Komatsu HD1500-5 Dump Truck Shop Manual CEBM012601 PDF

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM012601 – PDF DOWNLOAD

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM012601 – PDF DOWNLOAD 

Language : English
Pages : 1255
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-5 Dump Truck Shop Manual CEBM012601 – PDF DOWNLOAD 

SERIAL NUMBERS A30070, A30071, A30077

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 CEBM012601 – PDF DOWNLOAD 

SERIAL NUMBERS A30070, A30071, A30077

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
Removal 882
Installation 882
Disassembly and Adjustment 884
Potentiometer Check 884
Assembly 885
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 887
BRAKE CIRCUIT CHECK-OUT PROCEDURE 889
EQUIPMENT REQUIRED 892
Preparation 892
BRAKE SYSTEM CHECKOUT 894
Failure Modes Check-Out 895
RCM Calibration Check 897
RCM Calibration Procedure 898
Preparation 898
How to Perform Calibration 899
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 901
KOMATSU CHECK-OUT PROCEDURE 905
HYDRAULIC BRAKE SYSTEM DATA SHEET 905
KOMATSU CHECK-OUT PROCEDURE 906
HYDRAULIC BRAKE SYSTEM DATA SHEET 906
SECTION J5 – FRONT WET DISC BRAKES – INDEX 915
FRONT WET DISC BRAKES 917
DESCRIPTION 917
FRONT DISC BRAKE ASSEMBLY 918
Removal 918
Installation 919
BRAKE ASSEMBLY REBUILD 919
DISC BRAKE MAINTENANCE 919
Brake Disc Wear Indicator 919
Checking Disc Wear 920
WEAR INDICATOR SENSOR 921
SPEED SENSOR 921
WET DISC BRAKE BLEEDING PROCEDURE 921
SECTION J6 – REAR WET DISC BRAKES – INDEX 923
REAR WET DISC BRAKES 925
DESCRIPTION 925
Operation 925
MAINTENANCE 926
Brake Disc Wear Indicator 926
Checking Disc Wear 926
Wear Indicator Sensor 927
Brake Assembly Removal 928
Brake Assembly Installation 929
BRAKE ASSEMBLY REBUILD 930
Disassembly 930
Cleaning and Inspection 931
Assembly 932
Floating Ring Seal Assembly/Installation 934
Alternate Procedure: 935
SECTION J7 – PARKING BRAKE – INDEX 937
PARKING BRAKE 938
Description 939
Parking Brake Service Criteria 939
Removal 940
Installation 940
PARKING BRAKE SPRING CYLINDER REPLACEMENT 942
Removal 942
Installation 942
AUTOMATIC SLACK ADJUSTER 942
Adjustment Procedure 942
PARKING BRAKE CHECK-OUT 943
SECTION L – HYDRAULIC SYSTEM – INDEX 945
SECTION L2 – HYDRAULIC SYSTEM – INDEX 947
HYDRAULIC SYSTEM 949
HYDRAULIC SYSTEM DESCRIPTION 949
Hydraulic Tank 949
Bleeddown Manifold 950
Hoist Valve 950
Hoist Pump 951
Brake Cooling Pump 951
Brake Control Valve (BCV) 951
Filters 951
High Pressure Filter 951
Low pressure 951
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 953
HYDRAULIC COMPONENT REPAIR 955
HYDRAULIC TANK 955
FILLING INSTRUCTIONS 955
MAINTENANCE 955
Removal 956
Installation 958
Gap Measurement – Hydraulic Tank Mounting 958
STRAINERS AND DIFFUSERS 959
Removal 959
Cleaning and Inspection 959
Installation 960
HYDRAULIC TANK BREATHER 960
Service 961
HYDRAULIC SYSTEM FLUSHING 961
HYDRAULIC PUMPS 962
Removal 962
Installation 963
PUMP REBUILD 964
Disassembly 964
Inspection Of Parts 967
Assembly 967
Bearing Replacement 970
Seal Replacement 970
TROUBLESHOOTING GUIDE 973
SECTION L4 – STEERING CIRCUIT – INDEX 975
STEERING CIRCUIT 977
STEERING CIRCUIT OPERATION 977
COMPONENT DESCRIPTION 977
Steering Control Valve 977
Bleeddown Manifold 978
Bleeddown Solenoid 978
Accumulators 978
High Pressure Filter 978
Warning Devices 978
Flow Amplifier 978
FLOW AMPLIFIER SYSTEM OPERATION 980
Steering Left 982
STEERING/BRAKE PUMP 988
Construction 988
Principle of Operation 990
SECTION L5 – CONTROL UNIT – INDEX 991
STEERING CONTROL UNIT 993
Removal 993
Installation 993
REBUILD PROCEDURE 994
Disassembly 995
Cleaning and Inspection 996
Assembly 998
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 1003
STEERING CIRCUIT COMPONENT REPAIR 1005
BLEEDDOWN MANIFOLD 1005
Removal 1005
Adjusting Relief Valve 1005
Testing and Adjustment 1006
FLOW AMPLIFIER 1007
Removal 1007
Installation 1007
Disassembly 1007
Assembly 1010
ACCUMULATORS 1011
Removal 1011
Installation 1011
Disassembly 1012
Cleaning and Inspection 1012
Assembly 1013
Testing 1013
STEERING ACCUMULATOR CHARGING PROCEDURE 1014
STEERING CYLINDER 1015
Removal 1015
Installation 1015
STEERING CYLINDER REBUILD 1016
Disassembly 1016
Cleaning and Inspection 1016
Assembly 1017
STEERING/BRAKE PUMP 1018
Removal 1018
Installation 1019
PUMP REBUILD 1020
Disassembly 1020
Control Group 1021
Valve Plate Group 1022
Rotating Group 1022
Driveshaft Group 1023
Swashblock Group 1023
Inspection 1024
Control Group 1024
Valve Plate Group 1024
Rotating Group 1024
Swashblock Group 1025
Driveshaft Group 1025
Assembly 1025
Swashblock Group 1025
Driveshaft Group 1025
Rotating Group 1026
Valve Plate Group 1026
Control Group 1027
TROUBLESHOOTING CHART 1028
SECTION L7 – HOIST CIRCUIT – INDEX 1031
HOIST CIRCUIT 1033
HOIST CIRCUIT OPERATION 1033
COMPONENT DESCRIPTION 1034
Hydraulic Tank 1034
Hoist Pump 1034
Hoist Valve 1034
Hoist Pilot Valve 1035
Power Up Limit Solenoid 1036
Pilot Operated Check Valve 1036
Power Down Spool Limit Solenoid 1036
HOIST CIRCUIT OPERATION 1036
POWER UP Operation 1038
HOLD Operation 1040
POWER DOWN Operation 1042
FLOAT Operation 1044
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1047
HOIST CIRCUIT COMPONENT REPAIR 1049
HOIST VALVE 1049
Removal 1049
Installation 1049
O-Ring Replacement 1050
INLET SECTION 1051
Disassembly 1051
Cleaning and Inspection 1052
Assembly 1052
SPOOL SECTION 1052
Disassembly 1052
Cleaning and Inspection 1053
Assembly 1055
HOIST PILOT VALVE 1056
Removal 1056
Installation 1056
Disassembly 1057
Cleaning and Inspection 1058
Reassembly 1058
HOIST CYLINDERS 1059
Removal 1059
Installation 1061
Disassembly 1061
Cleaning and Inspection 1063
Assembly – Quill And Cylinder 1064
Quill Installation 1064
Installation Of Check Balls And Plugs In Quill 1065
Assembly of Cylinder 1066
POWER UP SPOOL LIMIT SOLENOID 1067
PILOT OPERATED CHECK VALVE 1067
POWER DOWN HOIST LIMIT SOLENOID 1067
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1069
HYDRAULIC SYSTEM FILTERS 1071
HIGH PRESSURE FILTER 1071
Removal 1071
Installation 1072
LOW PRESSURE FILTERS 1072
BRAKE COOLING & HOIST FILTERS 1072
TRANSMISSION FILTER 1072
Removal 1073
Installation 1073
SECTION L10 – HYDRAULIC CHECKOUT PROCEDURE – INDEX 1075
HYDRAULIC CHECK-OUT PROCEDURE 1077
GENERAL INFORMATION 1077
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1077
Equipment Requirements 1078
Pump Pressure Control Adjustment 1078
Steering Components Leakage Test 1080
CHECKING HOIST SYSTEM PRESSURES 1081
Equipment Requirements 1081
Power Down Relief Valve Adjustment 1082
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1083
SPECIAL TOOLS 1085
SECTION N – OPERATOR CAB – INDEX 1089
SECTION N2 – OPERATOR CAB – INDEX 1091
OPERATOR CAB 1093
Removal 1094
Installation 1096
CAB DOORS 1096
Removal 1096
Installation 1097
Door Striker Adjustment 1097
Door Handle Plunger Adjustment 1098
DOOR PANEL 1099
Removal 1099
Installation 1099
DOOR WINDOW 1100
Removal 1100
Installation 1102
WINDOW REGULATOR 1104
Removal 1104
Installation 1104
DOOR HANDLE AND DOOR LATCH 1104
Removal 1104
Installation 1104
DOOR SEALS 1105
Removal 1105
Installation 1105
DOOR OPENING SEAL 1105
Removal 1105
Installation 1105
GLASS REPLACEMENT 1106
Replacement 1106
REAR GLASS 1108
Removal 1108
Installation 1108
SECTION N3 – CAB COMPONENTS – INDEX 1109
CAB COMPONENTS 1111
WINDSHIELD WIPERS 1111
WIPER MOTOR 1111
Removal 1111
Installation 1111
WIPER ARM 1111
Removal 1111
Installation 1112
WIPER LINKAGE 1112
Removal 1112
Installation 1113
WINDSHIELD WASHER 1113
Operation 1113
Service 1113
OPERATOR SEAT 1114
Adjustment 1114
Seat Removal 1115
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX 1117
HEATING AND AIR CONDITIONING 1119
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 1119
HEATER/AIR CONDITIONER 1120
Operation 1120
HEATER COMPONENTS 1120
Circuit Breaker 1120
D/C – D/C Converter 1121
Flapper Door Motors 1121
Temperature Control Potentiometer 1121
Motorized Coolant Control Valve 1121
Heater Coil 1121
Fan Motor and Speed Control 1121
Test 1121
FILTER 1121
Service 1121
AIR CONDITIONING SYSTEM 1124
Environmental Impact 1124
OPERATOR CAB AIR CONDITIONING 1125
PRINCIPLES OF REFRIGERATION 1125
Air Conditioning 1125
Refrigeration – The Act Of Cooling 1126
The Refrigeration Cycle 1126
AIR CONDITIONER SYSTEM COMPONENTS 1127
Compressor (Refrigerant Pump) 1127
Service Valves 1127
Condenser 1127
Receiver-Drier 1127
Expansion Block Valve 1128
Evaporator 1128
ELECTRICAL CIRCUIT 1129
Thermostat 1129
Compressor Clutch 1129
Trinary™ Switch 1130
SYSTEM SERVICING 1131
SYSTEM OIL 1132
Handling and Reusing PAG Oil 1132
Oil Quantity 1132
Replacing Oil After Servicing the System 1132
Setting Up a New Compressor 1132
REFRIGERANT 1133
Recycled Refrigerant 1133
Reclaimed Refrigerant 1133
Refrigerant Quantity 1133
R-134a Refrigerant Containers 1133
SERVICE TOOLS AND EQUIPMENT 1134
Recovery/Recycle Station 1134
Leak Detector 1134
Service Valves 1135
Vacuum Pump 1135
Manifold Gauge Set 1136
Installing Manifold Gauge Set 1137
Purging Air From Service Hoses 1138
Stabilizing the AC System 1139
SYSTEM PERFORMANCE TEST 1139
SYSTEM LEAK TESTING 1140
Electronic leak detector 1140
Tracer dyes 1140
Soap and water 1140
A/C DRIVE BELT CHECKOUT PROCEDURE 1141
Pulley Alignment 1141
Belt Tension Check 1141
SYSTEM REPAIR 1143
System Cleaning 1143
Hoses and Fittings 1143
Lines 1143
Expansion Valve 1143
Receiver-Drier 1144
Thermostat 1144
Compressor 1144
Clutch 1144
Servicing the Compressor Clutch 1145
Pulley Removal 1147
Clutch Coil Check 1147
Pulley Installation 1147
Clutch Assembly Installation 1148
RECOVERING AND RECYCLING THE REFRIGERANT 1149
Performing the Recovery Cycle 1149
Performing the Recycling Procedure 1149
Evacuating and Charging the AC System 1149
EVACUATING THE SYSTEM 1150
CHARGING THE AC SYSTEM 1151
TROUBLESHOOTING 1152
Pre-Diagnosis Checks 1152
Preparing For Diagnosis 1152
Preliminary Steps 1152
System Performance Test 1152
Diagnosis Of Gauge Readings And System Performance 1153
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1154
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 1160
SECTION N5 – OPERATOR CAB & CONTROLS – INDEX 1161
OPERATOR CAB AND CONTROLS 1163
STEERING WHEEL AND CONTROLS 1164
Horn Button 1164
Telescope Lock Ring 1164
Tilt Wheel Lever 1164
Turn Signal / Headlight Dimmer 1164
Windshield Wiper / Washer Control 1165
RETARDER CONTROL LEVER 1165
STEERING WHEEL 1165
Removal 1165
Installation 1166
SERVICE BRAKE PEDAL 1166
ACCELERATOR PEDAL 1166
INSTRUMENT PANEL 1167
RETARDING CAPACITY CHART 1167
Radio Speakers 1168
MOM Display Screen 1168
MOM Dimmer Switch 1168
Warning Alarm Buzzer 1168
Cab Radio 1168
PMC Interface Connector 1168
Air Cleaner Vacuum Gauges 1168
Payload Meter 1168
Windshield Wipers 1168
CENTER CONSOLE 1169
Transmission Range Selector 1170
Control Switches 1171
Shift Limiter Switch 1171
F1 Start Switch 1171
Hoist Control Lever 1171
Parking Brake Switch 1171
Brake Lock Switch 1171
LH Window Control Switch 1172
RH Window Control Switch 1172
Ash Tray 1172
Lighter 1172
Passenger Seat w/Safety Belt 1172
INSTRUMENT PANEL AND INDICATORS 1173
Keyswitch 1174
Auxiliary Brake Switch 1174
RH Control/Indicator Panel (Pod) 1175
Center Display Panel 1175
LH Control/Indicator Panel (Pod) 1175
Ladder Light Switch 1175
Head Light Switch 1175
BackUp/Deck Lights Switch 1175
RH Control/Indicator Panel (Pod) 1176
Cold Weather Starting Aid (Ether Injection) Switch 1176
Hazard Warning Lights Switch 1176
Automatic Idle Selector Switch (AISS) 1177
Air Conditioner & Heater Vent 1177
ASR Cut (Traction Control) Switch (Option) 1177
Center Display Panel 1178
Air Pressure Monitor (Not Used) 1179
Air Pressure Gauge (Not Used) 1179
Coolant Temperature Monitor 1179
Engine Cooling Water Temperature Gauge 1179
Torque Converter Oil Temperature Monitor 1179
Torque Converter Oil Temperature Gauge 1179
Retarder Oil Temperature Monitor 1179
Retarder Oil Temperature Gauge 1179
Left Turn Signal Pilot Lamp 1180
High Beam Pilot Lamp 1180
Right Turn Signal Pilot Lamp 1180
Speedometer 1180
Tachometer 1180
Lock-up Pilot Lamp 1180
Shift Limiter Pilot Lamp 1180
Shift Indicator 1180
Transmission Shift Position Pilot Lamp 1180
Engine Controller Monitor 1180
Automatic Transmission Mechatronics Monitor 1180
Other Mechatronics Monitor (Optional) 1181
Fuel Level Monitor 1181
Fuel Gauge 1181
Engine Power Derate Monitor 1181
F1 Start Monitor 1181
Auto Cruise Control (Not Used) 1181
ASR Monitor (Optional) 1181
ABS Monitor (Not Used) 1181
Service Meter 1181
Odometer 1181
LH Control/Indicator Panel (Pod) 1182
LH Panel/Pod Assembly 1182
Engine Oil Temperature 1182
Engine Coolant Level 1182
Low Steering Pressure 1182
Accumulator Pre-Charge 1182
Battery Charge Amps 1183
Check Engine 1183
Parking Brake 1183
Body Float 1183
Transmission Oil Temperature 1183
Service Brakes Applied 1183
Maintenance Monitor 1183
Transmission Oil Filters 1183
Lamp Test 1184
Low Brake Pressure 1184
Lateral Slope Warning 1184
Crankcase Pressure 1184
Panel Dimmer Switch 1184
Engine Oil Pressure 1184
Central Warning Lamp 1185
AC/Heater Vent 1185
REAR OF OPERATOR CAB 1185
QUANTUM™ FUEL SYSTEM DIAGNOSTICS 1187
Determining Fault Codes 1187
Exiting The Diagnostics Mode 1188
SECTION P – LUBRICATION AND SERVICE – INDEX 1189
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1191
LUBRICATION AND SERVICE 1193
TRANSMISSION OIL LEVEL CHECK 1193
10 HOUR (DAILY) INSPECTION 1195
250 HOUR INSPECTION 1197
500 HOUR INSPECTION 1199
1000 HOUR INSPECTION 1200
2000 HOUR INSPECTION 1201
5000 HOUR INSPECTION 1202
HYDRAULIC TANK SERVICE 1203
Filling Instructions 1203
Hydraulic Tank Service 1203
STEERING CIRCUIT FILTER 1204
Removal 1204
Installation 1204
HYDRAULIC TANK BREATHER 1205
Cleaning 1205
SECTION P3 – AUTOMATIC LUBRICATION SYSTEM – INDEX 1207
LINCOLN AUTOMATIC LUBRICATION SYSTEM 1209
SYSTEM COMPONENTS 1209
System Operation 1212
System Priming 1213
System Checkout 1213
Pressure Reducer Adjustment 1213
24 VDC Solid State Timer Check 1214
24 VDC Solid State Timer Adjustment 1215
INJECTORS (SL-1 Series “H”) 1216
Injector Specifications 1216
Injector Adjustment 1216
INJECTOR OPERATION 1217
PUMP CYCLE TIMER (FLASHER TIMER) 1218
Pump Cycle Timer (Flasher Timer) Installation 1218
Pump Cycle Timer (Flasher Timer) Adjustment: 1218
TROUBLESHOOTING CHART 1220
RESERVOIR FILL PROCEDURE 1222
Lubricant Required for System 1222
Fill Procedure 1222
Preventive Maintenance Procedures 1223
Daily Lubrication System Inspection 1223
250 Hour Inspection 1223
SECTION R 1225
SECTION R – SYSTEM SCHEMATICS – INDEX 1225
HYDRAULIC SYSTEM SCHEMATIC 1227
HYDRAULIC BRAKE SCHEMATIC 1228
ELECTRICAL SCHEMATIC 1229

S.V 15/12/24