Komatsu HD1500-5 Dump Truck Shop Manual CEBM010701 PDF

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM010701 – PDF DOWNLOAD

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM010701 – PDF DOWNLOAD 

Language : English
Pages : 1248
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-5 Dump Truck Shop Manual CEBM010701 – PDF DOWNLOAD 

SERIAL NUMBERS A30049 – A30069

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 lb). 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 HD1500-5 Dump Truck Shop Manual CEBM010701 – PDF DOWNLOAD 

SERIAL NUMBERS A30049 – A30069

COVER 1
FOREWORD 5
TABLE OF CONTENTS 7
SECTION A – GENERAL INFORMATION – INDEX 9
SECTION A2 – MAJOR COMPONENTS AND SPECIFICATIONS 11
SPECIFICATIONS 13
SECTION A3 – SAFETY AND OPERATING INSTRUCTIONS – 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
PRECAUTIONS DURING OPERATION 20
Safety Is Thinking Ahead 20
BEFORE STARTING THE ENGINE 20
Safety At The Work Site 20
Fire Prevention 20
Preparing For Operation 20
Ventilation In Enclosed Areas 20
In Operator’s Cab – Before Starting The Engine 21
Mirrors, Windows, And Lights 21
OPERATING THE MACHINE 21
When Starting The Engine 21
Precautions For Starting Machine 21
Truck Operation – General 21
Traveling 22
Traveling In Reverse 22
Traveling On Slopes 23
Ensure Good Visibility 23
Operate Carefully On Snow 23
Avoid Damage To Dump Body 23
Driving Near High Voltage Cables 23
When Dumping 24
Working On Loose Ground 24
Loading The Body 24
Parking The Machine 24
TOWING 24
WORKING NEAR BATTERIES 25
Battery Hazard Prevention 25
Starting With Booster Cables 25
PRECAUTIONS FOR MAINTENANCE 26
BEFORE PERFORMING MAINTENANCE 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
Tire Maintenance 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
ENGINE START-UP SAFETY PRACTICES 36
Cold Weather Starting 37
Jump Starting 37
EMERGENCY STEERING SYSTEM 38
Operation 38
Pre-Operation Testing 38
AFTER THE ENGINE HAS STARTED 39
MACHINE OPERATION SAFETY PRECAUTIONS 41
LOADING 42
HAULING 43
RETARDER OPERATION 43
PASSING 44
DUMPING 44
Raising the Dump Body 45
Lowering The Dump Body 45
SAFE PARKING PROCEDURES 46
SHUTTING THE ENGINE OFF 46
SUDDEN LOSS OF ENGINE POWER 46
Secondary Steering And Braking 46
DISABLED TRUCK DUMPING PROCEDURE 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 100
Cleaning 100
Repair 100
Installation 100
FUEL GAUGE AND SENDING UNIT 101
Removal 101
Installation 101
WIGGINS QUICK FILL FUEL SYSTEM 102
FUEL RECEIVER 102
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 REMOVAL 110
RADIATOR REPAIR 111
Internal Inspection 111
External Cleaning 112
Disassembly 112
Cleaning and Inspection 113
Assembly 114
Pressure Testing 115
Additional Service Information 115
RADIATOR INSTALLATION 115
TRANSMISSION AND BRAKE COOLERS 117
Removal 117
Disassembly 117
Cleaning And Inspection 118
Assembly 118
Inspection 120
Installation 121
SECTION C4 – ENGINE – INDEX 123
ENGINE 125
Removal 125
Inspection 128
DRIVE LINE ADAPTER AND DAMPER 130
Removal 130
Disassembly 132
Assembly 132
Installation 134
SECTION C5 – AIR FILTRATION SYSTEM – INDEX 137
AIR FILTRATION SYSTEM 139
AIR CLEANER 139
Operation 139
General Maintenance 139
FILTER SERVICE INDICATOR 141
MAIN FILTER ELEMENT 141
Removal 141
Installation 141
SAFETY FILTER ELEMENT 141
Removal 141
Installation 141
MAIN FILTER CLEANING 142
PRECLEANER CLEANING 143
AIR INTAKE TROUBLESHOOTING 144
SECTION C7 – FAN CLUTCH – INDEX 145
FAN CLUTCH 147
REMOVAL & INSTALLATION TOOLING 147
FAN CLUTCH – DISASSEMBLY 150
CLEANING AND INSPECTION 160
ASSEMBLY – FAN CLUTCH 164
TEST PROCEDURE 178
SECTION D – ELECTRICAL SYSTEM AND POWERTRAIN MANAGEMENT CONTROL SYSTEM – INDEX 179
SECTION D2 – 24VDC ELECTRIC SUPPLY SYSTEM – INDEX 181
24VDC ELECTRIC SUPPLY SYSTEM 183
ELECTRICAL SYSTEM DESCRIPTION 183
BATTERY 183
Maintenance and Service 183
Troubleshooting 183
BATTERY CHARGING SYSTEM (Niehoff) 185
General Description 185
TROUBLESHOOTING PROCEDURES (On-Truck) 185
Equipment Required: 185
Preliminary Checks 186
Test Setup 186
Test Procedure 186
Regulator Bypass Test 187
ON VEHICLE TROUBLESHOOTING GUIDE 188
ALTERNATOR ELECTRICAL CONDITIONS – Low Voltage – High Voltage – No Voltage 188
BATTERY CONDITIONS AND CHARGE VOLTAGE REACTIONS: 188
CHARGE VOLT AND AMP VALUES 189
DEFINITIONS 189
ADVANCED SYSTEM TROUBLESHOOTING 190
Static Test – Engine OFF, Key ON, Battery Switch ON 190
Go To Alternator 190
Go To Regulator (If Required) 191
Go To Regulator Connector On The Alternator 191
24 VDC REMOTE MOUNT PRELUB™ SYSTEM 193
OPERATION 193
Pressure Switch 194
Check Valve 194
Timer Solenoid 195
MAINTENANCE 195
Prelub™ System Operation 195
Prelub Pump 195
Check Valve 195
Timer Solenoid 195
TROUBLESHOOTING PRELUB CIRCUIT 196
24 VDC ELECTRIC START SYSTEM 199
CRANKING MOTORS 199
Operation 199
Removal 199
Installation 199
CRANKING MOTOR TROUBLESHOOTING 200
Preliminary Inspection 200
No-Load Test 200
Interpreting Results of Tests 200
Disassembly 201
Cleaning and Inspection 201
Armature Servicing 201
Field Coil Checks 202
Field Coil Removal 202
Solenoid Checks 204
Assembly 205
Magnetic Switch 206
Removal 206
Installation 206
Coil Test 206
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 207
ELECTRICAL SYSTEM COMPONENTS 209
GENERAL TROUBLESHOOTING 209
CAB MOUNTED COMPONENTS 210
Circuit Breakers 210
RELAY BOARDS 213
Relay Boards (With Circuit Breakers) 213
Preliminary Checks 213
Service 214
Relay Board Description 216
Relay Board RB1 216
Relay Board RB4 216
Relay Board RB5 216
Relay Boards (Without Circuit Breakers) 217
Truck Inclination Sensors 219
Payload Meter Inclinometer Sensor 219
Lateral Inclination Sensor 219
Lubrication System Timer 219
ACCELERATOR PEDAL 220
Operation 220
AISS Operation 221
Throttle Pedal Malfunction 223
ACCELERATOR PEDAL CHECKS 223
Idle Validation Switch Continuity Check 223
24V COMPONENTS (Outside Cab) 224
Battery Box 224
Battery Disconnect Switch 224
Ground Level Shutdown Switch 224
Control Power Relays 224
Circuit Breakers 224
Level Sensor 224
Battery Equalizer 225
BODY POSITION SWITCHES 225
Proximity Switch Operation 225
Body-Up Switch Adjustment 226
Hoist Limit Switch Adjustment 228
Speed Sensors 229
Sensor Adjustment 229
24V/240 AMP ALTERNATOR TEST AND REBUILD 230
BENCH TEST 230
TEST 1 – No Load Test 230
STATIC TESTS 231
Regulator Tests 231
Control Box Tests 232
ALTERNATOR DISASSEMBLY 235
ASSEMBLY- ALTERNATOR 242
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 251
Stator Removal And Replacement 251
Stator Installation 252
SECTION D22 – POWERTRAIN MANAGEMENT CONTROL SYSTEM – INDEX 255
POWERTRAIN MANAGEMENT CONTROL™ SYSTEM 257
System Description 257
Engine (Cummins QSK45) 257
Transmission 257
Transmission Controller 257
Retard Control and Monitor 257
Powertrain Management Controller 257
Electronic Display Panel 257
Payload Meter 257
Message for Operator and Maintenance Display 257
Suspension Controller 257
Data Acquisition Device 257
Cummins Quantum 258
Cummins CENSE 258
PMC SYSTEM TROUBLESHOOTING 259
Preliminary Troubleshooting Procedures 259
Emergency Operation 259
Indication Of A Fault Occurrence 259
Action Codes 259
Fault History 259
System Troubleshooting 259
EMERGENCY TRUCK OPERATION 262
PMC SYSTEM FAULT CODES 264
SECTION D23 – POWERTRAIN MANAGEMENT CONTROLLER – INDEX 281
POWERTRAIN MANAGEMENT CONTROLLER (PMC) 283
PMC CONTROLLER FEATURES 283
LED Display 283
DIP Switch Settings 283
NORMAL OPERATION – PMC 284
Throttle Control 284
AISS Operation 284
Retarder Control 285
COMMUNICATION 285
S-NET 285
CENSE 285
RCM 285
PLM 285
“MOM” and “DAD” 285
Additional Functions 286
PMC CONTROLLER TROUBLESHOOTING 289
GENERAL TROUBLESHOOTING PROCEDURES 289
PMC FAULT CODE TROUBLESHOOTING 290
PMC CONTROLLER LOGIC 298
Fault Recovery Classifications 298
PMC FAULT CODE LOGIC DESCRIPTION 299
PMC WIRING HARNESS CONNECTORS 323
SECTION D24 – AUTOMATIC TRANSMISSION CONTROLLER – INDEX 329
AUTOMATIC TRANSMISSION CONTROLLER (ATC) 331
ATC CONTROLLER FEATURES 331
LED Display 331
Rotary Switch Settings 331
Shift Control 332
Range Selector Positions And Automatic Gear Shifting Ranges 332
Transmission Operation Modes 333
Braking Mode: 333
Normal Mode: 333
Automatic Gear Shifting 333
Automatic Shifting Sequence 334
Gearshifting time lag 334
Shift Skip Logic 334
Safety Functions 335
TROUBLESHOOTING – ATC 336
GENERAL TROUBLESHOOTING PROCEDURES 336
ATC FAULT CODE TROUBLESHOOTING 337
ATC FAULT CODE LOGIC DESCRIPTION 352
TRANSMISSION CONTROLLER HARNESS CONNECTORS 383
SECTION D25 – ELECTRONIC DISPLAY PANEL – INDEX 387
ELECTRONIC DISPLAY PANEL 389
Rotary Switch 389
Gauges and Indicators 390
External Indicator Lamps 392
Display Self-Check Function 394
Lamp Test 394
Action Code Display 395
Cancellation of Action Code 395
ELECTRONIC DISPLAY PANEL TROUBLESHOOTING 396
GENERAL TROUBLESHOOTING PROCEDURES 396
Harness Circuit Tests 396
Table 1: Continuity checks 396
Table 2: Short Circuit to Ground Checks 397
Table 3: Circuit Isolation Checks 397
EDP WIRING HARNESS CONNECTORS 415
SECTION D26 – RETARD CONTROL AND MONITOR (RCM) – INDEX 417
RETARD CONTROL AND MONITOR (RCM) 419
Description 419
RCM Calibration 419
GENERAL TROUBLESHOOTING PROCEDURES 420
RCM FAULT CODE TROUBLESHOOTING 422
Description 422
RCM WIRING HARNESS CONNECTORS 469
SECTION D27 – AUTOMATIC SUSPENSION SYSTEM – INDEX 471
AUTOMATIC SUSPENSION SYSTEM 473
Automatic Suspension Controller 473
Manifold Valve 473
Actuator 473
Steering Sensor 473
AUTOMATIC MODE SELECTION CONTROL 474
SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION 475
d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE 475
d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE 475
d015:TRANSMISSION SPEED SIGNAL LOST 476
d016:STEERING SPEED SIGNAL LOST 476
d021:SOLENOID OUTPUT 1 FAILURE 477
d022:SOLENOID OUTPUT 2 FAILURE 477
d023:SOLENOID OUTPUT 3 FAILURE 477
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING 478
SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed 478
SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed 479
SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed 480
SP-4: Fault Code d016: Fault in Steering Sensor System Displayed 481
SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed 482
SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed 483
SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed 484
SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS 485
SECTION D30 – MESSAGE FOR OPERATION AND MAINTENANCE (MOM) – INDEX 487
MOM – MESSAGE FOR OPERATION AND MAINTENANCE 489
INTRODUCTION 489
SYSTEM CONFIGURATION 489
SOFTWARE 490
Service Meters (SMR) 491
FUNCTION 492
Operator Information 492
Maintenance Information (Screen Hierarchy) 492
Display Able/Disable By Machine Status 494
Vehicle State 494
Display Able/Disable by Truck Model and Optional Equipment Status 495
SCREEN DATA 496
Realtime Data 496
Machine Trend Data 496
Fault Condition Data 496
Machine Information 497
Parameter Set 497
WARNING MESSAGE 498
HARDWARE TROUBLESHOOTING AND MAINTENANCE 499
TROUBLESHOOTING THE MOM UNIT 499
PROBLEMS AND CORRECTIVE ACTIONS 500
Program Errors 501
Warning & Communication Errors 502
SELF-DIAGNOSIS 503
System Check 503
System Information 503
Communication Port Check 503
Key Input Check 504
MAINTENANCE 505
Battery Replacement 505
Replacement of Protective Sheet 505
Back Light Replacement 506
Setting Display OFF Time 507
SECTION D31 – MOM SCREEN DISPLAYS – INDEX 509
MOM SCREEN DISPLAYS 511
i1 INITIAL MESSAGE 511
i2 INITIAL CHECK1 511
i3 INITIAL CHECK2 511
i4 NORMAL RUNNING 512
i7 BACKLIGHT OFF 513
To Access a Maintenance Information Screen: 514
i9 MENU SELECT 515
s1 SERVICE MENU 516
s2 COMPONENT CHECK MENU 516
s21 ENGINE 517
s212 MACHINE TREND MENU (ENG ) 518
s213 FAULT CONDITION MENU (ENG ) 518
s2131 FAULT CONDITION (ENG ) 519
s22 TRANSMISSION 520
s222 MACHINE TREND MENU (T/M) 521
s2221 L/C ON/OFF COUNT 521
s222E AB-USE COUNT 522
s223 FAULT CONDITION MENU (T/M) 523
S2231 FAULT CONDITION (T/M) 523
s23 BRAKE MENU 524
s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE) 524
s233 FAULT CONDITION MENU (BRAKE) 525
s2331 FAULT CONDITION (BRAKE) 525
s24 SUSPENSION MENU 526
s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION) 526
s242 FAULT CONDITION MENU (SUS) 527
s2421 FAULT CONDITION (SUS) 527
s25 PMC MENU 528
s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC) 528
s252 FAULT CONDITION MENU (PMC) 529
s2521 FAULT CONDITION (PMC) 529
s26 ELECTRONIC DISPLAY PANEL MENU 530
s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel) 530
s262 FAULT CONDITION MENU (ELE DISPLAY PANEL) 531
s2621 FAULT CONDITION (ELE DISPLAY PANEL) 531
s27 PLM MENU 532
s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM) 532
s272 CALIBRATION DATA 533
s28 TMS MENU 533
s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS) 534
s283 FAULT CONDITION MENU (TMS) 534
s2831 FAULT CONDITION (TMS) 535
s3 MACHINE INFORMATION MENU 535
s32-1/3 CONTROLLER INFORMATION 537
SELECTOR SWITCH STATUS of the PMC 537
s32-2/3 CONTROLLER INFORMATION 538
s32-3/3 CONTROLLER INFORMATION 539
s33 OPTIONAL FUNCTION INFORMATION 539
s34 HISTORY OF USE 540
t1 PARAMETER SET MENU 541
t2 TIME/DATE SET 541
t3 TRAVEL MODE MENU 542
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 542
t32 SPEED LIMITER 543
t33 T/M MAX GEAR SELECT 543
t34 T/M MAX GEAR SELECT (BODY UP) 544
t35 SUSPENSION MODE SET 544
t4 PARAMETER UNIT SET 545
t5 TMS SET MENU 545
t51 TIRE PRESSURE LIMIT SET 546
t52 TIRE TEMPERATURE LIMIT SET 547
t53 CORRELATION CONSTANTS SET 548
t54 TMS CLOCK SET 549
t55 ID CODE SET 550
SECTION D32 – DATA ACQUISITION DEVICE (DAD) – INDEX 551
DAD – DATA ACQUISITION DEVICE 553
INTRODUCTION 553
HARDWARE HOOKUP 553
SOFTWARE 554
Installation Requirements 554
Installing the Software 554
Starting the Software Program 554
Service Meters (SMR) 554
Display Able/disable By Machine Status 555
Vehicle State 555
MAINTENANCE INFORMATION (SCREEN HIERARCHY) 555
Display Enable/Disable by Truck Model and Optional Equipment Status 559
SCREEN DATA 560
Real Time Data 560
Fault condition data 560
Snap-Shot Data 560
Transmission Snapshot Example 561
Sample Snapshot Screens 565
Machine Trend Data 567
Machine Check 568
Machine Information 568
Event Recorder 568
Parameter Set 568
SECTION D33 – DAD SCREEN DISPLAYS – INDEX 569
DAD SCREEN DISPLAYS 571
PASSWORD INPUT 571
Changing the Password 571
i3 MENU SELECT 571
s1 SERVICE MENU 572
s2 COMPONENT CHECK MENU 572
s21 Engine 572
s21 CUMMINS ENG MENU (for the CUMMINS engine) 572
s21 KOMATSU ENG MENU (for the KOMATSU engine) 572
s22 TRANSMISSION 575
s23 BRAKE MENU 579
s24 SUSPENSION MENU 582
s25 PMC MENU 584
s26 ELECTRONIC DISPLAY PANEL MENU 586
s27 PLM MENU 588
s28 TMS MENU 589
s3 MACHINE INFORMATION MENU 592
s31 MACHINE INFORMATION MENU 592
s32-1/3 CONTROLLER INFORMATION 593
s32-2/3 CONTROLLER INFORMATION 594
s32-3/3 CONTROLLER INFORMATION 595
s33 OPTIONAL FUNCTION INFORMATION 595
s34 HISTORY OF USE 596
t1 PARAMETER SET MENU 597
t2 TIME/DATE SET 597
t3 TRAVEL MODE MENU 598
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 598
t32 SPEED LIMITER 599
t33 T/M MAX GEAR SELECT 599
t34 T/M MAX GEAR SELECT (BODY UP) 600
t35 SUSPENSION MODE SET 600
t4 PARAMETER UNIT SET 601
t5 TMS SET MENU 601
t51 TIRE PRESSURE LIMIT SET 602
t52 TIRE TEMPERATURE LIMIT SET 602
t53 CORRELATION CONSTANTS SET 603
t54 TMS CLOCK SET 603
t55 ID CODE SET 604
SECTION D34 – REAL TIME DATA TABLES – INDEX 605
REAL TIME DATA TABLES 607
ACCESSING REAL TIME DATA SCREENS 607
Real Time Data Screen Switches 607
SECTION D35 – PAYLOAD METER II – INDEX 617
GENERAL INFORMATION 619
Haul Cycles 619
LIGHTS, SWITCHES AND COMPONENTS 620
TIPS FOR OPERATION 621
EXTERNAL DISPLAY LIGHTS 621
THEORY OF OPERATION 622
Basic Description 622
Inclinometer 622
Linkage Factor 622
Gain Factor 623
Brake Lock 623
Sources of Error 623
Typical Data From Service Check Mode 623
Example Calculation of Payload 624
Viewing Payload Calculation Inputs 624
Checking the Gain 625
Adjusting the Gain 625
TYPES OF DATA STORED 626
Cycle Data 626
Engine ON/OFF Data 627
Fault Codes and Warning Data 627
Engine Operation 628
Total Payload and Total Number of Cycles 628
Other Data 628
OPERATOR FUNCTIONS 629
Using the Operator Load Counter 629
Viewing the Operator Load Counter 629
Clearing the Operator Load Counter 629
Dimming the Lights on the Display 629
INITIAL SETUP OF PAYLOAD METER 630
Switch Settings 630
Checking the Operator Check Mode 631
Checking the Service Check Mode 631
Checking the Gt setting: 632
Checking the Inclinometer Settings 632
Calibrating a Truck 632
DISPLAYS AT START-UP 633
Normal Operation 633
SETUP AND MAINTENANCE 634
Setting The Speed Limit 634
Setting the Option Code 634
Setting The Machine I D Code 635
Setting The Operator I D Code 635
Setting The Time and Date 635
DOWNLOAD OF INFORMATION 636
DISPLAY OF FAULT CODES 636
Monitoring Input Signals 640
Service Check Mode 640
UP FACTOR – PAYLOAD CALCULATION GAIN 641
PL MODE -LOAD CALCULATION TIMING 641
FINAL GEAR RATIO SELECTION 642
BATTERY REPLACEMENT PROCEDURE 643
Replacing the Battery 643
After Replacing the Battery 644
SUSPENSION PRESSURE SENSOR 644
Removal 644
Installation 645
INCLINOMETER 645
Removal 645
Installation 645
Adjustment 645
PAYLOAD METER BACK PANEL 646
CONNECTIONS 647
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 648
PAYLOAD CIRCUIT NUMBERS 649
TROUBLESHOOTING 650
COMMON PROBLEMS 650
Suspension Charging 650
Symptom Table 651
Missing Body-Up Signal 651
Missing Speed Signal 652
F-18: Alternator R-Terminal, Oil Pressure Signals 652
Shorted 18v Sensor Power Supply (930E) 652
FAULT TREE DIAGNOSIS 653
Payload Lights Won’t Illuminate 653
Red, Amber or Green Payload Light Does Not Illuminate 654
Cannot Download – PC Communications 655
PC Communications Configuration 656
F CAL: Payload Meter Won’t Calibrate 657
F-20: Sensor Power Fault 658
F-21, F-25: Left Front Pressure Sensor 660
F-22, F-26: Right Front Pressure Sensor 660
F-23, F-27: Left Rear Pressure Sensor 660
F-24, F-28: Right Rear Pressure Sensor 660
F-31, F-32: Inclinometer 662
Body Up Input 664
Brake Lock Input 665
Speed Signal 666
Adjusting the Speed Sensor 666
CONNECTORS AND PRESSURE SENSORS 668
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 671
Menu Functions 674
Using Scope 674
Log File Information 674
Connections to Payload Meter II™ 675
USING SCOPE 676
Monitoring Inputs Using Scope 676
Monitoring Suspension Charging Using Scope 676
Pressure Sensor Dummy Loads 679
GAIN ADJUSTMENT WORKSHEET 680
SECTION F – TRANSMISSION / TORQUE CONVERTER – INDEX 681
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 683
TRANSMISSION 685
TORQUE CONVERTER 686
MAIN RELIEF VALVE 688
Function 688
Operation 688
TORQUE CONVERTER RELIEF VALVE 688
Function 688
Operation 688
TORQUE CONVERTER REGULATOR VALVE 690
Operation 690
LOCK-UP CLUTCH 690
HYDRAULIC PUMP 691
TORQUE CONVERTER STALL CHECK 692
TRANSMISSION 693
LUBRICATION RELIEF VALVE 695
Function 695
TRANSMISSION CONTROL VALVE 696
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 698
Pressure Control Valve 699
Flow Sensor Valve 699
ECMV and Proportional Solenoid 699
ECMV and Fill Switch 699
Action of ECMV 700
ECMV REPAIR PROCEDURE 703
Filter Replacement Procedure 703
ECMV Removal 704
Disassembly 704
Reassembly 705
TRANSMISSION FILTERS 707
Service 707
Installation 707
TRANSMISSION REMOVAL 708
TRANSMISSION INSTALLATION 709
TRANSMISSION OIL LEVEL CHECK 711
SECTION F3 – TRANSMISSION OIL COOLER AND STRAINERS – INDEX 713
TRANSMISSION OIL COOLER & STRAINERS 715
TRANSMISSION OIL COOLER 715
Removal and Installation 715
Repair 715
TRANSMISSION OIL STRAINER 715
Removal 716
Inspection 716
Installation 716
SECTION F5 – DRIVE SHAFTS – INDEX 717
DRIVE SHAFTS 719
FRONT DRIVE SHAFT 719
Removal 719
Disassembly 719
Assembly 720
Installation 720
FRONT DRIVE SHAFT ALIGNMENT 721
REAR DRIVE SHAFT 724
Removal 724
Disassembly 724
Assembly 725
Installation 725
SECTION F6 – TRANSMISSION ELECTRICAL – INDEX 727
TRANSMISSION ELECTRICAL 729
TRANSMISSION SHIFT CONTROLLER 730
Event Memory 730
Fault History Data 730
Snap-Shot Data 730
Trend Data 731
TRANSMISSION RANGE SELECTOR 732
SENSORS AND SWITCHES 733
Transmission Speed Sensors 733
Adjustment Procedure 733
Fill Switch 734
Shift Limit Switch 734
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 735
Preliminary Checks 735
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 739
SECTION G2 – TIRES AND RIMS – INDEX 741
TIRES AND RIMS 743
GENERAL INFORMATION 743
FRONT TIRES AND RIMS 744
Removal 744
Installation 745
REAR TIRE AND RIM 745
Removal 745
Installation 746
TIRE MATCHING 747
RIM 748
Tire Removal From Rim 748
Tire Installation On Rim 748
FRONT WHEEL STUD INSTALLATION 749
REAR WHEEL STUD INSTALLATION 750
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 751
FRONT WHEEL HUB AND SPINDLE 753
OIL SAMPLE ANALYSIS 753
Oil Sampling Guidelines 753
Guidelines For Obtaining A Sample 753
FRONT WHEEL HUB 754
Removal 754
Disassembly 754
Inspection 754
Assembly and Installation 755
Front Wheel Hub Bearing Adjustment 757
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION 757
SUSPENSION A-ARM 757
Removal 757
Inspection of Parts 758
Installation 758
CENTER TIE ROD PIVOT 759
Removal 759
Inspection 759
Installation 759
TOE IN ADJUSTMENT 760
Adjustment Procedure 760
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 763
REAR AXLE ATTACHMENTS 765
CENTER LINK AND LOWER LINKS 765
Removal 765
Inspection 766
Spherical Bearing Replacement 766
Installation 766
PANHARD ROD (DIAGONAL LINK) 767
Removal 767
Inspection 768
Installation 768
SECTION G5 – REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 769
REAR AXLE & FINAL DRIVE ASSEMBLY 771
DIFFERENTIAL OPERATION 771
Straight-away-travel 771
Turning 771
REAR AXLE ASSEMBLY 772
Removal 772
Installation 772
DIFFERENTIAL OIL LEVEL CHECK 773
DIFFERENTIAL ASSEMBLY 774
Removal 774
Installation 775
Disassembly 775
Pinion Carrier Assembly 778
Differential Gear Unit 778
Differential Gear Unit 779
Assembly 782
Differential Bearing 782
Assembly Of Differential Gear Assembly 782
Installation Of Differential Assembly 784
Input Pinion and Carrier Assembly 785
Adjusting Tooth Contact, Backlash 789
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 793
FINAL DRIVE PLANETARIES AND WHEEL HUBS 795
FINAL DRIVE 795
Oil Level Check 796
FINAL DRIVE CARRIER ASSEMBLY 796
Removal 796
Installation 797
Disassembly 797
Assembly 798
FINAL DRIVE ASSEMBLY 799
Disassembly 799
Assembly 801
SECTION H – SUSPENSIONS – INDEX 803
SECTION H2 – FRONT SUSPENSION – INDEX 805
FRONT SUSPENSION 807
FRONT SUSPENSION ASSEMBLY 807
Suspension Operation 808
3-MODE SUSPENSION (Optional) 809
Variable Damping Operation 809
3-Mode Suspension System Components 810
Automatic Suspension Controller 810
Manifold Valve 810
Actuator 811
Steering Sensor 811
Suspension Removal 812
Suspension Installation 813
Disassembly 814
Inspection 814
Assembly 814
DAMPING VALVE REPAIR 816
Damping Valve (Fixed Rate) 816
Disassembly 816
Assembly 816
Damping Valve/Actuator 817
(3-Mode Damping Rate) 817
Cleaning and Inspection 817
Assembly 817
SECTION H3 – REAR SUSPENSION – INDEX 819
REAR SUSPENSION 821
OPERATION 822
Removal 823
Installation 823
Disassembly 823
Assembly 825
SPHERICAL BEARINGS 826
Removal 826
Inspection 826
Installation 826
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 827
SUSPENSION OILING AND CHARGING 829
GENERAL INFORMATION 829
Equipment List 829
FRONT SUSPENSION 831
Front Suspension Oiling 831
Front Suspension Nitrogen Charging 834
REAR SUSPENSION 836
General Information 836
Rear Suspension Oiling 837
Rear Suspension Nitrogen Charging 840
Length Adjustment – Front And Rear Cylinders 841
SECTION J – BRAKE SYSTEM – INDEX 843
SECTION J2 – BRAKE CIRCUIT – INDEX 845
BRAKE CIRCUIT 847
SERVICE BRAKE CIRCUIT 847
SECONDARY BRAKING AND AUTOMATIC APPLY 849
PARKING BRAKE CIRCUIT 849
Normal Operation 849
BRAKE LOCK CIRCUIT 850
AUXILIARY CIRCUIT 850
RETARDING CIRCUIT 850
WARNING CIRCUIT 850
BRAKE SYSTEM ELECTRICAL COMPONENTS 851
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 855
BRAKE CIRCUIT COMPONENT SERVICE 857
BRAKE VALVE 857
Rebuild Criteria 857
Removal 858
Installation 858
Disassembly 859
Cleaning and Inspection 860
Assembly 862
Actuator Base Threaded Inserts 862
Boot and Cap 862
Valve Body Seal Installation 862
Regulator Sleeve O-Ring Installation 862
Actuator Plunger O-ring Installation 863
Assembly of Valve 863
DIFFERENTIAL PRESSURE SWITCH 865
Disassembly 865
Cleaning and Inspection 865
Assembly 865
VALVE BENCH TEST AND ADJUSTMENT 866
Test Bench Only 867
Test Set Up Procedure 867
Brake Valve Output Pressure Adjustment 867
Differential Pressure Switch Adjustment 868
Final Test and Adjustment 868
Proximity Switch Installation and Adjustment 869
Installation Of Brake Pedal Actuator Assembly to Brake Valve 870
RELAY VALVES 871
Removal 871
Installation 871
Disassembly 872
Cleaning and Inspection 873
Assembly 873
VALVE TEST AND ADJUSTMENT 874
Test Set Up Procedure 875
Relay Valve 875
Output Pressure Adjustment 875
HYDRAULIC BRAKE ACCUMULATORS 876
Brake Accumulator Bleed Down Procedure 876
BRAKE ACCUMULATOR CHARGING PROCEDURE 877
BRAKE ACCUMULATOR REBUILD 878
Removal 878
Installation 878
Disassembly 878
Cleaning and Inspection 878
Assembly 879
Testing 880
Storage 880
BRAKE COOLING VALVE (BCV) 881
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 882
Lever Assembly Removal 882
Lever Assembly Installation 883
Disassembly and Adjustment 883
Potentiometer Check 883
Assembly 883
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 885
BRAKE CIRCUIT CHECK-OUT PROCEDURE 887
EQUIPMENT REQUIRED 890
Preparation 890
BRAKE SYSTEM CHECKOUT 892
Failure Modes Check-Out 893
RCM Calibration Check 895
RCM Calibration Procedure 896
Preparation 896
How to Perform Calibration 897
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 899
KOMATSU CHECK-OUT PROCEDURE 903
HYDRAULIC BRAKE SYSTEM DATA SHEET 903
KOMATSU CHECK-OUT PROCEDURE 904
HYDRAULIC BRAKE SYSTEM DATA SHEET 904
SECTION J5 – FRONT WET DISC BRAKES – INDEX 913
FRONT WET DISC BRAKES 915
DESCRIPTION 915
FRONT DISC BRAKE ASSEMBLY 916
Removal 916
Installation 917
BRAKE ASSEMBLY REBUILD 917
DISC BRAKE MAINTENANCE 917
Brake Disc Wear Indicator 917
Checking Disc Wear 918
WEAR INDICATOR SENSOR 919
SPEED SENSOR 919
WET DISC BRAKE BLEEDING PROCEDURE 919
SECTION J6 – REAR WET DISC BRAKES – INDEX 921
REAR WET DISC BRAKES 923
DESCRIPTION 923
Operation 923
MAINTENANCE 924
Brake Disc Wear Indicator 924
Checking Disc Wear 924
Wear Indicator Sensor 925
Brake Assembly Removal 926
Brake Assembly Installation 927
BRAKE ASSEMBLY REBUILD 928
Disassembly 928
Cleaning and Inspection 929
Assembly 930
Floating Ring Seal Assembly/Installation 932
Alternate Procedure: 933
SECTION J7 – PARKING BRAKE – INDEX 935
PARKING BRAKE 936
Description 937
Parking Brake Service Criteria 937
Removal 938
Installation 938
PARKING BRAKE SPRING CYLINDER REPLACEMENT 940
Removal 940
Installation 940
AUTOMATIC SLACK ADJUSTER 940
Adjustment Procedure 940
PARKING BRAKE CHECK-OUT 941
SECTION L – HYDRAULIC SYSTEM – INDEX 943
SECTION L2 – HYDRAULIC SYSTEM – INDEX 945
HYDRAULIC SYSTEM 947
HYDRAULIC SYSTEM DESCRIPTION 947
Hydraulic Tank 947
Bleeddown Manifold 948
Hoist Valve 948
Hoist Pump 949
Brake Cooling Pump 949
Brake Control Valve (BCV) 949
Filters 949
High Pressure Filter 949
Low pressure 949
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 951
HYDRAULIC COMPONENT REPAIR 953
HYDRAULIC TANK 953
FILLING INSTRUCTIONS 953
MAINTENANCE 953
Removal 954
Installation 956
Gap Measurement – Hydraulic Tank Mounting 956
STRAINERS AND DIFFUSERS 957
Removal 957
Cleaning and Inspection 957
Installation 958
HYDRAULIC TANK BREATHER 958
Service 959
HYDRAULIC SYSTEM FLUSHING 959
HYDRAULIC PUMPS 960
Removal 960
Installation 961
PUMP REBUILD 962
Disassembly 962
Inspection Of Parts 965
Assembly 965
Bearing Replacement 968
Seal Replacement 968
TROUBLESHOOTING GUIDE 971
SECTION L4 – STEERING CIRCUIT – INDEX 973
STEERING CIRCUIT 975
STEERING CIRCUIT OPERATION 975
COMPONENT DESCRIPTION 975
Steering Control Valve 975
Bleeddown Manifold 976
Bleeddown Solenoid 976
Accumulators 976
High Pressure Filter 976
Warning Devices 976
Flow Amplifier 976
FLOW AMPLIFIER SYSTEM OPERATION 978
Steering Left 980
STEERING/BRAKE PUMP 986
Construction 986
Principle of Operation 988
SECTION L5 – STEERING CONTROL UNIT – INDEX 989
STEERING CONTROL UNIT 991
Removal 991
Installation 991
REBUILD PROCEDURE 992
Disassembly 993
Cleaning and Inspection 993
Assembly 995
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 999
STEERING CIRCUIT COMPONENT REPAIR 1001
BLEEDDOWN MANIFOLD 1001
Removal 1001
Adjusting Relief Valve 1001
Testing and Adjustment 1002
FLOW AMPLIFIER 1003
Removal 1003
Installation 1003
Disassembly 1003
Assembly 1006
ACCUMULATORS 1007
Removal 1007
Installation 1007
Disassembly 1008
Cleaning and Inspection 1008
Assembly 1009
Testing 1009
STEERING ACCUMULATOR CHARGING PROCEDURE 1010
STEERING CYLINDER 1011
Removal 1011
Installation 1011
STEERING CYLINDER REBUILD 1012
Disassembly 1012
Cleaning and Inspection 1012
Assembly 1013
STEERING/BRAKE PUMP 1014
Removal 1014
Installation 1015
PUMP REBUILD 1016
Disassembly 1016
Control Group 1017
Valve Plate Group 1018
Rotating Group 1018
Driveshaft Group 1019
Swashblock Group 1019
Inspection 1020
Control Group 1020
Valve Plate Group 1020
Rotating Group 1020
Swashblock Group 1021
Driveshaft Group 1021
Assembly 1021
Swashblock Group 1021
Driveshaft Group 1021
Rotating Group 1022
Valve Plate Group 1022
Control Group 1023
TROUBLESHOOTING CHART 1024
SECTION L7 – HOIST CIRCUIT – INDEX 1027
HOIST CIRCUIT 1029
HOIST CIRCUIT OPERATION 1029
COMPONENT DESCRIPTION 1030
Hydraulic Tank 1030
Hoist Pump 1030
Hoist Valve 1030
Hoist Pilot Valve 1031
Power Up Limit Solenoid 1032
Pilot Operated Check Valve 1032
Power Down Spool Limit Solenoid 1032
HOIST CIRCUIT OPERATION 1032
POWER UP Operation 1034
HOLD Operation 1036
POWER DOWN Operation 1038
FLOAT Operation 1040
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1043
HOIST CIRCUIT COMPONENT REPAIR 1045
HOIST VALVE 1045
Removal 1045
Installation 1045
O-Ring Replacement 1046
INLET SECTION 1047
Disassembly 1047
Cleaning and Inspection 1048
Assembly 1048
SPOOL SECTION 1048
Disassembly 1048
Cleaning and Inspection 1049
Assembly 1051
HOIST PILOT VALVE 1052
Removal 1052
Installation 1052
Disassembly 1053
Cleaning and Inspection 1054
Reassembly 1054
HOIST CYLINDERS 1055
Removal 1055
Installation 1057
Disassembly 1057
Cleaning and Inspection 1059
Assembly – Quill And Cylinder 1060
Quill Installation 1060
Installation Of Check Balls And Plugs In Quill 1061
Assembly of Cylinder 1062
POWER UP SPOOL LIMIT SOLENOID 1063
PILOT OPERATED CHECK VALVE 1063
POWER DOWN HOIST LIMIT SOLENOID 1063
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1065
HYDRAULIC SYSTEM FILTERS 1067
HIGH PRESSURE FILTER 1067
Removal 1067
Installation 1068
LOW PRESSURE FILTERS 1068
BRAKE COOLING & HOIST FILTERS 1068
TRANSMISSION FILTER 1068
Removal 1069
Installation 1069
SECTION L10 – HYDRAULIC CHECKOUT PROCEDURE – INDEX 1071
HYDRAULIC CHECK-OUT PROCEDURE 1073
GENERAL INFORMATION 1073
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1073
Equipment Requirements 1074
Pump Pressure Control Adjustment 1074
Steering Components Leakage Test 1076
CHECKING HOIST SYSTEM PRESSURES 1077
Equipment Requirements 1077
Power Down Relief Valve Adjustment 1078
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1079
SPECIAL TOOLS 1081
SECTION N – OPERATOR CAB – INDEX 1085
SECTION N2 – OPERATOR CAB – INDEX 1087
OPERATOR CAB 1089
Removal 1090
Installation 1092
CAB DOORS 1092
Removal 1092
Installation 1093
Door Striker Adjustment 1093
Door Handle Plunger Adjustment 1094
DOOR PANEL 1095
Removal 1095
Installation 1095
DOOR WINDOW 1096
Removal 1096
Installation 1098
WINDOW REGULATOR 1100
Removal 1100
Installation 1100
DOOR HANDLE AND DOOR LATCH 1100
Removal 1100
Installation 1100
DOOR SEALS 1101
Removal 1101
Installation 1101
DOOR OPENING SEAL 1101
Removal 1101
Installation 1101
GLASS REPLACEMENT 1102
Replacement 1102
REAR GLASS 1104
Removal 1104
Installation 1104
SECTION N3 – CAB COMPONENTS – INDEX 1105
CAB COMPONENTS 1107
WINDSHIELD WIPERS 1107
Wiper Motor Replacement 1107
Removal 1107
Installation 1107
Wiper Arm Replacement 1107
Removal 1107
Installation 1108
Wiper Linkage Replacement 1108
Removal 1108
Installation 1108
WINDSHIELD WASHER 1109
Operation 1109
Service 1109
OPERATOR SEAT 1110
Adjustment 1110
Removal 1110
Installation 1110
SECTION N4 – OPERATOR COMFORT – INDEX 1111
OPERATOR COMFORT 1113
HEATER/AIR CONDITIONER 1113
Operation 1113
HEATER/AIR CONDITIONER 1114
Operation 1114
HEATER COMPONENTS 1114
Circuit Breaker 1114
D/C – D/C Converter 1115
Flapper Door Motors 1115
Temperature Control Potentiometer 1115
Motorized Coolant Control Valve 1115
Heater Coil 1115
Fan Motor and Speed Control 1115
Test 1115
FILTER 1115
Service 1115
AIR CONDITIONING SYSTEM 1117
Environmental Impact 1117
OPERATOR CAB AIR CONDITIONING 1118
PRINCIPLES OF REFRIGERATION 1118
Air Conditioning 1118
Refrigeration – The Act Of Cooling 1119
The Refrigeration Cycle 1119
AIR CONDITIONER SYSTEM COMPONENTS 1120
Compressor (Refrigerant Pump) 1120
Service Valves 1120
Condenser 1120
Receiver-Drier 1120
Expansion Block Valve 1121
Evaporator 1121
ELECTRICAL CIRCUIT 1122
Thermostat 1122
Compressor Clutch 1122
Trinary™ Switch 1123
SYSTEM SERVICING 1124
SYSTEM OIL 1125
Handling and Reusing PAG Oil 1125
Oil Quantity 1125
Replacing Oil After Servicing the System 1125
Setting Up a New Compressor 1125
REFRIGERANT 1126
Recycled Refrigerant 1126
Reclaimed Refrigerant 1126
Refrigerant Quantity 1126
R-134a Refrigerant Containers 1126
SERVICE TOOLS AND EQUIPMENT 1127
Recovery/Recycle Station 1127
Leak Detector 1127
Service Valves 1128
Vacuum Pump 1128
Manifold Gauge Set 1129
Installing Manifold Gauge Set 1130
Purging Air From Service Hoses 1131
Stabilizing the AC System 1132
SYSTEM PERFORMANCE TEST 1132
SYSTEM LEAK TESTING 1133
Electronic leak detector 1133
Tracer dyes 1133
Soap and water 1133
A/C DRIVE BELT CHECKOUT PROCEDURE 1134
Pulley Alignment 1134
Belt Tension Check 1134
SYSTEM REPAIR 1136
System Cleaning 1136
Hoses and Fittings 1136
Lines 1136
Expansion Valve 1136
Receiver-Drier 1137
Thermostat 1137
Compressor 1137
Clutch 1137
Servicing the Compressor Clutch 1138
Pulley Removal 1140
Clutch Coil Check 1140
Pulley Installation 1140
Clutch Assembly Installation 1141
RECOVERING AND RECYCLING THE REFRIGERANT 1142
Performing the Recovery Cycle 1142
Performing the Recycling Procedure 1142
Evacuating and Charging the AC System 1142
EVACUATING THE SYSTEM 1143
CHARGING THE AC SYSTEM 1144
TROUBLESHOOTING 1145
Pre-Diagnosis Checks 1145
Preparing For Diagnosis 1145
Preliminary Steps 1145
System Performance Test 1145
Diagnosis Of Gauge Readings And System Performance 1146
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1147
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 1153
SECTION N5 – OPERATOR CAB AND CONTROLS – INDEX 1155
OPERATOR CAB AND CONTROLS 1157
STEERING WHEEL AND CONTROLS 1158
Horn Button 1158
Telescope Lock Ring 1158
Tilt Wheel Lever 1158
Turn Signal / Headlight Dimmer 1158
Windshield Wiper / Washer Control 1159
RETARDER CONTROL LEVER 1159
STEERING WHEEL 1159
Removal 1159
Installation 1160
SERVICE BRAKE PEDAL 1160
ACCELERATOR (THROTTLE) PEDAL 1160
INSTRUMENT PANEL 1161
RETARDING CAPACITY CHART 1161
Radio Speakers 1162
MOM Display Screen 1162
MOM Dimmer Switch 1162
Warning Alarm Buzzer 1162
Cab Radio 1162
PMC Interface Connector 1162
Air Cleaner Vacuum Gauges 1162
Payload Meter 1162
Windshield Wipers 1162
CENTER CONSOLE 1163
Transmission Range Selector 1164
Control Switches 1165
Shift Limiter Switch 1165
F1 Start Switch 1165
Hoist Control Lever 1165
Parking Brake Switch 1165
Brake Lock Switch 1166
LH Window Control Switch 1166
RH Window Control Switch 1166
Ash Tray 1166
Lighter 1166
Passenger Seat w/Safety Belt 1166
INSTRUMENT PANEL AND INDICATORS 1167
Keyswitch 1168
Auxiliary Brake Switch 1168
RH Control/Indicator Panel (Pod) 1169
Center Display Panel 1169
LH Control/Indicator Panel (Pod) 1169
Ladder Light Switch 1169
Head Light Switch 1169
BackUp/Deck Lights Switch 1169
RH Control/Indicator Panel (Pod) 1170
Cold Weather Starting Aid (Ether Injection) Switch 1170
Hazard Warning Lights Switch 1170
Automatic Idle Selector Switch (AISS) 1171
Air Conditioner & Heater Vent 1171
ASR Cut (Traction Control) Switch (Option) 1171
Center Display Panel 1172
Air Pressure Monitor (Not Used) 1173
Air Pressure Gauge (Not Used) 1173
Coolant Temperature Monitor 1173
Engine Cooling Water Temperature Gauge 1173
Torque Converter Oil Temperature Monitor 1173
Torque Converter Oil Temperature Gauge 1173
Retarder Oil Temperature Monitor 1173
Retarder Oil Temperature Gauge 1173
Left Turn Signal Pilot Lamp 1174
High Beam Pilot Lamp 1174
Right Turn Signal Pilot Lamp 1174
Speedometer 1174
Tachometer 1174
Lock-up Pilot Lamp 1174
Shift Limiter Pilot Lamp 1174
Shift Indicator 1174
Transmission Shift Position Pilot Lamp 1174
Engine Controller Monitor 1174
Automatic Transmission Mechatronics Monitor 1174
Other Mechatronics Monitor (Optional) 1175
Fuel Level Monitor 1175
Fuel Gauge 1175
Engine Power Derate Monitor 1175
F1 Start Monitor 1175
Auto Cruise Control (Not Used) 1175
ASR Monitor (Optional) 1175
ABS Monitor (Not Used) 1175
Service Meter 1175
Odometer 1175
LH Control/Indicator Panel (Pod) 1176
LH Panel/Pod Assembly 1176
Engine Oil Temperature 1176
Engine Coolant Level 1176
Low Steering Pressure 1176
Accumulator Pre-Charge 1176
Battery Charge Amps 1177
Check Engine 1177
Parking Brake 1177
Body Float 1177
Transmission Oil Temperature 1177
Service Brakes Applied 1177
Maintenance Monitor 1177
Transmission Oil Filters 1177
Lamp Test 1178
Low Brake Pressure 1178
Lateral Slope Warning 1178
Crankcase Pressure 1178
Panel Dimmer Switch 1178
Engine Oil Pressure 1178
Central Warning Lamp 1179
AC/Heater Vent 1179
REAR OF OPERATOR CAB 1179
QUANTUM™ FUEL SYSTEM DIAGNOSTICS 1181
Determining Fault Codes 1181
Exiting The Diagnostics Mode 1182
SECTION P – LUBRICATION AND SERVICE – INDEX 1183
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1185
LUBRICATION AND SERVICE 1187
TRANSMISSION OIL LEVEL CHECK 1187
10 HOUR (DAILY) INSPECTION 1189
250 HOUR INSPECTION 1191
500 HOUR INSPECTION 1193
1000 HOUR INSPECTION 1194
2000 HOUR INSPECTION 1195
5000 HOUR INSPECTION 1196
HYDRAULIC TANK SERVICE 1197
Filling Instructions 1197
Hydraulic Tank Service 1197
STEERING CIRCUIT FILTER 1198
Removal 1198
Installation 1198
HYDRAULIC TANK BREATHER 1199
Cleaning 1199
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 1201
LINCOLN AUTOMATIC LUBRICATION SYSTEM 1203
SYSTEM COMPONENTS 1203
System Operation 1206
System Priming 1207
System Checkout 1207
Pressure Reducer Adjustment 1207
24 VDC Solid State Timer Check 1208
24 VDC Solid State Timer Adjustment 1209
INJECTORS (SL-1 Series “H”) 1210
Injector Specifications 1210
Injector Adjustment 1210
INJECTOR OPERATION 1211
PUMP CYCLE TIMER (FLASHER TIMER) 1212
Pump Cycle Timer (Flasher Timer) Installation 1212
Pump Cycle Timer (Flasher Timer) Adjustment: 1212
TROUBLESHOOTING CHART 1214
RESERVOIR FILL PROCEDURE 1216
Lubricant Required for System 1216
Fill Procedure 1216
Preventive Maintenance Procedures 1217
Daily Lubrication System Inspection 1217
250 Hour Inspection 1217
SECTION R – SYSTEM SCHEMATICS – INDEX 1219
HYDRAULIC SYSTEM SCHEMATIC 1221
HYDRAULIC BRAKE SCHEMATIC 1222
ELECTRICAL SCHEMATIC 1223

S.V 15/12/24