Komatsu 730E-8 Dump Truck Service Repair Manual CEBM026602 PDF

Description

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM026602 – PDF DOWNLOAD

FILE DETAILS:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM026602 – PDF DOWNLOAD

Language : English
Pages :810
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM026602 – PDF DOWNLOAD

SERIAL NUMBERS 730E-8 A40004 – A40014
ENGINE 16V159

Foreword

• This manual is written for use by the operator and/or the service technician. It is designed to help these persons to become fully knowledgeable of the truck and all of its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel should read and understand the information in this manual before operating the truck or performing maintenance and/or operational checks on the truck.
• All safety notices, warnings, and cautions should be understood and followed when operating the truck or performing repairs on the truck. The first section covers component descriptions, truck specifications and safe work practices, as well as other general information.
• The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example, the disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck. Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. This manual shows dimensioning of U.S. standard and metric (SI) units throughout. All references to “right,” “left,” “front,” or “rear” are made with respect to the operator’s normal seated position unless specifically stated otherwise.
• When assembly instructions are provided without references to specific torque values, standard torque values should be used. Standard torque values are shown in torque charts later in this section. Specific torques, when provided in the text, are in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified. A product identification plate is located on the frame in front of the right side front wheel. It designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum GVW (Gross Vehicle Weight) rating.
• The KOMATSU truck model designation consists of three numbers and one letter (i.e. 960E). The three numbers represent the basic truck model. The letter “E” designates an Electrical wheel motor drive system. The Product Identification Number (vehicle serial number) contains information which identifies several characteristics of this unit. For a more detailed explanation, refer to the Operation and Maintenance Manual. The Gross Vehicle Weight (GVW) is what determines the load on the drive train, frame, tires, and other components.
• The vehicle design and application guidelines are sensitive to the maximum GVW. GVW is total weight: empty vehicle weight + fuel & lubricants + payload. To determine the allowable payload, fill all lubricants to the proper level and fill the fuel tank of an empty truck (which includes all accessories, body liners, tailgates, etc.), and then weigh the truck. Record this value and subtract it from the GVW.
• The result is the allowable payload. NOTE: Accumulations of mud, frozen material, etc, become part of the GVW and reduces the allowable payload. To maximize payload and to keep from exceeding the maximum GVW rating, these accumulations should be removed as often as practical. Exceeding the allowable payload will reduce the expected life of truck component

TABLE OF CONTENTS:

Komatsu 730E-8 DUMP TRUCK Shop Manual CEBM026602 – PDF DOWNLOAD

SERIAL NUMBERS 730E-8 A40004 – A40014
ENGINE 16V159

00 Index and foreword 3
Index 3
Composition of shop manual 4
Table of contents 6
Foreword, safety and general information 17
Foreword 20
How to read the shop manual 21
Composition of shop manual 21
Revision and distribution 21
Symbols 22
General safety 23
Safety rules 23
Safety features 23
Fire extinguisher and first aid kit 23
Clothing and personal items 23
Leaving the operator seat 24
Mounting and dismounting 24
Fire prevention for fuel and oil 24
Precautions with high temperature fluids 25
Asbestos dust hazard prevention 25
Prevention of injury by work equipment 25
Unauthorized modification 25
Precautions when using ROPS 25
Precautions for attachments 26
Precautions for starting the truck 26
Precautions before operating the truck 26
Safety at the worksite 26
Fire prevention 27
Ventilation in enclosed areas 27
Preparing for operation 27
Mirrors, windows and lights 27
In operator cab (before starting the engine) 27
Seat Belts 27
Precautions while operating the truck 28
When starting the engine 28
General truck operation 28
Ensuring good visibility 28
Traveling 29
Traveling in reverse 29
Traveling on slopes 29
Operating on snow or ice 29
Avoid damage to dump body 29
Driving near high voltage cables 30
When dumping 30
When loading 30
Working on loose ground 30
Parking the truck 30
Towing 30
Working near batteries 31
Battery hazard prevention 31
Starting with jumper cables 32
Jump starting with receptacles 32
Precautions before performing service 33
Warning tag 33
Stopping the engine 33
Proper tools 33
Use of Tie-Off Anchor During Maintenance and Repair 33
Securing the dump body 34
Jack point locations 35
Precautions while performing service 36
Keep the truck clean 36
Attachments 36
Working under the truck 36
Rotating fan and belts 36
Adding fuel or oil 36
Use of lighting 36
Radiator coolant level 37
Precautions with the battery 37
Precautions with high pressure oil 37
Handling high pressure hoses 37
Precautions when performing maintenance near high temperature or high pressure 37
Waste materials 37
Tires 38
Inspection 38
Maintenance 38
Storage 39
Handling 40
Precautions for performing repairs 41
Engine shutdown procedure after AC drive system failure 41
Precautions for welding on the truck 42
Capacitor discharge system 43
Necessary tools 43
Warnings and cautions 44
Manual DC link capacitor discharge procedure 45
Failure of the discharge system 47
Manual discharge of capacitors 48
Short isolated capacitor terminals 50
Handling electrical equipment and hydraulic components 51
Points to remember when handling electrical equipment 51
Points to remember when handling hydraulic equipment 57
Standard tightening torques 59
Effect of special lubricants on fasteners and standard torque values 59
Suggested sources for rust preventive grease 59
SAE grade 5 and grade 8 hex head capscrew and nut assemblies 60
SAE grade 9 capscrews 61
Class 109 capscrews and class 10 nuts 61
Standard tightening torques for fittings 62
Conversion tables 64
Common conversion multipliers 64
01 Specification 69
Specification and technical data 69
Specification drawing 71
Specifications 72
Weight table 74
Fuel, coolant and lubricants 75
Suspension cylinder oil and nitrogen specifications 76
10 Structure, functions and maintenance standard 79
Steering circuit 79
Steering circuit operation 81
Steering circuit components 82
Steering control unit 82
High pressure filter 82
Steering accumulators 82
Low precharge warning switch 82
Bleeddown manifold 83
Steering accumulator bleeddown solenoid 83
Quick disconnect ports 83
Flow amplifier 83
Flow amplifier operation 86
No steer 86
Steering left 88
Steering right 90
No steer, external shock load 92
Steering/brake pump operation 94
Hoist circuit 97
Hoist circuit operation 98
Hoist circuit components 99
Hydraulic tank 99
Hoist pump 99
High pressure filters 99
Hoist valve 99
Hoist pilot valve100
Hoist up limit solenoid101
Hoist pilot valve101
Bleeddown manifold101
Counterbalance manifold101
Hoist pilot valve operation102
Float position with body coming down102
Power up operation104
Hold operation106
Power down operation108
Float operation110
Brake circuits113
General information115
Service brake circuit operation115
Secondary braking and auto apply117
Parking brake circuit operation117
Normal operation (key switch ON, engine running)117
Wheel brake lock circuit operation118
Brake warning circuit operation118
Suspensions121
General information123
Front suspension wear data123
Rear suspension wear data124
Electrical system, 24 volt127
Battery supply system129
24VDC battery charging alternator129
Battery box129
Engine start relays129
24VDC auxiliary battery receptacles129
Isolation box130
Engine shutdown switch130
Access ladder light switch130
Battery disconnect switches130
Propel lockout lever130
LED lights130
Auxiliary control cabinet components131
24VDC to 12VDC converter131
Circuit breaker131
Power distribution terminals131
Relays131
Fuses131
Relay boards132
Relay functions133
Electric cranking motor system (with prelube)134
Operation134
Body-up switch135
Hoist limit switch136
Interface module (IM)139
General information140
Sensors140
Temperature sensors140
Pressure sensors140
Interface module inputs and outputs141
Electrical system, AC drive145
General system operation146
AC drive system components148
Drive System Controller (DSC)148
Diagnostic information display (DID) panel149
DSC software functions150
Input Processing150
State Machine150
DC Link State153
Engine Control154
Alternator field control154
Desired DC Link Voltage154
Self-Load154
Propel Torque Control155
Retard Torque Control155
Wheel Slide Control155
Resistor Grid Control156
Chopper Voltage Control156
Event detection and processing156
Power-On Tests156
Initiated Tests157
Periodic Tests157
Event restrictions157
Event logging and storage157
Event History Buffer158
Data Packs158
Event Reset158
Abnormal conditions/overriding functions158
Fast Start159
Engine Shutdown/Engine Not Running159
Limp Home Mode159
Electronic accelerator and retard pedals159
Drive system component abbreviations & locations160
Cab air conditioning167
General information168
Environmental impact of air conditioning168
Air conditioning for off-highway vehicles168
Principles of refrigeration169
Air conditioning169
Refrigeration – the act of cooling169
The refrigeration cycle169
Air conditioning system components171
Relays171
Fan motor and speed control171
Cab air filter171
Heater core171
Actuators171
Compressor (refrigerant pump)173
Service valves173
Condenser173
Receiver-drier173
Expansion valve174
Accumulator174
Evaporator core174
Air conditioning system electrical circuit175
Thermostat175
Compressor clutch175
Trinary™ switch176
20 Standard value table179
Standard value table179
Standard value table for truck181
30 Testing and adjusting187
Steering and hoist hydraulic system187
General information on system checkout188
Steering system checkout procedures188
Steering and brake pump pressure control adjustments189
Steering Pump Leakage Check190
Bleeddown Manifold190
Shock and suction valve settings191
Leakage tests192
Steering control unit and flow amplifier192
Bleeddown manifold192
Accumulator bleed down procedure193
Low steering pressure switch193
Toe-in adjustment198
Steering system checkout data sheet200
Checking hoist system pressures201
Hoist System Relief Pressure Adjustment201
Power Down Relief Pressure Adjustment202
Hoist counterbalance valve203
Preparation:203
Counterbalance Valve Pressure Check Only:204
Counterbalance Valve Adjustment204
Hoist cylinder leakage test205
Hoist system checkout data sheet207
Hydraulic system flushing208
Hydraulic system flushing procedure208
Oil cleanliness check213
Hydraulic system flushing checkout data sheet214
Brake system217
General information on system checkout218
Brake circuit checkout procedure218
Initial system setup and service brake checkout220
Brake lock system checkout221
Parking brake checkout221
Parking brake troubleshooting222
Low brake pressure and auto apply222
Parking brake control logic checkout224
Brake lock control logic checkout225
Brake system checkout data sheet227
Service brake conditioning (burnishing) procedure233
Front brake conditioning234
Rear brake conditioning235
Parking brake adjustment procedure236
Brake bleeding procedure237
Service brake237
Parking brake (rear brake calipers only)237
Piston assembly return spring force and built-in clearance (BIC)238
Piston assembly adjuster grip force239
Adjuster force241
Piston return spring242
Valve bench test and adjustment244
Test set up procedure245
Brake valve output pressure adjustment245
Differential pressure switch test246
Final test and adjustment247
Accumulators and suspensions251
Accumulator charging and storage252
Temperature During Precharge252
Bladder accumulator charging procedure253
Precharge maintenance255
Bladder accumulator storage procedure256
Bladder storage256
Installing a bladder accumulator from storage256
Bladder accumulator leak testing257
Piston accumulator charging procedure258
Piston accumulator storage260
Piston accumulator leak testing260
Checking for improper suspension charge261
Suspension oiling and charging procedures262
Required equipment262
Installing the charging kit263
Removing the charging kit263
Support blocks for oiling and charging dimensions264
Front suspensions265
Rear suspensions268
Suspension pressure test271
KOMTRAX Plus273
General information274
Gather Data274
Convert and Record Data274
Communicate Data to Off-Board Systems276
Using the KOMTRAX Plus system277
Turning the KOMTRAX Plus System ON277
Normal KOMTRAX Plus Operation277
Turning the KOMTRAX Plus System OFF277
Downloading from the KOMTRAX Plus Controller278
KOMTRAX Plus data items279
Fault Codes279
Machine History279
KOMTRAX Plus History279
Snapshots279
Manual Snapshots281
Trends281
Histogram (Load Map) Data281
Haul Cycle Data283
Alarm and Snapshot Triggers284
Satellite Features284
KOMTRAX Plus diagnostic features286
Fault History286
KOMTRAX Plus LED Digits286
KOMTRAX Plus controller replacement287
Removal287
Installation288
KOMTRAX Plus software288
KOMTRAX Plus initialization procedure289
KOMTRAX Plus controller setup procedure289
KOMTRAX Plus snapshot procedure292
KOMTRAX Plus download procedure293
Verify location of download files293
KOMTRAX Plus FTP upload procedure294
KOMTRAX Plus initialization form295
Setting Date & Time, Satellite and Payload Meter298
Review setting information299
KOMTRAX Plus controller checkout procedure300
Necessary Equipment300
Preliminary301
Checkout procedure302
Orbcomm controller303
Removal303
Installation303
Interface module (IM)305
General information307
Interface module software308
Flashburn program installation308
Interface module application code installation309
Interface module realtime data monitor software installation309
Interface module checkout procedures310
Necessary equipment310
Preliminary311
Checking Inputs and Outputs From The Interface Module311
Check digital inputs to the interface module312
Check serial interfaces to the interface module314
Check analog inputs to the interface module315
CHECKOUT PROCEDURE316
Cab air conditioning321
General information323
Service tools and equipment324
Recovery/recycle station324
Leak detector324
Manifold gauge set325
Service valves326
Vacuum pump326
Detecting leaks327
System performance test328
Checking system oil329
System flushing330
Installing the manifold gauge set331
Purging air from the service hoses331
Recovering and recycling refrigerant332
Draining oil from previous recovery cycle333
Recovery cycle333
Recycling procedure333
Evacuating the air conditioning system334
Charging the air conditioning system335
40 Troubleshooting337
Fuse and circuit breaker locations337
Fuse and circuit breaker locations339
AC drive system fault codes (DSC)345
DID panel fault code tables347
Troubleshooting by fault code, Part 1371
Fault Code A001: Left front suspension pressure sensor signal high373
Related circuit diagram373
Fault Code A002: Left front suspension pressure sensor signal low374
Related circuit diagram374
Fault Code A003: Right front suspension pressure sensor signal high375
Related circuit diagram375
Fault Code A004: Right front suspension pressure sensor signal low376
Related circuit diagram376
Fault Code A005: Left rear suspension pressure sensor signal high377
Related circuit diagram377
Fault Code A006: Left rear suspension pressure sensor signal low378
Related circuit diagram378
Fault Code A007: Right rear suspension pressure sensor signal high379
Related circuit diagram379
Fault Code A008: Right rear suspension pressure sensor signal low380
Related circuit diagram380
Fault Code A009: Incline sensor signal high381
Related circuit diagram381
Fault Code A010: Incline sensor signal low382
Related circuit diagram382
Fault Code A011: Payload meter speed sensor signal has Failed383
Related circuit diagram383
Fault Code A013: Body up switch has Failed384
Related circuit diagram384
Fault Code A014: Payload meter checksum computation has Failed385
Related circuit diagram385
Fault Code A016: Payload meter write to flash memory has Failed386
Related circuit diagram386
Fault Code A017: Payload meter flash memory read has Failed387
Related circuit diagram387
Fault Code A018: Right rear flat suspension cylinder warning388
Related circuit diagram389
Fault Code A019: Left rear flat suspension cylinder warning390
Related circuit diagram391
Fault Code A022: Carryback load excessive392
Related circuit diagram393
Fault Code A101: High pressure detected across an hydraulic pump filter394
Related circuit diagram394
Fault Code A103: Hydraulic Oil Temp – Tank Sensor Low395
Related circuit diagram395
Fault Code A104: Hydraulic oil temp – Tank sensor high396
Related circuit diagram396
Fault Code A105: Fuel level sensor shorted to ground indicating a false high fuel level398
Related circuit diagram399
Fault Code A109: GE has generated a propel system reduced level signal400
Related circuit diagram400
Fault Code A111 & A247: Low steering pressure warnings402
Related circuit diagram403
Fault Code A115: Low steering precharge pressure detected404
Related circuit diagram404
Fault Code A117: Low brake accumulator pressure warnings406
Related circuit diagram407
Fault Code A118: Brake pressure is low while in brake lock408
Related circuit diagram408
Fault Code A123: GE has generated a reduced retarding caution409
Related circuit diagram409
Fault Code A124: GE has generated a no propel / no retard warning410
Related circuit diagram410
Fault Code A125: GE has generated a no propel warning411
Related circuit diagram411
Fault Code A126: Oil level in the hydraulic tank is low412
Related circuit diagram412
Fault Code A127: IM-furnished +5 volt output for sensors is low413
Related circuit diagram413
Fault Code A128: IM-furnished +5 volt output for sensors is high414
Related circuit diagram414
Fault Code A139 & A310: Low fuel warnings416
Related circuit diagram417
Troubleshooting by fault code, Part 2419
Fault Code A152: Starter failure421
Related circuit diagram421
Fault Code A153: Battery voltage is low with the truck in operation422
Related circuit diagram423
Fault Code A154: Battery charging voltage is excessive424
Related circuit diagram424
Fault Code A155: Battery charging voltage is low425
Related circuit diagram425
Fault Code A158: The fuel level sensor is open or shorted high indicating a false low fuel level426
Related circuit diagram426
Fault Code A184: J1939 data link is not connected427
Related circuit diagram427
Fault Code A190: Auto lube control has detected an incomplete lube cycle428
Related circuit diagram429
Fault Code A193: Hydraulic tank oil temperature is high430
Related circuit diagram430
Fault Code A198: Hoist pressure 1 sensor is high431
Related circuit diagram431
Fault Code A200: Steering pressure sensor is high432
Related circuit diagram432
Fault Code A201: Brake pressure sensor is high433
Related circuit diagram433
Fault Code A202: Hoist pressure 1 sensor is low434
Related circuit diagram434
Fault Code A204: Steering pressure sensor is low435
Related circuit diagram435
Fault Code A205: Brake pressure sensor is low436
Related circuit diagram436
Fault Code A206: Ambient temperature sensor is high437
Related circuit diagram437
Fault Code A207: Ambient temperature sensor is low438
Related circuit diagram438
Fault Code A213: Parking brake should have applied but is detected as not having applied440
Related circuit diagram441
Fault Code A214: Parking brake should have released but is detected as not having released442
Related circuit diagram443
Fault Code A216: An open or short to ground has been detected in the parking brake command valve circuit444
Related circuit diagram445
Fault Code A223: Excessive engine cranking has occurred or a jump start has been attempted446
Related circuit diagram447
Fault Code A230: Parking brake has been requested while truck still moving448
Related circuit diagram449
Fault Code A231: The body is up while traveling or intending to travel450
Related circuit diagram451
Fault Code A233: Drive system CAN/RPC Control Link not connected452
Related circuit diagram453
Fault Code A235: Steering accumulator is in the process of being bled down454
Related circuit diagram455
Fault Code A236: The steering accumulator has not properly bled after 90 seconds456
Related circuit diagram456
Fault Code A237: The CAN/RPC connection to the display is open457
Related circuit diagram457
Fault Code A240: The key switch input to the interface module is open458
Related circuit diagram458
Troubleshooting by fault code, Part 3461
Fault Code A242: Fuel gauge within the display panel is defective463
Related circuit diagram463
Fault Code A243: Engine coolant temperature gauge within the display panel is defective464
Related circuit diagram464
Fault Code A244: Drive system temperature gauge within the display panel is defective465
Related circuit diagram465
Fault Code A245: Hydraulic oil temperature gauge within the display panel is defective466
Related circuit diagram466
Fault Code A246: Payload meter reports truck overload467
Related circuit diagram467
Fault Code A248: Status module within the display panel is defective468
Related circuit diagram468
Fault Code A249: Red warning lamp within the display (driven by IM) is shorted469
Related circuit diagram469
Fault Code A250: Battery voltage is low with the truck parked470
Related circuit diagram471
Fault Code A251: Sonalert used with the display (driven by IM) is open or shorted to ground472
Related circuit diagram472
Fault Code A252: Start enable output circuit is either open or shorted to ground473
Related circuit diagram473
Fault Code A253: Steering bleed circuit is not open while running474
Related circuit diagram474
Fault Code A255: IM has detected a fault on IM output 1N475
Related circuit diagram475
Fault Code A256: Red warning lamp in the display (driven by IM) is open476
Related circuit diagram476
Fault Code A257: Payload CAN/RPC is not connected477
Related circuit diagram477
Fault Code A258: Steering accumulator bleed pressure switch circuit is defective478
Related circuit diagram478
Fault Code A260: Parking brake failure480
Related circuit diagram481
Fault Code A261: Low brake accumulator pressure warnings482
Related circuit diagram483
Fault Code A262: Steering bleed valve circuit open during shutdown484
Related circuit diagram485
Fault Code A264: Parking brake relay circuit is defective486
Related circuit diagram486
Fault Code A265: Service brake failure488
Related circuit diagram489
Fault Code A266: Selector lever was not in park while attempting to crank engine490
Related circuit diagram490
Fault Code A267: Parking brake was not set while attempting to crank engine491
Related circuit diagram491
Fault Code A268: Secondary engine shutdown while cranking492
Related circuit diagram492
Fault Code A270: Brake lock switch power supply is not on when required494
Related circuit diagram495
Fault Code A271: Shifter not in gear496
Related circuit diagram496
Fault Code A272: Brake lock switch power supply is not off when required498
Related circuit diagram499
Fault Code A273: A fault has been detected in the hoist or steering pump filter pressure switch circuit500
Related circuit diagram500
Fault Code A274: A brake setting fault has been detected502
Related circuit diagram503
Fault Code A275: A starter has been detected as engaged without a cranking attempt504
Related circuit diagram504
Troubleshooting by fault code, Part 4507
Fault Code A277: Parking brake applied while loading509
Related circuit diagram509
Fault Code A278: Service brake applied while loading510
Related circuit diagram510
Fault Code A279: Low steering pressure switch is defective511
Related circuit diagram511
Fault Code A280: Steering accumulator bleed down switch is defective512
Related circuit diagram512
Fault Code A281: Brake lock degrade switch is defective513
Related circuit diagram513
Fault Code A282: The number of excessive cranking counts and jump starts without the engine running has reached 7514
Related circuit diagram515
Fault Code A283: An engine shutdown delay was aborted because the parking brake was not set516
Related circuit diagram517
Fault Code A284: An engine shutdown delay was aborted because the secondary shutdown switch was operated518
Related circuit diagram518
Fault Code A285: The parking brake was not set when the key switch was turned off519
Related circuit diagram519
Fault Code A286: A fault was detected in the shutdown delay relay circuit520
Related circuit diagram520
Fault Code A292: The shutdown delay relay has remained on after the latched keyswitch circuit is off521
Related circuit diagram521
Fault Code A303: Shifter is defective522
Fault Code A304: Auto lube grease level fault523
Related circuit diagram523
Fault Code A305: Auto lube circuit is defective524
Related circuit diagram524
Fault Code A307: Both GE Inverters disabled525
Fault Code A309: No brakes applied when expected526
Related circuit diagram527
Fault Code A311: Brake lock switch on when it shouldn’t be528
Related circuit diagram528
Fault Code A312: The DCDC Converter 12 volt circuit sensing is producing low readings529
Related circuit diagram529
Fault Code A313: The DCDC converter 12 volt circuit sensing is producing high readings530
Related circuit diagram530
Fault Code A315: The DCDC converter 12 volt circuit is low531
Related circuit diagram531
Fault Code A316: Starter engagement has been attempted with engine running532
Related circuit diagram533
Fault Code A318: Unexpected power loss to Interface Module534
Related circuit diagram534
Fault Code A328: Drive system not powered up535
Related circuit diagram535
Fault Code A333: The hydraulic ladder controller has declared a ladder fault536
Related circuit diagram536
Fault Code A334: Selector switch not in park when propel was either not ready or at rest537
Related circuit diagram537
Troubleshooting by fault code, Part 5539
Fault Code A350: Overload on output 1B540
Related circuit diagram540
Fault Code A351: Overload on output 1E541
Related circuit diagram541
Fault Code A352: Overload on output 1H542
Related circuit diagram542
Fault Code A353: Overload on output 1J543
Related circuit diagram543
Fault Code A354: Overload on output 1K544
Related circuit diagram544
Fault Code A355: Overload on output 1L545
Related circuit diagram545
Fault Code A356: Overload on output 1M546
Related circuit diagram546
Fault Code A357: Overload on output 1N547
Related circuit diagram547
Fault Code A358: Overload on output 1P548
Related circuit diagram548
Fault Code A359: Overload on output 1R549
Related circuit diagram549
Fault Code A360: Overload on output 1S550
Related circuit diagram550
Fault Code A361: Overload on output 1T551
Related circuit diagram551
Fault Code A362: Overload on output 1U552
Related circuit diagram552
Fault Code A363: Overload on output 1X553
Related circuit diagram553
Fault Code A364: Overload on output 1Y554
Related circuit diagram554
Fault Code A365: Overload on output 1Z555
Related circuit diagram555
Cab air conditioning557
Preliminary checks559
Diagnosis of gauge readings and system performance559
Troubleshooting by manifold gauge set readings560
50 Disassembly and assembly567
Service tools567
Special tool group569
Additional service tools569
Locally made tools570
Wheels, spindles and rear axle575
General precautions for tires and rims577
Rim components578
Wheel stud maintenance579
Removal and installation of front wheel580
Removal580
Installation581
Removal and installation of rear wheel582
Removal582
Installation583
Rim and tire service585
Lubricants585
Tire inflation585
Removal (5-piece standard rim)585
Preparation before assembly589
Installation (5-piece standard rim)589
Removal and installation of front wheel hub and spindle592
Removal592
Spindle removal (off the truck)597
Installation599
Disassembly and assembly of front wheel hub and spindle600
Cross Section View600
Disassembly601
Cleaning and inspection605
Assembly606
Wheel bearing adjustment610
Speed sensor installation and adjustment612
Hub floating ring seal assembly and installation613
Removal and installation of rear axle618
Removal618
Cleaning and inspection619
Installation620
Removal and installation of anti-sway bar621
Removal621
Installation623
Removal and installation of pivot pin624
Removal624
Installation625
Pivot eye and bearing service626
Bearing replacement626
Pivot eye repair627
Removal and installation of wheel motor628
Preparation628
Removal628
Cleaning and inspection631
Installation631
Brake system637
Removal and installation of brake valve639
Removal639
Installation641
Disassembly and assembly of brake valve/pedal assembly642
Disassembly642
Assembly643
Removal and installation of brake manifold644
Removal644
Installation645
Disassembly and assembly of brake manifold646
Disassembly646
Assembly646
Disassembly and assembly of brake accumulator647
Cleaning and inspection648
Assembly649
Removal and installation of front brake caliper651
Removal651
Inspection652
Installation652
Disassembly and assembly of front brake caliper653
Disassembly653
Cleaning and inspection653
Brake lining replacement656
Assembly656
Removal and installation of rear brake caliper656
Removal656
Inspection659
Installation659
Disassembly and assembly of rear brake caliper662
Disassembly662
Piston subassembly665
Cleaning and inspection666
Assembly668
Piston subassembly668
Brake caliper669
Steering system677
Removal and installation of steering control unit679
Removal679
Installation680
Disassembly and assembly of steering control unit681
Disassembly681
Assembly683
Removal and installation of steering column686
Removal686
Inspection687
Installation688
Removal and installation of steering wheel689
Removal689
Installation689
Removal and installation of bleeddown manifold690
Removal690
Installation692
Removal and installation of flow amplifier693
Removal693
Installation695
Removal and installation of steering cylinders and tie rod695
Removal695
Installation697
Disassembly and assembly of steering cylinders698
Disassembly698
Cleaning and inspection700
Assembly701
Removal and installation of steering/brake pump701
Removal701
Installation704
Removal and installation of piston steering accumulator705
Removal705
Installation707
Disassembly and assembly of piston steering accumulators708
Disassembly708
Cleaning and inspection710
Piston seal replacement710
Assembly711
Suspensions713
Removal and installation of front suspension715
General information715
Removal715
Installation717
Upper mounting joint – 60° advance721
Lower mounting joint – 90° advance722
Inspection722
Disassembly and assembly of front suspension723
Disassembly723
Cleaning and inspection725
Assembly726
Removal and installation of rear suspension728
General information728
Removal728
Installation731
Disassembly and assembly of rear suspension732
Disassembly732
Cleaning and inspection734
Assembly735
Operator cab737
Removal and installation of operator cab739
Removal739
Installation742
Removal and installation of cab door743
Removal743
Installation743
Disassembly and assembly of cab door744
Removing door panel744
Installing door panel745
Replacing the door window regulator745
Replacing door handle or latch assembly746
Replacing door assembly seal and door hinge seal747
Replacing door opening seal747
Removing door glass748
Installing door glass749
Adjustment of cab door751
Door jamb bolt adjustment751
Door handle plunger adjustment752
Removal and installation of side window glass753
Recommended tools and supplies753
Removal754
Installation754
Removal and installation of windshield and rear window glass755
Removal755
Installation755
Removal and installation of windshield wiper motor756
Removal756
Installation757
Removal and installation of windshield wiper arm757
Removal757
Installation757
Removal and installation of windshield wiper linkage758
Removal758
Installation758
Removal and installation of operator seat759
Inspection759
Removal759
Installation759
Replacing the seat compressor (standard seat)760
Removal and installation of passenger seat (standard seat)765
Removal765
Installation765
Removal and installation of seat belts (standard seat)766
Removal766
Installation767
Removal and installation of seat belts (optional seat)768
General768
Removal768
Installation770
Cab air conditioning773
Replacement of air conditioning system components775
Hoses and fittings775
Lines775
Expansion valve775
Receiver-drier775
Thermostat775
Compressor776
Accumulator776
Clutch776
90 Diagrams and drawings779
Hydraulic circuit diagrams779
Electrical circuit diagrams785

IMAGES PREVIEW OF THE MANUAL:

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