Komatsu 830E-5 Dump Truck Shop Manual CEBM036802 – PDF DOWNLOAD

Description

Komatsu 830E-5 Dump Truck Shop Manual CEBM036802 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 830E-5 Dump Truck Shop Manual CEBM036802 – PDF DOWNLOAD

Language : English
Pages :1403
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 830E-5 Dump Truck Shop Manual CEBM036802 – PDF DOWNLOAD

 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 00 Index and foreword 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 830E-5 Dump Truck Shop Manual CEBM036802 – PDF DOWNLOAD

COVER 1
00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 23
Foreword 26
How to read the shop manual 27
Composition of shop manual 27
Revision and distribution 27
Symbols 28
General safety 29
Safety rules 29
Safety features 29
Fire extinguisher and first aid kit 29
Clothing and personal items 29
Leaving the operator seat 30
Mounting and dismounting 30
Fire prevention for fuel and oil 30
Precautions with high temperature fluids 31
Asbestos dust hazard prevention 31
Prevention of injury by work equipment 31
Unauthorized modification 31
Precautions when using ROPS 31
Precautions for attachments 32
Precautions for starting the truck 32
Precautions before operating the truck 32
Safety at the worksite 32
Fire prevention 33
Ventilation in enclosed areas 33
Preparing for operation 33
Mirrors, windows and lights 33
In operator cab (before starting the engine) 33
Seat Belts 33
Precautions while operating the truck 34
When starting the engine 34
General truck operation 34
Ensuring good visibility 34
Traveling 35
Traveling in reverse 35
Traveling on slopes 35
Operating on snow or ice 35
Avoid damage to dump body 35
Driving near high voltage cables 36
When dumping 36
When loading 36
Working on loose ground 36
Parking the truck 37
Towing 37
Working near batteries 38
Battery hazard prevention 38
Starting with jumper cables 39
Jump starting with receptacles 39
Precautions before performing service 40
Warning tag 40
Stopping the engine 40
Proper tools 40
Use of tie-off anchor during maintenance and repair 41
Tie-off anchor installation 41
Securing the dump body 42
Jack point locations 43
Precautions while performing service 44
Keep the truck clean 44
Attachments 44
Working under the truck 44
Rotating fan and belts 44
Adding fuel or oil 44
Use of lighting 44
Radiator coolant level 45
Precautions with the battery 45
Precautions with high pressure oil 45
Handling high pressure hoses 45
Precautions when performing maintenance near high temperature or high pressure 45
Waste materials 45
Tires 46
Inspection 46
Maintenance 46
Storage 47
Handling 48
Precautions for performing repairs 49
Engine shutdown procedure after AC drive system failure 49
Precautions for welding on the truck 50
Control cabinet capacitor discharge system 51
Handling electrical equipment and hydraulic components 53
Points to remember when handling electrical equipment 53
Points to remember when handling hydraulic equipment 59
Actions taken to meet exhaust gas regulations 61
About DEF 61
Precautions for diesel exhaust fluid (DEF) 62
About DEF 62
Precautions for handling DEF 62
Precautions for storing DEF 62
Precautions for disposing of DEF 63
Crystallization management 63
Precautions for cold weather operation 63
Standard tightening torques 64
Effect of special lubricants on fasteners and standard torque values 64
Suggested sources for rust preventive grease 64
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 65
SAE grade 9 capscrews 66
Class 109 capscrews and class 10 nuts 67
Standard tightening torques for fittings 67
Standard tightening torques for clamps 69
Conversion tables 70
Common conversion multipliers 70
01 Specification 75
Specification and technical data 75
Specification drawing 77
Specifications 78
Weight table 80
Fuel, coolant and lubricants 81
Suspension cylinder oil and nitrogen specifications 82
Wheel motor oil specifications 82
10 Structure and functions 85
Steering circuit 85
Steering circuit operation 87
Steering circuit components 91
Steering control unit 91
High pressure filter 91
Steering accumulators 91
Bleeddown manifold 92
Steering accumulator bleeddown solenoid 92
Quick disconnect ports 92
Flow amplifier 92
Steering/brake pump operation 93
High altitude operation 93
Neutral position 94
Full pump volume 95
Half pump volume 95
Flow amplifier operation 96
No steer 96
Steering left 98
Steering right 100
No steer, external shock load 102
Hoist circuit 105
Hoist circuit operation 106
Hydraulic circuit components 106
Hydraulic tank 106
Hoist pump 106
High pressure filters 106
Hoist valve 109
Inlet sections 109
Tank ports (front) spool section 109
Work ports (rear) spool section 110
Hoist pilot valve 110
Hoist limit solenoid 111
Pilot operated check valve 111
Overcenter manifold 111
Hoist pilot valve operation 112
Float position with body down 112
Power up operation 114
Hold operation 116
Power down operation 118
Float operation with body up 120
Brake circuits 123
General information 125
Service brake circuit operation 127
Secondary braking and auto apply 128
Parking brake circuit operation 129
Normal operation (engine start switch ON, engine on) 129
Wheel brake lock circuit operation 129
Brake warning circuit operation 130
Electrical system, 24 volt 133
Battery supply system 135
Batteries 135
24VDC auxiliary battery receptacles 135
Isolation box 136
Ground level shutdown switch 136
Battery disconnect switches 136
Propel lockout lever 136
System busy light 136
LED lights 136
Engine starting system with prelube 137
Prelube operation 137
Cranking operation 138
Auxiliary control cabinet components 139
VEC blocks 140
24VDC to 12VDC converter 140
Circuit breakers 140
Engine service light timer 140
Ground terminals 140
24VDC power terminals 140
Relays 141
Body-up switch 142
Hoist limit switch 143
Heating/air conditioning (HVAC) system 145
Basic air conditioning system operation 147
HVAC components 149
Control panel 149
Water valve 149
Expansion valve 149
Actuators 149
Blower 149
Heater core 149
Evaporator core 149
Cab air temperature sensor 149
ECU module 149
Air filters 151
Compressor (refrigerant pump) 151
Compressor clutch 151
Trinary™ switch 152
Receiver-drier 152
Condenser 152
Accumulator 152
Automatic lubrication (auto lube) system 155
General information 157
System operation 158
Engine emissions aftertreatment system 161
About emissions aftertreatment 164
DEF injection system 164
DEF heating system 164
Sensors 164
Exhaust system cleaning 165
Propel lockout precaution 165
Inducement strategy 165
20 Standard value table 167
Standard value table 167
Standard value table for truck 169
30 Testing and adjusting 175
Steering, hoist and auxiliary hydraulic systems 175
Hydraulic system bleeddown procedure 177
Hydraulic system vacuum procedure 180
General information on system checkout 180
Hydraulic system checkout procedures 181
Required equipment 181
Preliminary steps 181
Accumulator precharging 182
Pressure gauge installation 183
Initial startup and flushing 183
Steering flow amplifier adjustment 186
Steering pump unloader valve adjustment 187
Auxiliary accumulator checks 188
System diagnostics 188
Hoist relief valve adjustments 191
Hoist counterbalance adjustment 191
Auxiliary systems checks and adjustments 192
Brake cooling check 193
Oil cleanliness check 194
Hydraulic system checkout data sheet 195
Toe-in adjustment 198
Hoist cylinder leakage test 200
Steering cylinder leakage test 200
Brake system 203
Brake bleeddown procedure 205
General information on system checkout 208
Brake system checkout procedure 208
Required equipment 208
Pre-checkout items 208
Software operation and configuration 209
Hydraulic isolation and troubleshooting 209
GE Display Panel 209
Truck Starting Procedure 209
Initial System Set Up 210
Brake lock system check 211
Brake lock hydraulic circuit troubleshooting guide 211
Parking brake 212
Parking brake hydraulic circuit troubleshooting guide 212
Service brake system 213
Low brake pressure and auto apply 213
Brake reapplications 215
Parking brake control logic check 216
Brake lock control logic check 217
Brake system checkout data sheet 220
Brake piston leakage test 229
Brake seal pressure test 229
Oil separator seal pressure test 230
Method 1 230
Method 2 230
Brake bleeding procedure 231
Parking brake (rear brake calipers only) 232
Front wet brake wear inspection 233
Front brake friction disc inspection 235
Front brake separator plates inspection 237
Friction disc and separator plate checkout sheet 239
Rear brake burnishing 241
Burnishing event codes 245
Parking brake adjustment procedure 246
Piston assembly return spring force and built-in clearance (BIC) 247
Adjuster pin installation 248
Piston return spring 249
Adjuster pin and adjuster sleeve 250
Accumulators and suspensions 253
Accumulator charging and storage 255
Temperature during precharge 255
Bladder accumulator charging procedure 256
Precharge maintenance 258
Bladder accumulator storage procedure 258
Bladder storage 258
Installing a bladder accumulator from storage 259
Bladder accumulator leak testing 259
Piston accumulator charging procedure 260
Piston accumulator storage 263
Piston accumulator leak testing 264
Checking for improper suspension charge on operating trucks 265
Suspension oil change recommendations 266
Suspension oiling and charging procedures 267
Required equipment 267
Installing the charging kit 268
Removing the charging kit 268
Support blocks for oiling and charging dimensions 269
Front suspensions 272
TOP FILL METHOD 273
PRESSURE FILL METHOD 273
Rear suspensions 275
TOP FILL METHOD 277
PRESSURE FILL METHOD 277
Suspension pressure test 279
Electrical systems 281
General information on system checkout 283
Truck shutdown procedure 284
Required software and tools 284
Electrical system checkout procedures 286
Visual inspection 286
Resistance checks 286
Voltage checks 286
Truck function checks 287
Interface module (IM) checks 288
KOMTRAX Plus II checks 288
Payload meter (PLM) checks 288
Drive system checks 289
Engine delayed shutdown Smart Timer check 289
Body hoist limit switch check 289
Electrical checkout sheet 290
Interface module 2 (IM2) 295
Required tools 297
Programming the IM2 297
Updating the software 297
Configuring the IM2 298
Viewing IM2 real-time data 298
Interface module checkout procedures 299
Checking for IM fault codes 299
Checking digital inputs to the IM 299
Checking analog inputs to the IM 302
Checking serial communication to the IM 302
Checking outputs from the IM 303
IM checkout sheet 304
KOMTRAX Plus II 309
Required software and tools 311
Ethernet connection to KOMTRAX Plus II controller 311
KOMTRAX Plus II configuration 313
GPS connection test 315
Iridium satellite system opening 317
Data download over ethernet connection for KOMTRAX Plus II initialization 320
Payload meter IV 323
Payload meter IV software and tools 325
Payload meter IV system configuration 325
Connecting to the payload meter IV web server 325
Configuring a static IP address 325
Payload meter IV software installation 327
Inclinometer calibration and clean truck tare 328
Payload meter IV checkout procedure 328
PLM IV system checkout data sheet 334
Downloading PLM IV data and possible errors 335
Komatsu wireless bridge (KWB) 339
General information 341
Required software and tools 341
Configuring the Bullet wireless radio 342
Installing the Bullet wireless radio 345
Configuring the NanoStation access point 346
Testing the connection 349
Changing a service computer’s IP address 350
Cab air conditioning 353
General information 355
Service tools and equipment 356
Recovery/recycle station 356
Leak detector 356
Manifold gauge set 357
Service valves 358
Vacuum pump 358
Detecting leaks 359
System performance test 360
Checking system oil 361
System flushing 362
Installing the manifold gauge set 363
Purging air from the service hoses 364
Recovering and recycling refrigerant 365
Draining oil from previous recovery cycle 366
Recovery cycle 366
Recycling procedure 366
Evacuating the air conditioning system 367
Charging the air conditioning system 368
Automatic lubrication (auto lube) system 371
Priming the system 373
Checkout procedure 375
Adjusting the lubrication cycle timing 376
Trucks with Interface Module 1 376
Trucks with Interface Module 2 376
KomVision 379
Requirements 381
Initial setup 382
Checkout data sheet 391
Calibration sheets 396
Layout and assemblage 396
Unfolding a calibration sheet 399
Folding a calibration sheet 400
Placement of calibration sheets 401
Camera calibration procedures 403
Automatic 6 camera calibration 403
Manual 6 camera calibration 407
1 camera calibration 410
Radar setting procedure 413
Tire monitoring system 417
Tire monitoring system software and tools 419
Tire monitoring system configuration 419
Connecting to the tire monitoring system web server 419
Configuring a static IP address 419
Tire monitoring system software installation 421
Tire monitoring system checkout procedure 422
Field Troubleshooting 422
Ethernet troubleshooting 422
Tire monitoring system configuration 423
CAN RPC Troubleshooting 423
Resetting the tire monitoring system 423
Tire monitoring system checkout data sheet 424
40 Troubleshooting 427
Fuse, diode and relay locations 427
Vehicle Electrical Center (VEC-89) 429
Vehicle Electrical Center (VEC-90) 431
Vehicle Electrical Center (VEC-91) 433
Vehicle Electrical Center (VEC-92) 435
Rear Terminal Mini-fuse and Relay (RTMR3) 436
Rear Terminal Mini-fuse and Relay (RTMR4) 437
Circuit breakers 437
Troubleshooting by fault code, Part 1 439
Fault Code A001 442
Fault Code A002 443
Fault Code A003 444
Fault Code A004 445
Fault Code A005 446
Fault Code A006 447
Fault Code A007 448
Fault Code A008 449
Fault Code A009 450
Related circuit diagram 450
Fault Code A010 451
Related circuit diagram 451
Fault Code A011 452
Fault Code A013 453
Fault Code A014 454
Fault Code A016 455
Fault Code A017 456
Fault Code A018 457
Fault Code A019 458
Fault Code A022 459
Fault Code A100 460
Related circuit diagram 460
Fault Code A101 461
Fault Code A103 462
Fault Code A104 463
Fault Code A105 464
Fault Code A109 465
Fault Code A111 466
Fault Code A115 467
Fault Code A117 468
Fault Code A118 469
Fault Code A123 470
Fault Code A124 471
Fault Code A125 472
Fault Code A126 473
Fault Code A127 474
Fault Code A128 475
Fault Code A139 476
Troubleshooting by fault code, Part 2 479
Fault Code A145 482
Fault Code A146 483
Fault Code A152 484
Fault Code A153 485
Fault Code A154 486
Fault Code A155 487
Fault Code A158 488
Fault Code A166 489
Fault Code A167 490
Fault Code A168 491
Fault Code A169 492
Fault Code A170 493
Fault Code A171 494
Fault Code A172 495
Fault Code A173 496
Fault Code A184 497
Fault Code A190 498
Fault Code A193 499
Fault Code A194 500
Fault Code A195 501
Fault Code A196 502
Fault Code A197 503
Fault Code A198 504
Fault Code A199 505
Fault Code A200 506
Fault Code A201 507
Fault Code A202 508
Fault Code A203 509
Fault Code A204 510
Fault Code A205 511
Fault Code A206 512
Fault Code A207 513
Fault Code A213 514
Fault Code A214 515
Fault Code A215 516
Fault Code A216 517
Fault Code A223 518
Fault Code A230 519
Fault Code A231 520
Fault Code A233 521
Fault Code A235 522
Fault Code A236 523
Fault Code A237 524
Fault Code A238 525
Fault Code A239 527
Related circuit diagram 528
Fault Code A240 529
Fault Code A242 530
Fault Code A243 531
Fault Code A244 532
Fault Code A245 533
Fault Code A246 534
Troubleshooting by fault code, Part 3 537
Fault Code A248 541
Fault Code A249 542
Fault Code A250 543
Fault Code A251 544
Fault Code A252 545
Fault Code A253 546
Fault Code A256 547
Fault Code A257 548
Fault Code A258 549
Fault Code A260 550
Fault Code A261 551
Fault Code A262 552
Fault Code A264 553
Fault Code A265 554
Fault Code A266 555
Fault Code A267 556
Fault Code A268 557
Fault Code A270 558
Fault Code A271 559
Related circuit diagram 560
Fault Code A272 561
Fault Code A273 562
Fault Code A274 563
Fault Code A275 564
Fault Code A277 565
Fault Code A278 566
Fault Code A279 567
Fault Code A280 568
Fault Code A281 569
Fault Code A282 570
Fault Code A283 571
Fault Code A284 572
Fault Code A285 573
Fault Code A286 574
Fault Code A292 575
Troubleshooting by fault code, Part 4 577
Fault Code A303 580
Fault Code A304 581
Fault Code A305 582
Fault Code A307 583
Fault Code A309 584
Fault Code A310 585
Fault Code A311 586
Fault Code A312 587
Fault Code A313 588
Fault Code A315 589
Fault Code A316 590
Fault Code A317 591
Fault Code A318 592
Fault Code A328 593
Fault Code A332 594
Fault Code A333 595
Fault Code A334 596
Fault Code A335 597
Fault Code A337 598
Fault Code A338 599
Fault Code A339 600
Fault Code A340 601
Fault Code A341 602
Fault Code A342 603
Fault Code A343 604
Fault Code A344 605
Fault Code A345 606
Fault Code A346 607
Fault Code A347 608
Fault Code A348 609
Fault Code A349 610
Fault Code A350 611
Fault Code A351 612
Fault Code A352 613
Fault Code A353 614
Fault Code A354 615
Fault Code A355 616
Fault Code A356 617
Fault Code A357 618
Fault Code A358 619
Fault Code A359 620
Fault Code A360 621
Fault Code A361 622
Fault Code A362 623
Fault Code A363 624
Fault Code A364 625
Fault Code A365 626
Fault Code A366 627
Troubleshooting by fault code, Part 5 629
Fault Code A400 632
Fault Code A401 633
Fault Code A402 634
Fault Code A403 635
Fault Code A404 636
Fault Code A405 637
Fault Code A406 638
Fault Code A407 639
Fault Code A408 640
Fault Code A409 641
Fault Code A410 642
Fault Code A411 643
Fault Code A412 644
Fault Code A413 645
Fault Code A414 646
Fault Code A415 647
Fault Code A416 648
Fault Code A417 649
Fault Code A418 650
Fault Code A419 651
Fault Code A420 652
Fault Code A421 653
Fault Code A422 654
Fault Code A423 655
Fault Code A424 656
Fault Code A425 657
Fault Code A426 658
Fault Code A427 659
Fault Code A428 660
Fault Code A429 661
Fault Code A430 662
Fault Code A431 663
Fault Code A432 664
Fault Code A433 665
Fault Code A434 666
Fault Code A435 667
Fault Code A436 668
Fault Code A437 669
Fault Code A438 670
Fault Code A439 671
Fault Code A440 672
Fault Code A441 673
Fault Code A442 674
Fault Code A443 675
Fault Code A444 676
Fault Code A445 677
Fault Code A446 678
Fault Code A447 679
Aftertreatment system fault codes 681
Fault Code CA256 685
Fault Code CA1677 687
Fault Code CA1678 689
Fault Code CA1682 692
Fault Code CA1683 699
Fault Code CA1684 701
Fault Code CA1685 703
Fault Code CA1686 705
Fault Code CA1712 707
Fault Code CA1713 709
Fault Code CA1714 711
Fault Code CA1715 712
Fault Code CA1887 714
Fault Code CA2771 715
Fault Code CA3142 719
Fault Code CA3143 721
Fault Code CA3146 723
Fault Code CA3147 725
Fault Code CA3232 727
Fault Code CA3497 730
Fault Code CA3498 731
Fault Code CA3547 732
Fault Code CA3558 733
Fault Code CA3559 735
Fault Code CA3562 737
Fault Code CA3563 739
Fault Code CA3567 741
Fault Code CA3571 743
Fault Code CA3572 745
Fault Code CA3573 748
Fault Code CA3574 750
Fault Code CA3575 752
Fault Code CA3712 754
Fault Code CA3713 755
Fault Code CA3714 758
Fault Code CA3867 759
Fault Code CA3868 761
Fault Code CA3878 764
Fault Code CA3988 765
Fault Code CA3995 769
Fault Code CA4113 771
Fault Code CA4114 773
Fault Code CA4119 775
Fault Code CA4121 777
Fault Code CA4152 779
Fault Code CA4164 783
Fault Code CA4165 785
Fault Code CA4166 788
Fault Code CA4168 790
Fault Code CA4169 792
Fault Code CA4174 794
Fault Code CA4175 796
Fault Code CA4233 799
Fault Code CA4234 800
Fault Code CA4243 801
Fault Code CA4277 802
Fault Code CA4457 804
Fault Code CA4458 806
Fault Code CA4459 809
Fault Code CA4461 811
Fault Code CA4462 813
Fault Code CA4464 815
Fault Code CA4465 817
Fault Code CA4466 820
Fault Code CA4467 827
Fault Code CA4474 829
Fault Code CA4475 831
Fault Code CA4572 834
Fault Code CA4677 838
Fault Code CA4679 842
Fault Code CA4682 843
Fault Code CA4731 844
Fault Code CA4732 845
Fault Code CA4736 846
Fault Code CA4737 847
Fault Code CA4738 848
Fault Code CA4739 849
Fault Code CA4745 850
Fault Code CA4768 851
Fault Code CA4769 853
Fault Code CA4842 855
Fault Code CA4863 856
Fault Code CA4947 857
Fault Code CA5115 858
Fault Code CA5116 861
Fault Code CA5117 864
Fault Code CA5247 867
Fault Code CA5653 869
Fault Code CA5654 872
Fault Code CA5725 874
Fault Code CA5727 879
Fault Code CA5728 882
Fault Code CA5729 885
Fault Code CA5748 887
Fault Code CA5749 889
Fault Code CA5751 891
Fault Code CA5753 893
Fault Code CA5755 896
Fault Code CA5756 901
Fault Code CA5758 903
Fault Code CA5768 905
Fault Code CA5769 907
Fault Code CA5771 910
Fault Code CA5772 912
Fault Code CA5773 915
Fault Code CA5774 918
Fault Code CA5775 920
Fault Code CA5776 925
Fault Code CA5778 927
Fault Code CA5779 929
Fault Code CA5887 931
Fault Code CA5888 932
Fault Code CA5889 933
Fault Code CA5891 934
Fault Code CA5892 935
Fault Code CA5893 936
Fault Code CA6692 937
Fault Code CA6693 939
Fault Code CA6694 941
Fault Code CA6695 943
Fault Code CA6696 945
Fault Code CA6697 947
Fault Code CA6855 949
Fault Code CA6856 952
Steering system 955
Steering circuit troubleshooting chart 957
Steering circuit troubleshooting guidelines 961
Basic hydraulic system checks 962
System leakage check 963
Steering pump troubleshooting guide 965
Pump pressure control checks 968
Pump fails to unload 969
Pump fails to develop pressure 969
Pump slow in developing pressure 970
Pump control valve inspection and troubleshooting 970
Pump case drain check 972
KomVision 975
KomVision fault codes 977
Automatic lubrication (auto lube) system 987
Autolube troubleshooting chart 989
Heating/air conditioning (HVAC) system 993
Control panel configurations 995
Diagnostics mode 996
Error codes 996
Advanced diagnostics 996
Firmware version 997
Additional HVAC troubleshooting chart 997
Voltage levels 999
Electronic fan clutch1001
Electronic fan clutch troubleshooting1003
Electronic fan clutch fault codes1005
50 Disassembly and assembly1007
Service tools1007
Special tool group1009
Additional service tools1010
KomVision calibration tools1010
Locally made tools1010
Wheels, spindles and rear axle1013
General precautions for tires and rims1015
Wheel stud maintenance1016
Rear outer wheel stud installation1017
Removal and installation of front wheel1018
Removal1018
Installation1019
Removal and installation of rear wheel1020
Removal1020
Installation1021
Rim components1023
Smart rim component layout1023
Lubricants1023
Rim and tire service1024
Lubricants1024
Tire inflation1024
Lock ring retainer installation1024
Removing the lock ring1025
Installing the lock ring1026
Removing the tire from the front rim (5-piece rim)1027
Removing the tire from the rear outer dual rim (7-piece Smart rim)1030
Removing the tire from the rear inner dual rim (5-piece rim)1032
Preparation before assembly1033
Installing the tire on the front rim (5-piece rim)1034
Installing the tire on the rear inner dual rim (5-piece rim)1036
Installing the tire on the rear outer dual rim (7-piece Smart rim)1037
Removal and installation of front wheel hub and spindle1038
Removal1038
Spindle removal (off the truck)1043
Installation1045
Disassembly and assembly of front wheel hub and spindle1046
Cross Section View1046
Disassembly1047
Cleaning and inspection1056
Assembly1057
Wheel bearing adjustment1058
Brake seal installation1059
Oil separation seal assembly1062
Brake installation1064
Speed sensor installation and adjustment1067
Floating ring seal assembly and installation1069
Removal and installation of rear axle1078
Removal1078
Cleaning and inspection1080
Installation1080
Removal and installation of anti-sway bar1081
Removal1081
Installation1083
Removal and installation of pivot pin1084
Removal1084
Installation1085
Pivot eye and bearing service1086
Bearing replacement1086
Pivot eye repair1087
Removal of wheel motor1088
Preparation1088
Removal1088
Installation of wheel motor1090
Cleaning and inspection1090
Installation1091
Brake system1097
Removal and installation of brake valve1099
Removal1099
Installation1100
Disassembly and assembly of brake valve/pedal assembly1101
Disassembly1101
Assembly1102
Removal and installation of dual relay valve1105
Removal1105
Installation1106
Removal and installation of brake manifold1107
Removal1107
Installation1107
Disassembly and assembly of brake manifold1108
Disassembly1108
Assembly1108
Disassembly and assembly of brake bladder accumulator1109
Cleaning and inspection1110
Assembly1111
Removal and installation of piston brake accumulator1113
Removal1113
Installation1115
Disassembly and assembly of piston brake accumulator1117
Disassembly1117
Cleaning and inspection1119
Piston seal replacement1119
Assembly1120
Disassembly and assembly of front wheel brake1121
Disassembly1121
Cleaning and inspection1125
Assembly1127
Removal and installation of rear brake caliper1132
Removal1132
Inspection1135
Installation1135
Disassembly and assembly of rear brake caliper1139
Disassembly1139
Piston subassembly1142
Cleaning and inspection1143
Brake lining replacement1144
Assembly1144
Piston subassembly1144
Brake caliper1145
Steering system1151
Removal and installation of steering control unit1153
Removal1153
Installation1155
Disassembly and assembly of steering control unit1156
Disassembly1156
Assembly1158
Removal and installation of steering column1161
Removal1161
Installation1162
Removal and installation of steering wheel1163
Removal1163
Installation1163
Removal and installation of bleeddown manifold1164
Removal1164
Installation1165
Removal and installation of flow amplifier1165
Removal1165
Installation1166
Removal and installation of steering cylinders and tie rod1167
Removal1167
Installation1167
Disassembly and assembly of steering cylinders1169
Disassembly1169
Cleaning and inspection1171
Assembly1172
Removal and installation of steering/brake pump1173
Removal1173
Installation1174
Removal and installation of piston steering accumulator1175
Removal1175
Installation1177
Disassembly and assembly of piston steering accumulator1179
Disassembly1179
Cleaning and inspection1181
Piston seal replacement1181
Assembly1182
Suspensions1185
General information1187
Removal and installation of front suspension1187
Preparation1187
Removal1187
Cleaning and Inspection1189
Installation1190
Disassembly and assembly of front suspension1196
Disassembly1196
Cleaning and inspection1198
Assembly1199
Removal and installation of rear suspension1201
Removal1201
Installation1204
Disassembly and assembly of rear suspension1207
Disassembly1207
Cleaning and inspection1209
Assembly1210
Hoist circuit1213
Removal and installation of hoist pump1215
Removal1215
Installation1219
Disassembly and assembly of hoist pump1220
Disassembly1220
Inspection1225
Assembly1226
Removal and installation of hoist valve1229
Removal1229
Installation1231
Disassembly and assembly of hoist valve1231
O-ring replacement1231
Disassembly of inlet section1233
Assembly of inlet section1234
Disassembly of spool section1235
Assembly of spool section1237
Overcenter manifold service1238
Removal and installation of hoist pilot valve1239
Removal1239
Installation1239
Disassembly and assembly of hoist pilot valve1240
Disassembly1240
Cleaning and inspection1241
Assembly1241
Removal and installation of hoist cylinders1242
Removal1242
Installation1245
Disassembly and assembly of hoist cylinders1248
Disassembly1248
Cleaning and inspection1252
Installation of the quill1253
Installation of check balls and plugs in quill1254
Assembly1255
Body and structures1261
Removal and installation of dump body1263
Removal1263
Inspection1264
Installation1265
Removal and installation of body pads1266
Removal1266
Installation1266
Body pad shimming procedure1267
Removal and installation of diagonal ladder/ hood and grille assembly1268
Removal1268
Installation1268
Removal and installation of RH deck1270
Removal1270
Installation1270
Removal and installation of LH deck1272
Removal1272
Installation1272
Removal and installation of fuel tank1274
Removal1274
Cleaning and inspection1274
Installation1276
Removal and installation of fuel gauge sender1276
Removal1276
Installation1276
Removal and installation of hydraulic tank1277
Removal1277
Installation1278
Removal and installation of hydraulic tank strainers1279
Removal1279
Cleaning and inspection1280
Installation1280
Operator cab1283
Removal and installation of operator cab1285
Removal1285
Installation1288
Removal and installation of cab door1288
Removal1288
Installation1289
Disassembly and assembly of cab door1290
Removing the window regulator1290
Installing the window regulator1291
Removing the door glass1292
Installing the door glass1293
Replacing the inner door seal1294
Replacing the outer door seal1294
Removing the interior door handle and door latch (earlier models)1295
Installation and removal of interior door handle and door latch (later models)1298
Adjustment of cab door1300
Door jamb bolt adjustment1300
Exterior door handle release button adjustment1302
Removal and installation of side window glass1303
Recommended tools and supplies1303
Removal1303
Installation1304
Removal and installation of windshield and rear window glass1305
Removal1305
Installation1305
Removal and installation of windshield wiper components1306
Removing the windshield wiper motor1306
Installing the windshield wiper motor1306
Removing the windshield wiper arm and linkage1307
Installing the windshield wiper arm and linkage1308
Removal and installation of cab seats1308
Removal1308
Servicing the seat1309
Installation1309
Removal and installation of seat belts1310
Removal1310
Installation1311
Power module1313
Removal and installation of power module1315
General1315
Removal1316
Installation1325
Exhaust tube installation1335
Exhaust blanket installation1335
Removal and installation of alternator1336
Removal1336
Installation1339
Engine / alternator attachment checkout data sheet1349
Removal and installation of radiator1354
Removal1354
Installation1358
Repairing the radiator1359
Internal inspection1359
External cleaning1359
Disassembly1360
Cleaning and inspection1361
Assembly1361
Pressure testing1362
Removal and installation of engine1363
Removal1363
Service1363
Installation1364
Removal and installation of electronic fan clutch1365
Removal1365
Installation1366
Removal and installation of electronic fan clutch speed sensor1366
Removal1366
Installation1366
90 Diagrams and drawings1369
Hydraulic circuit diagrams1369
Steering and hoist hydraulic circuit diagram – 58E-60-513901371
Brake hydraulic circuit diagram – 58E-60-513801372
Auxiliary system hydraulic circuit schematic – 58E-60-016801373
Electrical circuit diagrams1376
Electrical circuit diagram – 58E-06-023171378
HVAC electrical circuit diagram – 58B-06-068301401

IMAGES PREVIEW OF THE MANUAL:

S.M 20/12/24