Komatsu 210M Dump Truck Service Repair Shop Manual - DG610

This complete service repair workshop manual PDF download for the 210M Komatsu Dump Truck has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

SERIAL SUFFIX :
BFA40A THRU BW
23858 THRU 24370


TABLE OF CONTENTS :

- GENERAL INFORMATION
- STRUCTURES
- ENGINE, FUEL, COOLING AND AIR CLEANER
- ELECTRIC SYSTEM (24 VDC. NON-PROPULSION)
- TRANSMISSION AND PTO
- DRIVE AXLE, SPINDLES AND WHEELS
- HYDRAIR® II SUSPENSIONS
- BRAKE CIRCUIT
- HYDRAULIC SYSTEM
- OPTIONS AND SPECIAL TOOLS
- OPERATOR’S CAB
- LUBRICATION AND SERVICE
- ALPHABETICAL INDEX
- SYSTEM SCHEMATICS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : DG610
Total Pages : 481


This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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GENERAL INFORMATION
TRUCK COMPONENT DESCRIPTION AND SPECIFICATIONS
GENERAL SAFETY AND TRUCK OPERATION
WARNINGS AND CAUTIONS
CHARTS AND TABLES
STORAGE PROCEDURES

STRUCTURES
STRUCTURAL COMPONENTS
COWL AND HOOD
DECKS
RIGHT DECK STRUCTURE
REMOVAL
INSTALLATION
INSPECTION
DUMP BODY
DUMP BODY
REMOVAL
INSTALLATION
BODY PIVOT PINS AND SPACERS
REMOVAL
INSTALLATION
BODY-UP PIN
INSTALLATION
BODY PAD
ROCK EJECTORS
INSPECTION
BODY POSITION INDICATOR
LINER PLATES/BODY REPAIR
BODY-UP LIMIT SWITCH
ADJUSTMENT
MAINTENANCE
FUEL TANK
REMOVAL
INSTALLATION
CLEANING
VENT
GAUGE
REMOVAL
INSTALLATION

ENGINE, FUEL, COOLING AND AIR CLEANER
COOLING SYSTEM
RADIATOR
REMOVAL
INSTALLATION
REPAIR
HEAT EXCHANGER
REMOVAL
INSTALLATION
REPAIR
ENGINE
ENGINE
REMOVAL
INSTALLATION
REPAIR
AIR FILTRATION SYSTEM
AIR CLEANER
SERVICE CHECKS
FILTER ELEMENT REPLACEMENT
MAIN FILTER ELEMENT
REMOVAL
INSTALLATION
MAIN FILTER ELEMENT CLEANING
PRECLEANER SECTION
CLEANING PRECLEANING TUBES
AIR INTAKE TROUBLESHOOTING
ENGINE COMPONENTS
THROTTLE CONTROL
THROTTLE CONTROL PEDAL
REMOVAL AND INSTALLATION
THROTTLE CONTROL LEVER
THROTTLE CONTROL ADJUSTMENT
ATEC THROTTLE POSITION SENSOR
THROTTLE POSITION SENSOR AND CABLE
REMOVAL
INSTALLATION
FAN
REMOVAL
INSTALLATION
FAN BELT ADJUSTMENT
ALTERNATOR BELT ADJUSTMENT

ELECTRIC SYSTEM (24 VDC. NON-PROPULSION)
24 VDC ELECTRIC SUPPLY SYSTEM
ELECTRICAL SYSTEM DESCRIPTION
BATTERY
SERVICE
STORAGE
MAINTENANCE AND TROUBLESHOOTING
SPILLAGE
BATTERY CHARGING ALTERNATOR
OPERATION
MAGNETIZING THE ROTOR
REGULATOR ADJUSTMENT
CIRCUIT CHECKOUT
BATTERY CHARGING CIRCUIT COMPONENTS
BATTERY EQUALIZER
PURPOSE
TROUBLESHOOTING
MONITOR
ELECTRICAL SYSTEM COMPONENTS
ELECTRICAL CIRCUIT CHECKOUT
HORN, WINDSHIELD WIPER AND WINDSHIELD WASHER CIRCUITS
WINDSHIELD WASHER CIRCUIT
WINDSHIELD WIPER CIRCUIT CHECKOUT PROCEDURE
BRAKE LOCK AND PARK BRAKE CIRCUITS
BRAKE LOCK SWITCH CIRCUIT
BRAKE LOCK CHECKOUT
PARK BRAKE SWITCH AND CIRCUIT
PARK BRAKE CHECKOUT
LOW BRAKE PRESSURE SWITCH AND CIRCUIT
GAUGES AND CIRCUIT COMPONENTS
CIRCUIT COMPONENTS
LOW BRAKE PRESSURE WARNING AND INDICATOR LIGHT CIRCUITS
CIRCUIT COMPONENTS
HOIST CONTROL CIRCUIT
HOIST CONTROL SWITCH CIRCUIT CHECKOUT
BODY-UP LIMIT SWITCH
BODY-UP LIMIT SWITCH CIRCUIT CHECKOUT
STEERING BLEEDDOWN TIMER CIRCUIT
CIRCUIT COMPONENTS
STEERING BLEEDDOWN CIRCUIT CHECKOUT
ACCUMULATOR PRECHARGE CIRCUIT
LIGHT CIRCUIT
CIRCUIT COMPONENTS
CIRCUIT CHECKOUT
HEATER AND AIR CONDITIONER CIRCUIT
CIRCUIT COMPONENTS
CIRCUIT CHECKOUT
24 VDC ELECTRIC START SYSTEM
24 VDC ELECTRIC START SYSTEM
OPERATION
CRANKING MOTOR
REMOVAL
INSTALLATION
CRANKING MOTOR TROUBLESHOOTING
PRELIMINARY INSPECTION
NO-LOAD TEST
INTERPRETING RESULTS OF TESTS
DISASSEMBLY
CLEANING AND INSPECTION
ARMATURE SERVICING
FIELD COIL CHECKS
FIELD COIL REMOVAL
SOLENOID CHECKS
ASSEMBLY
PINION CLEARANCE
MAGNETIC SWITCH
REMOVAL
INSTALLATION
COIL TEST
ELECTRIC START SYSTEM WIRING DIAGRAMS
STARTER, ENGINE 24 VDC
CIRCUIT CHECK-OUT
ALLISON TRANSMISSION ELECTRONIC CONTROL (ATEC)
ATEC SYSTEM OPERATION
RANGE SELECTOR
"DO NOT SHIFT" LIGHT
"CHECK TRANS" LIGHT
SYSTEM DESCRIPTION
TRANSMISSION CONTROL CIRCUITS
BATTERY CHARGING CIRCUIT
CONTROL POWER AND MEMORY CIRCUITS
START CIRCUIT
CHECK TRANSMISSION WARNING LIGHT CIRCUIT
BACKUP HORN AND LIGHT CIRCUIT
HOIST INTERLOCK CIRCUIT
AUTO/MANUAL CIRCUIT
OVERSPEED RELAY CIRCUIT (NOT USED)
SPEEDOMETER CIRCUIT
TRANSMISSION CIRCUIT COMPONENTS
CIRCUIT DESCRIPTION AND CHECKOUT
ATEC DIAGNOSTIC CODES

TRANSMISSION AND PTO
TRANSMISSION
TRANSMISSION
TRANSMISSION REMOVAL
TRANSMISSION INSTALLATION
TRANSMISSION FILL INSTRUCTIONS
TRANSMISSION FILTER
SERVICE
TRANSMISSION OIL COOLER
REMOVAL AND INSTALLATION
REPAIR
POWER TAKE OFF (PTO)
PTO GEARBOX
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
DRIVELINES
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY

DRIVE AXLE, SPINDLES AND WHEELS
TIRES AND RIMS
TIRES AND RIMS
GENERAL INFORMATION
TIRE REMOVAL FROM RIM
TIRE INSTALLATION ON RIM
FRONT TIRES AND RIMS
REMOVAL
INSTALLATION
REAR TIRE AND RIM
REMOVAL
INSTALLATION
TIRE MATCHING
FRONT WHEEL HUB AND SPINDLES
FRONT WHEEL HUB
REMOVAL
FRONT WHEEL BEARING AND BRAKE DISC REPLACEMENT
FRONT WHEEL HUB INSTALLATION AND BEARING ADJUSTMENT
FRONT WHEEL SPINDLE REMOVAL
FRONT WHEEL SPINDLE INSTALLATION
STEERING LINKAGE REMOVAL
STEERING LINKAGE BALL STUD AND BEARING REMOVAL
FRONT WHEEL TOE-IN ADJUSTMENT
BIAS PLY TIRES
RADIAL TIRES
FINAL DRIVE ATTACHMENTS
FINAL DRIVE ANCHOR
PIN REMOVAL
PIN INSTALLATION
BEARING REMOVAL AND INSPECTION
BEARING INSTALLATION
PANHARD ROD
REMOVAL
INSTALLATION
BEARING REPLACEMENT
FINAL DRIVE ASSEMBLY
COMPLETE FINAL DRIVE ASSEMBLY
REMOVAL
INSTALLATION
DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH COMPLETE FINAL DRIVE ASSEMBLY REMOVED FROM UNDER TRUCK
REMOVAL
INSTALLATION
DIFFERENTIAL CARRIER ASSEMBLY - SERVICE WITH FINAL DRIVE IN PLACE UNDER TRUCK
REMOVAL
INSTALLATION
DIFFERENTIAL CAGE REMOVAL
PINION REMOVAL
DIFFERENTIAL CAGE DISASSEMBLY
SPIDER GEAR BEARING REMOVAL
CLEANING AND INSPECTION
SPIDER GEAR BEARING INSTALLATION
DIFFERENTIAL CAGE ASSEMBLY
PINION INSTALLATION AND BEARING ADJUSTMENT
DIFFERENTIAL CAGE INSTALLATION
CARRIER BEARING AND BACKLASH ADJUSTMENT
FINAL DRIVE PLANETARIES AND WHEEL HUBS
PLANETARY DRIVE
PLANETARY DRIVE REMOVAL
PLANETARY REACTOR AND RING GEAR REMOVAL
PLANETARY REACTOR AND RING GEAR INSTALLATION
CLEANING AND INSPECTION
PLANETARY DRIVE INSTALLATION
PLANETARY CARRIER DISASSEMBLY
PLANETARY CARRIER ASSEMBLY
WHEEL HUB AND BEARINGS
REMOVAL
BEARING REPLACEMENT
INSTALLATION

HYDRAIR SUSPENSIONS
FRONT SUSPENSIONS
REMOVAL
INSTALLATION
DISASSEMBLY
INSPECTION
ASSEMBLY
REAR SUSPENSION
REAR SUSPENSIONS
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
REAR SUSPENSION SPHERICAL BEARING REPAIR
DISASSEMBLY
INSPECTION
ASSEMBLY
OILING AND CHARGING PROCEDURES
GENERAL
EQUIPMENT LIST
HYDRAIR SERVICE KIT
INSTALLATION OF CHARGING KIT
REMOVAL OF CHARGING KIT
SUPPORT BLOCKS FOR OILING AND CHARGING DIMENSIONS
FRONT SUSPENSION
FRONT SUSPENSION OILING
FRONT SUSPENSION NITROGEN CHARGING
REAR SUSPENSION
REAR SUSPENSION OILING
REAR SUSPENSION NITROGEN CHARGING
OIL AND NITROGEN SPECIFICATIONS CHART

BRAKE CIRCUIT
BRAKE CIRCUIT
CIRCUIT OPERATION
CHARGING
MANUAL APPLICATION
HYDRAULIC OIL MANIFOLD
BRAKE ACCUMULATORS
ACCUMULATOR PRECHARGE
LOW-PRESSURE BRAKE DETECTION MODULE
LOW-PRESSURE SENSING SHUTTLE VALVE
BRAKE ACCUMULATOR PRESSURE CHECKS
ACCUMULATOR SHUTTLE VALVE
ACCUMULATOR DISCHARGE VALVES (BLEEDDOWN VALVES)
EMERGENCY APPLY VALVE
BRAKE PRESSURE WARNING SWITCH
BRAKE MANIFOLD
BRAKE LOCK SHUTTLE VALVE
BRAKE LOCK SOLENOID VALVE
BRAKE MANIFOLD SHUTTLE VALVE
STEERING BLEEDDOWN SOLENOID VALVE
STEERING ACCUMULATOR PRESSURE CHECK
SERVICE BRAKE TREADLE VALVE
RETARDER TREADLE VALVE
SERVICE BRAKE/RETARDER SHUTTLE VALVE
STOP LIGHT MANIFOLD AND TEE
REAR BRAKE SHUTTLE VALVE
WET DISC BRAKE ASSEMBLY
BRAKE CIRCUIT COMPONENT SERVICE
LOW PRESSURE BRAKE DETECTION MODULE
BRAKE MANIFOLD
BRAKE ACCUMULATOR REPAIR
SERVICE BRAKE TREADLE VALVE
REMOVAL
INSTALLATION
DISASSEMBLY OF TREADLE VALVE ASSEMBLY
REMOVAL OF BRAKE MANIFOLD
BRAKE VALVE DISASSEMBLY
ASSEMBLY OF TREADLE VALVE ASSEMBLY
BRAKE VALVE ASSEMBLY
INSTALLATION OF BRAKE MANIFOLD
ADJUSTMENT FOR MAXIMUM DELIVERY PRESSURE
BRAKE PEDAL ADJUSTMENT
SERVICE BRAKE TREADLE PEDAL
PEDAL DISASSEMBLY
PEDAL ASSEMBLY
RETARDER TREADLE VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
RETARDER TREADLE PEDAL DISASSEMBLY
RETARDER TREADLE PEDAL ASSEMBLY
BRAKE CIRCUIT CHECKOUT PROCEDURE
CIRCUIT TRACKING
INITIAL SYSTEM SET-UP
CHECK OF BRAKE CIRCUIT SHUTTLE VALVES
BRAKE SYSTEM CHECKOUT
FAILURE MODE CHECKOUT
BRAKE VALVE LEAKAGE
TROUBLESHOOTING
CHECKOUT DATA SHEET
FRONT WHEEL SPEED DISC BRAKES
FRONT WHEEL SPEED DISC BRAKES
LINING REPLACEMENT ON TRUCK
BRAKE CALIPER REPAIR
REMOVAL
INSTALLATION
PISTON AND SEAL REMOVAL
PISTON AND SEAL INSTALLATION
BRAKE CALIPER BENCH TEST
FRONT BRAKE BLEEDING PROCEDURE
FRONT SERVICE BRAKE BURNISHING PROCEDURE
REAR WET DISC BRAKE ASSEMBLY
REAR WET DISC BRAKE ASSEMBLY
REMOVAL
INSTALLATION
WET DISC BRAKE DISASSEMBLY
BRAKE PISTON DISASSEMBLY
BRAKE PISTON INSPECTION
BRAKE PISTON ASEMBLY
FLOATING RING SEAL INSTALLATION
WET DISC BRAKE ASSEMBLY
REAR WET DISC BRAKE ASSEMBLY
REAR WET DISC BRAKE BLEEDING PROCEDURE
REAR BRAKE DISC WEAR INDICATOR
REMOVAL/INSTALLATION FROM ONE BRAKE TO ANOTHER
PARK BRAKE
PARK BRAKE
REMOVAL/INSTALLATION
PARK BRAKE LINING ADJUSTMENT
PARK BRAKE LINKAGE ADJUSTMENT
PARK BRAKE ACTUATOR ASSEMBLY REPAIR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
ACTUATOR SPRING POD DISASSEMBLY
ACTUATOR SPRING POD ASSEMBLY
PARK BRAKE BURNISHING

HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM DESCRIPTION
HYDRAULIC SYSTEM COMPONENT REPAIR
TANDEM HYDRAULIC PUMP
TANDEM HYDRAULIC PUMP
REMOVAL
INSTALLATION
PUMP DISASSEMBLY
PUMP ASSEMBLY
CARTRIDGE DISASSEMBLY
INSPECTION
CARTRIDGE ASEMBLY
HYDRAULIC TANK
FILLING INSTRUCTIONS
REMOVAL
INSTALLATION
HYDRAULIC TANK BREATHERS
HYDRAULIC FILTERS
HYDRAULIC FILTERS
REMOVAL
INSTALLATION
DIFFERENTIAL PRESSURE SWITCH TESTING
TEST PROCEDURES
STEERING CIRCUIT
STEERING CIRCUIT OPERATION
STEERING CIRCUIT COMPONENT DESCRIPTION
STEERING CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
ALTERNATE METHOD
STEERING CIRCUIT COMPONENT REPAIR
ACCUMULATORS
REMOVAL
INSTALLATION
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
LOW PRESSURE ACCUMULATOR PRESSURE SWITCH
ACCUMULATOR CHARGING PROCEDURE
INLINE FILTERS
SERVICE
STEERING CYLINDERS
DISASSEMBLY
ASSEMBLY
BRAKE/STEERING PUMP REPAIR
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PUMP SPECIFICATIONS CHART
HOIST CIRCUIT OPERATION AND COMPONENT DESCRIPTION
CIRCUIT OPERATION
HOIST VALVE
AUXILIARY MANIFOLD
COUNTER BALANCE VALVE
HOIST CYLINDERS
CHECK VALVES
HOIST CIRCUIT COMPONENT REPAIR
HOIST VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
HOIST CYLINDER
REMOVAL
INSTALLATION
DISASSEMBLY
CLEANING AND INSPECTION
ASSEMBLY
HOIST CYLINDER MOUNTING BEARING REPLACEMENT
HYDRAULIC CHECK-OUT PROCEDURE
GENERAL INFORMATION
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE
INITIAL SYSTEM SET-UP
ACCUMULATOR AND PISTON PUMP CHECKS
STEERING VALVE LEAKAGE CHECK
STEERING CYLINDER LEAKAGE CHECK
TROUBLESHOOTING CHART (STEERING SYSTEM)
HOIST CIRCUIT CHECKOUT & ADJUSTMENT PROCEDURE
AUXILIARY VALVE
PRESSURE CHECK
LEAKAGE CHECK
CHECKING AND ADJUSTING HOIST SYSTEM PRESSURE RELIEF VALVE
CHECKING AND ADJUSTING "POWER DOWN" PRESSURE
TROUBLESHOOTING CHART (HOIST SYSTEM)
STEERING SYSTEM DATA SHEET
HOIST SYSTEM DATA SHEET
HYDRAULIC SYSTEM FLUSHING PROCEDURE

OPTIONS AND SPECIAL TOOLS
LINCOLN AUTOMATIC LUBRICATION SYSTEM
QUICK FUEL SYSTEMS
WIGGINS QUICK FILL FUEL SYSTEM
BUCKEYE QUICK FUEL SYSTEM
KIM "HOTSTART" SYSTEM
SPECIAL TOOLS
AIR CONDITIONING SYSTEM
PRINCIPLES OF REFRIGERATION
AIR CONDITIONER SYSTEM COMPONENTS
ELECTRICAL CIRCUIT
SYSTEM SERVICING
INSTALLING MANIFOLD GAUGE SET
SYSTEM STABILIZING
ADDING R-12 (PRIOR TO PERFORMANCE TEST)
SYSTEM PERFORMANCE TEST
DISCHARGING SYSTEM
FLUSHING AIR CONDITIONER COMPONENTS
SYSTEM REPAIR
HOSES, FITTINGS AND LINES
EXPANSION VALVE
RECEIVER DRIER
THERMOSTAT
CLUTCH
COMPRESSOR
CHECKING COMPRESSOR OIL LEVEL
EVACUATING THE SYSTEM
CHARGING THE SYSTEM
TROUBLESHOOTING
PREPARING FOR DIAGNOSIS
TROUBLESHOOTING CHART
AUTOMATIC POSITIVE LOCKING DIFFERENTIAL
RADIATOR SHUTTERS

OPERATOR'S CAB
TRUCK CAB
REMOVAL
INSTALLATION
OPERATOR COMFORT
OPERATOR SEAT
ADJUSTMENT
REMOVAL
INSTALLATION
DISASSEMBLY
INSPECTION
ASSEMBLY
HEATER/AIR CONDITIONER
WATER CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
INSPECTION
ASSEMBLY
OPERATOR CONTROLS AND INSTRUMENT PANEL
OPERATOR CONTROLS
INSTRUMENT PANEL
RETARDER OPERATION
INSTRUMENT PANEL (RIGHT SIDE)
HEATER/AIR CONDITIONER CONTROLS
THROTTLE PEDAL
REMOVAL
INSTALLATION
DISASSEMBLY
INSPECTION
ASSEMBLY

LUBRICATION AND SERVICE
LUBRICATION AND SERVICE
LUBRICATION AND SPECIFICATIONS CHARTS
SERVICE CAPACITIES
ANTI-FREEZE SPECIFICATIONS
OIL AND GREASE SPECIFICATIONS
10 HOUR LUBRICATION AND MAINTENANCE CHECKS
100 HOUR LUBRICATION AND MAINTENANCE CHECKS
250 HOUR LUBRICATION AND MAINTENANCE CHECKS
1000 HOUR LUBRICATION AND MAINTENANCE CHECKS
5000 HOUR LUBRICATION AND MAINTENANCE CHECKS

ALPHABETICAL INDEX

SYSTEM SCHEMATICS
ELECTRIC SCHEMATIC
HYDRAULIC SYSTEM SCHEMATIC
ALLISON TRANSMISSION

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