Komatsu HD1500-5 Dump Truck Shop Manual CEBM013401 PDF

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM013401 – PDF DOWNLOAD

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM013401 – PDF DOWNLOAD 

Language : English
Pages : 1249
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-5 Dump Truck Shop Manual CEBM013401 – PDF DOWNLOAD 

SERIAL NUMBERS A30072 – A30076

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 CEBM013401 – PDF DOWNLOAD 

SERIAL NUMBERS A30072 – A30076

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 & 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 – STARTING SYSTEM – INDEX 181
STARTING SYSTEMS 183
24 VDC REMOTE MOUNT PRELUB™ SYSTEM 183
OPERATION 183
Oil Pressure Switch 185
Check Valve 185
Timer Solenoid 185
MAINTENANCE 185
Prelub™ System Operation 185
Prelub Pump 185
Check Valve 186
Timer Solenoid 186
PRELUB CIRCUIT TROUBLESHOOTING 187
24 VDC ELECTRIC START SYSTEM 189
OPERATION 189
CRANKING MOTORS 189
Removal 189
Installation 189
Disassembly 190
Cleaning and Inspection 190
Armature Servicing 190
Field Coil Checks 191
Field Coil Removal 191
Solenoid Checks 194
Assembly 195
Pinion Clearance Adjustment 196
MAGNETIC SWITCH 196
Removal 196
Installation 197
Coil Test 197
CRANKING MOTOR TROUBLESHOOTING 198
PRELIMINARY INSPECTION 198
NO-LOAD TEST 198
Load Test Diagnosis 199
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 201
ELECTRICAL SYSTEM COMPONENTS 203
GENERAL TROUBLESHOOTING 203
CAB MOUNTED COMPONENTS 204
Circuit Breakers 204
RELAY BOARDS 207
Relay Boards (With Circuit Breakers) 207
Preliminary Checks 207
Service 208
Relay Board Description 210
Relay Board RB1 210
Relay Board RB4 210
Relay Board RB5 210
Relay Boards (Without Circuit Breakers) 211
Truck Inclination Sensors 213
Payload Meter Inclinometer Sensor 213
Lateral Inclination Sensor 213
Lubrication System Timer 213
ACCELERATOR PEDAL 214
Operation 214
AISS Operation 215
Throttle Pedal Malfunction 217
ACCELERATOR PEDAL CHECKS 217
Idle Validation Switch Continuity Check 217
24V COMPONENTS (Outside Cab) 218
Battery Box 218
Battery Disconnect Switch 218
Ground Level Shutdown Switch 218
Control Power Relays 218
Circuit Breakers 218
Level Sensor 218
Battery Equalizer 219
BODY POSITION SWITCHES 219
Proximity Switch Operation 219
Body-Up Switch Adjustment 220
Hoist Limit Switch Adjustment 222
Speed Sensors 223
Sensor Adjustment 223
24V/240 AMP ALTERNATOR TEST AND REBUILD 224
BENCH TEST 224
TEST 1 – No Load Test 224
STATIC TESTS 225
Regulator Tests 225
Control Box Tests 226
ALTERNATOR DISASSEMBLY 229
ASSEMBLY- ALTERNATOR 236
BF4822 STATOR SERVICE TOOL INSTRUCTIONS 245
Stator Removal And Replacement 245
Stator Installation 246
SECTION D22 – POWERTRAIN MANAGEMENT CONTROL SYSTEM – INDEX 249
POWERTRAIN MANAGEMENT CONTROL™ SYSTEM 251
System Description 251
Engine (Cummins QSK45) 251
Transmission 251
Transmission Controller 251
Retard Control and Monitor 251
Powertrain Management Controller 251
Electronic Display Panel 251
Payload Meter 251
Message for Operator and Maintenance Display 251
Suspension Controller 251
Data Acquisition Device 251
Cummins Quantum 252
Cummins CENSE 252
PMC SYSTEM TROUBLESHOOTING 253
Preliminary Troubleshooting Procedures 253
Emergency Operation 253
Indication Of A Fault Occurrence 253
Action Codes 253
Fault History 253
System Troubleshooting 253
EMERGENCY TRUCK OPERATION 256
PMC SYSTEM FAULT CODES 258
SECTION D23 – POWERTRAIN MANAGEMENT CONTROLLER – INDEX 275
POWERTRAIN MANAGEMENT CONTROLLER (PMC) 277
PMC CONTROLLER FEATURES 277
LED Display 277
DIP Switch Settings 277
NORMAL OPERATION – PMC 278
Throttle Control 278
AISS Operation 278
Retarder Control 279
COMMUNICATION 279
S-NET 279
CENSE 279
RCM 279
PLM 279
“MOM” and “DAD” 279
Additional Functions 280
PMC CONTROLLER TROUBLESHOOTING 283
GENERAL TROUBLESHOOTING PROCEDURES 283
PMC FAULT CODE TROUBLESHOOTING 284
PMC CONTROLLER LOGIC 292
Fault Recovery Classifications 292
PMC FAULT CODE LOGIC DESCRIPTION 293
PMC WIRING HARNESS CONNECTORS 317
SECTION D24 – AUTOMATIC TRANSMISSION CONTROLLER – INDEX 323
AUTOMATIC TRANSMISSION CONTROLLER (ATC) 325
ATC CONTROLLER FEATURES 325
LED Display 325
Rotary Switch Settings 325
Shift Control 326
Range Selector Positions And Automatic Gear Shifting Ranges 326
Transmission Operation Modes 327
Braking Mode: 327
Normal Mode: 327
Automatic Gear Shifting 327
Automatic Shifting Sequence 328
Gearshifting time lag 328
Shift Skip Logic 328
Safety Functions 329
TROUBLESHOOTING – ATC 330
GENERAL TROUBLESHOOTING PROCEDURES 330
ATC FAULT CODE TROUBLESHOOTING 331
ATC FAULT CODE LOGIC DESCRIPTION 346
TRANSMISSION CONTROLLER HARNESS CONNECTORS 377
SECTION D25 – ELECTRONIC DISPLAY PANEL – INDEX 381
ELECTRONIC DISPLAY PANEL 383
Rotary Switch 383
Gauges and Indicators 384
External Indicator Lamps 386
Display Self-Check Function 388
Lamp Test 388
Action Code Display 389
Cancellation of Action Code 389
ELECTRONIC DISPLAY PANEL TROUBLESHOOTING 390
GENERAL TROUBLESHOOTING PROCEDURES 390
Harness Circuit Tests 390
Table 1: Continuity checks 390
Table 2: Short Circuit to Ground Checks 391
Table 3: Circuit Isolation Checks 391
EDP WIRING HARNESS CONNECTORS 409
SECTION D26 – RETARD CONTROL AND MONITOR (RCM) – INDEX 411
RETARD CONTROL AND MONITOR (RCM) 413
Description 413
RCM Calibration 413
GENERAL TROUBLESHOOTING PROCEDURES 414
RCM FAULT CODE TROUBLESHOOTING 416
Description 416
RCM WIRING HARNESS CONNECTORS 463
SECTION D27 – AUTOMATIC SUSPENSION SYSTEM – INDEX 465
AUTOMATIC SUSPENSION SYSTEM 467
Automatic Suspension Controller 467
Manifold Valve 467
Actuator 467
Steering Sensor 467
AUTOMATIC MODE SELECTION CONTROL 468
SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION 469
d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE 469
d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE 469
d015:TRANSMISSION SPEED SIGNAL LOST 470
d016:STEERING SPEED SIGNAL LOST 470
d021:SOLENOID OUTPUT 1 FAILURE 471
d022:SOLENOID OUTPUT 2 FAILURE 471
d023:SOLENOID OUTPUT 3 FAILURE 471
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING 472
SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed 472
SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed 473
SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed 474
SP-4: Fault Code d016: Fault in Steering Sensor System Displayed 475
SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed 476
SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed 477
SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed 478
SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS 479
SECTION D30 – MESSAGE FOR OPERATION AND MAINTENANCE – INDEX 481
MOM – MESSAGE FOR OPERATION AND MAINTENANCE 483
INTRODUCTION 483
SYSTEM CONFIGURATION 483
SOFTWARE 484
Service Meters (SMR) 485
FUNCTION 486
Operator Information 486
Maintenance Information (Screen Hierarchy) 486
Display Able/Disable By Machine Status 488
Vehicle State 488
Display Able/Disable by Truck Model and Optional Equipment Status 489
SCREEN DATA 490
Realtime Data 490
Machine Trend Data 490
Fault Condition Data 490
Machine Information 491
Parameter Set 491
WARNING MESSAGE 492
HARDWARE TROUBLESHOOTING AND MAINTENANCE 493
TROUBLESHOOTING THE MOM UNIT 493
PROBLEMS AND CORRECTIVE ACTIONS 494
Program Errors 495
Warning & Communication Errors 496
SELF-DIAGNOSIS 497
System Check 497
System Information 497
Communication Port Check 497
Key Input Check 498
MAINTENANCE 499
Battery Replacement 499
Replacement of Protective Sheet 499
Back Light Replacement 500
Setting Display OFF Time 501
SECTION D31 – MOM SCREEN DISPLAYS – INDEX 503
MOM SCREEN DISPLAYS 505
i1 INITIAL MESSAGE 505
i2 INITIAL CHECK1 505
i3 INITIAL CHECK2 505
i4 NORMAL RUNNING 506
i7 BACKLIGHT OFF 507
To Access a Maintenance Information Screen: 508
i9 MENU SELECT 509
s1 SERVICE MENU 510
s2 COMPONENT CHECK MENU 510
s21 ENGINE 511
s212 MACHINE TREND MENU (ENG ) 512
s213 FAULT CONDITION MENU (ENG ) 512
s2131 FAULT CONDITION (ENG ) 513
s22 TRANSMISSION 514
s222 MACHINE TREND MENU (T/M) 515
s2221 L/C ON/OFF COUNT 515
s222E AB-USE COUNT 516
s223 FAULT CONDITION MENU (T/M) 517
S2231 FAULT CONDITION (T/M) 517
s23 BRAKE MENU 518
s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE) 518
s233 FAULT CONDITION MENU (BRAKE) 519
s2331 FAULT CONDITION (BRAKE) 519
s24 SUSPENSION MENU 520
s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION) 520
s242 FAULT CONDITION MENU (SUS) 521
s2421 FAULT CONDITION (SUS) 521
s25 PMC MENU 522
s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC) 522
s252 FAULT CONDITION MENU (PMC) 523
s2521 FAULT CONDITION (PMC) 523
s26 ELECTRONIC DISPLAY PANEL MENU 524
s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel) 524
s262 FAULT CONDITION MENU (ELE DISPLAY PANEL) 525
s2621 FAULT CONDITION (ELE DISPLAY PANEL) 525
s27 PLM MENU 526
s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM) 526
s272 CALIBRATION DATA 527
s28 TMS MENU 527
s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS) 528
s283 FAULT CONDITION MENU (TMS) 528
s2831 FAULT CONDITION (TMS) 529
s3 MACHINE INFORMATION MENU 529
s32-1/3 CONTROLLER INFORMATION 531
SELECTOR SWITCH STATUS of the PMC 531
s32-2/3 CONTROLLER INFORMATION 532
s32-3/3 CONTROLLER INFORMATION 533
s33 OPTIONAL FUNCTION INFORMATION 533
s34 HISTORY OF USE 534
t1 PARAMETER SET MENU 535
t2 TIME/DATE SET 535
t3 TRAVEL MODE MENU 536
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 536
t32 SPEED LIMITER 537
t33 T/M MAX GEAR SELECT 537
t34 T/M MAX GEAR SELECT (BODY UP) 538
t35 SUSPENSION MODE SET 538
t4 PARAMETER UNIT SET 539
t5 TMS SET MENU 539
t51 TIRE PRESSURE LIMIT SET 540
t52 TIRE TEMPERATURE LIMIT SET 541
t53 CORRELATION CONSTANTS SET 542
t54 TMS CLOCK SET 543
t55 ID CODE SET 544
SECTION D32 – DATA ACQUISITION DEVICE (DAD) – INDEX 545
DAD – DATA ACQUISITION DEVICE 547
INTRODUCTION 547
HARDWARE HOOKUP 547
SOFTWARE 548
Installation Requirements 548
Installing the Software 548
Starting the Software Program 548
Service Meters (SMR) 548
Display Able/disable By Machine Status 549
Vehicle State 549
MAINTENANCE INFORMATION (SCREEN HIERARCHY) 549
Display Enable/Disable by Truck Model and Optional Equipment Status 553
SCREEN DATA 554
Real Time Data 554
Fault condition data 554
Snap-Shot Data 554
Transmission Snapshot Example 555
Sample Snapshot Screens 559
Machine Trend Data 561
Machine Check 562
Machine Information 562
Event Recorder 562
Parameter Set 562
SECTION D33 – DAD SCREEN DISPLAYS – INDEX 563
DAD SCREEN DISPLAYS 565
PASSWORD INPUT 565
Changing the Password 565
i3 MENU SELECT 565
s1 SERVICE MENU 566
s2 COMPONENT CHECK MENU 566
s21 Engine 566
s21 CUMMINS ENG MENU (for the CUMMINS engine) 566
s21 KOMATSU ENG MENU (for the KOMATSU engine) 566
s22 TRANSMISSION 569
s23 BRAKE MENU 573
s24 SUSPENSION MENU 576
s25 PMC MENU 578
s26 ELECTRONIC DISPLAY PANEL MENU 580
s27 PLM MENU 582
s28 TMS MENU 583
s3 MACHINE INFORMATION MENU 586
s31 MACHINE INFORMATION MENU 586
s32-1/3 CONTROLLER INFORMATION 587
s32-2/3 CONTROLLER INFORMATION 588
s32-3/3 CONTROLLER INFORMATION 589
s33 OPTIONAL FUNCTION INFORMATION 589
s34 HISTORY OF USE 590
t1 PARAMETER SET MENU 591
t2 TIME/DATE SET 591
t3 TRAVEL MODE MENU 592
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 592
t32 SPEED LIMITER 593
t33 T/M MAX GEAR SELECT 593
t34 T/M MAX GEAR SELECT (BODY UP) 594
t35 SUSPENSION MODE SET 594
t4 PARAMETER UNIT SET 595
t5 TMS SET MENU 595
t51 TIRE PRESSURE LIMIT SET 596
t52 TIRE TEMPERATURE LIMIT SET 596
t53 CORRELATION CONSTANTS SET 597
t54 TMS CLOCK SET 597
t55 ID CODE SET 598
SECTION D34 – REAL TIME DATA TABLES – INDEX 599
REAL TIME DATA TABLES 601
ACCESSING REAL TIME DATA SCREENS 601
Real Time Data Screen Switches 601
SECTION D35 – PAYLOAD METER II – INDEX 611
GENERAL INFORMATION 613
Haul Cycles 613
LIGHTS, SWITCHES AND COMPONENTS 614
TIPS FOR OPERATION 615
EXTERNAL DISPLAY LIGHTS 615
THEORY OF OPERATION 616
Basic Description 616
Inclinometer 616
Linkage Factor 616
Gain Factor 617
Brake Lock 617
Sources of Error 617
Typical Data From Service Check Mode 617
Example Calculation of Payload 618
Viewing Payload Calculation Inputs 618
Checking the Gain 619
Adjusting the Gain 619
TYPES OF DATA STORED 620
Cycle Data 620
Engine ON/OFF Data 621
Fault Codes and Warning Data 621
Engine Operation 622
Total Payload and Total Number of Cycles 622
Other Data 622
OPERATOR FUNCTIONS 623
Using the Operator Load Counter 623
Viewing the Operator Load Counter 623
Clearing the Operator Load Counter 623
Dimming the Lights on the Display 623
INITIAL SETUP OF PAYLOAD METER 624
Switch Settings 624
Checking the Operator Check Mode 625
Checking the Service Check Mode 625
Checking the Gt setting: 626
Checking the Inclinometer Settings 626
Calibrating a Truck 626
DISPLAYS AT START-UP 627
Normal Operation 627
SETUP AND MAINTENANCE 628
Setting The Speed Limit 628
Setting the Option Code 628
Setting The Machine I D Code 629
Setting The Operator I D Code 629
Setting The Time and Date 629
DOWNLOAD OF INFORMATION 630
DISPLAY OF FAULT CODES 630
Monitoring Input Signals 634
Service Check Mode 634
UP FACTOR – PAYLOAD CALCULATION GAIN 635
PL MODE -LOAD CALCULATION TIMING 635
FINAL GEAR RATIO SELECTION 636
BATTERY REPLACEMENT PROCEDURE 637
Replacing the Battery 637
After Replacing the Battery 638
SUSPENSION PRESSURE SENSOR 638
Removal 638
Installation 639
INCLINOMETER 639
Removal 639
Installation 639
Adjustment 639
PAYLOAD METER BACK PANEL 640
CONNECTIONS 641
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 642
PAYLOAD CIRCUIT NUMBERS 643
TROUBLESHOOTING 644
COMMON PROBLEMS 644
Suspension Charging 644
Symptom Table 645
Missing Body-Up Signal 645
Missing Speed Signal 646
F-18: Alternator R-Terminal, Oil Pressure Signals 646
Shorted 18v Sensor Power Supply (930E) 646
FAULT TREE DIAGNOSIS 647
Payload Lights Won’t Illuminate 647
Red, Amber or Green Payload Light Does Not Illuminate 648
Cannot Download – PC Communications 649
PC Communications Configuration 650
F CAL: Payload Meter Won’t Calibrate 651
F-20: Sensor Power Fault 652
F-21, F-25: Left Front Pressure Sensor 654
F-22, F-26: Right Front Pressure Sensor 654
F-23, F-27: Left Rear Pressure Sensor 654
F-24, F-28: Right Rear Pressure Sensor 654
F-31, F-32: Inclinometer 656
Body Up Input 658
Brake Lock Input 659
Speed Signal 660
Adjusting the Speed Sensor 660
CONNECTORS AND PRESSURE SENSORS 662
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 665
Menu Functions 668
Using Scope 668
Log File Information 668
Connections to Payload Meter II™ 669
USING SCOPE 670
Monitoring Inputs Using Scope 670
Monitoring Suspension Charging Using Scope 670
Pressure Sensor Dummy Loads 673
GAIN ADJUSTMENT WORKSHEET 674
SECTION F – TRANSMISSION / TORQUE CONVERTER – INDEX 675
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 677
TORQUE CONVERTER AND TRANSMISSION 679
TRANSMISSION 679
TORQUE CONVERTER 680
MAIN RELIEF VALVE 682
Function 682
Operation 682
TORQUE CONVERTER RELIEF VALVE 682
Function 682
Operation 682
TORQUE CONVERTER REGULATOR VALVE 684
Operation 684
LOCK-UP CLUTCH 685
Lock-up Clutch Accumulator 685
HYDRAULIC PUMP 686
TORQUE CONVERTER STALL CHECK 687
TRANSMISSION 688
LUBRICATION RELIEF VALVE 690
Function 690
TRANSMISSION CONTROL VALVE 691
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 693
Pressure Control Valve 694
Flow Sensor Valve 694
ECMV and Proportional Solenoid 694
ECMV and Fill Switch 694
ECMV Operation 695
ECMV REPAIR PROCEDURE 698
Filter Replacement Procedure 698
ECMV Removal 699
Disassembly 699
Assembly 700
TRANSMISSION FILTERS 702
Service 702
Installation 702
TRANSMISSION REMOVAL 703
TRANSMISSION INSTALLATION 704
TRANSMISSION OIL LEVEL CHECK 706
SECTION F3 – TRANSMISSION OIL COOLER AND STRAINERS – INDEX 707
TRANSMISSION OIL COOLER & STRAINERS 709
TRANSMISSION OIL COOLER 709
Removal and Installation 709
Repair 709
TRANSMISSION OIL STRAINER 709
Removal 710
Inspection 710
Installation 710
SECTION F5 – DRIVE SHAFTS – INDEX 711
DRIVE SHAFTS 713
FRONT DRIVE SHAFT 713
Removal 713
Disassembly 713
Assembly 714
Installation 714
FRONT DRIVE SHAFT ALIGNMENT 715
REAR DRIVE SHAFT 718
Removal 718
Disassembly 718
Assembly 719
Installation 719
SECTION F6 – TRANSMISSION ELECTRICAL – INDEX 721
TRANSMISSION ELECTRICAL 723
TRANSMISSION SHIFT CONTROLLER 724
Event Memory 724
Fault History Data 724
Snap-Shot Data 724
Trend Data 725
TRANSMISSION RANGE SELECTOR 726
SENSORS AND SWITCHES 727
Transmission Speed Sensors 727
Adjustment Procedure 727
Fill Switch 728
Shift Limit Switch 728
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 729
Preliminary Checks 729
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 733
SECTION G2 – TIRES AND RIMS – INDEX 735
TIRES AND RIMS 737
GENERAL INFORMATION 737
FRONT TIRES AND RIMS 738
Removal 738
Installation 739
REAR TIRE AND RIM 739
Removal 739
Installation 740
TIRE MATCHING 741
RIM 742
Tire Removal From Rim 742
Tire Installation On Rim 742
FRONT WHEEL STUD INSTALLATION 743
REAR WHEEL STUD INSTALLATION 744
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 745
FRONT WHEEL HUB AND SPINDLE 747
OIL SAMPLE ANALYSIS 747
Oil Sampling Guidelines 747
Guidelines For Obtaining A Sample 747
FRONT WHEEL HUB 748
Removal 748
Disassembly 748
Inspection 748
Assembly and Installation 749
Front Wheel Hub Bearing Adjustment 751
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION 751
SUSPENSION A-ARM 751
Removal 751
Inspection of Parts 752
Installation 752
CENTER TIE ROD PIVOT 753
Removal 753
Inspection 753
Installation 753
TOE IN ADJUSTMENT 754
Adjustment Procedure 754
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 757
REAR AXLE ATTACHMENTS 759
CENTER LINK AND LOWER LINKS 759
Removal 759
Inspection 760
Spherical Bearing Replacement 760
Installation 760
PANHARD ROD (DIAGONAL LINK) 761
Removal 761
Inspection 762
Installation 762
SECTION G5 – REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 763
REAR AXLE & FINAL DRIVE ASSEMBLY 765
DIFFERENTIAL OPERATION 765
Straight-away-travel 765
Turning 765
REAR AXLE ASSEMBLY 766
Removal 766
Installation 766
DIFFERENTIAL OIL LEVEL CHECK 767
DIFFERENTIAL ASSEMBLY 768
Removal 768
Installation 769
Disassembly 769
Pinion Carrier Assembly 772
Differential Gear Unit 772
Differential Gear Unit 773
Assembly 776
Differential Bearing 776
Assembly Of Differential Gear Assembly 776
Installation Of Differential Assembly 778
Input Pinion and Carrier Assembly 779
Adjusting Tooth Contact, Backlash 783
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 787
FINAL DRIVE PLANETARIES AND WHEEL HUBS 789
FINAL DRIVE 789
Oil Level Check 790
FINAL DRIVE CARRIER ASSEMBLY 790
Removal 790
Installation 791
Disassembly 791
Assembly 792
FINAL DRIVE ASSEMBLY 793
Disassembly 793
Assembly 795
SECTION H – SUSPENSIONS – INDEX 797
SECTION H2 – FRONT SUSPENSION – INDEX 799
FRONT SUSPENSION 801
FRONT SUSPENSION ASSEMBLY 801
Suspension Operation 802
3-MODE SUSPENSION (Optional) 803
Variable Damping Operation 803
3-Mode Suspension System Components 804
Automatic Suspension Controller 804
Manifold Valve 804
Actuator 805
Steering Sensor 805
Suspension Removal 806
Suspension Installation 807
Disassembly 808
Inspection 808
Assembly 808
DAMPING VALVE REPAIR 810
Damping Valve (Fixed Rate) 810
Disassembly 810
Assembly 810
Damping Valve/Actuator 811
(3-Mode Damping Rate) 811
Cleaning and Inspection 811
Assembly 811
SECTION H3 – REAR SUSPENSION – INDEX 813
REAR SUSPENSION 815
OPERATION 816
Removal 817
Installation 817
Disassembly 817
Assembly 819
SPHERICAL BEARINGS 820
Removal 820
Inspection 820
Installation 820
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 821
SUSPENSION OILING AND CHARGING 823
GENERAL INFORMATION 823
Equipment List 823
FRONT SUSPENSION 825
Front Suspension Oiling 825
Front Suspension Nitrogen Charging 828
REAR SUSPENSION 830
General Information 830
Rear Suspension Oiling 831
Rear Suspension Nitrogen Charging 834
Length Adjustment – Front And Rear Cylinders 835
SECTION J – BRAKE SYSTEM – INDEX 837
SECTION J2 – BRAKE CIRCUIT – INDEX 839
BRAKE CIRCUIT 841
SERVICE BRAKE CIRCUIT 841
SECONDARY BRAKING AND AUTOMATIC APPLY 843
PARKING BRAKE CIRCUIT 843
Normal Operation 843
BRAKE LOCK CIRCUIT 844
AUXILIARY CIRCUIT 844
RETARDING CIRCUIT 844
WARNING CIRCUIT 844
BRAKE SYSTEM ELECTRICAL COMPONENTS 845
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 849
BRAKE CIRCUIT COMPONENT SERVICE 851
BRAKE VALVE 851
Rebuild Criteria 851
Removal 852
Installation 852
Disassembly 853
Cleaning and Inspection 854
Assembly 856
Actuator Base Threaded Inserts 856
Boot and Cap 856
Valve Body Seal Installation 856
Regulator Sleeve O-Ring Installation 856
Actuator Plunger O-ring Installation 857
Assembly of Valve 857
DIFFERENTIAL PRESSURE SWITCH 859
Disassembly 859
Cleaning and Inspection 859
Assembly 859
VALVE BENCH TEST AND ADJUSTMENT 860
Test Bench Only 861
Test Set Up Procedure 861
Brake Valve Output Pressure Adjustment 861
Differential Pressure Switch Adjustment 862
Final Test and Adjustment 862
Proximity Switch Installation and Adjustment 863
Installation Of Brake Pedal Actuator Assembly to Brake Valve 864
RELAY VALVES 865
Removal 865
Installation 865
Disassembly 866
Cleaning and Inspection 867
Assembly 867
VALVE TEST AND ADJUSTMENT 868
Test Set Up Procedure 869
Relay Valve 869
Output Pressure Adjustment 869
HYDRAULIC BRAKE ACCUMULATORS 870
Brake Accumulator Bleed Down Procedure 870
BRAKE ACCUMULATOR CHARGING PROCEDURE 871
BRAKE ACCUMULATOR REBUILD 872
Removal 872
Installation 872
Disassembly 872
Cleaning and Inspection 872
Assembly 873
Testing 874
Storage 874
BRAKE COOLING VALVE (BCV) 875
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 876
Removal 876
Installation 876
Disassembly and Adjustment 878
Potentiometer Check 878
Assembly 879
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 881
BRAKE CIRCUIT CHECK-OUT PROCEDURE 883
EQUIPMENT REQUIRED 886
Preparation 886
BRAKE SYSTEM CHECKOUT 888
Failure Modes Check-Out 889
RCM Calibration Check 891
RCM Calibration Procedure 892
Preparation 892
How to Perform Calibration 893
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 895
KOMATSU CHECK-OUT PROCEDURE 899
HYDRAULIC BRAKE SYSTEM DATA SHEET 899
KOMATSU CHECK-OUT PROCEDURE 900
HYDRAULIC BRAKE SYSTEM DATA SHEET 900
SECTION J5 – FRONT WET DISC BRAKES – INDEX 909
FRONT WET DISC BRAKES 911
DESCRIPTION 911
FRONT DISC BRAKE ASSEMBLY 912
Removal 912
Installation 913
BRAKE ASSEMBLY REBUILD 913
DISC BRAKE MAINTENANCE 913
Brake Disc Wear Indicator 913
Checking Disc Wear 914
WEAR INDICATOR SENSOR 915
SPEED SENSOR 915
WET DISC BRAKE BLEEDING PROCEDURE 915
SECTION J6 – REAR WET DISC BRAKES – INDEX 917
REAR WET DISC BRAKES 919
DESCRIPTION 919
Operation 919
MAINTENANCE 920
Brake Disc Wear Indicator 920
Checking Disc Wear 920
Wear Indicator Sensor 921
Brake Assembly Removal 922
Brake Assembly Installation 923
BRAKE ASSEMBLY REBUILD 924
Disassembly 924
Cleaning and Inspection 925
Assembly 926
Floating Ring Seal Assembly/Installation 928
Alternate Procedure: 929
SECTION J7 – PARKING BRAKE – INDEX 931
PARKING BRAKE 932
Description 933
Parking Brake Service Criteria 933
Removal 934
Installation 934
PARKING BRAKE SPRING CYLINDER REPLACEMENT 936
Removal 936
Installation 936
AUTOMATIC SLACK ADJUSTER 936
Adjustment Procedure 936
PARKING BRAKE CHECK-OUT 937
SECTION L – HYDRAULIC SYSTEM – INDEX 939
SECTION L2 – HYDRAULIC SYSTEM OVERVIEW – INDEX 941
HYDRAULIC SYSTEM OVERVIEW 943
HYDRAULIC SYSTEM DESCRIPTION 943
Hydraulic Tank 943
Bleed-down Manifold 944
Hoist Valve 945
Hoist Pump 945
Brake Cooling Pump 945
Brake Control Valve (BCV) 945
High Pressure Filter 946
Low pressure Filter 946
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 947
HYDRAULIC COMPONENT REPAIR 949
HYDRAULIC TANK 949
FILLING INSTRUCTIONS 949
MAINTENANCE 949
Removal 950
Installation 952
Gap Measurement – Hydraulic Tank Mounting 952
STRAINERS AND DIFFUSERS 953
Removal 953
Cleaning and Inspection 953
Installation 954
HYDRAULIC TANK BREATHER 954
Service 955
HYDRAULIC SYSTEM FLUSHING 955
HYDRAULIC PUMPS 956
Removal 956
Installation 957
PUMP REBUILD 958
Disassembly 958
Inspection Of Parts 961
Assembly 961
Bearing Replacement 964
Seal Replacement 964
TROUBLESHOOTING GUIDE 967
SECTION L4 – STEERING CIRCUIT – INDEX 969
STEERING CIRCUIT 971
OPERATION 971
COMPONENT DESCRIPTION 971
Steering Control Valve 971
Bleed-down Manifold 971
Bleed-down Solenoid 972
Accumulators 972
Flow Amplifier 973
High Pressure Filter 973
Warning Devices 973
FLOW AMPLIFIER OPERATION 975
STEERING/BRAKE PUMP 983
COMPONENTS 983
OPERATION 985
SECTION L5 – STEERING CONTROL UNIT – INDEX 987
STEERING CONTROL UNIT 989
Removal 989
Installation 989
REBUILD PROCEDURE 990
Disassembly 991
Cleaning and Inspection 992
Assembly 994
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 999
STEERING CIRCUIT COMPONENT REPAIR 1001
BLEED-DOWN 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 1009
Assembly 1009
Testing 1010
STEERING ACCUMULATOR CHARGING PROCEDURE 1010
STEERING CYLINDER 1011
Removal 1011
Installation 1012
STEERING CYLINDER REBUILD 1013
Disassembly 1013
Cleaning and Inspection 1013
Assembly 1014
STEERING/BRAKE PUMP 1014
Removal 1014
Installation 1015
PUMP REBUILD 1016
Disassembly 1016
Control Group 1017
Valve Plate Group 1018
Rotating Group 1018
Drive Shaft Group 1019
Swashblock Group 1019
Inspection 1019
Control Group 1019
Valve Plate Group 1020
Rotating Group 1020
Swashblock Group 1021
Drive Shaft Group 1021
Assembly 1021
Swashblock Group 1021
Drive Shaft Group 1022
Rotating Group 1022
Valve Plate Group 1023
Control Group 1024
STEERING CIRCUIT FILTER 1025
Removal 1025
Installation 1025
TROUBLESHOOTING CHART 1026
SECTION L7 – HOIST CIRCUIT – INDEX 1029
HOIST CIRCUIT 1031
HOIST CIRCUIT OPERATION 1031
COMPONENT DESCRIPTION 1032
Hydraulic Tank 1032
Hoist Pump 1032
Hoist Valve 1032
Hoist Pilot Valve 1033
Power Up Limit Solenoid 1034
Pilot Operated Check Valve 1034
Power Down Spool Limit Solenoid 1034
HOIST CIRCUIT OPERATION 1034
POWER UP Operation 1036
HOLD Operation 1038
POWER DOWN Operation 1040
FLOAT Operation 1042
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1045
HOIST CIRCUIT COMPONENT REPAIR 1047
HOIST VALVE 1047
Removal 1047
Installation 1047
O-Ring Replacement 1048
INLET SECTION 1049
Disassembly 1049
Cleaning and Inspection 1050
Assembly 1050
SPOOL SECTION 1050
Disassembly 1050
Cleaning and Inspection 1051
Assembly 1053
HOIST PILOT VALVE 1054
Removal 1054
Installation 1054
Disassembly 1055
Cleaning and Inspection 1056
Reassembly 1056
HOIST CYLINDERS 1057
Removal 1057
Installation 1059
Disassembly 1059
Cleaning and Inspection 1061
Assembly – Quill And Cylinder 1062
Quill Installation 1062
Installation Of Check Balls And Plugs In Quill 1063
Assembly of Cylinder 1064
POWER UP SPOOL LIMIT SOLENOID 1065
PILOT OPERATED CHECK VALVE 1065
POWER DOWN HOIST LIMIT SOLENOID 1065
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1067
HYDRAULIC SYSTEM FILTERS 1069
HIGH PRESSURE FILTER 1069
Removal 1069
Installation 1070
LOW PRESSURE FILTERS 1070
BRAKE COOLING & HOIST FILTERS 1070
TRANSMISSION FILTER 1070
Removal 1071
Installation 1071
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 1073
HYDRAULIC CHECK-OUT PROCEDURE 1075
GENERAL INFORMATION 1075
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1075
Equipment Requirements 1076
Pump Pressure Control Adjustment 1076
Steering Components Leakage Test 1078
CHECKING HOIST SYSTEM PRESSURES 1079
Equipment Requirements 1079
Power Down Relief Valve Adjustment 1080
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1081
SPECIAL TOOLS 1083
SECTION N – OPERATOR CAB – INDEX 1087
SECTION N2 – OPERATOR CAB – INDEX 1089
OPERATOR CAB 1091
Removal 1092
Installation 1094
CAB DOORS 1094
Removal 1094
Installation 1095
Door Striker Adjustment 1095
Door Handle Plunger Adjustment 1096
DOOR PANEL 1097
Removal 1097
Installation 1097
DOOR WINDOW 1098
Removal 1098
Installation 1100
WINDOW REGULATOR 1102
Removal 1102
Installation 1102
DOOR HANDLE AND DOOR LATCH 1102
Removal 1102
Installation 1102
DOOR SEALS 1103
Removal 1103
Installation 1103
DOOR OPENING SEAL 1103
Removal 1103
Installation 1103
GLASS REPLACEMENT 1104
Replacement 1104
REAR GLASS 1106
Removal 1106
Installation 1106
SECTION N3 – CAB COMPONENTS – INDEX 1107
CAB COMPONENTS 1109
WINDSHIELD WIPERS 1109
WIPER MOTOR 1109
Removal 1109
Installation 1109
WIPER ARM 1109
Removal 1109
Installation 1110
WIPER LINKAGE 1110
Removal 1110
Installation 1111
WINDSHIELD WASHER 1111
Operation 1111
Service 1111
OPERATOR SEAT 1112
Adjustment 1112
Seat Removal 1113
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX 1115
HEATING AND AIR CONDITIONING 1117
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 1117
HEATER/AIR CONDITIONER 1118
Operation 1118
HEATER COMPONENTS 1118
Circuit Breaker 1118
D/C – D/C Converter 1119
Flapper Door Motors 1119
Temperature Control Potentiometer 1119
Motorized Coolant Control Valve 1119
Heater Coil 1119
Fan Motor and Speed Control 1119
Test 1119
FILTER 1119
Service 1119
AIR CONDITIONING SYSTEM 1122
Environmental Impact 1122
OPERATOR CAB AIR CONDITIONING 1123
PRINCIPLES OF REFRIGERATION 1123
Air Conditioning 1123
Refrigeration – The Act Of Cooling 1124
The Refrigeration Cycle 1124
AIR CONDITIONER SYSTEM COMPONENTS 1125
Compressor (Refrigerant Pump) 1125
Service Valves 1125
Condenser 1125
Receiver-Drier 1125
Expansion Block Valve 1126
Evaporator 1126
ELECTRICAL CIRCUIT 1127
Thermostat 1127
Compressor Clutch 1127
Trinary™ Switch 1128
SYSTEM SERVICING 1129
SYSTEM OIL 1130
Handling and Reusing PAG Oil 1130
Oil Quantity 1130
Replacing Oil After Servicing the System 1130
Setting Up a New Compressor 1130
REFRIGERANT 1131
Recycled Refrigerant 1131
Reclaimed Refrigerant 1131
Refrigerant Quantity 1131
R-134a Refrigerant Containers 1131
SERVICE TOOLS AND EQUIPMENT 1132
Recovery/Recycle Station 1132
Leak Detector 1132
Service Valves 1133
Vacuum Pump 1133
Manifold Gauge Set 1134
Installing Manifold Gauge Set 1135
Purging Air From Service Hoses 1136
Stabilizing the AC System 1137
SYSTEM PERFORMANCE TEST 1137
SYSTEM LEAK TESTING 1138
Electronic leak detector 1138
Tracer dyes 1138
Soap and water 1138
A/C DRIVE BELT CHECKOUT PROCEDURE 1139
Pulley Alignment 1139
Belt Tension Check 1139
SYSTEM REPAIR 1141
System Cleaning 1141
Hoses and Fittings 1141
Lines 1141
Expansion Valve 1141
Receiver-Drier 1142
Thermostat 1142
Compressor 1142
Clutch 1142
Servicing the Compressor Clutch 1143
Pulley Removal 1145
Clutch Coil Check 1145
Pulley Installation 1145
Clutch Assembly Installation 1146
RECOVERING AND RECYCLING THE REFRIGERANT 1147
Performing the Recovery Cycle 1147
Performing the Recycling Procedure 1147
Evacuating and Charging the AC System 1147
EVACUATING THE SYSTEM 1148
CHARGING THE AC SYSTEM 1149
TROUBLESHOOTING 1150
Pre-Diagnosis Checks 1150
Preparing For Diagnosis 1150
Preliminary Steps 1150
System Performance Test 1150
Diagnosis Of Gauge Readings And System Performance 1151
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1152
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 1158
SECTION N5 – OPERATOR CAB & CONTROLS – INDEX 1159
OPERATOR CAB AND CONTROLS 1161
STEERING WHEEL AND CONTROLS 1162
Horn Button 1162
Telescope Lock Ring 1162
Tilt Wheel Lever 1162
Turn Signal / Headlight Dimmer 1162
Windshield Wiper / Washer Control 1163
RETARDER CONTROL LEVER 1163
STEERING WHEEL 1163
Removal 1163
Installation 1164
SERVICE BRAKE PEDAL 1164
ACCELERATOR PEDAL 1164
INSTRUMENT PANEL 1165
RETARDING CAPACITY CHART 1165
Radio Speakers 1166
MOM Display Screen 1166
MOM Dimmer Switch 1166
Warning Alarm Buzzer 1166
Cab Radio 1166
PMC Interface Connector 1166
Air Cleaner Vacuum Gauges 1166
Payload Meter 1166
Windshield Wipers 1166
CENTER CONSOLE 1167
Transmission Range Selector 1168
Control Switches 1169
Shift Limiter Switch 1169
F1 Start Switch 1169
Hoist Control Lever 1169
Parking Brake Switch 1169
Brake Lock Switch 1169
LH Window Control Switch 1170
RH Window Control Switch 1170
Ash Tray 1170
Lighter 1170
Passenger Seat w/Safety Belt 1170
INSTRUMENT PANEL AND INDICATORS 1171
Keyswitch 1172
Auxiliary Brake Switch 1172
RH Control/Indicator Panel (Pod) 1173
Center Display Panel 1173
LH Control/Indicator Panel (Pod) 1173
Ladder Light Switch 1173
Head Light Switch 1173
BackUp/Deck Lights Switch 1173
RH Control/Indicator Panel (Pod) 1174
Cold Weather Starting Aid (Ether Injection) Switch 1174
Hazard Warning Lights Switch 1174
Automatic Idle Selector Switch (AISS) 1175
Air Conditioner & Heater Vent 1175
ASR Cut (Traction Control) Switch (Option) 1175
Center Display Panel 1176
Air Pressure Monitor (Not Used) 1177
Air Pressure Gauge (Not Used) 1177
Coolant Temperature Monitor 1177
Engine Cooling Water Temperature Gauge 1177
Torque Converter Oil Temperature Monitor 1177
Torque Converter Oil Temperature Gauge 1177
Retarder Oil Temperature Monitor 1177
Retarder Oil Temperature Gauge 1177
Left Turn Signal Pilot Lamp 1178
High Beam Pilot Lamp 1178
Right Turn Signal Pilot Lamp 1178
Speedometer 1178
Tachometer 1178
Lock-up Pilot Lamp 1178
Shift Limiter Pilot Lamp 1178
Shift Indicator 1178
Transmission Shift Position Pilot Lamp 1178
Engine Controller Monitor 1178
Automatic Transmission Mechatronics Monitor 1178
Other Mechatronics Monitor (Optional) 1179
Fuel Level Monitor 1179
Fuel Gauge 1179
Engine Power Derate Monitor 1179
F1 Start Monitor 1179
Auto Cruise Control (Not Used) 1179
ASR Monitor (Optional) 1179
ABS Monitor (Not Used) 1179
Service Meter 1179
Odometer 1179
LH Control/Indicator Panel (Pod) 1180
LH Panel/Pod Assembly 1180
Engine Oil Temperature 1180
Engine Coolant Level 1180
Low Steering Pressure 1180
Accumulator Pre-Charge 1180
Battery Charge Amps 1181
Check Engine 1181
Parking Brake 1181
Body Float 1181
Transmission Oil Temperature 1181
Service Brakes Applied 1181
Maintenance Monitor 1181
Transmission Oil Filters 1181
Lamp Test 1182
Low Brake Pressure 1182
Lateral Slope Warning 1182
Crankcase Pressure 1182
Panel Dimmer Switch 1182
Engine Oil Pressure 1182
Central Warning Lamp 1183
AC/Heater Vent 1183
REAR OF OPERATOR CAB 1183
QUANTUM™ FUEL SYSTEM DIAGNOSTICS 1185
Determining Fault Codes 1185
Exiting The Diagnostics Mode 1186
SECTION P – LUBRICATION AND SERVICE – INDEX 1187
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1189
LUBRICATION AND SERVICE 1191
10 HOUR (DAILY) INSPECTION 1193
250 HOUR INSPECTION 1195
500 HOUR INSPECTION 1197
1000 HOUR INSPECTION 1198
2000 HOUR INSPECTION 1199
5000 HOUR INSPECTION 1200
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 1219
SECTION R – SYSTEM SCHEMATICS – INDEX 1219
HYDRAULIC SYSTEM SCHEMATIC 1221
HYDRAULIC BRAKE SCHEMATIC 1222
ELECTRICAL WIRING SCHEMATIC 1223

S.V 15/12/24