Komatsu DUMP TRUCK HD1500-7 Shop Manual SEN05273-05 – PDF DOWNLOAD

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Komatsu DUMP TRUCK HD1500-7 Shop Manual SEN05273-05 – PDF DOWNLOAD

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Komatsu DUMP TRUCK HD1500-7 Shop Manual SEN05273-05 – PDF DOWNLOAD

Language : English
Pages :1320
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu DUMP TRUCK HD1500-7 Shop Manual SEN05273-05 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

FOREWORD

This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck.

• All safety notices, warnings and cautions must be understood before repairing the truck. This manual shows dimensioning of metric and (U.S. standard) 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. Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lbs). All torque specifications have ±10% tolerance unless otherwise specified.
• 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. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
• 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.
• The 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 total maximum GVW. GVW is the total truck weight. This is equal to the empty vehicle weight + the fuel & lubricants + the payload.
• To determine allowable payload: Service all lubricants to the proper level including the fuel tank. Weigh the empty truck. This includes all accessories, body liners, tailgates, etc. Record this value and subtract from the GVW rating. The result is the allowable payload.

TABLE OF CONTENTS:

Komatsu DUMP TRUCK HD1500-7 Shop Manual SEN05273-05 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A GENERAL INFORMATION INDEX 9
SECTION A2 – MAJOR COMPONENTS AND SPECIFICATIONS 11
SECTION A3 – SAFETY – INDEX 15
SAFETY 17
Safety Rules 17
Safety Features 17
Clothing And Personal Items 17
Unauthorized Modification 17
Leaving The Operator’s Seat 17
Mounting And Dismounting 18
Fire Prevention For Fuel And Oil 18
Precautions With High Temperature Fluids 18
Asbestos Dust Hazard Prevention 19
Prevention Of Injury By Work Equipment 19
Fire Extinguisher And First Aid Kit 19
Precautions For ROPS 19
Precautions For Attachments 19
HAUL ROADS 20
PRECAUTIONS DURING OPERATION 20
BEFORE STARTING THE ENGINE 20
Fire Prevention 21
Preparing For Operation 21
Ventilation In Enclosed Areas 21
In Operator’s Cab – Before Starting The Engine 21
Mirrors, Windows, And Lights 21
OPERATING THE MACHINE 22
When Starting The Engine 22
Precautions For Starting Machine 22
Truck Operation – General 22
Traveling 23
Traveling In Reverse 23
Traveling On Slopes 23
Ensure Good Visibility 23
Operate Carefully On Snow 24
Avoid Damage To Dump Body 24
Driving Near High Voltage Cables 24
When Dumping 24
Working On Loose Ground 24
Loading The Body 24
Parking The Machine 24
TOWING 25
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Starting With Booster Cables 25
MAINTENANCE PRECAUTIONS 26
Warning Tag 26
Proper Tools 26
Stopping The Engine Before Service 26
Securing The Dump Body 26
DURING MAINTENANCE 28
Personnel 28
Attachments 28
Working Under The Machine 28
Keep The Machine Clean 28
Rules To Follow When Adding Fuel Or Oil 28
Radiator Water Level 28
Use Of Lighting 28
Precautions With The Battery 29
Handling High Pressure Hoses 29
Precautions With High Pressure Oil 29
Precautions When Performing Maintenance Near High Temperature Or High Pressure 29
Rotating Fan And Belts 29
Waste Materials 29
TIRES 30
Handling Tires 30
Storing Tires After Removal 30
WHEN REPAIRS ARE NECESSARY 31
ADDITIONAL JOB SITE RULES 32
OPERATING INSTRUCTIONS 33
PREPARING FOR OPERATION 33
Safety Is Thinking Ahead 33
Walk Around Inspection 33
Cold Weather Heating System 36
ENGINE START-UP SAFETY PRACTICES 37
Cold Weather Starting 37
Jump Starting 38
AFTER THE ENGINE HAS STARTED 38
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 42
RETARDER OPERATION 43
PASSING 43
DUMPING 44
Raising the Dump Body 44
Lowering The Dump Body 45
SAFE PARKING PROCEDURES 45
TURNING OFF THE ENGINE 46
SUDDEN LOSS OF ENGINE POWER 46
Secondary Steering And Braking 46
DISABLED TRUCK DUMPING 47
Hookup 47
Raising the Body 48
Lowering the Body 48
DISABLED TRUCK STEERING AND BRAKING 49
TOWING 51
SECTION A4 – WARNINGS AND CAUTIONS 53
SECTION A5 – STANDARD TABLES 59
SECTION A7 – STORAGE PROCEDURES – INDEX 67
STORAGE AND IDLE MACHINE PREPARATION 69
SHORT TERM IDLE PERIODS 69
PREPARATION FOR STORAGE 69
REMOVAL FROM STORAGE 70
RECONDITIONING AN IDLE VEHICLE 72
ENGINE OPERATION 75
AFTER THE ENGINE HAS STARTED 75
SHORT TERM ENGINE STORAGE 76
Preparing the Engine 76
Removing the Engine from Long Term Storage 78
TRANSMISSION PRESERVATION AND STORAGE 78
Storage, New Transmission 78
Storage, One Year- Without Oil 78
Storage, One Year – With Oil – Normally Installed On The Truck 79
Restoring The Transmission For Service 79
SECTION B – STRUCTURES – INDEX 81
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 83
STRUCTURAL COMPONENTS 85
PREPARATION 85
GRILLE, HOOD AND LADDERS 86
DECKS 87
CENTER DECK 87
Removal 87
Installation 87
RIGHT DECK AND COMPONENTS 87
Removal 87
Installation 87
LEFT DECK AND CAB 88
Installation 88
SECTION B3 – DUMP BODY – INDEX 89
DUMP BODY 91
Removal 91
Installation 93
BODY PADS 93
Body Pad Adjustment 94
BODY GUIDE 94
BODY-UP RETENTION CABLE 95
ROCK EJECTORS 95
Inspection 95
SECTION B4 – FUEL TANK – INDEX 97
FUEL TANK 99
Removal 99
Cleaning 100
Repair 100
Installation 100
FUEL GAUGE AND SENDING UNIT 101
Removal 101
Installation 101
WIGGINS QUICK FILL FUEL SYSTEM 101
FUEL RECEIVER 101
FUEL TANK BREATHER 102
Removal 102
Installation 102
Disassembly 102
Assembly 102
LEFT SIDE FILL 103
SECTION C – ENGINE – INDEX 105
SECTION C3 – COOLING SYSTEM – INDEX 107
COOLING SYSTEM 109
DESCRIPTION 109
LEAKS AND CONTAMINATION 110
RADIATOR FILL PROCEDURE 110
RADIATOR REMOVAL 111
RADIATOR REPAIR 112
Internal Inspection 112
External Cleaning 112
Disassembly 113
Cleaning and Inspection 114
Assembly 114
Pressure Testing 115
Additional Service Information 115
RADIATOR INSTALLATION 116
TRANSMISSION AND BRAKE COOLERS 117
Removal 118
Disassembly 118
Cleaning And Inspection 119
Assembly 119
Inspection 120
Installation 121
SECTION C4 – ENGINE – INDEX 123
ENGINE 125
Removal 125
Inspection 128
Installation 129
DRIVE LINE ADAPTER 130
Removal 131
Disassembly 132
Cleaning and Inspection 134
Assembly 136
Installation 140
Bearing Tools 141
SECTION C5 – AIR FILTRATION SYSTEM – INDEX 143
AIR FILTRATION SYSTEM 145
AIR CLEANER 145
Operation 145
AIR CLEANER MAINTENANCE 145
Filter Service Indicator 147
Replacing The Elements 147
MAIN FILTER CLEANING 148
PRECLEANER CLEANING 149
AIR INTAKE TROUBLESHOOTING 150
SECTION C7 – FAN CLUTCH – INDEX 151
FAN CLUTCH 153
REMOVAL & INSTALLATION TOOLING 153
FAN CLUTCH – DISASSEMBLY 156
CLEANING AND INSPECTION 166
ASSEMBLY – FAN CLUTCH 170
TEST PROCEDURE 184
SECTION D – ELECTRICAL SYSTEM – INDEX 185
SECTION D2 – BATTERIES AND STARTING SYSTEM – INDEX 187
BATTERIES AND STARTING SYSTEM 189
BATTERIES 189
MAINTENANCE AND SERVICE 189
Electrolyte Levels 189
Cleaning 189
Other Maintenance 190
ENGINE PRELUB™ SYSTEM 192
OPERATION 192
Oil Pressure Switch 194
Check Valve 194
Timer Solenoid 194
MAINTENANCE 194
Prelub™ System Operation 194
Prelub Pump 194
Check Valve 195
Timer Solenoid 195
PRELUB CIRCUIT TROUBLESHOOTING 196
STARTING SYSTEM 198
CRANKING MOTORS 198
Removal 198
Disassembly 199
Cleaning and Inspection 199
Armature Servicing 199
Field Coil Checks 200
Field Coil Removal 200
Solenoid Checks 202
Assembly 203
Installation 205
TROUBLESHOOTING 205
Preliminary Inspection 205
No-Load Test 205
Interpreting The Results of The Tests 206
MAGNETIC SWITCH 207
Removal 207
Installation 207
Coil Test 207
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 209
ELECTRICAL SYSTEM COMPONENTS 211
CAB MOUNTED COMPONENTS 211
CIRCUIT BREAKERS 213
RELAY CENTER 214
FUSE PANEL 219
EXTERIOR COMPONENTS 223
BATTERY BOX 223
BATTERY DISCONNECT SWITCH 223
GROUND LEVEL SHUT OFF SWITCH 223
CONTROL POWER RELAYS 223
CIRCUIT BREAKERS 223
BATTERY EQUALIZER 223
Test 223
BODY POSITION SWITCHES 225
Proximity Switch Operation 225
Body-Up Switch Adjustment 226
Hoist Limit Switch Adjustment 226
SPEED SENSORS 228
Sensor Adjustment 229
GENERAL TROUBLESHOOTING 229
SECTION D10 – CHARGING SYSTEM – INDEX 231
CHARGING SYSTEM 233
PRIMARY CAUSES OF CHARGING SYSTEM MALFUNCTION 233
Excessive heat 233
Dirt and dust 233
Vibration 233
PREVENTIVE MAINTENANCE PROCEDURES 234
Alternator Cleanliness 234
Alternator Mounting 234
Belt Tension And Condition 234
TROUBLESHOOTING 234
ALTERNATOR PERFORMANCE TEST 234
ALTERNATOR CABLE TEST 235
VOLTAGE REGULATOR ADJUSTMENT 236
ALTERNATOR 237
Removal 237
Installation 238
SECTION D15 – MACHINE MONITOR – INDEX 241
MACHINE MONITOR 243
CHARACTER DISPLAY 243
Mode Select Switches 1 & 2 244
Service Meter 244
Odometer 244
Operation Information 244
Reverse Travel Odometer 245
Filter And Oil Change Display 245
Display Items 246
Resetting The Filter/Oil Replacement Meter 246
Inputting Telephone Numbers 247
Selecting A Language 247
ACTION CODE DISPLAYS 248
E03 Codes 248
E02 Codes 249
E01 Codes 249
REAL TIME MONITOR 250
USING REAL TIME MONITOR 250
Viewing Two Streams of Data At Once 251
MACHINE MONITOR FLOW CHART 256
SECTION D20 – FAILURE CODES – INDEX 261
FAILURE CODES 263
ACTION CODE DISPLAYS 263
CHECKING FAILURE CODES 264
LIMP HOME MODE 265
FAILURE CODE TABLE 266
SECTION D21 – TROUBLESHOOTING 283
FAILURE CODE [1500L0] DUAL ENGAGEMENT OF CLUTCHES 283
FAILURE CODE [15B0NX] TRANSMISSION OIL FILTER: RESTRICTION 284
FAILURE CODE [15F0KM] R to F SHIFTING ABUSE 1: OPERATOR ERROR 286
FAILURE CODE [15F0MB] R to F SHIFTING ABUSE 2: OPERATOR ERROR 286
FAILURE CODE [15F7KM] FORWARD CLUTCH DISC ABUSE: OPERATOR ERROR 287
FAILURE CODE [15G0MW] REVERSE CLUTCH: SLIPPING 288
FAILURE CODE [15G7KM] REVERSE CLUTCH DISC ABUSE: OPERATOR ERROR 290
FAILURE CODE [15H0MW] HIGH CLUTCH: SLIPPING 292
FAILURE CODE [15J0MW] LOW CLUTCH: SLIPPING 294
FAILURE CODE [15K0MW] 1st CLUTCH: SLIPPING 296
FAILURE CODE [15L0MW] 2nd CLUTCH: SLIPPING 298
FAILURE CODE [15M0MW] 3rd CLUTCH: SLIPPING 300
FAILURE CODE [15SBL1] R CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 302
FAILURE CODE[15SBMA] R CLUTCH ECMV: MALFUNCTION 304
FAILURE CODE [15SCL1] HIGH CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 306
FAILURE CODE [15SCMA] HIGH CLUTCH ECMV: MALFUNCTION 310
FAILURE CODE [15SDL1] LOW CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 312
FAILURE CODE [15SDMA] LOW CLUTCH ECMV: MALFUNCTION 316
FAILURE CODE [15SEL1] 1st CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 318
FAILURE CODE [15SEMA] 1st CLUTCH ECMV: MALFUNCTION 322
FAILURE CODE [15SFL1] 2nd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 324
FAILURE CODE [15SFMA] 2nd CLUTCH ECMV: MALFUNCTION 328
FAILURE CODE [15SGL1] 3rd CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 330
FAILURE CODE [15SGMA] 3rd CLUTCH ECMV: MALFUNCTION 334
FAILURE CODE [15SJMA] LOCKUP CLUTCH ECMV: MALFUNCTION 336
FAILURE CODE [15SSL1] MID CLUTCH ECMV: FILL SIGNAL ON, COMMAND CURRENT OFF 337
FAILURE CODE [15SSMA] MID CLUTCH ECMV: MALFUNCTION 340
FAILURE CODE [15X0MW] MID CLUTCH: SLIPPING 342
FAILURE CODE [2G39MA] BRAKE VALVE: MALFUNCTION 344
FAILURE CODE [2G3AMA] BRAKE RELAY VALVE: MALFUNCTION 345
FAILURE CODE [2G41ZG] ACCUMULATOR: LOW OIL PRESSURE 346
FAILURE CODE [2J00MA] AUTO EMERGENCY VALVE: ERRATIC BEHAVIOR 347
FAILURE CODE [4A00ZG] STEERING SYSTEM: LOW OIL PRESSURE 348
FAILURE CODE [4A5WZH] STEERING ACCUMULATOR 1: LOW OIL PRESSURE 349
FAILURE CODE [4A5XZH] STEERING ACCUMULATOR 2: LOW OIL PRESSURE 350
FAILURE CODE [6014NX] HYDRAULIC FILTER: RESTRICTION 351
FAILURE CODE [989A00] ENGINE OVER RUN PREVENTION COMMAND: ACTIVATED 352
FAILURE CODE [AB00MA] ALTERNATOR: MALFUNCTION 353
FAILURE CODE [B@BAZG] ENGINE OIL: LOW ENGINE OIL PRESSURE 354
FAILURE CODE [B@BCNS] ENGINE: OVERHEAT 355
FAILURE CODE [B@BFZK] FUEL SYSTEM: FUEL LEVEL LOW 356
FAILURE CODE [B@C6NS] BRAKE COOLING OIL (FRONT): OVERHEATING 357
FAILURE CODE [B@C7NS] BRAKE COOLING OIL (RIGHT REAR): OVERHEATING 358
FAILURE CODE [B@C8NS] BRAKE COOLING OIL (LEFT REAR): OVERHEATING 359
FAILURE CODE [B@CENS] TORQUE CONVERTER OIL: OVERHEATING 360
FAILURE CODE [B@M6NX] BRAKE COOLING OIL FILTER (FRONT): RESTRICTION 361
FAILURE CODE [B@M7NX] BRAKE COOLING OIL FILTER (#2 REAR): RESTRICTION 362
FAILURE CODE [B@M8NX] BRAKE COOLING OIL FILTER (#1 REAR): RESTRICTION 363
FAILURE CODE [DAF9KM] MACHINE MONITOR: POOR CONNECTION 364
FAILURE CODE [DAFRKR] MACHINE MONITOR: COMMUNICATION ERROR 366
FAILURE CODE [DAQ0KK] TRANSMISSION CONTROLLER POWER: SOURCE VOLTAGE LOW 370
FAILURE CODE [DAQ2KK] TRANSMISSION CONTROLLER / ECMV POWER: SOURCE VOLTAGE LOW 371
FAILURE CODE [DAQ9KQ] TRANSMISSION CONTROLLER: MODEL SELECTION ERROR 372
FAILURE CODE [DAQRKR] TRANSMISSION CONTROLLER: COMMUNICATION ERROR 373
FAILURE CODE [DAQRMA] TRANSMISSION CONTROLLER: OPTION SETTING ERROR 374
FAILURE CODE [DAQV00] NEUTRAL COAST CAUTION 375
FAILURE CODE [DAQW00] NEUTRAL OVER SPEED CAUTION 376
FAILURE CODE [DAS0MA] ENGINE MALFUNCTION: RED INDICATOR LIGHT 377
FAILURE CODE [DAS0MC] ENGINE MALFUNCTION: AMBER INDICATOR LIGHT 378
FAILURE CODE [DASRKR] ENGINE: COMMUNICATION ERROR 379
FAILURE CODE [DB10KT] RETARDER CONTROLLER NONVOLATILE MEMORY: CONTROLLER ERROR 380
FAILURE CODE [DB12KK] RETARDER CONTROLLER SOLENOID POWER SOURCE: MALFUNCTION 381
FAILURE CODE [DB13KK] RETARDER CONTROLLER BATTERY DIRECT POWER SOURCE: SOURCE VOLTAGE LOW 382
FAILURE CODE [DB19KQ] RETARDER CONTROLLER: MODEL SELECTION ERROR 383
FAILURE CODE [DB1RKR] RETARDER CONTROLLER: COMMUNICATION ERROR 384
FAILURE CODE [DB1RMA] RETARDER CONTROLLER: OPTION SETTING ERROR 386
FAILURE CODE [dBBRKR] VHMS: COMMUNICATION ERROR 387
FAILURE CODE [DDB4MA] BRAKE SENSOR: OPEN OR SHORT CIRCUIT 388
FAILURE CODE [DDD7KX] ARSC SWITCH: INPUT SIGNAL OUT OF RANGE 390
FAILURE CODE [DDD8KA] ARSC SWITCH: OPEN CIRCUIT 392
FAILURE CODE [DDD8KB] ARSC SWITCH: SHORT CIRCUIT 393
FAILURE CODE [DDDAKA] ASR CUT SWITCH: OPEN CIRCUIT 394
FAILURE CODE [DDDAKB] ASR CUT SWITCH: SHORT CIRCUIT 395
FAILURE CODE [DDP6MA] BRAKE SWITCH: OPEN OR SHORT CIRCUIT 396
FAILURE CODE [DDTHKA] HIGH CLUTCH FILL SWITCH: OPEN CIRCUIT 398
FAILURE CODE [DDTJKA] LOW CLUTCH FILL SWITCH: OPEN CIRCUIT 400
FAILURE CODE [DDTKKA] 1ST CLUTCH FILL SWITCH: OPEN CIRCUIT 402
FAILURE CODE [DDTLKA] 2ND CLUTCH FILL SWITCH: OPEN CIRCUIT 404
FAILURE CODE [DDTMKA] 3RD CLUTCH FILL SWITCH: OPEN CIRCUIT 406
FAILURE CODE [DDTNKA] REVERSE CLUTCH FILL SWITCH: OPEN CIRCUIT 408
FAILURE CODE [DDTRKA] MID CLUTCH FILL SWITCH: OPEN CIRCUIT 410
FAILURE CODE [DF10KA] SHIFT LEVER: OPEN CIRCUIT 412
FAILURE CODE [DF10KB] SHIFT LEVER: SHORT CIRCUIT 416
FAILURE CODE [DGF1KX] TRANSMISSION OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 419
FAILURE CODE [DGR2KB] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): SHORT TO GROUND 420
FAILURE CODE [DGR2KZ] RETARDER OIL TEMPERATURE SENSOR (RIGHT REAR): OPEN OR SHORT CIRCUIT 421
FAILURE CODE [DGR3KB] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): SHORT TO GROUND 422
FAILURE CODE [DGR3KZ] RETARDER OIL TEMPERATURE SENSOR (LEFT REAR): OPEN OR SHORT CIRCUIT 423
FAILURE CODE [DGR4KB] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): OPEN OR SHORT CIRCUIT 424
FAILURE CODE [DGR4KZ] RETARDER OIL TEMPERATURE SENSOR (FRONT WHEEL): SHORT TO GROUND 425
FAILURE CODE [DGT1KX] TORQUE CONVERTER OIL TEMPERATURE SENSOR: INPUT SIGNAL OUT OF RANGE 426
FAILURE CODE [dHP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 427
FAILURE CODE [DhP4KX] RIGHT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 428
FAILURE CODE [dHP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 429
FAILURE CODE [DhP5KX] LEFT FRONT SUSPENSION PRESSURE SENSOR: OUT OF RANGE 430
FAILURE CODE [DHP6KX] RIGHT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 431
FAILURE CODE [DHP7KX] LEFT REAR SUSPENSION PRESSURE SENSOR: OUT OF RANGE 432
FAILURE CODE [DHT5KX] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: OUT OF RANGE 433
FAILURE CODE [DHT5L6] TORQUE CONVERTER INLET OIL PRESSURE SENSOR: MALFUNCTION 434
FAILURE CODE [DHT7KX] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: OUT OF RANGE 435
FAILURE CODE [DHT7L6] TORQUE CONVERTER OUTLET OIL PRESSURE SENSOR: MALFUNCTION 436
FAILURE CODE [DJF1KA] FUEL LEVEL SENSOR: OPEN CIRCUIT 437
FAILURE CODE [DK11KX] ACCELERATOR PEDAL SENSOR: OUT OF RANGE 438
FAILURE CODE [DK30KX] STEERING ANGLE POTENTIOMETER: OPEN CIRCUIT 439
FAILURE CODE [DK51KX] RETARDER LEVER POTENTIOMETER: OUT OF RANGE 440
FAILURE CODE [DKH1KX] INCLINATION SENSOR: OUT OF RANGE 442
FAILURE CODE [DL10LC] WHEEL SPEED SENSOR CIRCUIT: MALFUNCTION 443
FAILURE CODE [DLE2KA] ENGINE SPEED SENSOR: OPEN CIRCUIT 444
FAILURE CODE [DLE2LC] ENGINE SPEED SENSOR: MALFUNCTION 445
FAILURE CODE [DLF1KA] TRANSMISSION INPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 446
FAILURE CODE [DLF1LC] TRANSMISSION INPUT SHAFT SPEED SENSOR: MALFUNCTION 447
FAILURE CODE [DLF2KA] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: OPEN CIRCUIT 448
FAILURE CODE [DLF2LC] TRANSMISSION INTERMEDIATE SHAFT SPEED SENSOR: MALFUNCTION 449
FAILURE CODE [DLF8LC] RIGHT REAR WHEEL SPEED SENSOR: MALFUNCTION 450
FAILURE CODE [DLF9LC] LEFT REAR WHEEL SPEED SENSOR: MALFUNCTION 451
FAILURE CODE [dLt3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 452
FAILURE CODE [dLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 453
FAILURE CODE [DLT3KA] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: OPEN CIRCUIT 454
FAILURE CODE [dLt3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 455
FAILURE CODE [dLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: MALFUNCTION 456
FAILURE CODE [DLT3LC] TRANSMISSION OUTPUT SHAFT SPEED SENSOR: DISAGREEMENT OF REVOLUTION SPEED SIGNAL 457
FAILURE CODE [DNCCMA] BRAKE PEDAL PROXIMITY SWITCH: SHORT CIRCUIT 458
FAILURE CODE [DV00KB] WARNING ALARM BUZZER OUTPUT: SHORT CIRCUIT 459
FAILURE CODE [DW78KZ] REAR BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 460
FAILURE CODE [DW79KZ] FRONT BRAKE COOLING VALVE: OPEN OR SHORT CIRCUIT 461
FAILURE CODE [DW7FMA] MANUAL EMERGENCY BRAKE VALVE: FAILURE 462
FAILURE CODE [DW7GMA] BRAKE VALVE (REAR) OR BRAKE LOCK VALVE: SHORT CIRCUIT 463
FAILURE CODE [DWA1K4] PPC CUT VALVE: MALFUNCTION (VALVE STUCK ON) 464
FAILURE CODE [DWA1KA] PPC CUT VALVE: OPEN CIRCUIT 465
FAILURE CODE [DWA1KB] PPC CUT VALVE: SHORT CIRCUIT 466
FAILURE CODE [DWA1KY] PPC CUT VALVE: SHORT TO POWER 467
FAILURE CODE [DWA1MA] PPC CUT VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 468
FAILURE CODE [DX12K4] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 470
FAILURE CODE [DX12KA] FRONT BRAKE PPC SOLENOID VALVE: OPEN CIRCUIT 472
FAILURE CODE [DX12KB] FRONT BRAKE PPC SOLENOID VALVE: SHORT CIRCUIT 473
FAILURE CODE [DX12KY] FRONT BRAKE PPC SOLENOID VALVE: SHORT TO POWER 474
FAILURE CODE [DX12MA] FRONT BRAKE PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 475
FAILURE CODE [DX27K4] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE STUCK ON) 476
FAILURE CODE [DX27KA] RIGHT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 478
FAILURE CODE [DX27KB] RIGHT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 479
FAILURE CODE [DX27KY] RIGHT REAR PPC SOLENOID VALVE: SHORT TO POWER 480
FAILURE CODE [DX27MA] RIGHT REAR PPC SOLENOID VALVE: MALFUNCTION 481
FAILURE CODE [DX28K4] LEFT REAR PPC SOLENOID VALVE: ERATIC OPERATION 482
FAILURE CODE [DX28KA] LEFT REAR PPC SOLENOID VALVE: OPEN CIRCUIT 484
FAILURE CODE [DX28KB] LEFT REAR PPC SOLENOID VALVE: SHORT CIRCUIT 485
FAILURE CODE [DX28KY] LEFT REAR PPC SOLENOID VALVE: SHORT TO POWER 486
FAILURE CODE [DX28MA] LEFT REAR PPC SOLENOID VALVE: MALFUNCTION (VALVE DOES NOT OPERATE) 487
FAILURE CODE [DXH1KA] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 488
FAILURE CODE [DXH1KB] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 489
FAILURE CODE [DXH1KY] LOCKUP CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 490
FAILURE CODE [DXH2KA] HIGH CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 492
FAILURE CODE [DXH2KB] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 494
FAILURE CODE [DXH2KY] HIGH CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 496
FAILURE CODE [DXH3KA] LOW CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 500
FAILURE CODE [DXH3KB] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 502
FAILURE CODE [DXH3KY] LOW CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 504
FAILURE CODE [DXH4KA] 1ST CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 508
FAILURE CODE [DXH4KB] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 510
FAILURE CODE [DXH4KY] 1ST CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 512
FAILURE CODE [DXH5KA] 2ND CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 516
FAILURE CODE [DXH5KB] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 518
FAILURE CODE [DXH5KY] 2ND CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 520
FAILURE CODE [DXH6KA] 3RD CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 524
FAILURE CODE [DXH6KB] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 526
FAILURE CODE [DXH6KY] 3RD CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 528
FAILURE CODE [DXH7KA] R CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 532
FAILURE CODE [DXH7KB] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 534
FAILURE CODE [DXH7KY] R CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 536
FAILURE CODE [DXJ7KA] MID CLUTCH ECMV OUTPUT CIRCUIT: OPEN CIRCUIT 540
FAILURE CODE [DXJ7KB] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT CIRCUIT 542
FAILURE CODE [DXJ7KY] MID CLUTCH ECMV OUTPUT CIRCUIT: SHORT TO POWER 544
SECTION D30 – VHMS INITIALIZATION – INDEX 547
INITIALIZATION OF VHMS CONTROLLER 549
Executing Quick PM 560
Downloading Existing VHMS Setting Data 565
Confirmation of Downloaded Data 566
Disconnecting the PC 566
Reporting to Komatsu 566
REPLACING THE VHMS CONTROLLER 568
Prior to Removing VHMS Controller 568
Confirming and Saving VHMS Controller Settings (Versions older than 3521) 568
Loading Saved VHMS Settings To New VHMS Controller (Versions older than 3521) 572
Confirming and Saving VHMS Controller Settings (Version 3521 or newer) 574
Loading Saved VHMS Settings To New VHMS Controller (Version 3521 or newer) 575
FINAL VHMS PROCEDURES-POST INSTALLATION 576
Correct the Load Weight Calculation 578
SECTION F – TRANSMISSION / TORQUE CONVERTER – INDEX 587
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 589
TORQUE CONVERTER AND TRANSMISSION 591
TRANSMISSION 591
TORQUE CONVERTER 592
MAIN RELIEF VALVE 594
Function 594
Operation 594
TORQUE CONVERTER RELIEF VALVE 594
Function 594
Operation 594
TORQUE CONVERTER REGULATOR VALVE 596
Operation 596
LOCK-UP CLUTCH 597
Lock-up Clutch Accumulator 597
HYDRAULIC PUMP 598
TORQUE CONVERTER STALL CHECK 599
TRANSMISSION 600
LUBRICATION RELIEF VALVE 602
Function 602
TRANSMISSION CONTROL VALVE 603
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 605
Pressure Control Valve 606
Flow Sensor Valve 606
ECMV and Proportional Solenoid 606
ECMV and Fill Switch 606
ECMV Operation 607
ECMV REPAIR PROCEDURE 610
Filter Replacement Procedure 610
ECMV Removal 611
Disassembly 611
Assembly 612
ECMV Identification 613
TRANSMISSION FILTERS 614
Service 614
Installation 614
TRANSMISSION REMOVAL 615
TRANSMISSION INSTALLATION 616
TRANSMISSION OIL LEVEL CHECK 618
SECTION F3 – TRANSMISSION OIL COOLER AND STRAINERS – INDEX 619
TRANSMISSION OIL COOLER & STRAINERS 621
TRANSMISSION OIL COOLER 621
Removal and Installation 621
Repair 621
TRANSMISSION OIL STRAINER 621
Removal 622
Inspection 622
Installation 622
SECTION F5 – DRIVE SHAFTS – INDEX 623
DRIVE SHAFTS 625
FRONT DRIVE SHAFT 625
Removal 625
Disassembly 625
Assembly 625
Installation 626
FRONT DRIVE SHAFT ALIGNMENT 627
REAR DRIVE SHAFT 630
Removal 630
Disassembly 631
Assembly 631
Installation 631
SECTION F8 – TORQUE CONVERTER REBUILD – INDEX 633
TORQUE CONVERTER REBUILD 635
REMOVAL 635
INSTALLATION 637
DISASSEMBLY 639
PTO COVER DISASSEMBLY 647
CLEANING & INSPECTION 648
TABLE I COMPONENT WEAR LIMITS 649
TABLE II Gear Backlash 649
ASSEMBLY 650
ONE-WAY CLUTCH ASSEMBLY 651
STATOR BEARING PRE-LOAD ADJUSTMENT 653
PTO DRIVE ASSEMBLY 656
SPECIAL TOOLS 662
SECTION F9 – TRANSMISSION REBUILD – INDEX 663
TRANSMISSION DISASSEMBLY 665
Number One Clutch Housing Disassembly 671
Bearing Cage & Cover Disassembly 673
Number Four Carrier Disassembly 674
Output Shaft Cover Disassembly 676
Rear Case Bearing Removal 676
Output Shaft Removal 676
Output Shaft Disassembly 677
Number Five/Six Carrier Disassembly 677
CLEANING AND INSPECTION 678
INSPECTION TABLE INDEX 678
TRANSMISSION ASSEMBLY 684
GENERAL INSTRUCTIONS 684
Number Five/Six Carrier Assembly 684
Output Shaft Assembly 685
Number Seven Clutch Assembly 686
Rear Case Assembly 687
Rear Case & Carrier Assembly 687
Number Six Clutch Assembly 689
Number Four Carrier Assembly 690
Number Four Carrier Bearing Cage Assembly 691
Number Five Clutch Assembly 691
Number Four Clutch Assembly 692
Number Three Clutch Assembly 692
Clutch Test 693
Number Two Clutch Ring Gear Installation 693
Number Three Carrier & Number Two Clutch Assembly 694
Number One Carrier Assembly 694
Checks Prior to Final Assembly 701
Final Assembly 702
Input Shaft Installation 703
External Components 705
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 707
SECTION G2 – TIRES AND RIMS – INDEX 709
TIRES AND RIMS 711
GENERAL INFORMATION 711
FRONT TIRES AND RIMS 712
Removal 712
Installation 713
REAR TIRE AND RIM 713
Removal 713
Installation 715
TIRE MATCHING 715
RIM 716
Tire Removal From Rim 716
Tire Installation On Rim 716
FRONT WHEEL STUD INSTALLATION 717
REAR WHEEL STUD INSTALLATION 718
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 721
FRONT WHEEL HUB AND SPINDLE 723
OIL SAMPLE ANALYSIS 723
Oil Sampling Guidelines 723
Guidelines For Obtaining A Sample 723
FRONT WHEEL HUB 724
Removal 724
Disassembly 724
Inspection 724
Assembly 725
Installation 727
Front Wheel Hub Bearing Adjustment 727
FRONT SPINDLE 728
A-ARM 728
Removal 728
Inspection 728
Installation 728
CENTER TIE ROD PIVOT 729
Removal 729
Inspection 729
Installation 729
TOE IN ADJUSTMENT 730
Adjustment Procedure 730
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 735
REAR AXLE ATTACHMENTS 737
CENTER LINK AND LOWER LINKS 737
Removal 737
Inspection 738
Spherical Bearing Replacement 738
Installation 738
PANHARD ROD (DIAGONAL LINK) 739
Removal 739
Inspection 740
Installation 740
SECTION G5 -REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 741
REAR AXLE & FINAL DRIVE ASSEMBLY 743
DIFFERENTIAL OPERATION 743
Straight-away-travel 743
Turning 743
REAR AXLE ASSEMBLY 744
Removal 744
Installation 744
DIFFERENTIAL OIL LEVEL CHECK 745
DIFFERENTIAL ASSEMBLY 746
Removal 746
Installation 747
Disassembly 747
Pinion Carrier Assembly 750
Differential Gear Unit 750
Differential Gear Unit 751
Cleaning and Inspection 754
Assembly 754
Differential Bearing 754
Assembly Of Differential Gear Assembly 754
Installation Of Differential Assembly 756
Input Pinion and Carrier Assembly 757
Adjusting Tooth Contact, Backlash 761
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 765
FINAL DRIVE PLANETARIES AND WHEEL HUBS 767
FINAL DRIVE 767
Oil Level Check 768
FINAL DRIVE CARRIER ASSEMBLY 768
Removal 768
Installation 769
Disassembly 769
Assembly 770
FINAL DRIVE ASSEMBLY 771
Disassembly 771
Assembly 773
SECTION H – SUSPENSIONS – INDEX 775
SECTION H2 – FRONT SUSPENSION – INDEX 777
FRONT SUSPENSION 779
Removal 781
Installation 782
Disassembly 783
Cleaning and Inspection 785
Assembly 785
Pressure Tests 786
DAMPING VALVE REPAIR 787
Disassembly 787
Assembly 788
SECTION H3 – REAR SUSPENSION – INDEX 789
REAR SUSPENSION 791
Operation 792
Removal 793
Installation 793
Disassembly 793
Cleaning and Inspection 797
Assembly 797
LEAK TESTING 798
SPHERICAL BEARINGS 798
Removal 798
Inspection 798
Installation 798
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 799
SUSPENSION OILING AND CHARGING 801
GENERAL INFORMATION 801
Equipment List 801
FRONT SUSPENSION 803
Front Suspension Oiling 803
Front Suspension Nitrogen Charging 806
REAR SUSPENSION 808
GENERAL INFORMATION 808
Rear Suspension Oiling 808
Rear Suspension Nitrogen Charging 812
FRONT AND REAR CYLINDER LENGTH ADJUSTMENT 812
SECTION J – BRAKE SYSTEM – INDEX 815
SECTION J2- BRAKE SYSTEM OPERATION – INDEX 817
BRAKE SYSTEM OPERATION 819
DESCRIPTION 819
SERVICE BRAKE OPERATION 820
SECONDARY BRAKING AND AUTOMATIC APPLY 820
BRAKE SYSTEM COMPONENTS 822
BRAKE MANIFOLD CARTRIDGE VALVES 824
SERVICE BRAKE CIRCUIT 828
RETARDING CIRCUIT 830
PARKING BRAKE CIRCUIT 832
AUTO APPLY 834
AUXILIARY BRAKE CIRCUIT 836
BRAKE LOCK CIRCUIT 838
AUTOMATIC SPIN REGULATOR 840
BRAKE COOLING CIRCUIT 842
BRAKE COOLING VALVE 843
COLD OIL DIVERTER VALVES 846
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 847
BRAKE CIRCUIT COMPONENT SERVICE 849
BRAKE VALVE 850
Rebuild Criteria 850
Removal 850
Installation 851
Disassembly 852
Cleaning and Inspection 853
Assembly 855
Actuator Base Threaded Inserts 855
Boot and Cap 855
Valve Body Seal Installation 855
Regulator Sleeve O-Ring Installation 855
Actuator Plunger O-ring Installation 856
Assembly of Valve 857
BENCH TEST AND ADJUSTMENT 858
Test Bench Only 858
Test Set Up Procedure 858
Brake Valve Output Pressure Adjustment 860
Final Test and Adjustment 861
Proximity Switch Installation and Adjustment 863
Installation Of Brake Pedal Actuator Assembly to Brake Valve 863
BRAKE ACCUMULATORS 864
Removal 865
Installation 865
Disassembly 865
Cleaning and Inspection 867
Assembly 867
Leak Testing 869
ACCUMULATOR CHARGING 870
Temperature During Precharge 872
ACCUMULATOR STORAGE 873
Installation 873
BRAKE COOLING VALVE (BCV) 874
RETARDER CONTROL LEVER 875
Removal 875
Installation 875
Disassembly and Adjustment 875
Potentiometer Check 877
Assembly 877
Retard Lever Calibration 878
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 879
BRAKE CIRCUIT CHECK-OUT 881
REQUIRED EQUIPMENT 881
PREPARATION 881
BRAKE CIRCUIT TESTING 882
Initial System Setup 882
Parking Brake 883
Brake Lock 884
Low-Brake Pressure and Auto-Apply 884
Validation 885
Retarding 885
BRAKE SYSTEM DATA SHEET 886
BRAKE CIRCUIT TROUBLESHOOTING 889
SECTION J5 – FRONT WET DISC BRAKES – INDEX 893
FRONT WET DISC BRAKES 895
BRAKE MAINTENANCE 896
Checking Disc Wear 896
FRONT BRAKE ASSEMBLY 898
Removal 898
Installation 898
Disassembly 898
Cleaning and Inspection 899
Assembly 900
Floating Seal Installation 903
BRAKE BLEEDING 906
SECTION J6 – REAR WET DISC BRAKES – INDEX 907
REAR WET DISC BRAKES 909
DESCRIPTION 909
OPERATION 909
MAINTENANCE 910
Checking Brake Disc Wear 910
REMOVAL 911
INSTALLATION 912
BRAKE REBUILD 914
Disassembly 914
Cleaning and Inspection 915
Assembly 915
Floating Ring Seal Assembly/Installation 916
WET DISC BRAKE BLEEDING 920
SECTION J7 – PARKING BRAKE – INDEX 921
PARKING BRAKE 923
Description 923
Parking Brake Service Criteria 923
Removal 924
Installation 924
PARKING BRAKE SPRING CYLINDER REPLACEMENT 926
Removal 926
Installation 926
AUTOMATIC SLACK ADJUSTER 926
Adjustment Procedure 926
PARKING BRAKE CHECK-OUT 927
SECTION L – HYDRAULIC SYSTEM – INDEX 929
SECTION L2 – HYDRAULIC SYSTEM OVERVIEW – INDEX 931
HYDRAULIC SYSTEM OVERVIEW 933
SYSTEM COMPONENTS 933
HYDRAULIC TANK 933
BLEED-DOWN MANIFOLD 935
HOIST VALVE 935
HOIST PUMP 935
BRAKE COOLING PUMP 936
BRAKE CONTROL VALVE (BCV) 936
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 937
HYDRAULIC COMPONENT REPAIR 939
HYDRAULIC TANK 939
FILLING INSTRUCTIONS 939
MAINTENANCE 939
Removal 940
Installation 942
Gap Measurement – Hydraulic Tank Mounting 942
STRAINERS AND DIFFUSERS 943
Removal 943
Cleaning and Inspection 943
Installation 944
HYDRAULIC TANK BREATHER 944
Service 945
HYDRAULIC SYSTEM FLUSHING 945
HYDRAULIC PUMPS 946
Removal 946
Installation 947
PUMP REBUILD 948
Disassembly 948
Inspection Of Parts 951
Assembly 951
Bearing Replacement 954
Seal Replacement 954
TROUBLESHOOTING GUIDE 957
SECTION L4 – STEERING CIRCUIT – INDEX 959
STEERING CIRCUIT 961
OPERATION 961
COMPONENT DESCRIPTION 961
Steering Control Valve 961
Bleed-down Manifold 961
Bleed-down Solenoid 962
Accumulators 963
Flow Amplifier 963
High Pressure Filter 963
Warning Devices 963
FLOW AMPLIFIER OPERATION 965
STEERING/BRAKE PUMP 973
COMPONENTS 973
OPERATION 975
SECTION L5 – STEERING CONTROL UNIT – INDEX 977
STEERING CONTROL UNIT 979
Removal 979
Installation 979
REBUILD PROCEDURE 980
Disassembly 981
Cleaning and Inspection 982
Assembly 984
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 989
STEERING CIRCUIT COMPONENT REPAIR 991
BLEED-DOWN MANIFOLD 991
Removal 991
Adjusting Relief Valve 991
Testing and Adjustment 992
FLOW AMPLIFIER 993
Removal 993
Installation 993
Disassembly 993
Assembly 996
ACCUMULATORS 997
Removal 997
Installation 998
Disassembly 999
Cleaning and Inspection 999
Assembly 999
Leak Testing1000
STEERING ACCUMULATOR CHARGING1002
Temperature During Precharge1005
ACCUMULATOR STORAGE1005
Installation1006
STEERING CYLINDER1007
Removal1007
Installation1007
STEERING CYLINDER REBUILD1008
Disassembly1008
Cleaning and Inspection1008
Assembly1009
STEERING/BRAKE PUMP1009
Removal1009
Installation1010
PUMP REBUILD1011
Disassembly1011
Control Group1012
Valve Plate Group1013
Rotating Group1013
Drive Shaft Group1014
Swashblock Group1014
Inspection1014
Control Group1014
Valve Plate Group1015
Rotating Group1015
Swashblock Group1016
Drive Shaft Group1016
Assembly1016
Swashblock Group1016
Drive Shaft Group1017
Rotating Group1017
Valve Plate Group1018
Control Group1019
STEERING CIRCUIT FILTER1020
Removal1020
Installation1020
TROUBLESHOOTING CHART1021
SECTION L7 – HOIST CIRCUIT – INDEX1023
HOIST CIRCUIT1025
HOIST CIRCUIT OPERATION1025
COMPONENT DESCRIPTION1026
Hydraulic Tank1026
Hoist Pump1026
Hoist Valve1026
Hoist Pilot Valve1027
Power Up Solenoid1028
Pilot Operated Check Valve1028
Power Down Spool Limit Solenoid1028
HOIST CIRCUIT HYDRAULIC FLOW1029
POWER UP1031
HOLD1033
POWER DOWN1035
FLOAT1037
SECTION L8 – HOIST CIRCUIT COMPONET REPAIR – INDEX1039
HOIST CIRCUIT COMPONENT REPAIR1041
HOIST VALVE1041
Removal1041
Installation1041
O-Ring Replacement1042
INLET SECTION1043
Disassembly1043
Cleaning and Inspection1044
Assembly1044
SPOOL SECTION1044
Disassembly1044
Cleaning and Inspection1045
Assembly1047
HOIST PILOT VALVE1048
Removal1048
Installation1048
Disassembly1049
Cleaning and Inspection1050
Assembly1050
HOIST CYLINDERS1051
Removal1051
Installation1053
Disassembly1053
Cleaning and Inspection1055
Assembly – Quill And Cylinder1056
Quill Installation1056
Installation Of Check Balls And Plugs In Quill1057
Assembly of Cylinder1058
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX1059
HYDRAULIC SYSTEM FILTERS1061
HIGH PRESSURE FILTER1061
Removal1061
Installation1062
LOW PRESSURE FILTERS1062
BRAKE COOLING & HOIST FILTERS1062
TRANSMISSION FILTER1062
Removal1063
Installation1063
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX1065
HYDRAULIC CHECK-OUT PROCEDURE1067
GENERAL INFORMATION1067
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE1067
Equipment Requirements1068
Installation Of Gauges1068
Initial Startup And Flushing1068
Component Checkout And Adjustment1069
CHECKING HOIST SYSTEM PRESSURES1071
Equipment Requirements1071
Steering Components Leakage Test1073
HYDRAULIC SYSTEM CHECKOUT DATA SHEET1074
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX1075
SECTION M7 HOT START SYSTEM INDEX1077
HOT START SYSTEM1079
SYSTEM OPERATION1079
HEATER INFORMATION1080
TROUBLESHOOTING GUIDELINES1082
SECTION M8 – SPECIAL TOOLS1083
SECTION N – OPERATOR CAB – INDEX1085
SECTION N2 – OPERATOR CAB – INDEX1087
OPERATOR CAB1089
Removal1090
Installation1092
CAB DOORS1092
Removal1092
Installation1093
Door Striker Adjustment1093
Door Handle Plunger Adjustment1094
DOOR PANEL1095
Removal1095
Installation1095
DOOR WINDOW1096
Removal1096
Installation1098
WINDOW REGULATOR1100
Removal1100
Installation1100
DOOR HANDLE AND DOOR LATCH1100
Removal1100
Installation1100
DOOR SEALS1101
Removal1101
Installation1101
DOOR OPENING SEAL1101
Removal1101
Installation1101
GLASS REPLACEMENT1102
Replacement1102
WINDSHIELD AND REAR GLASS1103
Removal1103
Installation1104
SECTION N3 CAB COMPONENTS INDEX1105
CAB COMPONENTS1107
WINDSHIELD WIPERS1107
WIPER MOTOR1107
Removal1107
Installation1107
WIPER ARM1107
Removal1107
Installation1108
WIPER LINKAGE1108
Removal1108
Installation1108
WINDSHIELD WASHER1109
Operation1109
Service1109
OPERATOR SEAT1110
Adjustment Controls1110
Seat Removal1111
Seat Installation1111
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX1113
HEATING AND AIR CONDITIONING1115
HEATER/AIR CONDITIONER UNIT1115
Fan Speed Control Knob1115
Temperature Control Knob1115
Air Flow Directional Knob1115
Heater/Air Conditioner Vents1116
COMPONENTS1116
Fuse1116
Relays1116
Heater Core1116
Fan Motor And Speed Control1117
Actuators1117
Cab Air Filter1117
ENVIRONMENTAL IMPACT OF AIR CONDITIONING1120
AIR CONDITIONING FOR OFF-HIGHWAY VEHICLES1120
PRINCIPLES OF REFRIGERATION1120
Air Conditioning1120
Refrigeration – The Act Of Cooling1121
The Refrigeration Cycle1121
AIR CONDITIONER SYSTEM COMPONENTS1122
Compressor (Refrigerant Pump)1122
Service Valves1122
Condenser1122
Receiver-Drier1122
Expansion Block Valve1123
Accumulator1123
Evaporator1123
ELECTRICAL CIRCUIT1124
Thermostat1124
Compressor Clutch1124
Trinary™ Switch1125
SYSTEM SERVICING1126
SERVICE TOOLS AND EQUIPMENT1127
Recovery/Recycle Station1127
Leak Detector1127
Service Valves1128
Vacuum Pump1128
Manifold Gauge Set1129
Installing Manifold Gauge Set1130
Purging Air From Service Hoses1130
SYSTEM PERFORMANCE TEST1131
SYSTEM OIL1132
Handling and Reusing PAG Oil1132
Oil Quantity1132
Checking System Oil1132
REFRIGERANT1133
Recycled Refrigerant1133
Reclaimed Refrigerant1133
Refrigerant Quantity1133
R-134a Refrigerant Containers1134
SYSTEM LEAK TESTING1134
Electronic Leak Detector1135
Tracer Dyes1135
Soap and Water1135
RECOVERING AND RECYCLING THE REFRIGERANT1135
Draining Oil from the Previous Recovery Cycle1135
Performing the Recovery Cycle1135
Performing the Recycling Procedure1136
Evacuating and Charging the A/C System1136
SYSTEM REPAIR1136
System Flushing1136
A/C DRIVE BELT CHECKOUT PROCEDURE1137
Pulley Alignment1137
Belt Tension Check1137
COMPONENT REPLACEMENT1139
Hoses and Fittings1139
Lines1139
Expansion Valve1139
Receiver-Drier1139
Thermostat1139
Compressor1140
Accumulator1140
Clutch1140
Servicing the Compressor Clutch1141
Pulley Removal1143
Clutch Coil Check1144
Pulley Installation1144
Clutch Assembly Installation1144
EVACUATING THE SYSTEM1146
CHARGING THE A/C SYSTEM1148
TROUBLESHOOTING1149
Preliminary Checks1149
Diagnosis Of Gauge Readings And System Performance1149
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS1150
PREVENTIVE MAINTENANCE SCHEDULE FOR A/C SYSTEM1156
SECTION N5 – OPERATOR CAB AND CONTROLS – INDEX1157
OPERATOR CAB AND CONTROLS1159
STEERING WHEEL AND CONTROLS1160
Horn Button1160
ARSC Set Lever1160
Telescoping/Tilt Wheel Lever1160
Multi-Function Turn Signal Lever1161
RETARDER CONTROL LEVER1161
STEERING WHEEL1162
Removal1162
Installation1162
SERVICE BRAKE PEDAL1162
ACCELERATOR PEDAL1163
INSTRUMENT PANEL1163
HEATER / AIR CONDITIONER CONTROLS1163
RETARDING CAPACITY CHART1163
RADIO SPEAKERS1164
AIR CLEANER VACUUM GAUGES1164
WARNING ALARM BUZZER1164
AM/FM RADIO / CD PLAYER1164
CENTER CONSOLE1165
Hoist Control Lever1166
Transmission Shift Lever1166
Parking Brake Switch1167
LH Window Control Switch1167
RH Window Control Switch1167
Auxiliary Power Outlets1167
INSTRUMENT PANEL AND INDICATORS1168
UPPER RH SWITCH PANEL1169
Brake Lock Switch1169
F1 Start Switch1169
Hazard Warning Lights Switch1169
LOWER RH SWITCH PANEL1170
Key Switch1170
Ether Starting Aid Switch1171
ASR Cut Switch1171
ARSC Switch1171
Automatic Idle Selector Switch (AISS)1171
Auxiliary Brake Switch1172
UPPER LH SWITCH PANEL1173
Automatic Lubrication System Indicator1173
LOWER LH SWITCH PANEL1174
Head Light Switch1174
Ladder Light Switch1174
BackUp/Deck Light Switch1175
Fog Light Switch1175
Mode Select Switches 1 & 21175
Panel Light Dimmer Switch1175
ELECTRONIC DISPLAY PANEL1176
PILOT DISPLAY ITEMS1177
METER DISPLAYS1179
CAUTION ITEMS1181
EMERGENCY STOP ITEMS1183
CHARACTER DISPLAY1186
REAR ELECTRICAL COMPARTMENT1187
AUTOMATIC RETARD SPEED CONTROL (ARSC)1190
AUTOMATIC SPIN REGULATOR (ASR)1193
SECTION P – LUBRICATION AND SERVICE – INDEX1195
SECTION P2 – LUBRICATION AND SERVICE – INDEX1197
LUBRICATION AND SERVICE1199
RADIATOR FILL PROCEDURE1199
HYDRAULIC TANK SERVICE1200
Filling Instructions1200
TRANSMISSION OIL LEVEL CHECK1200
PERIODIC REPLACEMENT OF CRITICAL PARTS1202
10 HOUR (DAILY) INSPECTION1203
10 HOUR (DAILY) INSPECTION (continued)1204
250 HOUR INSPECTION1205
250 HOUR INSPECTION (continued)1206
500 HOUR INSPECTION1207
1000 HOUR INSPECTION1208
2000 HOUR INSPECTION1209
5000 HOUR INSPECTION1210
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX1211
AUTOMATIC LUBRICATION SYSTEM1213
GENERAL DESCRIPTION1213
SYSTEM COMPONENTS1217
SYSTEM OPERATION1219
INJECTOR OPERATION1220
LUBRICANT PUMP1221
Pump Housing Oil Level1221
Pump Pressure Control1221
INJECTORS (SL-1 Series “H”))1222
Injector Specifications1222
Injector Adjustment1222
SYSTEM PRIMING1223
Filter Assembly1223
SYSTEM CHECK1224
Lubrication Controller Check1224
Lubrication Controller Operation1224
Lubrication Controller Components1224
Lubrication Controller Adjustment1224
SYSTEM TROUBLESHOOTING CHART1226
PREVENTATIVE MAINTENANCE1228
Daily Lubrication System Inspection1228
250 Hour Inspection1228
1000 Hour Inspection1229
PUMP REBUILD1230
Disassembly1230
Cleaning and Inspection1233
Assembly1233
SECTION R – SYSTEM SCHEMATICS – INDEX1235
HYDRAULIC SYSTEM SCHEMATIC1237
HYDRAULIC SYSTEM SCHEMATIC (COLD WEATHER -40C)1239
BRAKE SCHEMATIC1241
HOOKUP SCHEMATIC1243
ELECTRICAL WIRING SCHEMATIC1259
HVAC WIRING SCHEMATIC1305
CONNECTOR LOCATOR1307

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24