Komatsu HD1500-5 Dump Truck Shop Manual CEBM014402 PDF

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM014402 – PDF DOWNLOAD

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Komatsu HD1500-5 Dump Truck Shop Manual CEBM014402 – PDF DOWNLOAD 

Language : English
Pages : 1219
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HD1500-5 Dump Truck Shop Manual CEBM014402 – PDF DOWNLOAD 

SERIAL NUMBERS A30079 & UP

FOREWORD:

This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently.

• All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
• This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
• Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft 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 CEBM014402 – PDF DOWNLOAD 

SERIAL NUMBERS A30079 & UP

COVER 1
FOREWORD 4
TABLE OF CONTENTS 6
SECTION A GENERAL INFORMATION INDEX 8
SECTION A2 – MAJOR COMPONENTS AND SPECIFICATIONS 10
SECTION A3 – SAFETY & OPERATING INSTRUCTIONS – INDEX 14
SAFETY 16
Safety Rules 16
Safety Features 16
Clothing And Personal Items 16
Unauthorized Modification 16
Leaving The Operator’s Seat 16
Mounting And Dismounting 17
Fire Prevention For Fuel And Oil 17
Precautions With High Temperature Fluids 17
Asbestos Dust Hazard Prevention 18
Prevention Of Injury By Work Equipment 18
Fire Extinguisher And First Aid Kit 18
Precautions For ROPS 18
Precautions For Attachments 18
PRECAUTIONS DURING OPERATION 19
Safety Is Thinking Ahead 19
BEFORE STARTING THE ENGINE 19
Safety At The Work Site 19
Fire Prevention 19
Preparing For Operation 19
Ventilation In Enclosed Areas 19
In Operator’s Cab – Before Starting The Engine 20
Mirrors, Windows, And Lights 20
OPERATING THE MACHINE 20
When Starting The Engine 20
Precautions For Starting Machine 20
Truck Operation – General 20
Traveling 21
Traveling In Reverse 21
Traveling On Slopes 22
Ensure Good Visibility 22
Operate Carefully On Snow 22
Avoid Damage To Dump Body 22
Driving Near High Voltage Cables 22
When Dumping 23
Working On Loose Ground 23
Loading The Body 23
Parking The Machine 23
TOWING 23
WORKING NEAR BATTERIES 24
Battery Hazard Prevention 24
Starting With Booster Cables 24
PRECAUTIONS FOR MAINTENANCE 25
BEFORE PERFORMING MAINTENANCE 25
Warning Tag 25
Proper Tools 25
Stopping The Engine Before Service 25
Securing The Dump Body 25
DURING MAINTENANCE 27
Personnel 27
Attachments 27
Working Under The Machine 27
Keep The Machine Clean 27
Rules To Follow When Adding Fuel Or Oil 27
Radiator Water Level 27
Use Of Lighting 27
Precautions With The Battery 28
Handling High Pressure Hoses 28
Precautions With High Pressure Oil 28
Precautions When Performing Maintenance Near High Temperature Or High Pressure 28
Rotating Fan And Belts 28
Waste Materials 28
TIRES 29
Handling Tires 29
Tire Maintenance 29
Storing Tires After Removal 29
WHEN REPAIRS ARE NECESSARY 30
ADDITIONAL JOB SITE RULES 31
OPERATING INSTRUCTIONS 32
PREPARING FOR OPERATION 32
Safety Is Thinking Ahead 32
Walk Around Inspection 32
ENGINE START-UP SAFETY PRACTICES 35
Cold Weather Starting 36
Jump Starting 36
EMERGENCY STEERING SYSTEM 37
Operation 37
Pre-Operation Testing 37
AFTER THE ENGINE HAS STARTED 38
MACHINE OPERATION SAFETY PRECAUTIONS 40
LOADING 41
HAULING 42
RETARDER OPERATION 42
PASSING 43
DUMPING 43
Raising the Dump Body 44
Lowering The Dump Body 44
SAFE PARKING PROCEDURES 45
SHUTTING THE ENGINE OFF 45
SUDDEN LOSS OF ENGINE POWER 45
Secondary Steering And Braking 45
DISABLED TRUCK DUMPING PROCEDURE 46
Hookup 46
Raising the Body 47
Lowering the Body 47
DISABLED TRUCK STEERING AND BRAKING 48
TOWING 50
SECTION A4 – WARNINGS AND CAUTIONS 52
SECTION A5 – TORQUE TABLES AND CONVERSION CHARTS 58
EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values 59
STANDARD TIGHTENING TORQUES For Class 10 9 Cap screws & Class 10 Nuts 59
STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws 60
STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws 61
Hardware Tightening Method 69
SECTION A7 – STORAGE PROCEDURES – INDEX 70
STORAGE AND IDLE MACHINE PREPARATION 72
SHORT TERM IDLE PERIODS 72
PREPARATION FOR STORAGE 72
REMOVAL FROM STORAGE 73
RECONDITIONING AN IDLE VEHICLE 75
ENGINE OPERATION 78
AFTER THE ENGINE HAS STARTED 78
SHORT TERM ENGINE STORAGE 79
Preparing the Engine 79
Removing the Engine from Long Term Storage 81
TRANSMISSION PRESERVATION AND STORAGE 81
Storage, New Transmission 81
Storage, One Year- Without Oil 81
Storage, One Year – With Oil – Normally Installed On The Truck 82
Restoring The Transmission For Service 82
SECTION B – STRUCTURES – INDEX 84
SECTION B2 – STRUCTURAL COMPONENTS – INDEX 86
STRUCTURAL COMPONENTS 88
PREPARATION 88
GRILLE, HOOD AND LADDERS 89
DECKS 90
CENTER DECK 90
Removal 90
Installation 90
RIGHT DECK AND COMPONENTS 90
Removal 90
Installation 90
LEFT DECK AND CAB 91
Installation 91
SECTION B3 – DUMP BODY – INDEX 92
DUMP BODY 94
Removal 94
Installation 96
BODY PADS 96
Body Pad Adjustment 97
BODY GUIDE 97
BODY-UP RETENTION CABLE 98
ROCK EJECTORS 98
Inspection 98
SECTION B4 – FUEL TANK – INDEX 100
FUEL TANK 102
Removal 103
Cleaning 103
Repair 103
Installation 103
FUEL GAUGE AND SENDING UNIT 104
Removal 104
Installation 104
WIGGINS QUICK FILL FUEL SYSTEM 105
FUEL RECEIVER 105
FUEL TANK BREATHER 105
Removal 105
Installation 105
Disassembly 105
Assembly 105
LEFT SIDE FILL 106
SECTION C – ENGINE – INDEX 108
SECTION C3 – COOLING SYSTEM – INDEX 110
COOLING SYSTEM 112
DESCRIPTION 112
LEAKS AND CONTAMINATION 113
RADIATOR REMOVAL 113
RADIATOR REPAIR 114
Internal Inspection 114
External Cleaning 115
Disassembly 115
Cleaning and Inspection 116
Assembly 117
Pressure Testing 118
Additional Service Information 118
RADIATOR INSTALLATION 118
TRANSMISSION AND BRAKE COOLERS 120
Removal 120
Disassembly 120
Cleaning And Inspection 121
Assembly 121
Inspection 123
Installation 124
SECTION C4 – ENGINE – INDEX 126
ENGINE 128
Removal 128
Inspection 131
DRIVE LINE ADAPTER AND DAMPER 133
Removal 133
Disassembly 135
Assembly 135
Installation 137
SECTION C5 – AIR FILTRATION SYSTEM – INDEX 140
AIR FILTRATION SYSTEM 142
AIR CLEANER 142
Operation 142
General Maintenance 142
FILTER SERVICE INDICATOR 144
MAIN FILTER ELEMENT 144
Removal 144
Installation 144
SAFETY FILTER ELEMENT 144
Removal 144
Installation 144
MAIN FILTER CLEANING 145
PRECLEANER CLEANING 146
AIR INTAKE GUIDELINES 147
Installation 147
AIR INTAKE TROUBLESHOOTING 148
SECTION C7 – FAN CLUTCH – INDEX 150
FAN CLUTCH 152
REMOVAL & INSTALLATION TOOLING 152
FAN CLUTCH – DISASSEMBLY 155
CLEANING AND INSPECTION 165
ASSEMBLY – FAN CLUTCH 169
TEST PROCEDURE 183
SECTION D – ELECTRICAL SYSTEM AND POWERTRAIN MANAGEMENT CONTROL SYSTEM – INDEX 184
SECTION D2 – STARTING SYSTEM – INDEX 186
STARTING SYSTEMS 188
24 VDC REMOTE MOUNT PRELUB™ SYSTEM 188
OPERATION 188
Oil Pressure Switch 190
Check Valve 190
Timer Solenoid 190
MAINTENANCE 190
Prelub™ System Operation 190
Prelub Pump 190
Check Valve 191
Timer Solenoid 191
PRELUB CIRCUIT TROUBLESHOOTING 192
24 VDC ELECTRIC START SYSTEM 194
OPERATION 194
CRANKING MOTORS 194
Removal 194
Installation 194
Disassembly 195
Cleaning and Inspection 195
Armature Servicing 195
Field Coil Checks 196
Field Coil Removal 196
Solenoid Checks 199
Assembly 200
Pinion Clearance Adjustment 201
MAGNETIC SWITCH 201
Removal 201
Installation 202
Coil Test 202
CRANKING MOTOR TROUBLESHOOTING 203
PRELIMINARY INSPECTION 203
NO-LOAD TEST 203
Load Test Diagnosis 204
SECTION D3 – ELECTRICAL SYSTEM COMPONENTS – INDEX 206
ELECTRICAL SYSTEM COMPONENTS 208
GENERAL TROUBLESHOOTING 208
CAB MOUNTED COMPONENTS 209
CIRCUIT BREAKERS 209
RELAY BOARDS 212
Relay Boards – With Circuit Breakers 212
Preliminary Checks 213
Service 213
Relay Board Description 214
Relay Board RB1 214
Relay Board RB4 215
Relay Board RB5 215
Relay Boards – Without Circuit Breakers 215
INCLINATION SENSORS 218
Payload Meter Inclinometer Sensor 218
Lateral Inclination Sensor 218
LUBRICATION SYSTEM TIMER 218
ACCELERATOR PEDAL 219
AISS Operation 220
Accelerator Pedal Malfunction 222
Accelerator Pedal Checks 222
Idle Validation Switch Continuity Check 222
24V COMPONENTS – OUTSIDE CAB 223
BATTERY BOX 223
BATTERY DISCONNECT SWITCH 223
GROUND LEVEL SHUTDOWN SWITCH 223
CONTROL POWER RELAYS 223
CIRCUIT BREAKERS 223
BATTERY ELECTROLYTE LEVEL SENSOR 223
BATTERY EQUALIZER 224
BODY POSITION SWITCHES 224
Proximity Switch Operation 224
Body-Up Switch Adjustment 225
Hoist Limit Switch Adjustment 227
WHEEL SPEED SENSORS 228
Sensor Adjustment 228
SECTION D22- POWERTRAIN MANAGEMENT CONTROL SYSTEM – INDEX 230
POWERTRAIN MANAGEMENT CONTROL™ SYSTEM 232
System Description 232
Engine (Cummins QSK45) 232
Transmission 232
Transmission Controller 232
Retard Control and Monitor 232
Powertrain Management Controller 232
Electronic Display Panel 232
Payload Meter 232
Message for Operator and Maintenance Display 232
Suspension Controller 232
Data Acquisition Device 232
Cummins Quantum 233
Cummins CENSE 233
PMC SYSTEM TROUBLESHOOTING 234
Preliminary Troubleshooting Procedures 234
Emergency Operation 234
Indication Of A Fault Occurrence 234
Action Codes 234
Fault History 234
System Troubleshooting 234
EMERGENCY TRUCK OPERATION 237
PMC SYSTEM FAULT CODES 239
SECTION D23 – POWERTRAIN MANAGEMENT CONTROLLER – INDEX 256
POWERTRAIN MANAGEMENT CONTROLLER (PMC) 258
PMC CONTROLLER FEATURES 258
LED Display 258
DIP Switch Settings 258
NORMAL OPERATION – PMC 259
Throttle Control 259
AISS Operation 259
Retarder Control 260
COMMUNICATION 260
S-NET 260
CENSE 260
RCM 260
PLM 260
“MOM” and “DAD” 260
Additional Functions 261
PMC CONTROLLER TROUBLESHOOTING 264
GENERAL TROUBLESHOOTING PROCEDURES 264
PMC FAULT CODE TROUBLESHOOTING 265
PMC CONTROLLER LOGIC 273
Fault Recovery Classifications 273
PMC FAULT CODE LOGIC DESCRIPTION 274
PMC WIRING HARNESS CONNECTORS 298
SECTION D24 – AUTOMATIC TRANSMISSION CONTROLLER – INDEX 304
AUTOMATIC TRANSMISSION CONTROLLER (ATC) 306
ATC CONTROLLER FEATURES 306
LED Display 306
Rotary Switch Settings 306
Shift Control 307
Range Selector Positions And Automatic Gear Shifting Ranges 307
Transmission Operation Modes 308
Braking Mode: 308
Normal Mode: 308
Automatic Gear Shifting 308
Automatic Shifting Sequence 309
Gearshifting time lag 309
Shift Skip Logic 309
Safety Functions 310
TROUBLESHOOTING – ATC 311
GENERAL TROUBLESHOOTING PROCEDURES 311
ATC FAULT CODE TROUBLESHOOTING 312
ATC FAULT CODE LOGIC DESCRIPTION 327
TRANSMISSION CONTROLLER HARNESS CONNECTORS 358
SECTION D25 – ELECTRONIC DISPLAY PANEL – INDEX 362
ELECTRONIC DISPLAY PANEL 364
Rotary Switch 364
Gauges and Indicators 365
External Indicator Lamps 367
Display Self-Check Function 369
Lamp Test 369
Action Code Display 370
Cancellation of Action Code 370
ELECTRONIC DISPLAY PANEL TROUBLESHOOTING 371
GENERAL TROUBLESHOOTING PROCEDURES 371
Harness Circuit Tests 371
Table 1: Continuity checks 371
Table 2: Short Circuit to Ground Checks 372
Table 3: Circuit Isolation Checks 372
EDP WIRING HARNESS CONNECTORS 390
SECTION D26 – RETARD CONTROL AND MONITOR (RCM) – INDEX 392
RETARD CONTROL AND MONITOR (RCM) 394
Description 394
RCM Calibration 394
GENERAL TROUBLESHOOTING PROCEDURES 395
RCM FAULT CODE TROUBLESHOOTING 397
Description 397
RCM WIRING HARNESS CONNECTORS 444
SECTION D27 – AUTOMATIC SUSPENSION SYSTEM – INDEX 446
AUTOMATIC SUSPENSION SYSTEM 448
Automatic Suspension Controller 448
Manifold Valve 448
Actuator 448
Steering Sensor 448
AUTOMATIC MODE SELECTION CONTROL 449
SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION 450
d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE 450
d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE 450
d015:TRANSMISSION SPEED SIGNAL LOST 451
d016:STEERING SPEED SIGNAL LOST 451
d021:SOLENOID OUTPUT 1 FAILURE 452
d022:SOLENOID OUTPUT 2 FAILURE 452
d023:SOLENOID OUTPUT 3 FAILURE 452
SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING 453
SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed 453
SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed 454
SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed 455
SP-4: Fault Code d016: Fault in Steering Sensor System Displayed 456
SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed 457
SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed 458
SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed 459
SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS 460
SECTION D30 – MESSAGE FOR OPERATION AND MAINTENANCE (MOM) – INDEX 462
MOM — MESSAGE FOR OPERATION AND MAINTENANCE 464
INTRODUCTION 464
SYSTEM CONFIGURATION 464
SOFTWARE 465
Service Meters (SMR) 466
FUNCTION 467
Operator Information 467
Maintenance Information (Screen Hierarchy) 467
Display Able/Disable By Machine Status 469
Vehicle State 469
Display Able/Disable by Truck Model and Optional Equipment Status 470
SCREEN DATA 471
Realtime Data 471
Machine Trend Data 471
Fault Condition Data 471
Machine Information 472
Parameter Set 472
WARNING MESSAGE 473
HARDWARE TROUBLESHOOTING AND MAINTENANCE 474
TROUBLESHOOTING THE MOM UNIT 474
PROBLEMS AND CORRECTIVE ACTIONS 475
Program Errors 476
Warning & Communication Errors 477
SELF-DIAGNOSIS 478
System Check 478
System Information 478
Communication Port Check 478
Key Input Check 479
MAINTENANCE 480
Battery Replacement 480
Replacement of Protective Sheet 480
Back Light Replacement 481
Setting Display OFF Time 482
SECTION D31 – MOM SCREEN DISPLAYS – INDEX 484
MOM SCREEN DISPLAYS 486
i1 INITIAL MESSAGE 486
i2 INITIAL CHECK1 486
i3 INITIAL CHECK2 486
i4 NORMAL RUNNING 487
i7 BACKLIGHT OFF 488
To Access a Maintenance Information Screen: 489
i9 MENU SELECT 490
s1 SERVICE MENU 491
s2 COMPONENT CHECK MENU 491
s21 ENGINE 492
s212 MACHINE TREND MENU (ENG ) 493
s213 FAULT CONDITION MENU (ENG ) 493
s2131 FAULT CONDITION (ENG ) 494
s22 TRANSMISSION 495
s222 MACHINE TREND MENU (T/M) 496
s2221 L/C ON/OFF COUNT 496
s222E AB-USE COUNT 497
s223 FAULT CONDITION MENU (T/M) 498
S2231 FAULT CONDITION (T/M) 498
s23 BRAKE MENU 499
s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE) 499
s233 FAULT CONDITION MENU (BRAKE) 500
s2331 FAULT CONDITION (BRAKE) 500
s24 SUSPENSION MENU 501
s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION) 501
s242 FAULT CONDITION MENU (SUS) 502
s2421 FAULT CONDITION (SUS) 502
s25 PMC MENU 503
s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC) 503
s252 FAULT CONDITION MENU (PMC) 504
s2521 FAULT CONDITION (PMC) 504
s26 ELECTRONIC DISPLAY PANEL MENU 505
s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel) 505
s262 FAULT CONDITION MENU (ELE DISPLAY PANEL) 506
s2621 FAULT CONDITION (ELE DISPLAY PANEL) 506
s27 PLM MENU 507
s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM) 507
s272 CALIBRATION DATA 508
s28 TMS MENU 508
s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS) 509
s283 FAULT CONDITION MENU (TMS) 509
s2831 FAULT CONDITION (TMS) 510
s3 MACHINE INFORMATION MENU 510
s32-1/3 CONTROLLER INFORMATION 512
SELECTOR SWITCH STATUS of the PMC 512
s32-2/3 CONTROLLER INFORMATION 513
s32-3/3 CONTROLLER INFORMATION 514
s33 OPTIONAL FUNCTION INFORMATION 514
s34 HISTORY OF USE 515
t1 PARAMETER SET MENU 516
t2 TIME/DATE SET 516
t3 TRAVEL MODE MENU 517
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 517
t32 SPEED LIMITER 518
t33 T/M MAX GEAR SELECT 518
t34 T/M MAX GEAR SELECT (BODY UP) 519
t35 SUSPENSION MODE SET 519
t4 PARAMETER UNIT SET 520
t5 TMS SET MENU 520
t51 TIRE PRESSURE LIMIT SET 521
t52 TIRE TEMPERATURE LIMIT SET 522
t53 CORRELATION CONSTANTS SET 523
t54 TMS CLOCK SET 524
t55 ID CODE SET 525
SECTION D32 – DATA ACQUISITION DEVICE (DAD) – INDEX 526
DAD – DATA ACQUISITION DEVICE 528
INTRODUCTION 528
HARDWARE HOOKUP 528
SOFTWARE 529
Installation Requirements 529
Installing the Software 529
Starting the Software Program 529
Service Meters (SMR) 529
Display Able/disable By Machine Status 530
Vehicle State 530
MAINTENANCE INFORMATION (SCREEN HIERARCHY) 530
Display Enable/Disable by Truck Model and Optional Equipment Status 534
SCREEN DATA 535
Real Time Data 535
Fault condition data 535
Snap-Shot Data 535
Transmission Snapshot Example 536
Sample Snapshot Screens 540
Machine Trend Data 542
Machine Check 543
Machine Information 543
Event Recorder 543
Parameter Set 543
SECTION D33 – DAD SCREEN DISPLAYS – INDEX 544
DAD SCREEN DISPLAYS 546
PASSWORD INPUT 546
Changing the Password 546
i3 MENU SELECT 546
s1 SERVICE MENU 547
s2 COMPONENT CHECK MENU 547
s21 Engine 547
s21 CUMMINS ENG MENU (for the CUMMINS engine) 547
s21 KOMATSU ENG MENU (for the KOMATSU engine) 547
s22 TRANSMISSION 550
s23 BRAKE MENU 554
s24 SUSPENSION MENU 557
s25 PMC MENU 559
s26 ELECTRONIC DISPLAY PANEL MENU 561
s27 PLM MENU 563
s28 TMS MENU 564
s3 MACHINE INFORMATION MENU 567
s31 MACHINE INFORMATION MENU 567
s32-1/3 CONTROLLER INFORMATION 568
s32-2/3 CONTROLLER INFORMATION 569
s32-3/3 CONTROLLER INFORMATION 570
s33 OPTIONAL FUNCTION INFORMATION 570
s34 HISTORY OF USE 571
t1 PARAMETER SET MENU 572
t2 TIME/DATE SET 572
t3 TRAVEL MODE MENU 573
t31 ENG , T/M PATTERN SELECT (Komatsu Engine Only) 573
t32 SPEED LIMITER 574
t33 T/M MAX GEAR SELECT 574
t34 T/M MAX GEAR SELECT (BODY UP) 575
t35 SUSPENSION MODE SET 575
t4 PARAMETER UNIT SET 576
t5 TMS SET MENU 576
t51 TIRE PRESSURE LIMIT SET 577
t52 TIRE TEMPERATURE LIMIT SET 577
t53 CORRELATION CONSTANTS SET 578
t54 TMS CLOCK SET 578
t55 ID CODE SET 579
SECTION D34 – REAL TIME DATA TABLES – INDEX 580
REAL TIME DATA TABLES 582
ACCESSING REAL TIME DATA SCREENS 582
Real Time Data Screen Switches 582
SECTION D35 – PAYLOAD METER II – ON BOARD WEIGHING SYSTEM – INDEX 592
GENERAL INFORMATION 594
Haul Cycles 594
LIGHTS, SWITCHES AND COMPONENTS 595
TIPS FOR OPERATION 596
EXTERNAL DISPLAY LIGHTS 596
THEORY OF OPERATION 597
Basic Description 597
Inclinometer 597
Linkage Factor 597
Gain Factor 598
Brake Lock 598
Sources of Error 598
Typical Data From Service Check Mode 598
Example Calculation of Payload 599
Viewing Payload Calculation Inputs 599
Checking the Gain 600
Adjusting the Gain 600
TYPES OF DATA STORED 601
Cycle Data 601
Engine ON/OFF Data 602
Fault Codes and Warning Data 602
Engine Operation 603
Total Payload and Total Number of Cycles 603
Other Data 603
OPERATOR FUNCTIONS 604
Using the Operator Load Counter 604
Viewing the Operator Load Counter 604
Clearing the Operator Load Counter 604
Dimming the Lights on the Display 604
INITIAL SETUP OF PAYLOAD METER 605
Switch Settings 605
Checking the Operator Check Mode 606
Checking the Service Check Mode 606
Checking the Gt setting: 607
Checking the Inclinometer Settings 607
Calibrating a Truck 607
DISPLAYS AT START-UP 608
Normal Operation 608
SETUP AND MAINTENANCE 609
Setting The Speed Limit 609
Setting the Option Code 609
Setting The Machine I D Code 610
Setting The Operator I D Code 610
Setting The Time and Date 610
DOWNLOAD OF INFORMATION 611
DISPLAY OF FAULT CODES 611
Monitoring Input Signals 615
Service Check Mode 615
UP FACTOR – PAYLOAD CALCULATION GAIN 616
PL MODE -LOAD CALCULATION TIMING 616
FINAL GEAR RATIO SELECTION 617
BATTERY REPLACEMENT PROCEDURE 618
Replacing the Battery 618
After Replacing the Battery 619
SUSPENSION PRESSURE SENSOR 619
Removal 619
Installation 620
INCLINOMETER 620
Removal 620
Installation 620
Adjustment 620
PAYLOAD METER BACK PANEL 621
CONNECTIONS 622
PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE 623
PAYLOAD CIRCUIT NUMBERS 624
TROUBLESHOOTING 625
COMMON PROBLEMS 625
Suspension Charging 625
Symptom Table 626
Missing Body-Up Signal 626
Missing Speed Signal 627
F-18: Alternator R-Terminal, Oil Pressure Signals 627
Shorted 18v Sensor Power Supply (930E) 627
FAULT TREE DIAGNOSIS 628
Payload Lights Won’t Illuminate 628
Red, Amber or Green Payload Light Does Not Illuminate 629
Cannot Download – PC Communications 630
PC Communications Configuration 631
F CAL: Payload Meter Won’t Calibrate 632
F-20: Sensor Power Fault 633
F-21, F-25: Left Front Pressure Sensor 635
F-22, F-26: Right Front Pressure Sensor 635
F-23, F-27: Left Rear Pressure Sensor 635
F-24, F-28: Right Rear Pressure Sensor 635
F-31, F-32: Inclinometer 637
Body Up Input 639
Brake Lock Input 640
Speed Signal 641
Adjusting the Speed Sensor 641
CONNECTORS AND PRESSURE SENSORS 643
REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM 646
Menu Functions 649
Using Scope 649
Log File Information 649
Connections to Payload Meter II™ 650
USING SCOPE 651
Monitoring Inputs Using Scope 651
Monitoring Suspension Charging Using Scope 651
Pressure Sensor Dummy Loads 654
GAIN ADJUSTMENT WORKSHEET 655
SECTION F – TRANSMISSION/TORQUE CONVERTER – INDEX 656
SECTION F2 – TORQUE CONVERTER AND TRANSMISSION – INDEX 658
TORQUE CONVERTER AND TRANSMISSION 660
TRANSMISSION 660
TORQUE CONVERTER 661
MAIN RELIEF VALVE 663
Function 663
Operation 663
TORQUE CONVERTER RELIEF VALVE 663
Function 663
Operation 663
TORQUE CONVERTER REGULATOR VALVE 665
Operation 665
LOCK-UP CLUTCH 666
Lock-up Clutch Accumulator 666
HYDRAULIC PUMP 667
TORQUE CONVERTER STALL CHECK 668
TRANSMISSION 669
LUBRICATION RELIEF VALVE 671
Function 671
TRANSMISSION CONTROL VALVE 672
ELECTRONIC CONTROL MODULATION VALVE (ECMV) 674
Pressure Control Valve 675
Flow Sensor Valve 675
ECMV and Proportional Solenoid 675
ECMV and Fill Switch 675
ECMV Operation 676
ECMV REPAIR PROCEDURE 679
Filter Replacement Procedure 679
ECMV Removal 680
Disassembly 680
Assembly 681
TRANSMISSION FILTERS 683
Service 683
Installation 683
TRANSMISSION REMOVAL 684
TRANSMISSION INSTALLATION 685
TRANSMISSION OIL LEVEL CHECK 687
SECTION F3 – TRANSMISSION OIL COOLER & STRAINERS – INDEX 688
TRANSMISSION OIL COOLER & STRAINERS 690
TRANSMISSION OIL COOLER 690
Removal and Installation 690
Repair 690
TRANSMISSION OIL STRAINER 690
Removal 691
Inspection 691
Installation 691
SECTION F5 – DRIVE SHAFTS – INDEX 692
DRIVE SHAFTS 694
FRONT DRIVE SHAFT 694
Removal 694
Disassembly 694
Assembly 695
Installation 695
FRONT DRIVE SHAFT ALIGNMENT 696
REAR DRIVE SHAFT 699
Removal 699
Disassembly 699
Assembly 700
Installation 700
SECTION F6 – TRANSMISSION ELECTRICAL – INDEX 702
TRANSMISSION ELECTRICAL 704
TRANSMISSION SHIFT CONTROLLER 705
Event Memory 705
Fault History Data 705
Snap-Shot Data 705
Trend Data 706
TRANSMISSION RANGE SELECTOR 707
SENSORS AND SWITCHES 708
Transmission Speed Sensors 708
Adjustment Procedure 708
Fill Switch 709
Shift Limit Switch 709
TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING 710
Preliminary Checks 710
SECTION G – DRIVE AXLE, SPINDLES AND WHEELS – INDEX 714
SECTION G2 – TIRES AND RIMS – INDEX 716
TIRES AND RIMS 718
GENERAL INFORMATION 718
FRONT TIRES AND RIMS 719
Removal 719
Installation 720
REAR TIRE AND RIM 720
Removal 720
Installation 721
TIRE MATCHING 722
RIM 723
Tire Removal From Rim 723
Tire Installation On Rim 723
FRONT WHEEL STUD INSTALLATION 724
REAR WHEEL STUD INSTALLATION 725
SECTION G3 – FRONT WHEEL HUB AND SPINDLE – INDEX 726
FRONT WHEEL HUB AND SPINDLE 728
OIL SAMPLE ANALYSIS 728
Oil Sampling Guidelines 728
Guidelines For Obtaining A Sample 728
FRONT WHEEL HUB 729
Removal 729
Disassembly 729
Inspection 729
Assembly and Installation 730
Front Wheel Hub Bearing Adjustment 732
FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION 732
SUSPENSION A-ARM 732
Removal 732
Inspection of Parts 733
Installation 733
CENTER TIE ROD PIVOT 734
Removal 734
Inspection 734
Installation 734
TOE IN ADJUSTMENT 735
Adjustment Procedure 735
SECTION G4 – REAR AXLE ATTACHMENTS – INDEX 738
REAR AXLE ATTACHMENTS 740
CENTER LINK AND LOWER LINKS 740
Removal 740
Inspection 741
Spherical Bearing Replacement 741
Installation 741
PANHARD ROD (DIAGONAL LINK) 742
Removal 742
Inspection 743
Installation 743
SECTION G5 – REAR AXLE AND FINAL DRIVE ASSEMBLY – INDEX 744
REAR AXLE & FINAL DRIVE ASSEMBLY 746
DIFFERENTIAL OPERATION 746
Straight-away-travel 746
Turning 746
REAR AXLE ASSEMBLY 747
Removal 747
Installation 747
DIFFERENTIAL OIL LEVEL CHECK 748
DIFFERENTIAL ASSEMBLY 749
Removal 749
Installation 750
Disassembly 750
Pinion Carrier Assembly 753
Differential Gear Unit 753
Differential Gear Unit 754
Assembly 757
Differential Bearing 757
Assembly Of Differential Gear Assembly 757
Installation Of Differential Assembly 759
Input Pinion and Carrier Assembly 760
Adjusting Tooth Contact, Backlash 764
SECTION G6 – FINAL DRIVE PLANETARIES AND WHEEL HUBS – INDEX 768
FINAL DRIVE PLANETARIES AND WHEEL HUBS 770
FINAL DRIVE 770
Oil Level Check 771
FINAL DRIVE CARRIER ASSEMBLY 771
Removal 771
Installation 772
Disassembly 772
Assembly 773
FINAL DRIVE ASSEMBLY 774
Disassembly 774
Assembly 776
SECTION H – SUSPENSIONS – INDEX 778
SECTION H2 – FRONT SUSPENSION – INDEX 780
FRONT SUSPENSION 782
DESCRIPTION 782
OPERATION 783
THREE-MODE SUSPENSION (OPTIONAL) 784
Variable Damping Operation 784
Three-Mode Suspension System Components 785
Automatic Suspension Controller 785
Manifold Valve 785
Actuator 786
Steering Sensor 786
Removal 787
Installation 788
Disassembly 788
Inspection 790
Assembly 790
DAMPING VALVE 791
DAMPING VALVE – FIXED RATE 791
Disassembly 791
Assembly 791
DAMPING VALVE & ACTUATOR – 3 MODE DAMPING RATE 792
Disassembly 792
Cleaning and Inspection 792
Assembly 793
SECTION H3 – REAR SUSPENSION – INDEX 796
REAR SUSPENSION 798
OPERATION 799
Removal 800
Installation 800
Disassembly 800
Assembly 802
SPHERICAL BEARINGS 803
Removal 803
Inspection 803
Installation 803
SECTION H4 – SUSPENSION OILING AND CHARGING – INDEX 804
SUSPENSION OILING AND CHARGING 806
GENERAL INFORMATION 806
Equipment List 806
FRONT SUSPENSION 808
Front Suspension Oiling 808
Front Suspension Nitrogen Charging 811
REAR SUSPENSION 813
General Information 813
Rear Suspension Oiling 814
Rear Suspension Nitrogen Charging 817
Length Adjustment – Front And Rear Cylinders 818
SECTION J – BRAKE SYSTEM – INDEX 820
SECTION J2 – BRAKE CIRCUIT – INDEX 822
BRAKE CIRCUIT 824
SERVICE BRAKE CIRCUIT 824
SECONDARY BRAKING AND AUTOMATIC APPLY 826
PARKING BRAKE CIRCUIT 826
Normal Operation 826
BRAKE LOCK CIRCUIT 827
AUXILIARY CIRCUIT 827
RETARDING CIRCUIT 827
WARNING CIRCUIT 827
BRAKE SYSTEM ELECTRICAL COMPONENTS 828
SECTION J3 – BRAKE CIRCUIT COMPONENT SERVICE – INDEX 832
BRAKE CIRCUIT COMPONENT SERVICE 834
BRAKE VALVE 834
Rebuild Criteria 834
Removal 835
Installation 835
Disassembly 836
Cleaning and Inspection 837
Assembly 839
Actuator Base Threaded Inserts 839
Boot and Cap 839
Valve Body Seal Installation 839
Regulator Sleeve O-Ring Installation 839
Actuator Plunger O-ring Installation 840
Assembly of Valve 840
VALVE BENCH TEST AND ADJUSTMENT 842
Test Bench Only 843
Test Set Up Procedure 843
Brake Valve Output Pressure Adjustment 843
Final Test and Adjustment 844
Proximity Switch Installation and Adjustment 845
Installation Of Brake Pedal Actuator Assembly to Brake Valve 845
RELAY VALVES 846
Removal 846
Installation 847
Disassembly 848
Cleaning and Inspection 848
Assembly 848
VALVE TEST AND ADJUSTMENT 850
Test Set Up Procedure 851
Relay Valve 851
Output Pressure Adjustment 851
HYDRAULIC BRAKE ACCUMULATORS 852
Brake Accumulator Bleed Down Procedure 852
BRAKE ACCUMULATOR CHARGING PROCEDURE 853
BRAKE ACCUMULATOR REBUILD 854
Removal 854
Installation 854
Disassembly 854
Cleaning and Inspection 854
Assembly 855
Testing 856
Storage 856
BRAKE COOLING VALVE (BCV) 857
RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED) 858
Removal 858
Installation 858
Disassembly and Adjustment 860
Potentiometer Check 860
Assembly 861
SECTION J4 – BRAKE CIRCUIT CHECKOUT – INDEX 862
BRAKE CIRCUIT CHECK-OUT PROCEDURE 864
Required Equipment 867
Preparation 867
Initial System Setup 867
Parking Brake 868
Brake Lock 869
Low-Brake Pressure and Auto-Apply 869
Reapplications 869
RCM Calibration 870
How to Perform Calibration 870
HD1500 HYDRAULIC BRAKE SYSTEM CHECKOUT DATA SHEET 872
BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING 875
SECTION J5 – FRONT WET DISC BRAKES – INDEX 880
FRONT WET DISC BRAKES 882
DESCRIPTION 882
FRONT DISC BRAKE ASSEMBLY 883
Removal 883
Installation 884
BRAKE ASSEMBLY REBUILD 884
DISC BRAKE MAINTENANCE 884
Brake Disc Wear Indicator 884
Checking Disc Wear 885
WEAR INDICATOR SENSOR 886
SPEED SENSOR 886
WET DISC BRAKE BLEEDING PROCEDURE 886
SECTION J6 – REAR WET DISC BRAKES – INDEX 888
REAR WET DISC BRAKES 890
DESCRIPTION 890
Operation 890
MAINTENANCE 891
Brake Disc Wear Indicator 891
Checking Disc Wear 891
Wear Indicator Sensor 892
Brake Assembly Removal 893
Brake Assembly Installation 894
BRAKE ASSEMBLY REBUILD 895
Disassembly 895
Cleaning and Inspection 896
Assembly 897
Floating Ring Seal Assembly/Installation 899
Alternate Procedure: 900
SECTION J7 – PARKING BRAKE – INDEX 902
PARKING BRAKE 904
Description 904
Parking Brake Service Criteria 904
Removal 905
Installation 905
PARKING BRAKE SPRING CYLINDER REPLACEMENT 907
Removal 907
Installation 907
AUTOMATIC SLACK ADJUSTER 907
Adjustment Procedure 907
PARKING BRAKE CHECK-OUT 908
SECTION L – HYDRAULIC SYSTEM – INDEX 910
SECTION L2 – HYDRAULIC SYSTEM OVERVIEW – INDEX 912
HYDRAULIC SYSTEM OVERVIEW 914
HYDRAULIC SYSTEM DESCRIPTION 914
Hydraulic Tank 914
Bleed-down Manifold 915
Hoist Valve 916
Hoist Pump 916
Brake Cooling Pump 916
Brake Control Valve (BCV) 916
High Pressure Filter 917
Low pressure Filter 917
SECTION L3 – HYDRAULIC SYSTEM COMPONENT REPAIR – INDEX 918
HYDRAULIC COMPONENT REPAIR 920
HYDRAULIC TANK 920
FILLING INSTRUCTIONS 920
MAINTENANCE 920
Removal 921
Installation 923
Gap Measurement – Hydraulic Tank Mounting 923
STRAINERS AND DIFFUSERS 924
Removal 924
Cleaning and Inspection 924
Installation 925
HYDRAULIC TANK BREATHER 925
Service 926
HYDRAULIC SYSTEM FLUSHING 926
HYDRAULIC PUMPS 927
Removal 927
Installation 928
PUMP REBUILD 929
Disassembly 929
Inspection Of Parts 932
Assembly 932
Bearing Replacement 935
Seal Replacement 935
TROUBLESHOOTING GUIDE 938
SECTION L4 – STEERING CIRCUIT – INDEX 940
STEERING CIRCUIT 942
OPERATION 942
COMPONENT DESCRIPTION 942
Steering Control Valve 942
Bleed-down Manifold 942
Bleed-down Solenoid 943
Accumulators 943
Flow Amplifier 944
High Pressure Filter 944
Warning Devices 944
FLOW AMPLIFIER OPERATION 946
STEERING/BRAKE PUMP 954
COMPONENTS 954
OPERATION 956
SECTION L5 – STEERING CONTROL UNIT – INDEX 958
STEERING CONTROL UNIT 960
Removal 960
Installation 960
REBUILD PROCEDURE 961
Disassembly 962
Cleaning and Inspection 963
Assembly 965
SECTION L6 – STEERING CIRCUIT COMPONENT REPAIR – INDEX 970
STEERING CIRCUIT COMPONENT REPAIR 972
BLEED-DOWN MANIFOLD 972
Removal 972
Adjusting Relief Valve 972
Testing and Adjustment 973
FLOW AMPLIFIER 974
Removal 974
Installation 974
Disassembly 974
Assembly 977
ACCUMULATORS 978
Removal 978
Installation 978
Disassembly 979
Cleaning and Inspection 980
Assembly 980
Testing 981
STEERING ACCUMULATOR CHARGING PROCEDURE 981
STEERING CYLINDER 982
Removal 982
Installation 983
STEERING CYLINDER REBUILD 984
Disassembly 984
Cleaning and Inspection 984
Assembly 985
STEERING/BRAKE PUMP 985
Removal 985
Installation 986
PUMP REBUILD 987
Disassembly 987
Control Group 988
Valve Plate Group 989
Rotating Group 989
Drive Shaft Group 990
Swashblock Group 990
Inspection 990
Control Group 990
Valve Plate Group 991
Rotating Group 991
Swashblock Group 992
Drive Shaft Group 992
Assembly 992
Swashblock Group 992
Drive Shaft Group 993
Rotating Group 993
Valve Plate Group 994
Control Group 995
STEERING CIRCUIT FILTER 996
Removal 996
Installation 996
TROUBLESHOOTING CHART 997
SECTION L7 – HOIST CIRCUIT – INDEX 1000
HOIST CIRCUIT 1002
HOIST CIRCUIT OPERATION 1002
COMPONENT DESCRIPTION 1003
Hydraulic Tank 1003
Hoist Pump 1003
Hoist Valve 1003
Hoist Pilot Valve 1004
Power Up Limit Solenoid 1005
Pilot Operated Check Valve 1005
Power Down Spool Limit Solenoid 1005
HOIST CIRCUIT OPERATION 1005
POWER UP Operation 1007
HOLD Operation 1009
POWER DOWN Operation 1011
FLOAT Operation 1013
SECTION L8 – HOIST CIRCUIT COMPONENT REPAIR – INDEX 1016
HOIST CIRCUIT COMPONENT REPAIR 1018
HOIST VALVE 1018
Removal 1018
Installation 1018
O-Ring Replacement 1019
INLET SECTION 1020
Disassembly 1020
Cleaning and Inspection 1021
Assembly 1021
SPOOL SECTION 1021
Disassembly 1021
Cleaning and Inspection 1022
Assembly 1024
HOIST PILOT VALVE 1025
Removal 1025
Installation 1025
Disassembly 1026
Cleaning and Inspection 1027
Reassembly 1027
HOIST CYLINDERS 1028
Removal 1028
Installation 1030
Disassembly 1030
Cleaning and Inspection 1032
Assembly – Quill And Cylinder 1033
Quill Installation 1033
Installation Of Check Balls And Plugs In Quill 1034
Assembly of Cylinder 1035
Pressure Testing 1035
POWER UP SPOOL LIMIT SOLENOID 1036
PILOT OPERATED CHECK VALVE 1036
POWER DOWN HOIST LIMIT SOLENOID 1036
SECTION L9 – HYDRAULIC SYSTEM FILTERS – INDEX 1038
HYDRAULIC SYSTEM FILTERS 1040
HIGH PRESSURE FILTER 1040
Removal 1040
Installation 1041
LOW PRESSURE FILTERS 1041
BRAKE COOLING & HOIST FILTERS 1041
TRANSMISSION FILTER 1041
Removal 1042
Installation 1042
SECTION L10 – HYDRAULIC CHECK-OUT PROCEDURE – INDEX 1044
HYDRAULIC CHECK-OUT PROCEDURE 1046
GENERAL INFORMATION 1046
STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE 1046
Equipment Requirements 1047
Pump Pressure Control Adjustment 1047
Steering Components Leakage Test 1049
CHECKING HOIST SYSTEM PRESSURES 1050
Equipment Requirements 1050
Power Down Relief Valve Adjustment 1051
SECTION M – OPTIONS AND SPECIAL TOOLS – INDEX 1052
SECTION M8 – SPECIAL TOOLS 1054
SECTION N – OPERATOR CAB – INDEX 1058
SECTION N2 – OPERATOR CAB – INDEX 1060
OPERATOR CAB 1062
Removal 1063
Installation 1065
CAB DOORS 1065
Removal 1065
Installation 1066
Door Striker Adjustment 1066
Door Handle Plunger Adjustment 1067
DOOR PANEL 1068
Removal 1068
Installation 1068
DOOR WINDOW 1069
Removal 1069
Installation 1071
WINDOW REGULATOR 1073
Removal 1073
Installation 1073
DOOR HANDLE AND DOOR LATCH 1073
Removal 1073
Installation 1073
DOOR SEALS 1074
Removal 1074
Installation 1074
DOOR OPENING SEAL 1074
Removal 1074
Installation 1074
GLASS REPLACEMENT 1075
Replacement 1075
REAR GLASS 1077
Removal 1077
Installation 1077
SECTION N3 – CAB COMPONENTS – INDEX 1078
CAB COMPONENTS 1080
WINDSHIELD WIPERS 1080
WIPER MOTOR 1080
Removal 1080
Installation 1080
WIPER ARM 1080
Removal 1080
Installation 1081
WIPER LINKAGE 1081
Removal 1081
Installation 1082
WINDSHIELD WASHER 1082
Operation 1082
Service 1082
OPERATOR SEAT 1083
Seat Belts 1083
Adjustment 1083
Seat Removal 1084
SECTION N4 – HEATING AND AIR CONDITIONING – INDEX 1086
HEATING AND AIR CONDITIONING 1088
HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS 1088
HEATER/AIR CONDITIONER 1089
Operation 1089
HEATER COMPONENTS 1089
Circuit Breaker 1089
D/C – D/C Converter 1090
Flapper Door Motors 1090
Temperature Control Potentiometer 1090
Motorized Coolant Control Valve 1090
Heater Coil 1090
Fan Motor and Speed Control 1090
Test 1090
FILTER 1090
Service 1090
AIR CONDITIONING SYSTEM 1093
Environmental Impact 1093
OPERATOR CAB AIR CONDITIONING 1094
PRINCIPLES OF REFRIGERATION 1094
Air Conditioning 1094
Refrigeration – The Act Of Cooling 1095
The Refrigeration Cycle 1095
AIR CONDITIONER SYSTEM COMPONENTS 1096
Compressor (Refrigerant Pump) 1096
Service Valves 1096
Condenser 1096
Receiver-Drier 1096
Expansion Block Valve 1097
Evaporator 1097
ELECTRICAL CIRCUIT 1098
Thermostat 1098
Compressor Clutch 1098
Trinary™ Switch 1099
SYSTEM SERVICING 1100
SYSTEM OIL 1101
Handling and Reusing PAG Oil 1101
Oil Quantity 1101
Replacing Oil After Servicing the System 1101
Setting Up a New Compressor 1101
REFRIGERANT 1102
Recycled Refrigerant 1102
Reclaimed Refrigerant 1102
Refrigerant Quantity 1102
R-134a Refrigerant Containers 1102
SERVICE TOOLS AND EQUIPMENT 1103
Recovery/Recycle Station 1103
Leak Detector 1103
Service Valves 1104
Vacuum Pump 1104
Manifold Gauge Set 1105
Installing Manifold Gauge Set 1106
Purging Air From Service Hoses 1107
Stabilizing the AC System 1108
SYSTEM PERFORMANCE TEST 1108
SYSTEM LEAK TESTING 1109
Electronic leak detector 1109
Tracer dyes 1109
Soap and water 1109
A/C DRIVE BELT CHECKOUT PROCEDURE 1110
Pulley Alignment 1110
Belt Tension Check 1110
SYSTEM REPAIR 1112
System Cleaning 1112
Hoses and Fittings 1112
Lines 1112
Expansion Valve 1112
Receiver-Drier 1113
Thermostat 1113
Compressor 1113
Clutch 1113
Servicing the Compressor Clutch 1114
Pulley Removal 1116
Clutch Coil Check 1116
Pulley Installation 1116
Clutch Assembly Installation 1117
RECOVERING AND RECYCLING THE REFRIGERANT 1118
Performing the Recovery Cycle 1118
Performing the Recycling Procedure 1118
Evacuating and Charging the AC System 1118
EVACUATING THE SYSTEM 1119
CHARGING THE AC SYSTEM 1120
TROUBLESHOOTING 1121
Pre-Diagnosis Checks 1121
Preparing For Diagnosis 1121
Preliminary Steps 1121
System Performance Test 1121
Diagnosis Of Gauge Readings And System Performance 1122
TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS 1123
PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM 1129
SECTION N5 – OPERATOR CAB & CONTROLS – INDEX 1130
OPERATOR CAB AND CONTROLS 1132
STEERING WHEEL AND CONTROLS 1133
Horn Button 1133
Telescope Lock Ring 1133
Tilt Wheel Lever 1133
Turn Signal / Headlight Dimmer 1133
Windshield Wiper / Washer Control 1134
RETARDER CONTROL LEVER 1134
STEERING WHEEL 1134
Removal 1134
Installation 1135
SERVICE BRAKE PEDAL 1135
ACCELERATOR PEDAL 1135
INSTRUMENT PANEL 1136
RETARDING CAPACITY CHART 1136
Radio Speakers 1137
MOM Display Screen 1137
MOM Dimmer Switch 1137
Warning Alarm Buzzer 1137
Cab Radio 1137
PMC Interface Connector 1137
Air Cleaner Vacuum Gauges 1137
Payload Meter 1137
Windshield Wipers 1137
CENTER CONSOLE 1138
Transmission Range Selector 1139
Control Switches 1140
Shift Limiter Switch 1140
F1 Start Switch 1140
Hoist Control Lever 1140
Parking Brake Switch 1140
Brake Lock Switch 1140
LH Window Control Switch 1141
RH Window Control Switch 1141
Ash Tray 1141
Lighter 1141
Passenger Seat w/Safety Belt 1141
INSTRUMENT PANEL AND INDICATORS 1142
Keyswitch 1143
Auxiliary Brake Switch 1143
RH Control/Indicator Panel (Pod) 1144
Center Display Panel 1144
LH Control/Indicator Panel (Pod) 1144
Ladder Light Switch 1144
Head Light Switch 1144
BackUp/Deck Lights Switch 1144
RH Control/Indicator Panel (Pod) 1145
Cold Weather Starting Aid (Ether Injection) Switch 1145
Hazard Warning Lights Switch 1145
Automatic Idle Selector Switch (AISS) 1146
Air Conditioner & Heater Vent 1146
ASR Cut (Traction Control) Switch (Option) 1146
Center Display Panel 1147
Air Pressure Monitor (Not Used) 1148
Air Pressure Gauge (Not Used) 1148
Coolant Temperature Monitor 1148
Engine Cooling Water Temperature Gauge 1148
Torque Converter Oil Temperature Monitor 1148
Torque Converter Oil Temperature Gauge 1148
Retarder Oil Temperature Monitor 1148
Retarder Oil Temperature Gauge 1148
Left Turn Signal Pilot Lamp 1149
High Beam Pilot Lamp 1149
Right Turn Signal Pilot Lamp 1149
Speedometer 1149
Tachometer 1149
Lock-up Pilot Lamp 1149
Shift Limiter Pilot Lamp 1149
Shift Indicator 1149
Transmission Shift Position Pilot Lamp 1149
Engine Controller Monitor 1149
Automatic Transmission Mechatronics Monitor 1149
Other Mechatronics Monitor (Optional) 1150
Fuel Level Monitor 1150
Fuel Gauge 1150
Engine Power Derate Monitor 1150
F1 Start Monitor 1150
Auto Cruise Control (Not Used) 1150
ASR Monitor (Optional) 1150
ABS Monitor (Not Used) 1150
Service Meter 1150
Odometer 1150
LH Control/Indicator Panel (Pod) 1151
LH Panel/Pod Assembly 1151
Engine Oil Temperature 1151
Engine Coolant Level 1151
Low Steering Pressure 1151
Accumulator Pre-Charge 1151
Battery Charge Amps 1152
Check Engine 1152
Parking Brake 1152
Body Float 1152
Transmission Oil Temperature 1152
Service Brakes Applied 1152
Maintenance Monitor 1152
Transmission Oil Filters 1152
Lamp Test 1153
Low Brake Pressure 1153
Lateral Slope Warning 1153
Crankcase Pressure 1153
Panel Dimmer Switch 1153
Engine Oil Pressure 1153
Central Warning Lamp 1154
AC/Heater Vent 1154
REAR OF OPERATOR CAB 1154
QUANTUM™ FUEL SYSTEM DIAGNOSTICS 1156
Determining Fault Codes 1156
Exiting The Diagnostics Mode 1157
SECTION P – LUBRICATION AND SERVICE – INDEX 1158
SECTION P2 – LUBRICATION AND SERVICE – INDEX 1160
LUBRICATION AND SERVICE 1162
COOLANT SPECIFICATIONS 1162
Unacceptable Practices 1162
QUICK FILL SERVICE CENTER 1162
10 HOUR (DAILY) INSPECTION 1164
250 HOUR INSPECTION 1166
500 HOUR INSPECTION 1168
1000 HOUR INSPECTION 1169
2000 HOUR INSPECTION 1170
5000 HOUR INSPECTION 1171
SECTION P3 – LINCOLN AUTOMATIC LUBRICATION SYSTEM – INDEX 1172
LINCOLN AUTOMATIC LUBRICATION SYSTEM 1174
SYSTEM COMPONENTS 1174
System Operation 1177
System Priming 1178
System Checkout 1178
Pressure Reducer Adjustment 1178
24 VDC Solid State Timer Check 1179
24 VDC Solid State Timer Adjustment 1180
INJECTORS (SL-1 Series “H”) 1181
Injector Specifications 1181
Injector Adjustment 1181
INJECTOR OPERATION 1182
PUMP CYCLE TIMER (FLASHER TIMER) 1183
Pump Cycle Timer (Flasher Timer) Installation 1183
Pump Cycle Timer (Flasher Timer) Adjustment: 1183
TROUBLESHOOTING CHART 1185
RESERVOIR FILL PROCEDURE 1187
Lubricant Required for System 1187
Fill Procedure 1187
Preventive Maintenance Procedures 1188
Daily Lubrication System Inspection 1188
250 Hour Inspection 1188
SECTION R – SYSTEM SCHEMATICS – INDEX 1190
HYDRAULIC SYSTEM SCHEMATIC 1192
BRAKE SCHEMATIC 1193
ELECTRICAL WIRING SCHEMATIC 1194

S.V 15/12/24