Komatsu Dump Truck 210M Shop Manual – PDF DOWNLOAD

Description

Komatsu Dump Truck 210M Shop Manual

TABLE OF CONTENTS:

Komatsu Dump Truck 210M 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
		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....................................................................................... 91
			REPAIR............................................................................................. 93
	AIR FILTRATION SYSTEM...................................................................................... 95
		AIR CLEANER............................................................................................ 95
			SERVICE CHECKS..................................................................................... 95
			FILTER ELEMENT REPLACEMENT......................................................................... 95
		MAIN FILTER ELEMENT.................................................................................... 95
			REMOVAL............................................................................................ 95
			INSTALLATION....................................................................................... 95
			MAIN FILTER ELEMENT CLEANING....................................................................... 97
			PRECLEANER SECTION................................................................................. 98
			CLEANING PRECLEANING TUBES......................................................................... 98
			AIR INTAKE TROUBLESHOOTING......................................................................... 99
	ENGINE COMPONENTS..........................................................................................101
		THROTTLE CONTROL.......................................................................................101
		THROTTLE CONTROL PEDAL.................................................................................101
			REMOVAL AND INSTALLATION...........................................................................101
		THROTTLE CONTROL LEVER.................................................................................101
			THROTTLE CONTROL ADJUSTMENT........................................................................103
		ATEC THROTTLE POSITION SENSOR..........................................................................104
			THROTTLE POSITION SENSOR AND CABLE.................................................................104
			REMOVAL............................................................................................104
			INSTALLATION.......................................................................................105
		FAN....................................................................................................105
			REMOVAL............................................................................................105
			INSTALLATION.......................................................................................105
		FAN BELT ADJUSTMENT....................................................................................105
		ALTERNATOR BELT ADJUSTMENT.............................................................................106
ELECTRIC SYSTEM (24 VDC. NON-PROPULSION).......................................................................107
	24 VDC ELECTRIC SUPPLY SYSTEM..............................................................................109
		ELECTRICAL SYSTEM DESCRIPTION..........................................................................109
		BATTERY................................................................................................109
			SERVICE............................................................................................109
			STORAGE............................................................................................109
			MAINTENANCE AND TROUBLESHOOTING....................................................................110
			SPILLAGE...........................................................................................111
		BATTERY CHARGING ALTERNATOR............................................................................111
			OPERATION..........................................................................................111
			MAGNETIZING THE ROTOR..............................................................................113
			REGULATOR ADJUSTMENT...............................................................................113
			CIRCUIT CHECKOUT...................................................................................113
		BATTERY CHARGING CIRCUIT COMPONENTS....................................................................113
		BATTERY EQUALIZER......................................................................................114
			PURPOSE............................................................................................114
			TROUBLESHOOTING....................................................................................114
			MONITOR............................................................................................115
	ELECTRICAL SYSTEM COMPONENTS...............................................................................117
		ELECTRICAL CIRCUIT CHECKOUT............................................................................117
		HORN, WINDSHIELD WIPER AND WINDSHIELD WASHER CIRCUITS..................................................117
		WINDSHIELD WASHER CIRCUIT..............................................................................117
			WINDSHIELD WIPER CIRCUIT CHECKOUT PROCEDURE........................................................117
		BRAKE LOCK AND PARK BRAKE CIRCUITS.....................................................................118
			BRAKE LOCK SWITCH CIRCUIT..........................................................................118
			BRAKE LOCK CHECKOUT................................................................................118
			PARK BRAKE SWITCH AND CIRCUIT......................................................................118
			PARK BRAKE CHECKOUT................................................................................118
		LOW BRAKE PRESSURE SWITCH AND CIRCUIT..................................................................118
		GAUGES AND CIRCUIT COMPONENTS..........................................................................118
			CIRCUIT COMPONENTS.................................................................................118
		LOW BRAKE PRESSURE WARNING AND INDICATOR LIGHT CIRCUITS................................................119
			CIRCUIT COMPONENTS.................................................................................119
		HOIST CONTROL CIRCUIT..................................................................................121
			HOIST CONTROL SWITCH CIRCUIT CHECKOUT..............................................................121
		BODY-UP LIMIT SWITCH...................................................................................121
			BODY-UP LIMIT SWITCH CIRCUIT CHECKOUT..............................................................121
		STEERING BLEEDDOWN TIMER CIRCUIT.......................................................................121
			CIRCUIT COMPONENTS.................................................................................122
			STEERING BLEEDDOWN CIRCUIT CHECKOUT................................................................122
			ACCUMULATOR PRECHARGE CIRCUIT......................................................................122
		LIGHT CIRCUIT..........................................................................................122
			CIRCUIT COMPONENTS.................................................................................122
			CIRCUIT CHECKOUT...................................................................................123
		HEATER AND AIR CONDITIONER CIRCUIT.....................................................................123
			CIRCUIT COMPONENTS.................................................................................123
			CIRCUIT CHECKOUT...................................................................................123
	24 VDC ELECTRIC START SYSTEM...............................................................................124
		24 VDC ELECTRIC START SYSTEM...........................................................................124
			OPERATION..........................................................................................124
			CRANKING MOTOR.....................................................................................124
				REMOVAL........................................................................................124
				INSTALLATION...................................................................................124
		CRANKING MOTOR TROUBLESHOOTING.........................................................................125
			PRELIMINARY INSPECTION.............................................................................125
			NO-LOAD TEST.......................................................................................125
			INTERPRETING RESULTS OF TESTS......................................................................125
			DISASSEMBLY........................................................................................126
			CLEANING AND INSPECTION............................................................................128
			ARMATURE SERVICING.................................................................................128
			FIELD COIL CHECKS..................................................................................128
			FIELD COIL REMOVAL.................................................................................128
			SOLENOID CHECKS....................................................................................129
			ASSEMBLY...........................................................................................130
			PINION CLEARANCE...................................................................................130
		MAGNETIC SWITCH........................................................................................131
			REMOVAL............................................................................................131
			INSTALLATION.......................................................................................131
			COIL TEST..........................................................................................131
	ELECTRIC START SYSTEM WIRING DIAGRAMS......................................................................132
	STARTER, ENGINE 24 VDC.....................................................................................133
		CIRCUIT CHECK-OUT......................................................................................133
	ALLISON TRANSMISSION ELECTRONIC CONTROL (ATEC).............................................................135
		ATEC SYSTEM OPERATION..................................................................................135
			RANGE SELECTOR.....................................................................................135
			"DO NOT SHIFT" LIGHT...............................................................................135
			"CHECK TRANS" LIGHT................................................................................135
		SYSTEM DESCRIPTION.....................................................................................136
		TRANSMISSION CONTROL CIRCUITS..........................................................................137
			BATTERY CHARGING CIRCUIT...........................................................................137
			CONTROL POWER AND MEMORY CIRCUITS..................................................................139
			START CIRCUIT......................................................................................139
			CHECK TRANSMISSION WARNING LIGHT CIRCUIT...........................................................139
			BACKUP HORN AND LIGHT CIRCUIT......................................................................139
			HOIST INTERLOCK CIRCUIT............................................................................139
			AUTO/MANUAL CIRCUIT................................................................................139
			OVERSPEED RELAY CIRCUIT (NOT USED).................................................................139
			SPEEDOMETER CIRCUIT................................................................................139
		TRANSMISSION CIRCUIT COMPONENTS........................................................................140
		CIRCUIT DESCRIPTION AND CHECKOUT.......................................................................141
		ATEC DIAGNOSTIC CODES..................................................................................144
TRANSMISSION AND PTO...........................................................................................145
	TRANSMISSION...............................................................................................147
		TRANSMISSION...........................................................................................147
			TRANSMISSION REMOVAL...............................................................................147
			TRANSMISSION INSTALLATION..........................................................................148
			TRANSMISSION FILL INSTRUCTIONS.....................................................................149
		TRANSMISSION FILTER....................................................................................150
			SERVICE............................................................................................150
	TRANSMISSION OIL COOLER....................................................................................151
		REMOVAL AND INSTALLATION...............................................................................151
		REPAIR.................................................................................................151
	POWER TAKE OFF (PTO).......................................................................................153
		PTO GEARBOX............................................................................................153
			REMOVAL............................................................................................153
			INSTALLATION.......................................................................................153
			DISASSEMBLY........................................................................................154
			ASSEMBLY...........................................................................................155
	DRIVELINES.................................................................................................157
		REMOVAL................................................................................................157
		INSTALLATION...........................................................................................157
		DISASSEMBLY............................................................................................157
		ASSEMBLY...............................................................................................158
DRIVE AXLE, SPINDLES AND WHEELS................................................................................159
	TIRES AND RIMS.............................................................................................161
		TIRES AND RIMS.........................................................................................161
			GENERAL INFORMATION................................................................................161
			TIRE REMOVAL FROM RIM..............................................................................162
			TIRE INSTALLATION ON RIM...........................................................................162
		FRONT TIRES AND RIMS...................................................................................163
			REMOVAL............................................................................................163
			INSTALLATION.......................................................................................163
		REAR TIRE AND RIM......................................................................................164
			REMOVAL............................................................................................164
			INSTALLATION.......................................................................................164
		TIRE MATCHING..........................................................................................165
	FRONT WHEEL HUB AND SPINDLES...............................................................................167
		FRONT WHEEL HUB........................................................................................167
			REMOVAL............................................................................................167
			FRONT WHEEL BEARING AND BRAKE DISC REPLACEMENT.....................................................168
			FRONT WHEEL HUB INSTALLATION AND BEARING ADJUSTMENT................................................168
			FRONT WHEEL SPINDLE REMOVAL........................................................................169
			FRONT WHEEL SPINDLE INSTALLATION...................................................................170
			STEERING LINKAGE REMOVAL...........................................................................171
			STEERING LINKAGE BALL STUD AND BEARING REMOVAL.....................................................171
			FRONT WHEEL TOE-IN ADJUSTMENT......................................................................172
				BIAS PLY TIRES.................................................................................172
				RADIAL TIRES...................................................................................172
	FINAL DRIVE ATTACHMENTS....................................................................................173
		FINAL DRIVE ANCHOR.....................................................................................173
			PIN REMOVAL........................................................................................173
			PIN INSTALLATION...................................................................................174
			BEARING REMOVAL AND INSPECTION.....................................................................174
			BEARING INSTALLATION...............................................................................174
		PANHARD ROD............................................................................................174
			REMOVAL............................................................................................174
			INSTALLATION.......................................................................................174
			BEARING REPLACEMENT................................................................................175
	FINAL DRIVE ASSEMBLY.......................................................................................177
		COMPLETE FINAL DRIVE ASSEMBLY..........................................................................177
			REMOVAL............................................................................................177
			INSTALLATION.......................................................................................178
		DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH COMPLETE FINAL DRIVE ASSEMBLY REMOVED FROM UNDER TRUCK....179
			REMOVAL............................................................................................179
			INSTALLATION.......................................................................................180
		DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH FINAL DRIVE IN PLACE UNDER TRUCK..........................181
			REMOVAL............................................................................................181
			INSTALLATION.......................................................................................182
			DIFFERENTIAL CAGE REMOVAL..........................................................................183
			PINION REMOVAL.....................................................................................183
			DIFFERENTIAL CAGE DISASSEMBLY......................................................................183
			SPIDER GEAR BEARING REMOVAL........................................................................184
			CLEANING AND INSPECTION............................................................................185
			SPIDER GEAR BEARING INSTALLATION...................................................................185
			DIFFERENTIAL CAGE ASSEMBLY.........................................................................185
			PINION INSTALLATION AND BEARING ADJUSTMENT.........................................................186
			DIFFERENTIAL CAGE INSTALLATION.....................................................................187
			CARRIER BEARING AND BACKLASH ADJUSTMENT............................................................188
	FINAL DRIVE PLANETARIES AND WHEEL HUBS.....................................................................189
		PLANETARY DRIVE........................................................................................189
		PLANETARY DRIVE REMOVAL................................................................................189
		PLANETARY REACTOR AND RING GEAR REMOVAL................................................................190
		PLANETARY REACTOR AND RING GEAR INSTALLATION...........................................................190
		CLEANING AND INSPECTION................................................................................191
		PLANETARY DRIVE INSTALLATION...........................................................................191
		PLANETARY CARRIER DISASSEMBLY..........................................................................191
		PLANETARY CARRIER ASSEMBLY.............................................................................192
	WHEEL HUB AND BEARINGS.....................................................................................192
		REMOVAL................................................................................................192
		BEARING REPLACEMENT....................................................................................192
		INSTALLATION...........................................................................................193
HYDRAIR SUSPENSIONS............................................................................................197
	FRONT SUSPENSIONS..........................................................................................199
		REMOVAL................................................................................................199
		INSTALLATION...........................................................................................200
		DISASSEMBLY............................................................................................201
		INSPECTION.............................................................................................201
		ASSEMBLY...............................................................................................202
	REAR SUSPENSION............................................................................................203
		REAR SUSPENSIONS.......................................................................................203
			REMOVAL............................................................................................203
			INSTALLATION.......................................................................................204
			DISASSEMBLY........................................................................................204
			ASSEMBLY...........................................................................................205
		REAR SUSPENSION SPHERICAL BEARING REPAIR...............................................................206
			DISASSEMBLY........................................................................................206
			INSPECTION.........................................................................................206
			ASSEMBLY...........................................................................................206
	OILING AND CHARGING PROCEDURES.............................................................................207
		GENERAL................................................................................................207
		EQUIPMENT LIST.........................................................................................207
		HYDRAIR SERVICE KIT....................................................................................207
			INSTALLATION OF CHARGING KIT.......................................................................207
			REMOVAL OF CHARGING KIT............................................................................208
		SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS......................................................208
		FRONT SUSPENSION.......................................................................................208
			FRONT SUSPENSION OILING............................................................................208
			FRONT SUSPENSION NITROGEN CHARGING.................................................................209
		REAR SUSPENSION........................................................................................210
			REAR SUSPENSION OILING.............................................................................210
			REAR SUSPENSION NITROGEN CHARGING..................................................................211
		OIL AND NITROGEN SPECIFICATIONS CHART..................................................................212
BRAKE CIRCUIT..................................................................................................213
	BRAKE CIRCUIT..............................................................................................215
		CIRCUIT OPERATION......................................................................................215
			CHARGING...........................................................................................215
			MANUAL APPLICATION.................................................................................216
		HYDRAULIC OIL MANIFOLD.................................................................................216
		BRAKE ACCUMULATORS.....................................................................................216
		ACCUMULATOR PRECHARGE..................................................................................216
		LOW-PRESSURE BRAKE DETECTION MODULE....................................................................216
			LOW-PRESSURE SENSING SHUTTLE VALVE.................................................................216
			BRAKE ACCUMULATOR PRESSURE CHECKS..................................................................216
			ACCUMULATOR SHUTTLE VALVE..........................................................................217
			ACCUMULATOR DISCHARGE VALVES (BLEEDDOWN VALVES)....................................................217
			EMERGENCY APPLY VALVE..............................................................................217
			BRAKE PRESSURE WARNING SWITCH......................................................................217
		BRAKE MANIFOLD.........................................................................................217
			BRAKE LOCK SHUTTLE VALVE...........................................................................217
			BRAKE LOCK SOLENOID VALVE..........................................................................218
			BRAKE MANIFOLD SHUTTLE VALVE.......................................................................218
			STEERING BLEEDDOWN SOLENOID VALVE..................................................................218
			STEERING ACCUMULATOR PRESSURE CHECK................................................................218
		SERVICE BRAKE TREADLE VALVE............................................................................218
		RETARDER TREADLE VALVE.................................................................................218
		SERVICE BRAKE/RETARDER SHUTTLE VALVE...................................................................219
		STOP LIGHT MANIFOLD AND TEE............................................................................219
		REAR BRAKE SHUTTLE VALVE...............................................................................219
		WET DISC BRAKE ASSEMBLY................................................................................219
	BRAKE CIRCUIT COMPONENT SERVICE............................................................................221
		LOW PRESSURE BRAKE DETECTION MODULE....................................................................221
		BRAKE MANIFOLD.........................................................................................221
		BRAKE ACCUMULATOR REPAIR...............................................................................222
		SERVICE BRAKE TREADLE VALVE............................................................................222
			REMOVAL............................................................................................222
			INSTALLATION.......................................................................................223
			DISASSEMBLY OF TREADLE VALVE ASSEMBLY..............................................................223
				REMOVAL OF BRAKE MANIFOLD......................................................................223
				BRAKE VALVE DISASSEMBLY........................................................................225
			ASSEMBLY OF TREADLE VALVE ASSEMBLY.................................................................225
				BRAKE VALVE ASSEMBLY...........................................................................225
				INSTALLATION OF BRAKE MANIFOLD.................................................................227
			ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE...........................................................227
			BRAKE PEDAL ADJUSTMENT.............................................................................229
		SERVICE BRAKE TREADLE PEDAL............................................................................230
			PEDAL DISASSEMBLY..................................................................................230
			PEDAL ASSEMBLY.....................................................................................230
		RETARDER TREADLE VALVE.................................................................................231
			REMOVAL............................................................................................231
			INSTALLATION.......................................................................................231
			DISASSEMBLY........................................................................................231
			ASSEMBLY...........................................................................................233
			RETARDER TREADLE PEDAL DISASSEMBLY.................................................................234
			RETARDER TREADLE PEDAL ASSEMBLY....................................................................234
	BRAKE CIRCUIT CHECKOUT PROCEDURE...........................................................................235
		CIRCUIT TRACKING.......................................................................................235
		INITIAL SYSTEM SET-UP..................................................................................236
		CHECK OF BRAKE CIRCUIT SHUTTLE VALVES..................................................................236
		BRAKE SYSTEM CHECKOUT..................................................................................237
		FAILURE MODE CHECKOUT..................................................................................237
		BRAKE VALVE LEAKAGE....................................................................................236
		TROUBLESHOOTING........................................................................................239
		CHECKOUT DATA SHEET....................................................................................243
	FRONT WHEEL SPEED DISC BRAKES..............................................................................245
		FRONT WHEEL SPEED DISC BRAKES..........................................................................245
			LINING REPLACEMENT ON TRUCK........................................................................245
		BRAKE CALIPER REPAIR...................................................................................246
			REMOVAL............................................................................................246
			INSTALLATION.......................................................................................246
			PISTON AND SEAL REMOVAL............................................................................246
			PISTON AND SEAL INSTALLATION.......................................................................247
		BRAKE CALIPER BENCH TEST...............................................................................247
		FRONT BRAKE BLEEDING PROCEDURE.........................................................................248
		FRONT SERVICE BRAKE BURNISHING PROCEDURE...............................................................248
	REAR WET DISC BRAKE ASSEMBLY...............................................................................251
		REAR WET DISC BRAKE ASSEMBLY...........................................................................251
			REMOVAL............................................................................................251
			INSTALLATION.......................................................................................252
			WET DISC BRAKE DISASSEMBLY.........................................................................253
			BRAKE PISTON DISASSEMBLY...........................................................................256
			BRAKE PISTON INSPECTION............................................................................256
			BRAKE PISTON ASEMBLY...............................................................................256
			FLOATING RING SEAL INSTALLATION....................................................................257
			WET DISC BRAKE ASSEMBLY............................................................................261
			REAR WET DISC BRAKE ASSEMBLY.......................................................................251
		REAR WET DISC BRAKE BLEEDING PROCEDURE.................................................................263
		REAR BRAKE DISC WEAR INDICATOR.........................................................................264
			REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER.....................................................264
	PARK BRAKE.................................................................................................265
		PARK BRAKE.............................................................................................265
			REMOVAL/INSTALLATION...............................................................................265
			PARK BRAKE LINING ADJUSTMENT.......................................................................265
			PARK BRAKE LINKAGE ADJUSTMENT......................................................................265
		PARK BRAKE ACTUATOR ASSEMBLY REPAIR....................................................................266
			REMOVAL............................................................................................266
			INSTALLATION.......................................................................................266
			DISASSEMBLY........................................................................................267
			ASSEMBLY...........................................................................................267
			ACTUATOR SPRING POD DISASSEMBLY....................................................................267
			ACTUATOR SPRING POD ASSEMBLY.......................................................................268
		PARK BRAKE BURNISHING..................................................................................268
HYDRAULIC SYSTEM...............................................................................................269
	HYDRAULIC SYSTEM...........................................................................................271
		HYDRAULIC SYSTEM DESCRIPTION...........................................................................271
	HYDRAULIC SYSTEM COMPONENT REPAIR..........................................................................275
		TANDEM HYDRAULIC PUMP..................................................................................275
			TANDEM HYDRAULIC PUMP..............................................................................275
				REMOVAL........................................................................................275
				INSTALLATION...................................................................................275
			PUMP DISASSEMBLY...................................................................................276
			PUMP ASSEMBLY......................................................................................278
			CARTRIDGE DISASSEMBLY..............................................................................279
				INSPECTION.....................................................................................279
			CARTRIDGE ASEMBLY..................................................................................281
		HYDRAULIC TANK.........................................................................................283
			FILLING INSTRUCTIONS...............................................................................283
				REMOVAL........................................................................................283
				INSTALLATION...................................................................................284
		HYDRAULIC TANK BREATHERS...............................................................................284
		HYDRAULIC FILTERS......................................................................................284
			HYDRAULIC FILTERS..................................................................................284
				REMOVAL........................................................................................285
				INSTALLATION...................................................................................285
			DIFFERENTIAL PRESSURE SWITCH TESTING...............................................................286
				TEST PROCEDURES................................................................................286
	STEERING CIRCUIT...........................................................................................289
		STEERING CIRCUIT OPERATION.............................................................................289
		STEERING CIRCUIT COMPONENT DESCRIPTION.................................................................289
	STEERING CONTROL VALVE.....................................................................................293
		REMOVAL................................................................................................293
		INSTALLATION...........................................................................................293
		DISASSEMBLY............................................................................................294
		CLEANING AND INSPECTION................................................................................297
		ASSEMBLY...............................................................................................297
		ALTERNATE METHOD.......................................................................................297
	STEERING CIRCUIT COMPONENT REPAIR..........................................................................301
		ACCUMULATORS...........................................................................................301
			REMOVAL............................................................................................301
			INSTALLATION.......................................................................................302
			DISASSEMBLY........................................................................................302
			CLEANING AND INSPECTION............................................................................302
			ASSEMBLY...........................................................................................302
		LOW PRESSURE ACCUMULATOR PRESSURE SWITCH...............................................................303
		ACCUMULATOR CHARGING PROCEDURE.........................................................................304
		INLINE FILTERS.........................................................................................305
			SERVICE............................................................................................305
		STEERING CYLINDERS.....................................................................................306
			DISASSEMBLY........................................................................................306
			ASSEMBLY...........................................................................................306
		BRAKE/STEERING PUMP REPAIR.............................................................................307
			REMOVAL............................................................................................307
			INSTALLATION.......................................................................................307
			DISASSEMBLY........................................................................................307
			ASSEMBLY...........................................................................................313
		PUMP SPECIFICATIONS CHART..............................................................................321
	HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION..........................................................323
		CIRCUIT OPERATION......................................................................................323
			HOIST VALVE........................................................................................323
			AUXILIARY MANIFOLD.................................................................................324
			COUNTER BALANCE VALVE..............................................................................324
			HOIST CYLINDERS....................................................................................324
			CHECK VALVES.......................................................................................324
	HOIST CIRCUIT COMPONENT REPAIR.............................................................................325
		HOIST VALVE............................................................................................325
			REMOVAL............................................................................................325
			INSTALLATION.......................................................................................325
			DISASSEMBLY........................................................................................326
			ASSEMBLY...........................................................................................327
		HOIST CYLINDER.........................................................................................328
			REMOVAL............................................................................................328
			INSTALLATION.......................................................................................328
			DISASSEMBLY........................................................................................330
			CLEANING AND INSPECTION............................................................................330
			ASSEMBLY...........................................................................................330
			HOIST CYLINDER MOUNTING BEARING REPLACEMENT........................................................330
	HYDRAULIC CHECK-OUT PROCEDURE..............................................................................331
		GENERAL INFORMATION....................................................................................331
		STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE......................................................331
		INITIAL SYSTEM SET-UP..................................................................................331
			ACCUMULATOR AND PISTON PUMP CHECKS.................................................................331
			STEERING VALVE LEAKAGE CHECK.......................................................................333
			STEERING CYLINDER LEAKAGE CHECK....................................................................333
		TROUBLESHOOTING CHART (STEERING SYSTEM)................................................................334
		HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE..........................................................336
		AUXILIARY VALVE........................................................................................336
			PRESSURE CHECK.....................................................................................336
			LEAKAGE CHECK......................................................................................336
		CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE..............................................337
		CHECKING AND ADJUSTING "POWER DOWN" PRESSURE...........................................................337
	TROUBLESHOOTING CHART (HOIST SYSTEM).......................................................................338
	STEERING SYSTEM DATA SHEET.................................................................................341
	HOIST SYSTEM DATA SHEET....................................................................................342
	HYDRAULIC SYSTEM FLUSHING PROCEDURE........................................................................343
OPTIONS AND SPECIAL TOOLS......................................................................................345
	LINCOLN AUTOMATIC LUBRICATION SYSTEM.......................................................................347
	QUICK FUEL SYSTEMS.........................................................................................355
		WIGGINS QUICK FILL FUEL SYSTEM.........................................................................355
		BUCKEYE QUICK FUEL SYSTEM..............................................................................359
	KIM "HOTSTART" SYSTEM......................................................................................361
	SPECIAL TOOLS..............................................................................................365
	AIR CONDITIONING SYSTEM....................................................................................383
		PRINCIPLES OF REFRIGERATION............................................................................384
		AIR CONDITIONER SYSTEM COMPONENTS......................................................................385
		ELECTRICAL CIRCUIT.....................................................................................387
		SYSTEM SERVICING.......................................................................................389
			INSTALLING MANIFOLD GAUGE SET......................................................................393
			SYSTEM STABILIZING.................................................................................396
			ADDING R-12 (PRIOR TO PERFORMANCE TEST)............................................................396
			SYSTEM PERFORMANCE TEST............................................................................398
			DISCHARGING SYSTEM.................................................................................399
			FLUSHING AIR CONDITIONER COMPONENTS................................................................399
		SYSTEM REPAIR..........................................................................................400
			HOSES, FITTINGS AND LINES..........................................................................400
			EXPANSION VALVE....................................................................................400
			RECEIVER DRIER.....................................................................................401
			THERMOSTAT.........................................................................................401
			CLUTCH.............................................................................................401
			COMPRESSOR.........................................................................................401
		CHECKING COMPRESSOR OIL LEVEL..........................................................................402
		EVACUATING THE SYSTEM..................................................................................404
			CHARGING THE SYSTEM................................................................................404
		TROUBLESHOOTING........................................................................................406
			PREPARING FOR DIAGNOSIS............................................................................406
		TROUBLESHOOTING CHART..................................................................................407
	AUTOMATIC POSITIVE LOCKING DIFFERENTIAL....................................................................411
	RADIATOR SHUTTERS..........................................................................................413
OPERATOR'S CAB.................................................................................................415
	TRUCK CAB..................................................................................................417
		REMOVAL................................................................................................417
		INSTALLATION...........................................................................................420
	OPERATOR COMFORT...........................................................................................423
		OPERATOR SEAT..........................................................................................423
			ADJUSTMENT.........................................................................................423
			REMOVAL............................................................................................423
			INSTALLATION.......................................................................................423
			DISASSEMBLY........................................................................................424
			INSPECTION.........................................................................................424
			ASSEMBLY...........................................................................................424
		HEATER/AIR CONDITIONER.................................................................................426
			WATER CONTROL VALVE................................................................................426
			REMOVAL............................................................................................426
			INSTALLATION.......................................................................................428
			DISASSEMBLY........................................................................................429
			INSPECTION.........................................................................................429
			ASSEMBLY...........................................................................................429
	OPERATOR CONTROLS AND INSTRUMENT PANEL.....................................................................431
		OPERATOR CONTROLS......................................................................................431
		INSTRUMENT PANEL.......................................................................................434
			RETARDER OPERATION.................................................................................438
		INSTRUMENT PANEL (RIGHT SIDE)..........................................................................439
		HEATER/AIR CONDITIONER CONTROLS........................................................................442
		THROTTLE PEDAL.........................................................................................443
			REMOVAL............................................................................................443
			INSTALLATION.......................................................................................443
			DISASSEMBLY........................................................................................444
			INSPECTION.........................................................................................445
			ASSEMBLY...........................................................................................445
LUBRICATION AND SERVICE........................................................................................447
	LUBRICATION AND SERVICE....................................................................................449
	LUBRICATION AND SPECIFICATIONS CHARTS......................................................................449
		SERVICE CAPACITIES.....................................................................................449
		ANTI-FREEZE SPECIFICATIONS.............................................................................449
		OIL AND GREASE SPECIFICATIONS..........................................................................450
	10 HOUR LUBRICATION AND MAINTENANCE CHECKS.................................................................451
	100 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................453
	250 HOUR LUBRICATION AND MAINTENANCE CHECKS................................................................455
	1000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................457
	5000 HOUR LUBRICATION AND MAINTENANCE CHECKS...............................................................459
ALPHABETICAL INDEX.............................................................................................461
SYSTEM SCHEMATICS..............................................................................................465
	ELECTRIC SCHEMATIC.........................................................................................467
	HYDRAULIC SYSTEM SCHEMATIC.................................................................................476
	ALLISON TRANSMISSION.......................................................................................479

KOMATSU DUMP TRUCK 210M SHOP MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu Dump Truck 210M Shop Manual 

FOREWORD: 

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.

PLEASE NOTE:

• This is the same manual used by the DEALERSHIPS to SERVICE your vehicle.
• The manual can be all yours – Once payment is complete, you will be taken to the download page from where you can download the manual. All in 2-5 minutes time!!
• Need any other service / repair / parts manual, please feel free to contact us at heydownloadss @gmail.com . We may surprise you with a nice offer