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Komatsu Dump Truck 210M DG715 Shop Manual – PDF DOWNLOAD
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Komatsu Dump Truck 210M DG715 Shop Manual
MACHINE MODEL SERIAL SUFFIX :
210M BFA40DA THRU EP
24501 THRU 24647
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Description
Komatsu Dump Truck 210M DG715 Shop Manual
FILE DETAILS:
Komatsu Dump Truck 210M DG715 Shop Manual
File Format: PDF
Language: English
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Pages:475
Requirements: Adobe PDF Reader
KOMATSU DUMP TRUCK 210M DG715 SHOP MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu Dump Truck 210M DG715 Shop Manual
This Service Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, warnings and cautions should be understood and followed when accomplishing 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, at times, typical of the component shown and may not necessarily depict a specific model.
- This manual shows dimensioning of U.S. standard and metric (SI) units throughout and all references to “Right”, “Left”, “Front”, or “Rear” are made with respect to the operator’s normal seated position, unless specifically stated otherwise. Standard torque requirements are shown in torque charts in the general information section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 N.m) torque.
- All torque specifications have ± 10% tolerance unless otherwise specified. A Product Identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The HAULPAK® Model designation consists of three numbers and one letter (i.e. 210M). The three numbers represent the basic truck model. The letter “M” designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu Dump Truck 210M DG715 Shop Manual
MAIN MENU...................................................................................................... 0 COVER PAGE..................................................................................................... 1 TABLE OF CONTENTS.............................................................................................. 7 GENERAL INFORMATION............................................................................................ 9 TRUCK COMPONENT DESCRIPTION AND SPECIFICATIONS............................................................. 11 GENERAL SAFETY AND TRUCK OPERATION......................................................................... 15 WARNINGS AND CAUTIONS...................................................................................... 37 CHARTS AND TABLES.......................................................................................... 43 STORAGE PROCEDURES......................................................................................... 49 STRUCTURES..................................................................................................... 69 STRUCTURAL COMPONENTS...................................................................................... 71 COWL AND HOOD.......................................................................................... 71 DECKS.................................................................................................. 71 RIGHT DECK STRUCTURE................................................................................... 71 REMOVAL............................................................................................ 71 INSTALLATION....................................................................................... 71 INSPECTION......................................................................................... 72 DUMP BODY.................................................................................................. 73 DUMP BODY.............................................................................................. 73 REMOVAL............................................................................................ 73 INSTALLATION....................................................................................... 74 BODY PIVOT PINS AND SPACERS............................................................................ 74 REMOVAL............................................................................................ 74 INSTALLATION....................................................................................... 74 BODY-UP PIN............................................................................................ 75 INSTALLATION....................................................................................... 75 BODY PAD............................................................................................... 75 ROCK EJECTORS.......................................................................................... 76 INSPECTION......................................................................................... 76 BODY POSITION INDICATOR................................................................................ 76 LINER PLATES/BODY REPAIR............................................................................... 76 BODY-UP LIMIT SWITCH................................................................................... 76 ADJUSTMENT......................................................................................... 76 MAINTENANCE........................................................................................ 78 FUEL TANK.................................................................................................. 79 FUEL TANK.............................................................................................. 79 REMOVAL............................................................................................ 79 INSTALLATION....................................................................................... 80 CLEANING........................................................................................... 80 VENT................................................................................................... 80 GAUGE.................................................................................................. 80 REMOVAL............................................................................................ 80 INSTALLATION....................................................................................... 80 ENGINE, FUEL, COOLING AND AIR CLEANER.......................................................................... 81 COOLING SYSTEM............................................................................................. 83 RADIATOR............................................................................................... 83 REMOVAL............................................................................................ 83 INSTALLATION....................................................................................... 85 REPAIR............................................................................................. 86 HEAT EXCHANGER......................................................................................... 86 REMOVAL............................................................................................ 86 INSTALLATION....................................................................................... 87 REPAIR............................................................................................. 87 ENGINE..................................................................................................... 89 ENGINE................................................................................................. 89 REMOVAL............................................................................................ 89 INSTALLATION....................................................................................... 90 REPAIR............................................................................................. 92 AIR FILTRATION SYSTEM...................................................................................... 93 AIR CLEANER............................................................................................ 93 SERVICE CHECKS..................................................................................... 93 FILTER ELEMENT REPLACEMENT......................................................................... 93 MAIN FILTER ELEMENT.................................................................................... 93 REMOVAL............................................................................................ 93 INSTALLATION....................................................................................... 93 MAIN FILTER ELEMENT CLEANING....................................................................... 95 PRECLEANER SECTION................................................................................. 96 CLEANING PRECLEANER TUBES.......................................................................... 96 AIR INTAKE TROUBLESHOOTING......................................................................... 97 ENGINE COMPONENTS.......................................................................................... 99 FAN.................................................................................................... 99 REMOVAL............................................................................................ 99 INSTALLATION....................................................................................... 99 FAN BELT............................................................................................... 99 REPLACEMENT........................................................................................ 99 ADJUSTMENT.........................................................................................100 ALTERNATOR BELT ADJUSTMENT.............................................................................100 ELECTRIC SYSTEM (24 VDC. NON PROPULSION).......................................................................103 24VDC ELECTRICAL SUPPLY SYSTEM.............................................................................105 ELECTRICAL SYSTEM DESCRIPTION..........................................................................105 BATTERY................................................................................................105 SERVICE............................................................................................105 STORAGE............................................................................................105 MAINTENANCE AND TROUBLESHOOTING....................................................................106 SPILLAGE...........................................................................................107 BATTERY CHARGING ALTERNATOR............................................................................107 OPERATION..........................................................................................107 MAGNETIZING THE ROTOR..............................................................................109 REGULATOR ADJUSTMENT...............................................................................109 CIRCUIT CHECKOUT...................................................................................109 BATTERY CHARGING CIRCUIT COMPONENTS....................................................................109 BATTERY EQUALIZER......................................................................................110 PURPOSE............................................................................................110 TROUBLESHOOTING....................................................................................110 MONITOR............................................................................................111 ELECTRICAL SYSTEM COMPONENTS...............................................................................113 ELECTRICAL CIRCUIT CHECKOUT............................................................................113 HORN, WINDSHIELD WIPER, AND WINDSHIELD WASHER CIRCUITS.................................................113 WINDSHIELD WASHER CIRCUIT..............................................................................113 WINDSHIELD WIPER CIRCUIT CHECKOUT PROCEDURE........................................................113 BRAKE LOCK AND PARK BRAKE CIRCUIT......................................................................114 BRAKE LOCK SWITCH CIRCUIT..........................................................................114 BRAKE LOCK CHECKOUT................................................................................114 PARK BRAKE SWITCH AND CIRCUIT......................................................................114 PARK BRAKE CHECKOUT................................................................................114 LOW BRAKE PRESSURE SWITCH AND CIRCUIT..................................................................114 GAUGES AND CIRCUIT COMPONENTS..........................................................................114 CIRCUIT COMPONENTS.................................................................................115 LOW BRAKE PRESSURE WARNING AND INDICATOR LIGHT CIRCUITS................................................115 CIRCUIT COMPONENTS.................................................................................115 HOIST CONTROL CIRCUIT..................................................................................117 HOIST CONTROL SWITCH CIRCUIT CHECKOUT..............................................................117 BODY-UP LIMIT SWITCH...................................................................................117 BODY-UP LIMIT SWTICH CIRCUIT CHECKOUT..............................................................117 STEERING BLEEDDOWN TIMER CIRCUIT.......................................................................117 CIRCUIT COMPONENTS.................................................................................118 STEERING BLEEDDOWN CIRCUIT CHECKOUT................................................................118 ACCUMULATOR PRECHARGE CIRCUIT......................................................................118 LIGHT CIRCUIT..........................................................................................118 CIRCUIT COMPONENTS.................................................................................118 CIRCUIT CHECKOUT...................................................................................119 HEATER AND AIR CONDITIONER CIRCUIT.....................................................................119 CIRCUIT COMPONENTS.................................................................................119 CIRCUIT CHECKOUT...................................................................................119 24 VDC ELECTRIC START SYSTEM...............................................................................120 OPERATION..............................................................................................120 OPERATION..........................................................................................120 CRANKING MOTOR.....................................................................................120 REMOVAL........................................................................................120 INSTALLATION...................................................................................120 CRANKING MOTOR TROUBLESHOOTING.........................................................................121 PRELIMINARY INSPECTION.............................................................................121 NO-LOAD TEST.......................................................................................121 INTERPRETING RESULTS OF TESTS......................................................................121 DISASSEMBLY........................................................................................122 CLEANING AND INSPECTION............................................................................124 ARMATURE SERVICING.................................................................................124 FIELD COIL CHECKS..................................................................................124 FIELD COIL REMOVAL.................................................................................124 SOLENOID CHECKS....................................................................................125 ASSEMBLY...........................................................................................126 PINION CLEARANCE...................................................................................126 MAGNETIC SWITCH........................................................................................127 REMOVAL............................................................................................127 INSTALLATION.......................................................................................127 COIL TEST..........................................................................................127 ELECTRIC START SYSTEM WIRING DIAGRAMS......................................................................128 STARTER, ENGINE 24 VDC.....................................................................................129 CIRCUIT CHECK - OUT....................................................................................129 COMMERCIAL ELECTRONIC CONTROL (CEC)........................................................................131 ELECTRONIC THROTTLE PEDAL..............................................................................131 ADJUSTMENT.........................................................................................131 REMOVAL............................................................................................131 INSTALLATION.......................................................................................131 DISASSEMBLY........................................................................................132 ASSEMBLY...........................................................................................132 CEC SYSTEM OPERATION...................................................................................133 RANGE SELECTOR.....................................................................................133 "DO NOT SHIFT" LIGHT...............................................................................133 "CHECK TRANS" LIGHT................................................................................134 SYSTEM DESCRIPTION.....................................................................................134 TRANSMISSION CONTROL CIRCUITS..........................................................................135 BATTERY CHARGING CIRCUIT...........................................................................135 CONTROL POWER AND MEMORY CIRCUITS..................................................................136 START CIRCUIT......................................................................................136 CHECK TRANSMISSION WARNING LIGHT CIRCUIT...........................................................136 BACKUP HORN AND LIGHT CIRCUIT......................................................................136 HOIST INTERLOCK CIRCUIT............................................................................136 AUTO/MANUAL CIRCUIT................................................................................136 OVERSPEED RELAY CIRCUIT (NOT USED).................................................................136 SPEEDOMETER CIRCUIT................................................................................137 TRANSMISSION CIRCUIT COMPONENTS........................................................................138 CIRCUIT DESCRIPTION AND CHECKOUT.......................................................................139 CEC DIAGNOSTIC CODES...................................................................................142 TRANSMISSION AND PTO...........................................................................................143 TRANSMISSION...............................................................................................145 TRANSMISSION...........................................................................................145 TRANSMISSION REMOVAL...............................................................................145 TRANSMISSION INSTALLATION..........................................................................146 TRANSMISSION FILL INSTRUCTION......................................................................147 TRANSMISSION FILTER....................................................................................148 SERVICE............................................................................................148 TRANSMISSION OIL COOLER....................................................................................149 REMOVAL AND INSTALLATION...............................................................................149 REPAIR.................................................................................................149 POWER TAKE OFF (PTO).......................................................................................151 PTO GEAR BOX...........................................................................................151 REMOVAL............................................................................................151 INSTALLATION.......................................................................................151 DISASSEMBLY........................................................................................153 ASSEMBLY...........................................................................................153 DRIVELINES & U-JOINTS......................................................................................155 REMOVAL................................................................................................155 INSTALLATION...........................................................................................155 DISASSEMBLY............................................................................................155 ASSEMBLY...............................................................................................156 DRIVE AXLE, SPINDLES AND WHEELS................................................................................157 TIRES AND RIMS.............................................................................................159 TIRES AND RIMS.........................................................................................159 GENERAL INFORMATION................................................................................159 TIRE REMOVAL FROM RIM..............................................................................160 TIRE INSTALLATION ON RIM...........................................................................160 FRONT TIRES AND RIMS...................................................................................161 REMOVAL............................................................................................161 INSTALLATION.......................................................................................161 REAR TIRE AND RIM......................................................................................162 REMOVAL............................................................................................162 INSTALLATION.......................................................................................162 TIRE MATCHING..........................................................................................163 FRONT WHEEL HUB AND SPINDLES...............................................................................165 FRONT WHEEL HUB........................................................................................165 REMOVAL............................................................................................165 FRONT WHEEL BEARING AND BRAKE DISC REPLACEMENT.....................................................166 FRONT WHEEL HUB INSTALLATION AND BEARING ADJUSTMENT................................................166 FRONT WHEEL SPINDLE REMOVAL........................................................................167 FRONT WHEEL SPINDLE INSTALLATION...................................................................168 STEERING LINKAGE REMOVAL...........................................................................169 STEERING LINKAGE BALL STUD AND BEARING REMOVAL.....................................................169 FRONT WHEEL TOE-IN ADJUSTMENT......................................................................170 BIAS PLY TIRES.................................................................................170 RADIAL TIRES...................................................................................170 FINAL DRIVE ATTACHMENTS....................................................................................171 FINAL DRIVE ANCHOR.....................................................................................171 PIN REMOVAL........................................................................................171 PIN INSTALLATION...................................................................................172 BEARING REMOVAL AND INSPECTION.....................................................................172 BEARING INSTALLATION...............................................................................172 PANHARD ROD............................................................................................172 REMOVAL............................................................................................172 INSTALLATION.......................................................................................172 BEARING REPLACEMENT................................................................................173 FINAL DRIVE ASSEMBLY.......................................................................................175 COMPLETE FINAL DRIVE ASSEMBLY..........................................................................175 REMOVAL............................................................................................175 INSTALLATION.......................................................................................176 DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH COMPLETE FINAL DRIVE ASSEMBLY REMOVED FROM UNDER TRUCK....177 REMOVAL............................................................................................177 INSTALLATION.......................................................................................178 DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH FINAL DRIVE IN PLACE UNDER TRUCK..........................179 REMOVAL............................................................................................179 INSTALLATION.......................................................................................180 DIFFERENTIAL CAGE REMOVAL..........................................................................181 PINION REMOVAL.....................................................................................181 DIFFERENTIAL CAGE DISASSEMBLY......................................................................181 SPIDER GEAR BEARING REMOVAL........................................................................182 CLEANING AND INSPECTION............................................................................183 SPIDER GEAR BEARING INSTALLATION...................................................................183 DIFFERENTIAL CAGE ASSEMBLY.........................................................................183 PINION INSTALLATION AND BEARING ADJUSTMENT.........................................................184 DIFFERENTIAL CAGE INSTALLATION.....................................................................185 CARRIER BEARING AND BACKLASH ADJUSTMENT............................................................186 FINAL DRIVE PLANETARIES AND WHEEL HUBS.....................................................................187 PLANETARY DRIVE........................................................................................187 PLANETARY DRIVE REMOVAL............................................................................187 PLANETARY REACTOR AND RING GEAR REMOVAL............................................................188 PLANETARY REACTOR AND RING GEAR INSTALLATION.......................................................188 CLEANING AND INSPECTION............................................................................189 PLANETARY DRIVE INSTALLATION.......................................................................189 PLANETARY CARRIER DISASSEMBLY......................................................................189 PLANETARY CARRIER ASSEMBLY.........................................................................190 WHEEL HUB AND BEARINGS.................................................................................190 REMOVAL............................................................................................190 BEARING REPLACEMENT................................................................................190 INSTALLATION.......................................................................................191 HYDRAIR SUSPENSIONS............................................................................................195 FRONT SUSPENSIONS..........................................................................................197 FRONT SUSPENSIONS......................................................................................197 REMOVAL............................................................................................197 INSTALLATION.......................................................................................198 DISASSEMBLY........................................................................................199 INSPECTION.........................................................................................199 ASSEMBLY...........................................................................................200 REAR SUSPENSIONS...........................................................................................201 REAR SUSPENSIONS.......................................................................................201 REMOVAL............................................................................................201 INSTALLATION.......................................................................................202 DISASSEMBLY........................................................................................202 ASSEMBLY...........................................................................................203 REAR SUSPENSION SPHERICAL BEARING REPAIR...............................................................204 DISASSEMBLY........................................................................................204 INSPECTION.........................................................................................204 ASSEMBLY...........................................................................................204 OIL AND CHARGING PROCEDURES................................................................................205 GENERAL................................................................................................205 EQUIPMENT LIST.........................................................................................205 HYDRAIR SERVICE KIT....................................................................................205 INSTALLATION OF CHARGING KIT.......................................................................205 REMOVAL OF CHARGING KIT............................................................................206 SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................206 FRONT SUSPENSION.......................................................................................206 FRONT SUSPENSION OILING............................................................................206 FRONT SUSPENSION NITROGEN CHARGING.................................................................207 REAR SUSPENSION........................................................................................208 REAR SUSPENSION OILING.............................................................................208 REAR SUSPENSION NITROGEN CHARGING..................................................................209 OIL AND NITROGEN SPECIFICATIONS CHART..................................................................210 BRAKE CIRCUIT..................................................................................................211 BRAKE CIRCUIT..............................................................................................213 CIRCUIT OPERATION......................................................................................213 CHARGING...........................................................................................213 MANUAL APPLICATION.................................................................................214 HYDRAULIC OIL MANIFOLD.................................................................................214 BRAKE ACCUMULATORS.....................................................................................214 ACCUMULATOR PRECHARGE..................................................................................214 LOW-PRESSURE BRAKE DETECTION MODULE....................................................................214 LOW-PRESSURE SENSING SHUTTLE VALVE.................................................................214 BRAKE ACCUMULATOR PRESSURE CHECKS..................................................................214 ACCUMULATOR SHUTTLE VALVE..........................................................................215 ACCUMULATOR DISCHARGE VALVES (BLEEDDOWN VALVES)....................................................215 EMERGENCY APPLY VALVE..............................................................................215 BRAKE PRESSURE WARNING SWITCH......................................................................215 BRAKE MANIFOLD.........................................................................................215 BRAKE LOCK SHUTTLE VALVE...........................................................................215 BRAKE LOCK SOLENOID VALVE..........................................................................216 BRAKE MANIFOLD SHUTTLE VALVE.......................................................................216 STEERING BLEEDDOWN SOLENOID VALVE..................................................................216 STEERING ACCUMULATOR PRESSURE CHECK................................................................216 SERVICE BRAKE TREADLE VALVE............................................................................216 RETARDER TREADLE VALVE.................................................................................216 SERVICE BRAKE/RETARDER SHUTTLE VALVE...................................................................217 STOP LIGHT MANIFOLD AND TEE............................................................................217 REAR BRAKE SHUTTLE VALVES..............................................................................217 WET DISC BRAKE ASSEMBLY................................................................................217 BRAKE CIRCUIT COMPONENT SERVICE............................................................................219 LOW PRESSURE BRAKE DETECTION MODULE....................................................................219 BRAKE MANIFOLD.........................................................................................219 BRAKE ACCUMULATOR REPAIR...............................................................................220 SERVICE BRAKE TREADLE VALVE REPAIR.....................................................................220 REMOVAL............................................................................................220 INSTALLATION.......................................................................................221 DISASSEMBLY OF TREADLE VALVE ASSEMBLY..............................................................221 REMOVAL OF BRAKE MANIFOLD......................................................................221 BRAKE VALVE DISASSEMBLY........................................................................223 ASSEMBLY OF TREADLE VALVE ASSEMBLY.................................................................223 BRAKE VALVE ASSEMBLY...........................................................................223 INSTALLATION OF BRAKE MANIFOLD.................................................................225 ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE...........................................................225 BRAKE PEDAL ADJUSTMENT.............................................................................227 SERVICE BRAKE TREADLE PEDAL............................................................................228 PEDAL DISASSEMBLY..................................................................................228 PEDAL ASSEMBLY.....................................................................................228 RETARDER TREADLE VALVE.................................................................................229 REMOVAL............................................................................................229 INSTALLATION.......................................................................................229 DISASSEMBLY........................................................................................229 ASSEMBLY...........................................................................................231 RETARDER TREADLE PEDAL DISASSEMBLY.................................................................232 RETARDER TREADLE PEDAL ASSEMBLY....................................................................232 BRAKE CIRCUIT CHECKOUT PROCEDURE...........................................................................233 CIRCUIT TRACKING.......................................................................................233 INITIAL SYSTEM SET-UP..................................................................................234 CHECK OF BRAKE CIRCUIT SHUTTLE VALVES..................................................................237 BRAKE SYSTEM CHECKOUT..................................................................................241 FAILURE MODE CHECKOUT..................................................................................234 BRAKE VALVE LEAKAGE....................................................................................234 TROUBLESHOOTING........................................................................................237 CHECKOUT DATA SHEET....................................................................................241 FRONT WHEEL SPEED DISC BRAKES..............................................................................243 LINING REPLACEMENT.....................................................................................243 LINING REPLACEMENT ON TRUCK........................................................................243 BRAKE CALIPER REPAIR...................................................................................244 REMOVAL............................................................................................244 INSTALLATION.......................................................................................244 PISTON AND SEAL REMOVAL............................................................................244 PISTON AND SEAL INSTALLATION.......................................................................245 BRAKE CALIPER BENCH TEST...............................................................................245 FRONT BRAKE BLEEDING PROCEDURE.........................................................................246 FRONT SERVICE BRAKE BURNISHING PROCEDURE...............................................................246 REAR WET DISC BRAKE ASSEMBLY...............................................................................249 WET DISC BRAKE ASSEMBLY................................................................................249 REMOVAL............................................................................................249 INSTALLATION.......................................................................................250 WET DISC BRAKE DISASSEMBLY.........................................................................251 BRAKE PISTON DISASSEMBLY...........................................................................254 BRAKE PISTON INSPECTION............................................................................254 BRAKE PISTON ASSEMBLY..............................................................................254 FLOATING RING SEAL ASSEMBLY/INSTALLATION...........................................................255 WET DISC BRAKE ASSEMBLY............................................................................259 REAR WET DISC BRAKE BLEEDING PROCEDURE.................................................................261 REAR BRAKE DISC WEAR INDICATOR.........................................................................262 REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER.....................................................262 PARK BRAKE.................................................................................................263 PARKING BRAKE..........................................................................................263 REMOVAL/INSTALLATION...............................................................................263 PARK BRAKE LINING ADJUSTMENT.......................................................................263 PARK BRAKE LINKAGE ADJUSTMENT......................................................................263 PARK BRAKE ACTUATOR ASSEMBLY REPAIR....................................................................264 REMOVAL............................................................................................264 INSTALLATION.......................................................................................264 DISASSEMBLY........................................................................................265 ASSEMBLY...........................................................................................265 ACTUATOR SPRING POD DISASSEMBLY....................................................................265 ACTUATOR SPRING POD ASSEMBLY.......................................................................266 PARK BRAKE BURNISHING..................................................................................266 HYDRAULIC SYSTEM...............................................................................................267 HYDRAULIC SYSTEM...........................................................................................269 HYDRAULIC SYSTEM DESCRIPTION...........................................................................269 HYDRAULIC SYSTEM COMPONENT REPAIR..........................................................................273 TANDEM HYDRAULIC PUMP..................................................................................273 REMOVAL............................................................................................273 REMOVAL........................................................................................273 INSTALLATION...................................................................................273 PUMP DISASSEMBLY...................................................................................274 PUMP ASSEMBLY......................................................................................276 CARTRIDGE DISASSEMBLY..............................................................................277 INSPECTION.....................................................................................277 CARTRIDGE ASSEMBLY.................................................................................279 HYDRAULIC TANK.........................................................................................281 FILLING INSTRUCTIONS...............................................................................281 REMOVAL........................................................................................281 INSTALLATION...................................................................................282 HYDRAULIC TANK RELIEF CHECK VALVE......................................................................282 HYDRAULIC TANK BREATHER................................................................................283 HYDRAULIC FILTERS......................................................................................283 REMOVAL............................................................................................284 REMOVAL........................................................................................284 INSTALLATION...................................................................................284 DIFFERENTIAL PRESSURE SWITCH TESTING...............................................................285 TEST PROCEDURES................................................................................285 STEERING CIRCUIT...........................................................................................287 STEERING CIRCUIT OPERATION.............................................................................287 STEERING CIRCUIT COMPONENT DESCRIPTION.................................................................287 STEERING CONTROL VALVE.....................................................................................291 REMOVAL................................................................................................291 INSTALLATION...........................................................................................291 DISASSEMBLY............................................................................................292 CLEANING AND INSPECTION................................................................................295 ASSEMBLY...............................................................................................295 ALTERNATE METHOD.......................................................................................295 STEERING CIRCUIT COMPONENT REPAIR..........................................................................299 ACCUMULATORS...........................................................................................299 REMOVAL............................................................................................299 INSTALLATION.......................................................................................300 DISASSEMBLY........................................................................................300 CLEANING AND INSPECTION............................................................................300 ASSEMBLY...........................................................................................300 LOW PRESSURE ACCUMULATOR PRESSURE SWITCH...............................................................301 ACCUMULATOR CHARGING PROCEDURE.........................................................................302 INLINE FILTERS.........................................................................................303 SERVICE............................................................................................303 STEERING CYLINDERS.....................................................................................304 DISASSEMBLY........................................................................................304 ASSEMBLY...........................................................................................304 BRAKE/STEERING PUMP REPAIR.............................................................................305 BRAKE/STEERING PUMP REPAIR.........................................................................305 REMOVAL........................................................................................305 INSTALLATION...................................................................................305 SHAFT SEAL REPLACEMENT.............................................................................306 PUMP DISASSEMBLY...............................................................................308 PUMP ASSEMBLY..................................................................................312 CONTROL (COMPENSATOR) VALVE........................................................................314 HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION..........................................................317 CIRCUIT OPERATION......................................................................................317 HOIST VALVE........................................................................................317 AUXILIARY MANIFOLD.................................................................................318 COUNTER-BALANCE VALVE..............................................................................318 HOIST CYLINDERS....................................................................................318 CHECK VALVES.......................................................................................318 HOIST CIRCUIT COMPONENT REPAIR.............................................................................319 HOIST VALVE............................................................................................319 REMOVAL............................................................................................319 INSTALLATION.......................................................................................319 DISASSEMBLY........................................................................................320 ASSEMBLY...........................................................................................321 HOIST CYLINDER.........................................................................................322 REMOVAL............................................................................................322 INSTALLATION.......................................................................................322 DISASSEMBLY........................................................................................324 CLEANING AND INSPECTION............................................................................324 ASSEMBLY...........................................................................................324 HOIST CYLINDER MOUNTING BEARING REPLACEMENT........................................................324 HYDRAULIC CHECK-OUT PROCEDURE..............................................................................325 GENERAL INFORMATION....................................................................................325 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................325 INITIAL SYSTEM-SET UP..................................................................................325 ACCUMULATOR AND BRAKE/STEERING PUMP CHECKS.........................................................325 STEERING VALVE LEAKAGE CHECK.......................................................................327 STEERING CYLINDER LEAKAGE CHECK....................................................................327 TROUBLESHOOTING CHART (STEERING SYSTEM)................................................................328 HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE..........................................................330 AUXILIARY VALVE....................................................................................330 PRESSURE CHECK.................................................................................330 LEAKAGE CHECK..................................................................................330 CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE..........................................331 CHECKING AND ADJUSTING "POWER DOWN" PRESSURE.......................................................331 TROUBLESHOOTING CHART (HOIST SYSTEM).......................................................................332 STEERING SYSTEM DATA SHEET.................................................................................335 HOIST SYSTEM DATA SHEET....................................................................................336 HYDRAULIC SYSTEM FLUSHING PROCEDURE........................................................................337 OPTIONS AND SPECIAL TOOLS......................................................................................339 LINCOLN AUTOMATIC LUBRICATION SYSTEM.......................................................................341 QUICK FUEL SYSTEMS.........................................................................................349 WIGGINS QUICK FILL FUEL SYSTEM.........................................................................349 BUCKEYE QUICK FUEL SYSTEM..............................................................................353 KIM "HOTSTART SYSTEM"......................................................................................355 SPECIAL TOOLS..............................................................................................359 AIR CONDITIONING SYSTEM....................................................................................377 PRINCIPLES OF REFRIGERATION............................................................................378 AIR CONDITIONER SYSTEM COMPONENTS......................................................................380 ELECTRICAL CIRCUIT.....................................................................................382 SYSTEM SERVICING.......................................................................................383 INSTALLING MANIFOLD GAUGE SET......................................................................387 SYSTEM STABILIZATION...............................................................................389 ADDING R-12 (PRIOR TO PERFORMANCE TEST)............................................................389 SYSTEM PERFORMANCE TEST............................................................................391 DISCHARGING SYSTEM.................................................................................390 FLUSHING AIR CONDITIONER COMPONENTS................................................................388 SYSTEM REPAIR..........................................................................................392 HOSES, FITTINGS AND LINES..........................................................................392 EXPANSION VALVE....................................................................................392 RECEIVER DRIER.....................................................................................393 THERMOSTAT.........................................................................................393 CLUTCH.............................................................................................393 COMPRESSOR.........................................................................................393 CHECKING COMPRESSOR OIL LEVEL..........................................................................393 EVACUATING THE SYSTEM..................................................................................394 CHARGING THE SYSTEM....................................................................................390 TROUBLESHOOTING........................................................................................395 PREPARING FOR DIAGNOSIS............................................................................395 TROUBLESHOOTING CHART..................................................................................397 OPERATOR'S CAB.................................................................................................405 TRUCK CAB..................................................................................................407 REMOVAL................................................................................................407 INSTALLATION...........................................................................................410 OPERATOR COMFORT...........................................................................................413 OPERATOR SEAT..........................................................................................413 ADJUSTMENT INSTRUCTIONS............................................................................413 REMOVAL............................................................................................413 INSTALLATION.......................................................................................413 DISASSEMBLY........................................................................................414 INSPECTION.........................................................................................414 ASSEMBLY...........................................................................................414 HEATER/AIR CONDITIONER.................................................................................416 WATER CONTROL VALVE................................................................................416 HEATER/AIR CONDITIONER ............................................................................416 REMOVAL........................................................................................416 INSTALLATION...................................................................................418 OPERATOR CONTROLS AND INSTRUMENT PANEL.....................................................................421 OPERATOR CONTROLS......................................................................................421 INSTRUMENT PANEL.......................................................................................426 RETARDER OPERATION.................................................................................428 INSTRUMENT PANEL (RIGHT SIDE)..........................................................................429 CUMMINS ENGINE ELECTRONIC CONTROL SYSTEM...............................................................430 HEATER/AIR CONDITIONER CONTROLS........................................................................436 LUBRICATION AND SERVICE........................................................................................437 LUBRICATION AND SERVICE....................................................................................439 LUBRICATION SPECIFICATION CHARTS...........................................................................439 SERVICE CAPACITIES.....................................................................................439 ANTI-FREEZE SPECIFICATIONS.............................................................................439 OIL & GREASE SPECIFICATIONS............................................................................440 10 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................441 100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................443 250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................445 1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................447 5000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................449 ALPHABETICAL INDEX.............................................................................................451 SYSTEM SCHEMATICS..............................................................................................455 ELECTRIC SCHEMATIC.........................................................................................457 HYDRAULIC SYSTEM SCHEMATIC.................................................................................469 ALLISON TRANSMISSION - HYDRAULIC SCHEMATIC.................................................................472
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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