Komatsu 93-E-5 Dump Truck Shop Manual CEBM038100 – PDF DOWNLOAD

Description

Komatsu 93-E-5 Dump Truck Shop Manual CEBM038100 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 93-E-5 Dump Truck Shop Manual CEBM038100 – PDF DOWNLOAD

Language : English
Pages :1378
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 93-E-5 Dump Truck Shop Manual CEBM038100 – PDF DOWNLOAD

SERIAL NUMBERS
930E-5
A50330 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 Nm (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
• The KOMATSU truck model designation consists of three numbers and one letter (i.e. 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 93-E-5 Dump Truck Shop Manual CEBM038100 – PDF DOWNLOAD

SERIAL NUMBERS
930E-5
A50330 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 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 66
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 86
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
Hoist 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 128
Secondary braking and auto apply 129
Parking brake circuit operation 130
Normal operation (key start switch ON, engine on) 130
Wheel brake lock circuit operation 131
Brake warning circuit operation 131
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, brake cooling and auxiliary hydraulic systems 175
Hydraulic system bleeddown procedure 177
Hydraulic system vacuum procedure 179
General information on system checkout 180
Hydraulic system checkout procedures 180
Required equipment 180
Preliminary steps 181
Hydraulic system flushing procedure 181
Flow amplifier adjustment 185
Steering pump unloader valve adjustment 186
Auxiliary accumulator pressure verification 186
System diagnostics 187
Hoist pilot relief valve adjustment 189
Hoist counterbalance valve adjustment 190
Final steps 191
Oil cleanliness check 191
Hydraulic system checkout data sheet 192
Toe-in adjustment 195
Hoist cylinder leakage test 196
Steering cylinder leakage test 196
Brake system 199
General information on system checkout 201
Brake system checkout procedures 201
Required equipment 201
Bleeddown procedure 201
Preliminary steps 204
Service brake checkout (front and rear) 205
Brake lock system checkout 206
Low brake pressure and auto apply checkout 206
Service brake checkout (left and right) 208
Parking brake checkout 209
Parking brake control logic checkout 209
Brake lock control logic checkout 211
Brake system checkout data sheet 214
Brake piston leakage test 223
Brake seal pressure test 223
Oil separator seal pressure test 223
Method 1 223
Method 2 224
Wet disc brake bleeding procedure 224
Parking brake bleeding procedure 225
Service brake disc wear inspection 226
Parking brake disc wear inspection 227
Accumulators and suspensions 229
Accumulator charging and storage 231
Temperature during precharge 231
Bladder accumulator charging procedure 232
Precharge maintenance 234
Bladder accumulator storage procedure 234
Bladder storage 234
Installing a bladder accumulator from storage 235
Bladder accumulator leak testing 235
Piston accumulator charging procedure 236
Piston accumulator storage 239
Piston accumulator leak testing 240
Checking for improper suspension charge on operating trucks 241
Suspension oil change recommendations 242
Suspension oiling and charging procedures 243
Required equipment 243
Installing the charging kit 244
Removing the charging kit 244
Support blocks for oiling and charging dimensions 245
Front suspensions 248
TOP FILL METHOD 249
PRESSURE FILL METHOD 249
Rear suspensions 251
TOP FILL METHOD 253
PRESSURE FILL METHOD 253
Suspension pressure test 256
Electrical systems 259
General information on system checkout 261
Loadbox test information 261
Truck shutdown procedure 262
Required software and tools 262
Electrical system checkout procedures 264
Visual inspection 264
Resistance checks 264
Voltage checks 265
Truck function checks 267
Interface module (IM) checks 268
KOMTRAX Plus II checks 268
Payload meter (PLM) checks 268
Drive system checks 268
Engine delayed shutdown Smart Timer check 269
Body hoist limit switch check 269
Electrical checkout sheet 270
Interface module 2 (IM2) 275
Required tools 277
Programming the IM2 277
Updating the software 277
Configuring the IM2 278
Viewing IM2 real-time data 278
Interface module checkout procedures 279
Checking for IM fault codes 279
Checking digital inputs to the IM 279
Checking analog inputs to the IM 282
Checking serial communication to the IM 282
Checking outputs from the IM 283
IM checkout sheet 284
Payload meter IV 289
Payload meter IV software and tools 291
Payload meter IV system configuration 291
Connecting to the payload meter IV web server 291
Configuring a static IP address 291
Payload meter IV software installation 293
Inclinometer calibration and clean truck tare 294
Payload meter IV checkout procedure 294
PLM IV system checkout data sheet 300
Downloading PLM IV data and possible errors 301
KOMTRAX Plus II 305
Required software and tools 307
Ethernet connection to KOMTRAX Plus II controller 307
KOMTRAX Plus II configuration 309
GPS connection test 311
Iridium satellite system opening 313
Data download over ethernet connection for KOMTRAX Plus II initialization 316
Komatsu wireless bridge (KWB) 319
General information 321
Required software and tools 321
Configuring the Bullet wireless radio 322
Installing the Bullet wireless radio 325
Configuring the NanoStation access point 326
Testing the connection 329
Changing a service computer’s IP address 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 369
Calibration sheets 374
Layout and assemblage 374
Unfolding a calibration sheet 377
Folding a calibration sheet 378
Placement of calibration sheets 379
Camera calibration procedures 381
Automatic 6 camera calibration 381
Manual 6 camera calibration 385
1 camera calibration 388
Radar setting procedure 391
Tire monitoring system 395
Tire monitoring system software and tools 397
Tire monitoring system configuration 397
Connecting to the tire monitoring system web server 397
Configuring a static IP address 397
Tire monitoring system software installation 399
Tire monitoring system checkout procedure 400
Field Troubleshooting 400
Ethernet troubleshooting 400
Tire monitoring system configuration 401
CAN RPC Troubleshooting 401
Resetting the tire monitoring system 401
Tire monitoring system checkout data sheet 402
40 Troubleshooting 405
Fuse, diode and relay locations 405
Vehicle Electrical Center (VEC-89) 407
Vehicle Electrical Center (VEC-90) 409
Vehicle Electrical Center (VEC-91) 411
Vehicle Electrical Center (VEC-92) 413
Rear Terminal Mini-fuse and Relay (RTMR3) 414
Rear Terminal Mini-fuse and Relay (RTMR4) 415
Circuit breakers 415
Troubleshooting by fault code, Part 1 417
Fault Code A001 420
Fault Code A002 421
Fault Code A003 422
Fault Code A004 423
Fault Code A005 424
Fault Code A006 425
Fault Code A007 426
Fault Code A008 427
Fault Code A009 428
Related circuit diagram 428
Fault Code A010 429
Related circuit diagram 429
Fault Code A011 430
Fault Code A013 431
Fault Code A014 432
Fault Code A016 433
Fault Code A017 434
Fault Code A018 435
Fault Code A019 436
Fault Code A022 437
Fault Code A100 438
Related circuit diagram 438
Fault Code A101 439
Fault Code A103 440
Fault Code A104 441
Fault Code A105 442
Fault Code A109 443
Fault Code A111 444
Fault Code A115 445
Fault Code A117 446
Fault Code A118 447
Fault Code A123 448
Fault Code A124 449
Fault Code A125 450
Fault Code A126 451
Fault Code A127 452
Fault Code A128 453
Fault Code A139 454
Troubleshooting by fault code, Part 2 457
Fault Code A145 460
Fault Code A146 461
Fault Code A152 462
Fault Code A153 463
Fault Code A154 464
Fault Code A155 465
Fault Code A158 466
Fault Code A166 467
Fault Code A167 468
Fault Code A168 469
Fault Code A169 470
Fault Code A170 471
Fault Code A171 472
Fault Code A172 473
Fault Code A173 474
Fault Code A184 475
Fault Code A190 476
Fault Code A193 477
Fault Code A194 478
Fault Code A195 479
Fault Code A196 480
Fault Code A197 481
Fault Code A198 482
Fault Code A199 483
Fault Code A200 484
Fault Code A201 485
Fault Code A202 486
Fault Code A203 487
Fault Code A204 488
Fault Code A205 489
Fault Code A206 490
Fault Code A207 491
Fault Code A213 492
Fault Code A214 493
Fault Code A215 494
Fault Code A216 495
Fault Code A223 496
Fault Code A230 497
Fault Code A231 498
Fault Code A233 499
Fault Code A235 500
Fault Code A236 501
Fault Code A237 502
Fault Code A238 503
Fault Code A239 505
Related circuit diagram 506
Fault Code A240 507
Fault Code A242 508
Fault Code A243 509
Fault Code A244 510
Fault Code A245 511
Fault Code A246 512
Troubleshooting by fault code, Part 3 515
Fault Code A247 517
Fault Code A248 518
Fault Code A249 519
Fault Code A250 520
Fault Code A251 521
Fault Code A252 522
Fault Code A253 523
Fault Code A256 524
Fault Code A257 525
Fault Code A258 526
Fault Code A260 527
Fault Code A261 528
Fault Code A262 529
Fault Code A264 530
Fault Code A265 531
Fault Code A266 532
Fault Code A267 533
Fault Code A268 534
Fault Code A270 535
Fault Code A271 536
Related circuit diagram 537
Fault Code A272 538
Fault Code A273 539
Fault Code A274 540
Fault Code A275 541
Fault Code A277 542
Fault Code A278 543
Fault Code A279 544
Fault Code A280 545
Fault Code A281 546
Fault Code A282 547
Fault Code A283 548
Fault Code A284 549
Fault Code A285 550
Fault Code A286 551
Fault Code A292 552
Troubleshooting by fault code, Part 4 555
Fault Code A303 558
Fault Code A304 559
Fault Code A305 560
Fault Code A307 561
Fault Code A309 562
Fault Code A310 563
Fault Code A311 564
Fault Code A312 565
Fault Code A313 566
Fault Code A315 567
Fault Code A316 568
Fault Code A317 569
Fault Code A318 570
Fault Code A328 571
Fault Code A332 572
Fault Code A333 573
Fault Code A334 574
Fault Code A335 575
Fault Code A337 576
Fault Code A338 577
Fault Code A339 578
Fault Code A340 579
Fault Code A341 580
Fault Code A342 581
Fault Code A343 582
Fault Code A344 583
Fault Code A345 584
Fault Code A346 585
Fault Code A347 586
Fault Code A348 587
Fault Code A349 588
Fault Code A350 589
Fault Code A351 590
Fault Code A352 591
Fault Code A353 592
Fault Code A354 593
Fault Code A355 594
Fault Code A356 595
Fault Code A357 596
Fault Code A358 597
Fault Code A359 598
Fault Code A360 599
Fault Code A361 600
Fault Code A362 601
Fault Code A363 602
Fault Code A364 603
Fault Code A365 604
Fault Code A366 605
Troubleshooting by fault code, Part 5 607
Fault Code A400 610
Fault Code A401 611
Fault Code A402 612
Fault Code A403 613
Fault Code A404 614
Fault Code A405 615
Fault Code A406 616
Fault Code A407 617
Fault Code A408 618
Fault Code A409 619
Fault Code A410 620
Fault Code A411 621
Fault Code A412 622
Fault Code A413 623
Fault Code A414 624
Fault Code A415 625
Fault Code A416 626
Fault Code A417 627
Fault Code A418 628
Fault Code A419 629
Fault Code A420 630
Fault Code A421 631
Fault Code A422 632
Fault Code A423 633
Fault Code A424 634
Fault Code A425 635
Fault Code A426 636
Fault Code A427 637
Fault Code A428 638
Fault Code A429 639
Fault Code A430 640
Fault Code A431 641
Fault Code A432 642
Fault Code A433 643
Fault Code A434 644
Fault Code A435 645
Fault Code A436 646
Fault Code A437 647
Fault Code A438 648
Fault Code A439 649
Fault Code A440 650
Fault Code A441 651
Fault Code A442 652
Fault Code A443 653
Fault Code A444 654
Fault Code A445 655
Fault Code A446 656
Fault Code A447 657
Aftertreatment system fault codes 659
Fault Code CA256 663
Fault Code CA1677 665
Fault Code CA1678 667
Fault Code CA1682 670
Fault Code CA1683 677
Fault Code CA1684 679
Fault Code CA1685 681
Fault Code CA1686 683
Fault Code CA1712 685
Fault Code CA1713 687
Fault Code CA1714 689
Fault Code CA1715 690
Fault Code CA1887 692
Fault Code CA2771 693
Fault Code CA3142 697
Fault Code CA3143 699
Fault Code CA3146 701
Fault Code CA3147 703
Fault Code CA3232 705
Fault Code CA3497 708
Fault Code CA3498 709
Fault Code CA3547 710
Fault Code CA3558 711
Fault Code CA3559 713
Fault Code CA3562 715
Fault Code CA3563 717
Fault Code CA3567 719
Fault Code CA3571 721
Fault Code CA3572 723
Fault Code CA3573 726
Fault Code CA3574 728
Fault Code CA3575 730
Fault Code CA3712 732
Fault Code CA3713 733
Fault Code CA3714 736
Fault Code CA3867 737
Fault Code CA3868 739
Fault Code CA3878 742
Fault Code CA3988 743
Fault Code CA3995 747
Fault Code CA4113 749
Fault Code CA4114 751
Fault Code CA4119 753
Fault Code CA4121 755
Fault Code CA4152 757
Fault Code CA4164 761
Fault Code CA4165 763
Fault Code CA4166 766
Fault Code CA4168 768
Fault Code CA4169 770
Fault Code CA4174 772
Fault Code CA4175 774
Fault Code CA4233 777
Fault Code CA4234 778
Fault Code CA4243 779
Fault Code CA4277 780
Fault Code CA4457 782
Fault Code CA4458 784
Fault Code CA4459 787
Fault Code CA4461 789
Fault Code CA4462 791
Fault Code CA4464 793
Fault Code CA4465 795
Fault Code CA4466 798
Fault Code CA4467 805
Fault Code CA4474 807
Fault Code CA4475 809
Fault Code CA4572 812
Fault Code CA4677 816
Fault Code CA4679 820
Fault Code CA4682 821
Fault Code CA4731 822
Fault Code CA4732 823
Fault Code CA4736 824
Fault Code CA4737 825
Fault Code CA4738 826
Fault Code CA4739 827
Fault Code CA4745 828
Fault Code CA4768 829
Fault Code CA4769 831
Fault Code CA4842 833
Fault Code CA4863 834
Fault Code CA4947 835
Fault Code CA5115 836
Fault Code CA5116 839
Fault Code CA5117 842
Fault Code CA5247 845
Fault Code CA5653 847
Fault Code CA5654 850
Fault Code CA5725 852
Fault Code CA5727 857
Fault Code CA5728 860
Fault Code CA5729 863
Fault Code CA5748 865
Fault Code CA5749 867
Fault Code CA5751 869
Fault Code CA5753 871
Fault Code CA5755 874
Fault Code CA5756 879
Fault Code CA5758 881
Fault Code CA5768 883
Fault Code CA5769 885
Fault Code CA5771 888
Fault Code CA5772 890
Fault Code CA5773 893
Fault Code CA5774 896
Fault Code CA5775 898
Fault Code CA5776 903
Fault Code CA5778 905
Fault Code CA5779 907
Fault Code CA5887 909
Fault Code CA5888 910
Fault Code CA5889 911
Fault Code CA5891 912
Fault Code CA5892 913
Fault Code CA5893 914
Fault Code CA6692 915
Fault Code CA6693 917
Fault Code CA6694 919
Fault Code CA6695 921
Fault Code CA6696 923
Fault Code CA6697 925
Fault Code CA6855 927
Fault Code CA6856 930
Steering system 933
Steering circuit troubleshooting chart 935
Steering circuit troubleshooting guidelines 937
Basic hydraulic system checks 938
System leakage check 939
Steering pump troubleshooting guide 941
Pump pressure control checks 944
Pump fails to unload 945
Pump fails to develop pressure 945
Pump slow in developing pressure 946
Pump control valve inspection and troubleshooting 947
Pump case drain check 949
Setting pump pressure controls 949
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
Electronic fan clutch 979
Electronic fan clutch troubleshooting 981
Electronic fan clutch fault codes 983
50 Disassembly and assembly 985
Service tools 985
Special tool group 987
Additional service tools 988
KomVision calibration tools 989
Locally made tools 989
Wheels, spindles and rear axle 991
General precautions for tires and rims 993
Wheel stud maintenance 994
Rear outer wheel stud installation 995
Removal and installation of front wheel 996
Removal 996
Installation 997
Removal and installation of rear wheel 998
Removal 998
Installation 999
Rim components1001
Smart Rim Component Layout1001
Rim and tire service1002
Lubricants1002
Tire inflation1002
Lock ring retainer installation1002
Removing the lock ring1003
Installing the lock ring1004
Removing the tire from the front rim (5-piece rim)1005
Removing the tire from the rear outer dual rim (7-piece Smart rim)1008
Removing the tire from the rear inner dual rim (5-piece rim)1010
Preparation before assembly1011
Installing the tire on the front rim (5-piece rim)1012
Installing the tire on the rear inner dual rim (5-piece rim)1014
Installing the tire on the rear outer dual rim (7-piece Smart rim)1015
Removal and installation of front wheel hub and spindle1016
Removal1016
Spindle removal (off the truck)1022
Installation1024
Disassembly and assembly of front wheel hub and spindle1025
Cross Section View1025
Disassembly1026
Cleaning and inspection1033
Assembly1034
Wheel bearing adjustment1036
Seal assembly gap adjustment1037
Brake seal installation1038
Oil separation seal installation1039
Brake installation1040
Speed sensor installation and adjustment1044
Floating ring seal assembly and installation1046
Removal and installation of rear axle1055
Removal1055
Cleaning and inspection1057
Installation1057
Removal and installation of anti-sway bar1058
Removal1058
Installation1060
Removal and installation of pivot pin1061
Removal1061
Installation1062
Removal and installation of pivot bearing1063
Replacement criteria1063
Removal1065
Inspection1065
Installation1065
Removal and installation of pivot eye1066
Removal1066
Inspection1066
Installation1066
Removal of wheel motor1067
Preparation1067
Installation of wheel motor1069
Cleaning and inspection1069
Installation1070
Removal and installation of rear brake assembly1073
Brake system1075
Removal and installation of brake valve1077
Removal1077
Installation1078
Disassembly and assembly of brake valve/pedal assembly1079
Disassembly1079
Assembly1080
Removal and installation of dual relay valve1083
Removal1083
Installation1084
Removal and installation of brake manifold1085
Removal1085
Installation1085
Disassembly and assembly of brake manifold1086
Disassembly1086
Assembly1086
Removal and installation of piston brake accumulator1087
Removal1087
Installation1089
Disassembly and assembly of piston brake accumulator1089
Disassembly1089
Cleaning and inspection1091
Piston seal replacement1092
Assembly1092
Disassembly and assembly of front wheel brake1094
Disassembly1094
Cleaning and inspection1097
Assembly1098
Disassembly and assembly of rear wheel brake1100
Disassembly1100
Cleaning and inspection1104
Assembly1105
Brake floating ring seal assembly and installation1109
Rear hub floating ring seal assembly and installation1118
Removal and installation of parking brake1124
Removal1124
Installation1126
Disassembly and assembly of parking brake1127
Disassemble and reassemble the brake assembly on a clean, dry work surface The work surface should be wooden If the work surface is metal or concrete, use padding to prevent damage to machined surfaces Handle all parts carefully to avoid damage to1127
Disassembly1127
Cleaning and inspection1130
Cleaning and inspecting new discs1132
Assembly1133
Steering system1135
Removal and installation of steering control unit1137
Removal1137
Installation1138
Disassembly and assembly of steering control unit1139
Disassembly1139
Assembly1141
Removal and installation of steering column1144
Removal1144
Installation1145
Removal and installation of steering wheel1146
Removal1146
Installation1146
Removal and installation of bleeddown manifold1147
Removal1147
Installation1148
Removal and installation of flow amplifier1149
Removal1149
Installation1149
Removal and installation of steering cylinders and tie rod1150
Removal1150
Installation1150
Disassembly and assembly of steering cylinders1152
Disassembly1152
Cleaning and inspection1154
Assembly1154
Removal and installation of steering/brake pump1155
Removal1155
Installation1157
Removal and installation of piston steering accumulator1158
Removal1158
Installation1160
Disassembly and assembly of piston steering accumulator1162
Disassembly1162
Cleaning and inspection1164
Piston seal replacement1164
Assembly1165
Suspensions1169
General information1171
Removal and installation of front suspension1171
Preparation1171
Removal1171
Cleaning and Inspection1173
Installation1174
Disassembly and assembly of front suspension1179
Disassembly1179
Cleaning and inspection1182
Assembly1182
Removal and installation of rear suspension1184
Removal1184
Installation1187
Disassembly and assembly of rear suspension1190
Disassembly1190
Cleaning and inspection1192
Assembly1193
Hoist circuit1195
Removal and installation of hoist pump1197
Removal1197
Installation1201
Disassembly and assembly of hoist pump1202
Disassembly1202
Inspection1207
Assembly1208
Removal and installation of hoist valve1211
Removal1211
Installation1213
Disassembly and assembly of hoist valve1213
O-ring replacement1213
Disassembly of inlet section1215
Assembly of inlet section1216
Disassembly of rear spool section1217
Assembly of rear spool section1219
Disassembly of front spool section1220
Assembly of front spool section1221
Overcenter manifold service1221
Removal and installation of hoist pilot valve1222
Removal1222
Installation1222
Disassembly and assembly of hoist pilot valve1224
Disassembly1224
Cleaning and inspection1225
Assembly1225
Removal and installation of hoist cylinders1226
Removal1226
Installation1228
Disassembly and assembly of hoist cylinders1229
Disassembly1229
Cleaning and inspection1233
Installation of the quill1234
Assembly1236
Body and structures1241
Removal and installation of dump body1243
Removal1243
Inspection1244
Installation1245
Removal and installation of body pads1246
Removal1246
Installation1246
Body pad shimming procedure1247
Removal and installation of diagonal ladder/ hood and grille assembly1248
Removal1248
Installation1248
Removal and installation of RH deck1250
Removal1250
Installation1250
Removal and installation of LH deck1252
Removal1252
Installation1252
Removal and installation of fuel tank1254
Removal1254
Cleaning and inspection1254
Installation1256
Removal and installation of fuel gauge sender1256
Removal1256
Installation1256
Removal and installation of hydraulic tank1257
Removal1257
Installation1258
Removal and installation of hydraulic tank strainers1259
Removal1259
Cleaning and inspection1260
Installation1260
Operator cab1263
Removal and installation of operator cab1265
Removal1265
Installation1268
Removal and installation of cab door1268
Removal1268
Installation1269
Disassembly and assembly of cab door1270
Removing the window regulator1270
Installing the window regulator1271
Removing the door glass1272
Installing the door glass1273
Replacing the inner door seal1274
Replacing the outer door seal1274
Removing the interior door handle and door latch (earlier models)1275
Installation and removal of interior door handle and door latch (later models)1278
Adjustment of cab door1280
Door jamb bolt adjustment1280
Exterior door handle release button adjustment1282
Removal and installation of side window glass1283
Recommended tools and supplies1283
Removal1283
Installation1284
Removal and installation of windshield and rear window glass1285
Removal1285
Installation1285
Removal and installation of windshield wiper components1286
Removing the windshield wiper motor1286
Installing the windshield wiper motor1286
Removing the windshield wiper arm and linkage1287
Installing the windshield wiper arm and linkage1288
Removal and installation of cab seats1288
Removal1288
Servicing the seat1289
Installation1289
Removal and installation of seat belts1290
Removal1290
Installation1291
Power module1293
Removal and installation of power module1295
General1295
Removal1296
Installation1304
Exhaust tube installation1307
Exhaust blanket installation1307
Removal and installation of alternator1308
Removal1308
Installation1311
Engine/alternator attachment checkout data sheet1321
Removal and installation of radiator1327
Removal1327
Installation1331
Repairing the radiator1332
Internal inspection1332
External cleaning1332
Disassembly1333
Cleaning and inspection1334
Assembly1334
Pressure testing1335
Removal and installation of engine1336
Removal1336
Service1336
Installation1337
Removal and installation of electronic fan clutch1338
Removal1338
Installation1339
Removal and installation of electronic fan clutch speed sensor1339
Removal1339
Installation1339
90 Diagrams and drawings1348
Hydraulic circuit diagrams1341
Electrical circuit diagrams1348

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24