Fault Code A245 493
Fault Code A246 494
Troubleshooting by fault code, Part 3 497
Fault Code A248 501
Fault Code A249 502
Fault Code A250 503
Fault Code A251 504
Fault Code A252 505
Fault Code A253 506
Fault Code A256 507
Fault Code A257 508
Fault Code A258 509
Fault Code A260 510
Fault Code A261 511
Fault Code A262 512
Fault Code A264 513
Fault Code A265 514
Fault Code A266 515
Fault Code A267 516
Fault Code A268 517
Fault Code A270 518
Fault Code A271 519
Related circuit diagram 520
Fault Code A272 521
Fault Code A273 522
Fault Code A274 523
Fault Code A275 524
Fault Code A277 525
Fault Code A278 526
Fault Code A279 527
Fault Code A280 528
Fault Code A281 529
Fault Code A282 530
Fault Code A283 531
Fault Code A284 532
Fault Code A285 533
Fault Code A286 534
Fault Code A292 535
Troubleshooting by fault code, Part 4 537
Fault Code A303 540
Fault Code A304 541
Fault Code A305 542
Fault Code A307 543
Fault Code A309 544
Fault Code A310 545
Fault Code A311 546
Fault Code A312 547
Fault Code A313 548
Fault Code A315 549
Fault Code A316 550
Fault Code A317 551
Fault Code A318 552
Fault Code A328 553
Fault Code A332 554
Fault Code A333 555
Fault Code A334 556
Fault Code A335 557
Fault Code A337 558
Fault Code A338 559
Fault Code A339 560
Fault Code A340 561
Fault Code A341 562
Fault Code A342 563
Fault Code A343 564
Fault Code A344 565
Fault Code A345 566
Fault Code A346 567
Fault Code A347 568
Fault Code A348 569
Fault Code A349 570
Fault Code A350 571
Fault Code A351 572
Fault Code A352 573
Fault Code A353 574
Fault Code A354 575
Fault Code A355 576
Fault Code A356 577
Fault Code A357 578
Fault Code A358 579
Fault Code A359 580
Fault Code A360 581
Fault Code A361 582
Fault Code A362 583
Fault Code A363 584
Fault Code A364 585
Fault Code A365 586
Fault Code A366 587
Troubleshooting by fault code, Part 5 589
Fault Code A400 592
Fault Code A401 593
Fault Code A402 594
Fault Code A403 595
Fault Code A404 596
Fault Code A405 597
Fault Code A406 598
Fault Code A407 599
Fault Code A408 600
Fault Code A409 601
Fault Code A410 602
Fault Code A411 603
Fault Code A412 604
Fault Code A413 605
Fault Code A414 606
Fault Code A415 607
Fault Code A416 608
Fault Code A417 609
Fault Code A418 610
Fault Code A419 611
Fault Code A420 612
Fault Code A421 613
Fault Code A422 614
Fault Code A423 615
Fault Code A424 616
Fault Code A425 617
Fault Code A426 618
Fault Code A427 619
Fault Code A428 620
Fault Code A429 621
Fault Code A430 622
Fault Code A431 623
Fault Code A432 624
Fault Code A433 625
Fault Code A434 626
Fault Code A435 627
Fault Code A436 628
Fault Code A437 629
Fault Code A438 630
Fault Code A439 631
Fault Code A440 632
Fault Code A441 633
Fault Code A442 634
Fault Code A443 635
Fault Code A444 636
Fault Code A445 637
Fault Code A446 638
Fault Code A447 639
Steering system 641
Steering circuit troubleshooting chart 643
Steering circuit troubleshooting guidelines 645
Basic hydraulic system checks 646
System leakage check 647
Steering pump troubleshooting guide 649
Pump pressure control checks 652
Pump fails to unload 653
Pump fails to develop pressure 653
Pump slow in developing pressure 654
Pump control valve inspection 654
Pump case drain check 656
Setting pump pressure controls 656
Steering pump adjustment 657
KomVision 659
KomVision fault codes 661
Automatic lubrication (auto lube) system 671
Autolube troubleshooting chart 673
Heating/air conditioning (HVAC) system 677
Control panel configurations 679
Diagnostics mode 680
Error codes 680
Advanced diagnostics 680
Firmware version 681
Additional HVAC troubleshooting chart 681
Voltage levels 683
50 Disassembly and assembly 685
Service tools 685
Special tool group 687
Heated body tool group 688
Additional service tools 689
KomVision calibration tools 690
Locally made tools 690
Wheels, spindles and rear axle 693
General precautions for tires and rims 695
Wheel stud maintenance 696
Rear outer wheel stud installation 697
Removal and installation of front wheel 698
Removal 698
Installation 699
Removal and installation of rear wheel 700
Removal 700
Installation 701
Rim components 703
Smart rim component layout 703
Rim and tire service 704
Lubricants 704
Tire inflation 704
Removal (5-piece standard rim) 704
Preparation before assembly 708
Installation (5-piece standard rim) 708
Removal and installation of front wheel hub and spindle 710
Removal 710
Spindle removal (off the truck) 715
Installation 717
Disassembly and assembly of front wheel hub and spindle 718
Cross Section View 718
Disassembly 719
Cleaning and inspection 723
Assembly 724
Wheel bearing adjustment 728
Speed sensor installation and adjustment 730
Floating ring seal assembly and installation 731
Floating seal test procedure 739
Removal and installation of rear axle 741
Removal 741
Cleaning and inspection 742
Installation 743
Removal and installation of anti-sway bar 744
Removal 744
Installation 746
Removal and installation of pivot pin 747
Removal 747
Installation 748
Pivot eye and bearing service 749
Bearing replacement 749
Pivot eye repair 750
Removal of wheel motor 751
Preparation 751
Removal 751
Installation of wheel motor 753
Cleaning and inspection 753
Installation 754
Brake system 759
Removal and installation of brake valve 761
Removal 761
Disassembly and assembly of brake valve/pedal assembly 764
Disassembly 764
Assembly 765
Removal and installation of brake manifold 767
Removal 767
Installation 768
Disassembly and assembly of brake manifold 769
Disassembly 769
Assembly 769
Installation of pressure reducing valve 770
Disassembly and assembly of brake accumulator 771
Cleaning and inspection 772
Assembly 773
Removal and installation of front brake caliper 775
Removal 775
Inspection 776
Installation 776
Disassembly and assembly of front brake caliper 777
Disassembly 777
Cleaning and inspection 777
Brake lining replacement 780
Assembly 780
Removal and installation of rear brake caliper 780
Removal 780
Inspection 783
Installation 783
Disassembly and assembly of rear brake caliper 786
Disassembly 786
Piston subassembly 789
Cleaning and inspection 790
Assembly 792
Piston subassembly 792
Brake caliper 793
Steering system 801
Removal and installation of steering control unit 803
Removal 803
Installation 804
Disassembly and assembly of steering control unit 805
Disassembly 805
Assembly 807
Removal and installation of steering column 810
Removal 810
Installation 811
Removal and installation of steering wheel 812
Removal 812
Installation 812
Removal and installation of bleeddown manifold 813
Removal 813
Installation 814
Removal and installation of flow amplifier 815
Removal 815
Installation 815
Removal and installation of steering cylinders and tie rod 816
Removal 816
Installation 816
Disassembly and assembly of steering cylinders 818
Disassembly 818
Cleaning and inspection 821
Assembly 821
Removal and installation of steering/brake pump 822
Removal 822
Installation 823
Removal and installation of piston steering accumulator 824
Removal 824
Installation 826
Disassembly and assembly of piston steering accumulator 828
Disassembly 828
Cleaning and inspection 830
Piston seal replacement 830
Assembly 831
Suspensions 833
Removal and installation of front suspension 835
Preparation 835
Removal 835
Cleaning and Inspection 837
Installation 838
Disassembly and assembly of front suspension 844
Disassembly 844
Cleaning and inspection 846
Assembly 847
Removal and installation of rear suspension 849
Removal 849
Installation 852
Disassembly and assembly of rear suspension 855
Disassembly 855
Cleaning and inspection 857
Assembly 858
Hoist circuit 861
Removal and installation of hoist pump 863
Removal 863
Installation 867
Disassembly and assembly of hoist pump 868
Disassembly 868
Inspection 873
Assembly 874
Removal and installation of hoist valve 877
Removal 877
Installation 879
Disassembly and assembly of hoist valve 879
O-ring replacement 879
Disassembly of inlet section 881
Assembly of inlet section 882
Disassembly of spool section 883
Assembly of spool section 885
Overcenter manifold service 886
Removal and installation of hoist pilot valve 887
Removal 887
Installation 887
Disassembly and assembly of hoist pilot valve 889
Disassembly 889
Cleaning and inspection 890
Assembly 891
Removal and installation of hoist cylinders 892
Removal 892
Installation 895
Disassembly and assembly of hoist cylinders 898
Disassembly 898
Cleaning and inspection 902
Installation of the quill 903
Assembly 905
Body and structures 911
Removal and installation of dump body 913
Removal 913
Inspection 914
Installation 915
Removal and installation of body pads 916
Removal 916
Installation 916
Body pad shimming procedure 917
Removal and installation of diagonal ladder/ hood and grille assembly 918
Removal 918
Installation 918
Removal and installation of RH deck 920
Removal 920
Installation 920
Removal and installation of LH deck 922
Removal 922
Installation 922
Removal and installation of fuel tank 924
Removal 924
Cleaning and inspection 926
Installation 926
Removal and installation of fuel gauge sender 927
Removal 927
Installation 927
Removal and installation of hydraulic tank 928
Removal 928
Installation 930
Removal and installation of hydraulic tank strainers 930
Removal 930
Cleaning and inspection 931
Installation 931
Operator cab 933
Removal and installation of operator cab 935
Removal 935
Installation 938
Removal and installation of cab door 938
Removal 938
Installation 939
Disassembly and assembly of cab door 940
Removing the window regulator 940
Installing the window regulator 941
Removing the door glass 942
Installing the door glass 943
Replacing the inner door seal 944
Replacing the outer door seal 944
Removing the interior door handle and door latch (earlier models) 945
Installation and removal of interior door handle and door latch (later models) 948
Adjustment of cab door 950
Door jamb bolt adjustment 950
Exterior door handle release button adjustment 952
Removal and installation of side window glass 953
Recommended tools and supplies 953
Removal 953
Installation 954
Removal and installation of windshield and rear window glass 955
Removal 955
Installation 955
Removal and installation of windshield wiper components 956
Removing the windshield wiper motor 956
Installing the windshield wiper motor 956
Removing the windshield wiper arm and linkage 957
Installing the windshield wiper arm and linkage 958
Removal and installation of cab seats 958
Removal 958
Servicing the seat 959
Installation 959
Removal and installation of seat belts 960
Removal 960
Installation 961
Power module 963
Removal and installation of power module 965
General 965
Removal 966
Installation 974
Exhaust tube installation 978
Exhaust blanket installation 978
Removal and installation of alternator 979
Removal 979
Installation 982
Engine/alternator attachment checkout data sheet 992
Removal and installation of radiator 997
Removal 997
Installation1001
Repairing the radiator1002
Internal inspection1002
External cleaning1002
Disassembly1003
Cleaning and inspection1004
Assembly1004
Pressure testing1005
Removal and installation of engine1006
Removal1006
Service1007
Installation1007
90 Diagrams and drawings1009
Hydraulic circuit diagrams1009
Steering & hoist hydraulic schematic1011
Brake hydraulic circuit diagram1012
Auxiliary hydraulic schematic1013
Electrical circuit diagrams1016
Electrical schematic1018
HVAC electrical schematic1041

IMAGES PREVIEW OF THE MANUAL:

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