Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM032503 – PDF DOWNLOAD

Description

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM032503 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM032503 – PDF DOWNLOAD

Language : English
Pages :934
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM032503 – PDF DOWNLOAD

SERIAL NUMBERS 730E-8 A40018 – A40034,
A40041 – A40044,
A40065, A40066

General safety

Safety records from most organizations will show that the greatest percentage of accidents are caused by unsafe acts performed by people. The remainder are caused by unsafe mechanical or physical conditions. Report all unsafe conditions to the proper authority. The following safety rules are provided as a guide for the operator. However, local conditions and regulations may add many more to this list.

TABLE OF CONTENTS:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM032503 – PDF DOWNLOAD

SERIAL NUMBERS 730E-8 A40018 – A40034,
A40041 – A40044,
A40065, A40066

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 17
Foreword 20
How to read the shop manual 21
Composition of shop manual 21
Revision and distribution 21
Symbols 22
General safety 23
Safety rules 23
Safety features 23
Fire extinguisher and first aid kit 23
Clothing and personal items 23
Leaving the operator seat 24
Mounting and dismounting 24
Fire prevention for fuel and oil 24
Precautions with high temperature fluids 25
Asbestos dust hazard prevention 25
Prevention of injury by work equipment 25
Unauthorized modification 25
Precautions when using ROPS 25
Precautions for attachments 26
Precautions for starting the truck 26
Precautions before operating the truck 26
Safety at the worksite 26
Fire prevention 27
Ventilation in enclosed areas 27
Preparing for operation 27
Mirrors, windows and lights 27
In operator cab (before starting the engine) 27
Seat Belts 27
Precautions while operating the truck 28
When starting the engine 28
General truck operation 28
Ensuring good visibility 28
Traveling 29
Traveling in reverse 29
Traveling on slopes 29
Operating on snow or ice 29
Avoid damage to dump body 29
Driving near high voltage cables 30
When dumping 30
When loading 30
Working on loose ground 30
Parking the truck 30
Towing 30
Working near batteries 31
Battery hazard prevention 31
Starting with jumper cables 32
Jump starting with receptacles 32
Precautions before performing service 33
Warning tag 33
Stopping the engine 33
Proper tools 33
Use of tie-off anchor during maintenance and repair 34
Securing the dump body 35
Jack point locations 36
Precautions while performing service 37
Keep the truck clean 37
Attachments 37
Working under the truck 37
Rotating fan and belts 37
Adding fuel or oil 37
Use of lighting 37
Radiator coolant level 38
Precautions with the battery 38
Precautions with high pressure oil 38
Handling high pressure hoses 38
Precautions when performing maintenance near high temperature or high pressure 38
Waste materials 38
Tires 39
Inspection 39
Maintenance 39
Storage 40
Handling 41
Precautions for performing repairs 42
Engine shutdown procedure after AC drive system failure 42
Precautions for welding on the truck 43
Capacitor discharge system 44
Necessary tools 44
Warnings and cautions 45
Manual DC link capacitor discharge procedure 46
Failure of the discharge system 48
Manual discharge of capacitors 49
Short isolated capacitor terminals 51
Handling electrical equipment and hydraulic components 52
Points to remember when handling electrical equipment 52
Points to remember when handling hydraulic equipment 58
Standard tightening torques 60
Effect of special lubricants on fasteners and standard torque values 60
Suggested sources for rust preventive grease 60
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 61
SAE grade 9 capscrews 62
Class 109 capscrews and class 10 nuts 62
Standard tightening torques for fittings 63
Standard tightening torques for clamps 65
Conversion tables 66
Common conversion multipliers 66
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
01 Specification 71
Specification and technical data 71
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 86
Steering accumulator bleeddown solenoid 86
Quick disconnect ports 86
Flow amplifier 86
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 circuit101
Hoist circuit operation102
Hoist circuit components103
Hydraulic tank103
Hoist pump103
High pressure filters103
Hoist valve103
Hoist pilot valve104
Hoist up limit solenoid105
Hoist pilot manifold105
Counterbalance manifold105
Hoist pilot valve operation106
Float position with body coming down106
Power up operation108
Hold operation110
Power down operation112
Float operation114
Brake circuits117
General information119
Service brake circuit operation119
Secondary braking and auto apply121
Parking brake circuit operation121
Normal operation (key switch ON, engine running)121
Wheel brake lock circuit operation122
Brake warning circuit operation122
Electrical system, 24 volt125
Battery supply system127
24VDC battery charging alternator127
Battery box127
24VDC auxiliary battery receptacles127
Isolation box128
Engine shutdown switch128
Access ladder light switch128
Battery disconnect switches128
Propel lockout lever128
LED lights128
Auxiliary control cabinet components129
VEC blocks130
24VDC to 12VDC converter130
Circuit breakers130
Engine service light timer130
Ground terminals130
24VDC power terminals130
Relays131
Body-up switch132
Hoist limit switch133
Electrical system, AC drive135
General system operation136
AC drive system components138
Drive System Controller (DSC)138
Diagnostic information display (DID) panel139
DSC software functions140
Input Processing140
State Machine140
DC Link State143
Engine Control144
Alternator field control144
Desired DC Link Voltage144
Self-Load144
Propel Torque Control145
Retard Torque Control145
Wheel Slide Control145
Resistor Grid Control146
Chopper Voltage Control146
Event detection and processing146
Power-On Tests146
Initiated Tests147
Periodic Tests147
Event restrictions147
Event logging and storage147
Event History Buffer148
Data Packs148
Event Reset148
Abnormal conditions/overriding functions148
Fast Start149
Engine Shutdown/Engine Not Running149
Limp Home Mode149
Electronic accelerator and retard pedals149
Drive system component abbreviations & locations150
Cab air conditioning157
General information159
Environmental impact of air conditioning159
Air conditioning for off-highway vehicles159
Principles of refrigeration160
Air conditioning160
Refrigeration – the act of cooling160
The refrigeration cycle160
Air conditioning system components162
Relays162
Fan motor and speed control162
Cab air filter162
Heater core162
Actuators162
Compressor (refrigerant pump)164
Service valves164
Condenser164
Receiver-drier164
Expansion valve165
Accumulator165
Evaporator core165
Air conditioning system electrical circuit166
Thermostat166
Compressor clutch166
Trinary™ switch167
20 Standard value table169
Standard value table169
Standard value table for truck171
30 Testing and adjusting177
Steering, hoist and auxiliary hydraulic systems177
General information on system checkout178
Hydraulic system checkout procedures179
Required equipment179
Bleeddown procedure179
Preliminary steps181
Hydraulic system flushing procedure181
Flow amplifier adjustment185
Steering pump unloader valve adjustment185
Auxiliary accumulator pressure verification186
System diagnostics186
Hoist pilot valve adjustment188
Hoist counterbalance valve adjustment188
Final steps189
Oil cleanliness check190
Hydraulic system checkout data sheet191
Toe-in adjustment195
Hoist cylinder leakage test196
Steering cylinder leakage test196
Brake system199
General information on system checkout200
Brake circuit checkout procedure200
Initial system setup and service brake checkout202
Brake lock system checkout203
Parking brake checkout203
Parking brake troubleshooting203
Low brake pressure and auto apply204
Parking brake control logic checkout206
Brake lock control logic checkout207
Brake system checkout data sheet209
Service brake conditioning (burnishing)215
Front brake conditioning216
Rear brake conditioning217
Parking brake adjustment procedure218
Brake bleeding procedure219
Service brake219
Parking brake (rear brake calipers only)219
Piston assembly return spring force and built-in clearance (BIC)220
Piston assembly adjuster grip force221
Adjuster force223
Piston return spring224
Accumulators and suspensions227
Accumulator charging and storage229
Temperature during precharge229
Bladder accumulator charging procedure230
Precharge maintenance232
Bladder accumulator storage procedure232
Bladder storage232
Installing a bladder accumulator from storage233
Bladder accumulator leak testing233
Piston accumulator charging procedure234
Piston accumulator storage237
Piston accumulator leak testing238
Checking for improper suspension charge on operating trucks239
Suspension oil change recommendations240
Suspension oiling and charging procedures241
Required equipment241
Installing the charging kit242
Removing the charging kit242
Support blocks for oiling and charging dimensions243
Front suspensions246
TOP FILL METHOD247
PRESSURE FILL METHOD247
Rear suspensions249
TOP FILL METHOD251
PRESSURE FILL METHOD251
Suspension pressure test253
Interface module 1 (IM1)255
Required software and tools257
Interface module checkout procedures258
Initial startup258
Checking digital inputs to the IM258
Checking analog inputs to the IM260
Checking serial communication to the IM260
Checking outputs from the IM260
IM checkout sheet261
KOMTRAX Plus265
KOMTRAX Plus software and tools267
KOMTRAX Plus controller setup procedure267
Preliminary steps267
Setup procedure267
KOMTRAX Plus initialization form271
Precautions when replacing the KOMTRAX Plus controller272
KOMTRAX Plus controller checkout procedure274
Preliminary steps274
Checkout procedure274
Payload meter IV277
Payload meter IV software and tools279
Payload meter IV system configuration279
Connecting to the payload meter IV web server279
Configuring a static IP address279
Payload meter IV software installation281
Inclinometer calibration and clean truck tare282
Payload meter IV checkout procedure282
PLM IV system checkout data sheet288
Downloading PLM IV data and possible errors289
Cab air conditioning293
General information295
Service tools and equipment296
Recovery/recycle station296
Leak detector296
Manifold gauge set297
Service valves298
Vacuum pump298
Detecting leaks299
System performance test300
Checking system oil301
System flushing302
Installing the manifold gauge set303
Purging air from the service hoses304
Recovering and recycling refrigerant305
Draining oil from previous recovery cycle306
Recovery cycle306
Recycling procedure306
Evacuating the air conditioning system307
Charging the air conditioning system308
40 Troubleshooting311
Fuse and circuit breaker locations311
Fuse and circuit breaker locations313
AC drive system fault codes (DSC)319
Fault code tables321
Troubleshooting by fault code, Part 1349
Fault Code A001: Left front suspension pressure sensor signal high351
Related circuit diagram351
Fault Code A002: Left front suspension pressure sensor signal low352
Related circuit diagram352
Fault Code A003: Right front suspension pressure sensor signal high353
Related circuit diagram353
Fault Code A004: Right front suspension pressure sensor signal low354
Related circuit diagram354
Fault Code A005: Left rear suspension pressure sensor signal high355
Related circuit diagram355
Fault Code A006: Left rear suspension pressure sensor signal low356
Related circuit diagram356
Fault Code A007: Right rear suspension pressure sensor signal high357
Related circuit diagram357
Fault Code A008: Right rear suspension pressure sensor signal low358
Related circuit diagram358
Fault Code A009: Incline sensor signal high359
Related circuit diagram359
Fault Code A010: Incline sensor signal low360
Related circuit diagram360
Fault Code A011: Payload meter speed sensor signal has Failed361
Related circuit diagram361
Fault Code A013: Body up switch has Failed362
Related circuit diagram362
Fault Code A014: Payload meter checksum computation has Failed363
Related circuit diagram363
Fault Code A016: Payload meter write to flash memory has Failed364
Related circuit diagram364
Fault Code A017: Payload meter flash memory read has Failed365
Related circuit diagram365
Fault Code A018: Right rear flat suspension cylinder warning366
Related circuit diagram367
Fault Code A019: Left rear flat suspension cylinder warning368
Related circuit diagram369
Fault Code A022: Carryback load excessive370
Related circuit diagram371
Fault Code A101: High pressure detected across an hydraulic pump filter372
Related circuit diagram372
Fault Code A103: Hydraulic Oil Temp – Tank Sensor Low373
Related circuit diagram373
Fault Code A104: Hydraulic oil temp – Tank sensor high374
Related circuit diagram374
Fault Code A105: Fuel level sensor shorted to ground indicating a false high fuel level376
Related circuit diagram377
Fault Code A109: GE has generated a propel system reduced level signal378
Related circuit diagram378
Fault Code A111 & A247: Low steering pressure warnings380
Related circuit diagram381
Fault Code A115: Low steering precharge pressure detected382
Related circuit diagram382
Fault Code A117: Low brake accumulator pressure warnings384
Related circuit diagram385
Fault Code A118: Brake pressure is low while in brake lock386
Related circuit diagram386
Fault Code A123: GE has generated a reduced retarding caution387
Related circuit diagram387
Fault Code A124: GE has generated a no propel / no retard warning388
Related circuit diagram388
Fault Code A125: GE has generated a no propel warning389
Related circuit diagram389
Fault Code A126: Oil level in the hydraulic tank is low390
Related circuit diagram390
Fault Code A127: IM-furnished +5 volt output for sensors is low391
Related circuit diagram391
Fault Code A128: IM-furnished +5 volt output for sensors is high392
Related circuit diagram392
Fault Code A139 & A310: Low fuel warnings394
Related circuit diagram395
Troubleshooting by fault code, Part 2397
Fault Code A152: Starter failure399
Related circuit diagram399
Fault Code A153: Battery voltage is low with the truck in operation400
Related circuit diagram401
Fault Code A154: Battery charging voltage is excessive402
Related circuit diagram402
Fault Code A155: Battery charging voltage is low403
Related circuit diagram403
Fault Code A158: Fuel level sensor open or shorted high indicating a false low fuel level404
Related circuit diagram404
Fault Code A184: J1939 data link is not connected405
Related circuit diagram405
Fault Code A190: Auto lube control has detected an incomplete lube cycle406
Related circuit diagram407
Fault Code A193: Hydraulic tank oil temperature is high408
Related circuit diagram408
Fault Code A198: Hoist pressure 1 sensor is high409
Related circuit diagram409
Fault Code A200: Steering pressure sensor is high410
Related circuit diagram410
Fault Code A201: Brake pressure sensor is high411
Related circuit diagram411
Fault Code A202: Hoist pressure 1 sensor is low412
Related circuit diagram412
Fault Code A204: Steering pressure sensor is low413
Related circuit diagram413
Fault Code A205: Brake pressure sensor is low414
Related circuit diagram414
Fault Code A206: Ambient temperature sensor is high415
Related circuit diagram415
Fault Code A207: Ambient temperature sensor is low416
Related circuit diagram416
Fault Code A213: Parking brake should have applied; detected as not having applied418
Related circuit diagram419
Fault Code A214: Parking brake should have released; detected as not having released420
Related circuit diagram421
Fault Code A216: Open or short to ground in parking brake command valve circuit422
Related circuit diagram423
Fault Code A223: Excessive engine cranking occurred or a jump start attempted424
Related circuit diagram425
Fault Code A230: Parking brake has been requested while truck still moving426
Related circuit diagram427
Fault Code A231: The body is up while traveling or intending to travel428
Related circuit diagram429
Fault Code A233: Drive system CAN/RPC Control Link not connected430
Related circuit diagram431
Fault Code A235: Steering accumulator is in the process of being bled down432
Related circuit diagram433
Fault Code A236: The steering accumulator has not properly bled after 90 seconds434
Related circuit diagram434
Fault Code A237: The CAN/RPC connection to the display is open435
Related circuit diagram435
Fault Code A240: The key switch input to the interface module is open436
Related circuit diagram436
Troubleshooting by fault code, Part 3439
Fault Code A242: Fuel gauge within the display panel is defective441
Related circuit diagram441
Fault Code A243: Engine coolant temperature gauge within the display panel is defective442
Related circuit diagram442
Fault Code A244: Drive system temperature gauge within the display panel is defective443
Related circuit diagram443
Fault Code A245: Hydraulic oil temperature gauge within the display panel is defective444
Related circuit diagram444
Fault Code A246: Payload meter reports truck overload445
Related circuit diagram445
Fault Code A248: Status module within the display panel is defective446
Related circuit diagram446
Fault Code A249: Red warning lamp within the display (driven by IM) is shorted447
Related circuit diagram447
Fault Code A250: Battery voltage is low with the truck parked448
Related circuit diagram449
Fault Code A251: Sonalert used with display (driven by IM) is open or shorted to ground450
Related circuit diagram450
Fault Code A252: Start enable output circuit is open or shorted to ground451
Related circuit diagram451
Fault Code A253: Steering bleed circuit is not open while running452
Related circuit diagram452
Fault Code A255: IM has detected a fault on IM output 1N453
Related circuit diagram453
Fault Code A256: Red warning lamp in the display (driven by IM) is open454
Related circuit diagram454
Fault Code A257: Payload CAN/RPC is not connected455
Related circuit diagram455
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective456
Related circuit diagram456
Fault Code A260: Parking brake failure458
Related circuit diagram459
Fault Code A261: Low brake accumulator pressure warnings460
Related circuit diagram461
Fault Code A262: Steering bleed valve circuit open during shutdown462
Related circuit diagram463
Fault Code A264: Parking brake relay circuit is defective464
Related circuit diagram464
Fault Code A265: Service brake failure466
Related circuit diagram467
Fault Code A266: Selector lever was not in park while attempting to crank engine468
Related circuit diagram468
Fault Code A267: Parking brake was not set while attempting to crank engine469
Related circuit diagram469
Fault Code A268: Secondary engine shutdown while cranking470
Related circuit diagram470
Fault Code A270: Brake lock switch power supply is not on when required472
Related circuit diagram473
Fault Code A271: Shifter not in gear474
Related circuit diagram474
Fault Code A272: Brake lock switch power supply is not off when required476
Related circuit diagram477
Fault Code A273: Fault detected in hoist or steering filter pressure switch circuit478
Related circuit diagram478
Fault Code A274: A brake setting fault has been detected480
Related circuit diagram481
Fault Code A275: A starter has been detected as engaged without a cranking attempt482
Related circuit diagram482
Troubleshooting by fault code, Part 4485
Fault Code A277: Parking brake applied while loading487
Related circuit diagram487
Fault Code A278: Service brake applied while loading488
Related circuit diagram488
Fault Code A279: Low steering pressure switch is defective489
Related circuit diagram489
Fault Code A280: Steering accumulator bleed down switch is defective490
Related circuit diagram490
Fault Code A281: Brake lock degrade switch is defective491
Related circuit diagram491
Fault Code A282: Excessive cranking or jump starts without the engine running492
Related circuit diagram493
Fault Code A283: Engine shutdown delay aborted; parking brake not set494
Related circuit diagram495
Fault Code A284: Engine shutdown delay aborted; secondary shutdown switch used496
Related circuit diagram496
Fault Code A285: The parking brake was not set when the key switch was turned off497
Related circuit diagram497
Fault Code A286: A fault was detected in the shutdown delay relay circuit498
Related circuit diagram498
Fault Code A292: Shutdown delay relay stayed on after latched keyswitch circuit is off499
Related circuit diagram499
Fault Code A303: Shifter is defective500
Fault Code A304: Auto lube grease level fault501
Related circuit diagram501
Fault Code A305: Auto lube circuit is defective502
Related circuit diagram502
Fault Code A307: Both GE Inverters disabled503
Fault Code A309: No brakes applied when expected504
Related circuit diagram505
Fault Code A311: Brake lock switch on when it shouldn’t be506
Related circuit diagram506
Fault Code A312: The DCDC Converter 12 volt circuit sensing is producing low readings507
Related circuit diagram507
Fault Code A313: The DCDC converter 12 volt circuit sensing is producing high readings508
Related circuit diagram508
Fault Code A315: The DCDC converter 12 volt circuit is low509
Related circuit diagram509
Fault Code A316: Starter engagement has been attempted with engine running510
Related circuit diagram511
Fault Code A318: Unexpected power loss to Interface Module512
Related circuit diagram512
Fault Code A328: Drive system not powered up513
Related circuit diagram513
Fault Code A333: The hydraulic ladder controller has declared a ladder fault514
Related circuit diagram514
Fault Code A334: Selector switch not in park when propel was either not ready or at rest515
Related circuit diagram515
Fault Code A335: Manual/Auto Apply Pressure Fault516
Troubleshooting by fault code, Part 5519
Fault Code A350: Overload on output 1B520
Related circuit diagram520
Fault Code A351: Overload on output 1E521
Related circuit diagram521
Fault Code A352: Overload on output 1H522
Related circuit diagram522
Fault Code A353: Overload on output 1J523
Related circuit diagram523
Fault Code A354: Overload on output 1K524
Related circuit diagram524
Fault Code A355: Overload on output 1L525
Related circuit diagram525
Fault Code A356: Overload on output 1M526
Related circuit diagram526
Fault Code A357: Overload on output 1N527
Related circuit diagram527
Fault Code A358: Overload on output 1P528
Related circuit diagram528
Fault Code A359: Overload on output 1R529
Related circuit diagram529
Fault Code A360: Overload on output 1S530
Related circuit diagram530
Fault Code A361: Overload on output 1T531
Related circuit diagram531
Fault Code A362: Overload on output 1U532
Related circuit diagram532
Fault Code A363: Overload on output 1X533
Related circuit diagram533
Fault Code A364: Overload on output 1Y534
Related circuit diagram534
Fault Code A365: Overload on output 1Z535
Related circuit diagram535
Cab air conditioning537
Preliminary checks539
Diagnosis of gauge readings and system performance539
Troubleshooting by manifold gauge set readings540
Steering system547
Steering circuit troubleshooting chart549
Steering circuit troubleshooting guidelines551
Basic hydraulic system checks552
System leakage check553
Steering pump troubleshooting guide555
Pump pressure control checks558
Pump fails to unload559
Pump fails to develop pressure559
Pump slow in developing pressure560
Pump control valve inspection560
Pump case drain check562
Setting pump pressure controls562
Steering pump adjustment563
Automatic lubrication (auto lube) system565
Autolube troubleshooting chart567
50 Disassembly and assembly571
Service tools571
Special tool group573
KomVision calibration tools573
Additional service tools574
Locally made tools575
Wheels, spindles and rear axle579
General precautions for tires and rims581
Wheel stud maintenance582
Rear outer wheel stud installation583
Removal and installation of front wheel584
Removal584
Installation585
Removal and installation of rear wheel586
Removal586
Installation587
Rim components589
Rim and tire service590
Lubricants590
Tire inflation590
Removal (5-piece standard rim)590
Preparation before assembly594
Installation (5-piece standard rim)594
Removal and installation of front wheel hub and spindle596
Removal596
Spindle removal (off the truck)602
Installation604
Disassembly and assembly of front wheel hub and spindle605
Cross Section View605
Disassembly606
Cleaning and inspection610
Assembly611
Wheel bearing adjustment615
Speed sensor installation and adjustment617
Hub floating ring seal assembly and installation619
Removal and installation of rear axle624
Removal624
Cleaning and inspection625
Installation626
Removal and installation of anti-sway bar627
Removal627
Installation629
Removal and installation of pivot pin630
Removal630
Installation631
Pivot eye and bearing service632
Bearing replacement632
Pivot eye repair633
Removal and installation of wheel motor634
Preparation634
Removal634
Cleaning and inspection637
Installation637
Brake system643
Removal and installation of brake valve645
Removal645
Disassembly and assembly of brake valve/pedal assembly648
Disassembly648
Assembly649
Removal and installation of brake manifold650
Removal650
Installation651
Disassembly and assembly of brake manifold652
Disassembly652
Assembly652
Disassembly and assembly of brake accumulator653
Cleaning and inspection654
Assembly655
Removal and installation of front brake caliper657
Removal657
Inspection658
Installation658
Disassembly and assembly of front brake caliper659
Disassembly659
Cleaning and inspection659
Brake lining replacement662
Assembly662
Removal and installation of rear brake caliper662
Removal662
Inspection665
Installation666
Disassembly and assembly of rear brake caliper669
Disassembly669
Piston subassembly672
Cleaning and inspection673
Assembly674
Piston subassembly674
Brake caliper675
Steering system683
Removal and installation of steering control unit685
Removal685
Installation686
Disassembly and assembly of steering control unit687
Disassembly687
Assembly689
Removal and installation of steering column692
Removal692
Inspection693
Installation694
Removal and installation of steering wheel695
Removal695
Installation695
Removal and installation of bleeddown manifold696
Removal696
Installation699
Removal and installation of flow amplifier699
Removal699
Installation701
Removal and installation of steering cylinders and tie rod702
Removal702
Installation704
Disassembly and assembly of steering cylinders705
Disassembly705
Cleaning and inspection707
Assembly708
Removal and installation of steering/brake pump708
Removal708
Installation711
Removal and installation of piston steering accumulator712
Removal712
Installation714
Disassembly and assembly of piston steering accumulators715
Disassembly715
Cleaning and inspection717
Piston seal replacement718
Assembly719
Suspensions721
Removal and installation of front suspension723
Preparation723
Removal723
Cleaning and Inspection725
Installation726
Disassembly and assembly of front suspension732
Disassembly732
Cleaning and inspection734
Assembly735
Removal and installation of rear suspension737
Removal737
Installation740
Disassembly and assembly of rear suspension743
Disassembly743
Cleaning and inspection745
Assembly746
Hoist circuit749
Removal and installation of hoist pump751
Removal751
Installation755
Disassembly and assembly of hoist pump756
Disassembly756
Inspection761
Assembly762
Removal and installation of hoist valve765
Removal765
Installation767
Disassembly and assembly of hoist valve767
O-ring replacement767
Disassembly of inlet section769
Assembly of inlet section770
Disassembly of spool section771
Assembly of spool section773
Overcenter manifold service774
Removal and installation of hoist pilot valve775
Removal775
Installation775
Disassembly and assembly of hoist pilot valve777
Disassembly777
Cleaning and inspection778
Assembly779
Removal and installation of hoist cylinders780
Removal780
Installation783
Disassembly and assembly of hoist cylinders786
Disassembly786
Cleaning and inspection790
Installation of the quill791
Assembly793
Body and structures799
Removal and installation of dump body801
Removal801
Inspection802
Installation803
Removal and installation of body pads804
Removal804
Installation804
Body pad shimming procedure805
Removal and installation of diagonal ladder/ hood and grille assembly806
Removal806
Installation806
Removal and installation of RH deck808
Removal808
Installation808
Removal and installation of LH deck810
Removal810
Installation810
Removal and installation of fuel tank812
Removal812
Cleaning and inspection814
Installation814
Removal and installation of fuel gauge sender815
Removal815
Installation815
Removal and installation of hydraulic tank816
Removal816
Installation818
Removal and installation of hydraulic tank strainers818
Removal818
Cleaning and inspection819
Installation819
Operator cab821
Removal and installation of operator cab823
Removal823
Installation826
Removal and installation of cab door827
Removal827
Installation827
Disassembly and assembly of cab door828
Removing door panel828
Installing door panel829
Replacing the door window regulator829
Replacing door handle or latch assembly830
Replacing door assembly seal and door hinge seal831
Replacing door opening seal831
Removing door glass832
Installing door glass833
Adjustment of cab door835
Door jamb bolt adjustment835
Door handle plunger adjustment836
Removal and installation of side window glass837
Recommended tools and supplies837
Removal838
Installation838
Removal and installation of windshield and rear window glass839
Removal839
Installation839
Removal and installation of windshield wiper motor840
Removal840
Installation841
Removal and installation of windshield wiper arm841
Removal841
Installation841
Removal and installation of windshield wiper linkage842
Removal842
Installation842
Removal and installation of operator seat843
Inspection843
Removal843
Installation843
Replacing the seat compressor (standard seat)844
Removal and installation of passenger seat (standard seat)849
Removal849
Installation849
Removal and installation of seat belts (standard seat)850
Removal850
Installation851
Removal and installation of seat belts (optional seat)852
General852
Removal852
Installation854
Cab air conditioning857
Replacement of air conditioning system components859
Hoses and fittings859
Lines859
Expansion valve859
Receiver-drier859
Thermostat859
Compressor860
Accumulator860
Clutch860
Power module863
Removal and installation of power module865
General865
Removal866
Installation874
Exhaust tube installation877
Exhaust blanket installation877
Removal and installation of alternator878
Removal878
Installation881
Removal and installation of radiator889
Removal889
Installation894
Repairing the radiator895
Internal inspection895
External cleaning895
Disassembly896
Cleaning and inspection897
Assembly897
Pressure testing898
Removal and installation of engine899
Removal899
Service900
Installation900
90 Diagrams and drawings903
Hydraulic circuit diagrams903
Steering and hoist hydraulic circuit diagram – 58D-60-00521905
Brake hydraulic circuit diagram – XS7600906
Auxiliary hydraulic circuit diagram – 58E-60-01680907
Electrical circuit diagrams910
Electrical circuit diagram – 58D-06-00445912
Connectors table and arrangement drawing – HE491932

IMAGES PREVIEW OF THE MANUAL:

S.M 21/12/24