Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM036703 – PDF DOWNLOAD

Description

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM036703 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM036703 – PDF DOWNLOAD

Language : English
Pages :1337
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E-10 DUMP TRUCK Shop Manual CEBM036703 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50023, A50026 and up

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. 960E). 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 CEBM036703 – PDF DOWNLOAD

SERIAL NUMBERS 730E-10 A50023, A50026 and up

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
Cranking operation 132
Auxiliary control cabinet components 133
VEC blocks 134
24VDC to 12VDC converter 134
Circuit breakers 134
Engine service light timer 134
Ground terminals 134
24VDC power terminals 134
Relays 135
Body-up switch 136
Hoist limit switch 137
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 261
Electrical systems 263
General information on system checkout 265
Truck shutdown procedure 266
Required software and tools 266
Electrical system checkout procedures 268
Visual inspection 268
Resistance checks 268
Voltage checks 269
Truck function checks 272
Interface module (IM) checks 273
KOMTRAX Plus II checks 273
Payload meter (PLM) checks 273
Drive system checks 274
Engine delayed shutdown Smart Timer check 275
Body hoist limit switch check 275
Electrical checkout sheet 276
Interface module 2 (IM2) 281
Required tools 283
Programming the IM2 283
Updating the software 283
Configuring the IM2 284
Viewing IM2 real-time data 284
Interface module checkout procedures 285
Checking for IM fault codes 285
Checking digital inputs to the IM 285
Checking analog inputs to the IM 288
Checking serial communication to the IM 288
Checking outputs from the IM 289
IM checkout sheet 290
Payload meter IV 295
Payload meter IV software and tools 297
Payload meter IV system configuration 297
Connecting to the payload meter IV web server 297
Configuring a static IP address 297
Payload meter IV software installation 299
Inclinometer calibration and clean truck tare 300
Payload meter IV checkout procedure 300
PLM IV system checkout data sheet 306
Downloading PLM IV data and possible errors 307
KOMTRAX Plus II 311
Required software and tools 313
Ethernet connection to KOMTRAX Plus II controller 313
KOMTRAX Plus II configuration 315
GPS connection test 317
Iridium satellite system opening 319
Data download over ethernet connection for KOMTRAX Plus II initialization 322
Komatsu wireless bridge (KWB) 325
General information 327
Required software and tools 327
Download tools, firmware and scripts 327
Configure Mikrotik radio 328
Verify KWB_Connect bridge configuration 330
Verify KWB_Connect access point configuration 330
Verify 0002KPLUS access point configuration 330
Verify 0002KPLUS bridge configuration 330
Cab air conditioning 333
General information 335
Service tools and equipment 336
Recovery/recycle station 336
Leak detector 336
Manifold gauge set 337
Service valves 338
Vacuum pump 338
Detecting leaks 339
System performance test 340
Checking system oil 341
System flushing 342
Installing the manifold gauge set 343
Purging air from the service hoses 344
Recovering and recycling refrigerant 345
Draining oil from previous recovery cycle 346
Recovery cycle 346
Recycling procedure 346
Evacuating the air conditioning system 347
Charging the air conditioning system 348
Automatic lubrication (auto lube) system 351
Priming the system 353
Checkout procedure 355
Adjusting the lubrication cycle timing 356
Trucks with Interface Module 1 356
Trucks with Interface Module 2 356
KomVision 359
Requirements 361
Initial setup 362
Checkout data sheet 371
Calibration sheets 376
Layout and assemblage 376
Unfolding a calibration sheet 379
Folding a calibration sheet 380
Placement of calibration sheets 381
Camera calibration procedures 383
Automatic 6 camera calibration 383
Manual 6 camera calibration 387
1 camera calibration 390
Radar setting procedure 393
Tire monitoring system 397
Tire monitoring system software and tools 399
Tire monitoring system configuration 399
Connecting to the tire monitoring system web server 399
Configuring a static IP address 399
Tire monitoring system software installation 401
Tire monitoring system checkout procedure 402
Field Troubleshooting 402
Ethernet troubleshooting 402
Tire monitoring system configuration 403
CAN RPC Troubleshooting 403
Resetting the tire monitoring system 403
Tire monitoring system checkout data sheet 404
40 Troubleshooting 407
Fuse, diode and relay locations 407
Vehicle Electrical Center (VEC-89) 408
Vehicle Electrical Center (VEC-90) 410
Vehicle Electrical Center (VEC-91) 412
Vehicle Electrical Center (VEC-92) 414
Rear Terminal Mini-fuse and Relay (RTMR3) 415
Rear Terminal Mini-fuse and Relay (RTMR4) 416
Circuit breakers 416
Troubleshooting by fault code, Part 1 419
Fault Code A001 422
Fault Code A002 423
Fault Code A003 424
Fault Code A004 425
Fault Code A005 426
Fault Code A006 427
Fault Code A007 428
Fault Code A008 429
Fault Code A009 430
Related circuit diagram 430
Fault Code A010 431
Related circuit diagram 431
Fault Code A011 432
Fault Code A013 433
Fault Code A014 434
Fault Code A016 435
Fault Code A017 436
Fault Code A018 437
Fault Code A019 438
Fault Code A022 439
Fault Code A100 440
Related circuit diagram 440
Fault Code A101 441
Fault Code A103 442
Fault Code A104 443
Fault Code A105 444
Fault Code A109 445
Fault Code A111 446
Fault Code A115 447
Fault Code A117 448
Fault Code A118 449
Fault Code A123 450
Fault Code A124 451
Fault Code A125 452
Fault Code A126 453
Fault Code A127 454
Fault Code A128 455
Fault Code A139 456
Troubleshooting by fault code, Part 2 459
Fault Code A145 462
Fault Code A146 463
Fault Code A152 464
Fault Code A153 465
Fault Code A154 466
Fault Code A155 467
Fault Code A158 468
Fault Code A166 469
Fault Code A167 470
Fault Code A168 471
Fault Code A169 472
Fault Code A170 473
Fault Code A171 474
Fault Code A172 475
Fault Code A173 476
Fault Code A184 477
Fault Code A190 478
Fault Code A193 479
Fault Code A194 480
Fault Code A195 481
Fault Code A196 482
Fault Code A197 483
Fault Code A198 484
Fault Code A199 485
Fault Code A200 486
Fault Code A201 487
Fault Code A202 488
Fault Code A203 489
Fault Code A204 490
Fault Code A205 491
Fault Code A206 492
Fault Code A207 493
Fault Code A213 494
Fault Code A214 495
Fault Code A215 496
Fault Code A216 497
Fault Code A223 498
Fault Code A230 499
Fault Code A231 500
Fault Code A233 501
Fault Code A235 502
Fault Code A236 503
Fault Code A237 504
Fault Code A238 505
Fault Code A239 507
Related circuit diagram 508
Fault Code A240 509
Fault Code A242 510
Fault Code A243 511
Fault Code A244 512
Fault Code A245 513
Fault Code A246 514
Troubleshooting by fault code, Part 3 517
Fault Code A248 521
Fault Code A249 522
Fault Code A250 523
Fault Code A251 524
Fault Code A252 525
Fault Code A253 526
Fault Code A256 527
Fault Code A257 528
Fault Code A258 529
Fault Code A260 530
Fault Code A261 531
Fault Code A262 532
Fault Code A264 533
Fault Code A265 534
Fault Code A266 535
Fault Code A267 536
Fault Code A268 537
Fault Code A270 538
Fault Code A271 539
Related circuit diagram 540
Fault Code A272 541
Fault Code A273 542
Fault Code A274 543
Fault Code A275 544
Fault Code A277 545
Fault Code A278 546
Fault Code A279 547
Fault Code A280 548
Fault Code A281 549
Fault Code A282 550
Fault Code A283 551
Fault Code A284 552
Fault Code A285 553
Fault Code A286 554
Fault Code A292 555
Troubleshooting by fault code, Part 4 557
Fault Code A303 560
Fault Code A304 561
Fault Code A305 562
Fault Code A307 563
Fault Code A309 564
Fault Code A310 565
Fault Code A311 566
Fault Code A312 567
Fault Code A313 568
Fault Code A315 569
Fault Code A316 570
Fault Code A317 571
Fault Code A318 572
Fault Code A328 573
Fault Code A332 574
Fault Code A333 575
Fault Code A334 576
Fault Code A335 577
Fault Code A337 578
Fault Code A338 579
Fault Code A339 580
Fault Code A340 581
Fault Code A341 582
Fault Code A342 583
Fault Code A343 584
Fault Code A344 585
Fault Code A345 586
Fault Code A346 587
Fault Code A347 588
Fault Code A348 589
Fault Code A349 590
Fault Code A350 591
Fault Code A351 592
Fault Code A352 593
Fault Code A353 594
Fault Code A354 595
Fault Code A355 596
Fault Code A356 597
Fault Code A357 598
Fault Code A358 599
Fault Code A359 600
Fault Code A360 601
Fault Code A361 602
Fault Code A362 603
Fault Code A363 604
Fault Code A364 605
Fault Code A365 606
Fault Code A366 607
Troubleshooting by fault code, Part 5 609
Fault Code A400 612
Fault Code A401 613
Fault Code A402 614
Fault Code A403 615
Fault Code A404 616
Fault Code A405 617
Fault Code A406 618
Fault Code A407 619
Fault Code A408 620
Fault Code A409 621
Fault Code A410 622
Fault Code A411 623
Fault Code A412 624
Fault Code A413 625
Fault Code A414 626
Fault Code A415 627
Fault Code A416 628
Fault Code A417 629
Fault Code A418 630
Fault Code A419 631
Fault Code A420 632
Fault Code A421 633
Fault Code A422 634
Fault Code A423 635
Fault Code A424 636
Fault Code A425 637
Fault Code A426 638
Fault Code A427 639
Fault Code A428 640
Fault Code A429 641
Fault Code A430 642
Fault Code A431 643
Fault Code A432 644
Fault Code A433 645
Fault Code A434 646
Fault Code A435 647
Fault Code A436 648
Fault Code A437 649
Fault Code A438 650
Fault Code A439 651
Fault Code A440 652
Fault Code A441 653
Fault Code A442 654
Fault Code A443 655
Fault Code A444 656
Fault Code A445 657
Fault Code A446 658
Fault Code A447 659
Aftertreatment system fault codes 661
Fault Code CA256 665
Fault Code CA1677 667
Fault Code CA1678 669
Fault Code CA1682 672
Fault Code CA1683 679
Fault Code CA1684 681
Fault Code CA1685 683
Fault Code CA1686 685
Fault Code CA1712 687
Fault Code CA1713 689
Fault Code CA1714 691
Fault Code CA1715 692
Fault Code CA1887 694
Fault Code CA2771 695
Fault Code CA3142 699
Fault Code CA3143 701
Fault Code CA3146 703
Fault Code CA3147 705
Fault Code CA3232 707
Fault Code CA3497 710
Fault Code CA3498 711
Fault Code CA3547 712
Fault Code CA3558 713
Fault Code CA3559 715
Fault Code CA3562 717
Fault Code CA3563 719
Fault Code CA3567 721
Fault Code CA3571 723
Fault Code CA3572 725
Fault Code CA3573 728
Fault Code CA3574 730
Fault Code CA3575 732
Fault Code CA3712 734
Fault Code CA3713 735
Fault Code CA3714 738
Fault Code CA3867 739
Fault Code CA3868 741
Fault Code CA3878 744
Fault Code CA3988 745
Fault Code CA3995 749
Fault Code CA4113 751
Fault Code CA4114 753
Fault Code CA4119 755
Fault Code CA4121 757
Fault Code CA4152 759
Fault Code CA4164 763
Fault Code CA4165 765
Fault Code CA4166 768
Fault Code CA4168 770
Fault Code CA4169 772
Fault Code CA4174 774
Fault Code CA4175 776
Fault Code CA4233 779
Fault Code CA4234 780
Fault Code CA4243 781
Fault Code CA4277 782
Fault Code CA4457 784
Fault Code CA4458 786
Fault Code CA4459 789
Fault Code CA4461 791
Fault Code CA4462 793
Fault Code CA4464 795
Fault Code CA4465 797
Fault Code CA4466 800
Fault Code CA4467 807
Fault Code CA4474 809
Fault Code CA4475 811
Fault Code CA4572 814
Fault Code CA4677 818
Fault Code CA4679 822
Fault Code CA4682 823
Fault Code CA4731 824
Fault Code CA4732 825
Fault Code CA4736 826
Fault Code CA4737 827
Fault Code CA4738 828
Fault Code CA4739 829
Fault Code CA4745 830
Fault Code CA4768 831
Fault Code CA4769 833
Fault Code CA4842 835
Fault Code CA4863 836
Fault Code CA4947 837
Fault Code CA5115 838
Fault Code CA5116 841
Fault Code CA5117 844
Fault Code CA5247 847
Fault Code CA5653 849
Fault Code CA5654 852
Fault Code CA5725 854
Fault Code CA5727 859
Fault Code CA5728 862
Fault Code CA5729 865
Fault Code CA5748 867
Fault Code CA5749 869
Fault Code CA5751 871
Fault Code CA5753 873
Fault Code CA5755 876
Fault Code CA5756 881
Fault Code CA5758 883
Fault Code CA5768 885
Fault Code CA5769 887
Fault Code CA5771 890
Fault Code CA5772 892
Fault Code CA5773 895
Fault Code CA5774 898
Fault Code CA5775 900
Fault Code CA5776 905
Fault Code CA5778 907
Fault Code CA5779 909
Fault Code CA5887 911
Fault Code CA5888 912
Fault Code CA5889 913
Fault Code CA5891 914
Fault Code CA5892 915
Fault Code CA5893 916
Fault Code CA6692 917
Fault Code CA6693 919
Fault Code CA6694 921
Fault Code CA6695 923
Fault Code CA6696 925
Fault Code CA6697 927
Fault Code CA6855 929
Fault Code CA6856 932
Steering system 935
Steering circuit troubleshooting chart 937
Steering circuit troubleshooting guidelines 939
Basic hydraulic system checks 940
System leakage check 941
Steering pump troubleshooting guide 943
Pump pressure control checks 946
Pump fails to unload 947
Pump fails to develop pressure 947
Pump slow in developing pressure 948
Pump control valve inspection 948
Pump case drain check 950
Setting pump pressure controls 950
Steering pump adjustment 951
KomVision 953
KomVision fault codes 955
Automatic lubrication (auto lube) system 965
Autolube troubleshooting chart 967
Heating/air conditioning (HVAC) system 971
Control panel configurations 973
Diagnostics mode 974
Error codes 974
Advanced diagnostics 974
Firmware version 975
Additional HVAC troubleshooting chart 975
Voltage levels 977
50 Disassembly and assembly 979
Service tools 979
Special tool group 981
Heated body tool group 982
Additional service tools 983
KomVision calibration tools 984
Locally made tools 984
Wheels, spindles and rear axle 987
General precautions for tires and rims 989
Wheel stud maintenance 990
Rear outer wheel stud installation 991
Removal and installation of front wheel 992
Removal 992
Installation 993
Removal and installation of rear wheel 994
Removal 994
Installation 995
Rim components 997
Smart rim component layout 997
Rim and tire service 998
Lubricants 998
Tire inflation 998
Removal (5-piece standard rim) 998
Preparation before assembly1002
Installation (5-piece standard rim)1002
Removal and installation of front wheel hub and spindle1004
Removal1004
Spindle removal (off the truck)1009
Installation1011
Disassembly and assembly of front wheel hub and spindle1012
Cross Section View1012
Disassembly1013
Cleaning and inspection1017
Assembly1018
Wheel bearing adjustment1022
Speed sensor installation and adjustment1024
Floating ring seal assembly and installation1025
Floating seal test procedure1033
Removal and installation of rear axle1035
Removal1035
Cleaning and inspection1036
Installation1037
Removal and installation of anti-sway bar1038
Removal1038
Installation1040
Removal and installation of pivot pin1041
Removal1041
Installation1042
Pivot eye and bearing service1043
Bearing replacement1043
Pivot eye repair1044
Removal of wheel motor1045
Preparation1045
Removal1045
Installation of wheel motor1047
Cleaning and inspection1047
Installation1048
Brake system1053
Removal and installation of brake valve1055
Removal1055
Disassembly and assembly of brake valve/pedal assembly1058
Disassembly1058
Assembly1059
Removal and installation of brake manifold1061
Removal1061
Installation1062
Disassembly and assembly of brake manifold1063
Disassembly1063
Assembly1063
Installation of pressure reducing valve1064
Disassembly and assembly of brake accumulator1065
Cleaning and inspection1066
Assembly1067
Removal and installation of front brake caliper1069
Removal1069
Inspection1070
Installation1070
Disassembly and assembly of front brake caliper1071
Disassembly1071
Cleaning and inspection1071
Brake lining replacement1074
Assembly1074
Removal and installation of rear brake caliper1074
Removal1074
Inspection1077
Installation1077
Disassembly and assembly of rear brake caliper1080
Disassembly1080
Piston subassembly1083
Cleaning and inspection1084
Assembly1086
Piston subassembly1086
Brake caliper1087
Steering system1095
Removal and installation of steering control unit1097
Removal1097
Installation1098
Disassembly and assembly of steering control unit1099
Disassembly1099
Assembly1101
Removal and installation of steering column1104
Removal1104
Installation1105
Removal and installation of steering wheel1106
Removal1106
Installation1106
Removal and installation of bleeddown manifold1107
Removal1107
Installation1108
Removal and installation of flow amplifier1109
Removal1109
Installation1109
Removal and installation of steering cylinders and tie rod1110
Removal1110
Installation1110
Disassembly and assembly of steering cylinders1112
Disassembly1112
Cleaning and inspection1115
Assembly1115
Removal and installation of steering/brake pump1116
Removal1116
Installation1117
Removal and installation of piston steering accumulator1118
Removal1118
Installation1120
Disassembly and assembly of piston steering accumulator1122
Disassembly1122
Cleaning and inspection1124
Piston seal replacement1124
Assembly1125
Suspensions1127
Removal and installation of front suspension1129
Preparation1129
Removal1129
Cleaning and Inspection1131
Installation1132
Disassembly and assembly of front suspension1138
Disassembly1138
Cleaning and inspection1140
Assembly1141
Removal and installation of rear suspension1143
Removal1143
Installation1146
Disassembly and assembly of rear suspension1149
Disassembly1149
Cleaning and inspection1151
Assembly1152
Hoist circuit1155
Removal and installation of hoist pump1157
Removal1157
Installation1161
Disassembly and assembly of hoist pump1162
Disassembly1162
Inspection1167
Assembly1168
Removal and installation of hoist valve1171
Removal1171
Installation1173
Disassembly and assembly of hoist valve1173
O-ring replacement1173
Disassembly of inlet section1175
Assembly of inlet section1176
Disassembly of spool section1177
Assembly of spool section1179
Overcenter manifold service1180
Removal and installation of hoist pilot valve1181
Removal1181
Installation1181
Disassembly and assembly of hoist pilot valve1183
Disassembly1183
Cleaning and inspection1184
Assembly1185
Removal and installation of hoist cylinders1186
Removal1186
Installation1189
Disassembly and assembly of hoist cylinders1192
Disassembly1192
Cleaning and inspection1196
Installation of the quill1197
Assembly1199
Body and structures1205
Removal and installation of dump body1207
Removal1207
Inspection1208
Installation1209
Removal and installation of body pads1210
Removal1210
Installation1210
Body pad shimming procedure1211
Removal and installation of diagonal ladder/ hood and grille assembly1212
Removal1212
Installation1212
Removal and installation of RH deck1214
Removal1214
Installation1214
Removal and installation of LH deck1216
Removal1216
Installation1216
Removal and installation of fuel tank1218
Removal1218
Cleaning and inspection1220
Installation1220
Removal and installation of fuel gauge sender1221
Removal1221
Installation1221
Removal and installation of hydraulic tank1222
Removal1222
Installation1224
Removal and installation of hydraulic tank strainers1224
Removal1224
Cleaning and inspection1225
Installation1225
Operator cab1227
Removal and installation of operator cab1229
Removal1229
Installation1232
Removal and installation of cab door1232
Removal1232
Installation1233
Disassembly and assembly of cab door1234
Removing the window regulator1234
Installing the window regulator1235
Removing the door glass1236
Installing the door glass1237
Replacing the inner door seal1238
Replacing the outer door seal1238
Removing the interior door handle and door latch (earlier models)1239
Installation and removal of interior door handle and door latch (later models)1242
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
Engine/alternator attachment checkout data sheet1286
Removal and installation of radiator1291
Removal1291
Installation1295
Repairing the radiator1296
Internal inspection1296
External cleaning1296
Disassembly1297
Cleaning and inspection1298
Assembly1298
Pressure testing1299
Removal and installation of engine1300
Removal1300
Service1301
Installation1301
90 Diagrams and drawings1303
Hydraulic circuit diagrams1303
Steering & hoist hydraulic schematic1305
Brake hydraulic circuit diagram1306
Auxiliary hydraulic schematic1307
Electrical circuit diagrams1310
Electrical schematic1312
HVAC electrical schematic1335

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24