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Komatsu HD1500-5 Dump Truck Shop Manual SN A30039-A30048 – PDF DOWNLOAD
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Komatsu HD1500-5 Dump Truck Shop Manual
SERIAL NUMBERS A30039 – A30048
Book Code: CEBM006204
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Description
Komatsu HD1500-5 Dump Truck Shop Manual
FILE DETAILS:
Komatsu HD1500-5 Dump Truck Shop Manual
Brands: Komatsu
Equipment Type: Dump Truck
Manuals Type: Shop Manual
Machine Model: HD1500-5
Serial Number: A30039-A30048
Book Code: CEBM006204
Language: English
Pages: 1254
File Format: Portable Document Format (PDF)
KOMATSU HD1500-5 DUMP TRUCK SHOP MANUAL SN A30039-A30048 – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HD1500-5 Dump Truck Shop Manual
FOREWORD:
This Shop Manual is written for use by the service technician and is designed to help the technician become fully knowledgeable of the truck and all its systems in order to keep it running and in production. All maintenance personnel should read and understand the materials in this manual before performing maintenance and/or operational checks on the truck. All safety notices, wamings and cautions should be understood and followed when accomplishing repairs on the truck.
- The first section covers component descriptions, truck specifications and safe work practices, as well as other general infom’ration. The major portion of the manual pertains to disassembly, service and reassembly. Each major serviceable area is dealt with individually. For example: The disassembly, service and reassembly of the radiator group is discussed as a unit. The same is true of the engine and engine accessories, and so on through the entire mechanical detail of the truck.
- Disassembly should be carried only as far as necessary to accomplish needed repairs. The illustrations used in this manual are, at times, typical of the component shown and may not necessarily depict a specific model. This manual shows dimensioning of US. and metric (SI) units throughout and all references to “Right”, “Left”.
- ‘Front‘, or “Rear” are made with respect to the operator’s nomtal seated position, unless specifically stated otherwise- Standard torque requirements are shown in torque charts in the general infomiation section and individual torques are provided in the text in bold face type, such as 100 ft.lbs. (135 Mm) torque- All torque specifications have i 10% tolerance unless otherwise specified.
- A Product identification plate is normally located on the truck frame in front of the right side front wheel and designates the Truck Model Number, Product Identification Number (vehicle serial number), and Maximum G.V.W. (Gross Vehicle Weight) rating.
- The KOMATSU Haulpak Truck Model designation consists of three numbers and one letter (i.e. 730E). The three numbers represent the basic truck model. The letter ‘M’ designates a Mechanical drive and the letter “E” designates an Electrical propulsion system.
- The Product Identification Number (vehicle serial number) contains infomiation which will identify the original manufacturing bill of material forthis unit. This complete number will be necessary for proper ordering of many service parts andlor warranty consideration.
TABLE OF CONTENTS:
Komatsu HD1500-5 Dump Truck Shop Manual
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 ELECTRIC STARTER SYSTEM (WITH PRELUB).............................................. 193 OPERATION............................................................................. 193 Pressure Switch................................................................... 193 Check Valve....................................................................... 193 Timer Solenoid.................................................................... 194 MAINTENANCE........................................................................... 195 Prelub™ System Operation.......................................................... 195 Starter/Prelub Pump............................................................... 195 Check Valve....................................................................... 195 Timer Solenoid.................................................................... 195 TROUBLESHOOTING PRELUB STARTER 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 Sensor Switches..................................................... 226 Body-Up Switch Adjustment......................................................... 226 Hoist Limit Switch Adjustment..................................................... 226 Speed Sensors..................................................................... 228 Sensor Adjustment................................................................. 228 24V/240 AMP ALTERNATOR TEST AND REBUILD................................................... 229 BENCH TEST............................................................................ 229 TEST 1 - No Load Test............................................................. 229 STATIC TESTS.......................................................................... 230 Regulator Tests................................................................... 230 Control Box Tests................................................................. 231 ALTERNATOR DISASSEMBLY................................................................ 234 ASSEMBLY- ALTERNATOR.................................................................. 241 BF4822 STATOR SERVICE TOOL INSTRUCTIONS................................................... 250 Stator Removal And Replacement........................................................ 250 Stator Installation................................................................... 251 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 (Wheel Hub Only; Brake Assy. Remains In Place).................................... 754 Disassembly....................................................................... 754 Inspection........................................................................ 754 Assembly and Installation......................................................... 755 Front Wheel Hub Bearing Adjustment................................................ 757 FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION.......................................... 757 SUSPENSION A-FRAME.................................................................... 757 Removal........................................................................... 757 Inspection of Parts............................................................... 758 Installation...................................................................... 758 CENTER TIE ROD PIVOT.................................................................. 758 Removal........................................................................... 758 Inspection........................................................................ 759 Installation...................................................................... 759 TOE IN ADJUSTMENT..................................................................... 760 Adjustment Procedure.............................................................. 760 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX.................................................... 763 REAR AXLE ATTACHMENTS..................................................................... 765 CENTER LINK AND LOWER LINKS........................................................... 765 Removal........................................................................... 765 Inspection........................................................................ 766 Spherical Bearing Replacement..................................................... 766 Installation...................................................................... 766 PANHARD ROD (DIAGONAL LINK)........................................................... 767 Removal........................................................................... 767 Inspection........................................................................ 768 Installation...................................................................... 768 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX....................................... 769 REAR AXLE & FINAL DRIVE ASSEMBLY.......................................................... 771 DIFFERENTIAL OPERATION................................................................ 771 Straight-away-travel.............................................................. 771 Turning........................................................................... 771 REAR AXLE ASSEMBLY................................................................ 772 Removal....................................................................... 772 Installation.................................................................. 772 DIFFERENTIAL OIL LEVEL CHECK...................................................... 773 DIFFERENTIAL ASSEMBLY............................................................. 774 Removal....................................................................... 774 Installation.................................................................. 775 Disassembly................................................................... 775 Pinion Carrier Assembly....................................................... 778 Differential Gear Unit........................................................ 778 Differential Gear Unit........................................................ 779 Assembly...................................................................... 782 Differential Bearing.......................................................... 782 Assembly Of Differential Gear Assembly........................................ 782 Installation Of Differential Assembly......................................... 784 Input Pinion and Carrier Assembly............................................. 785 Adjusting Tooth Contact, Backlash............................................. 789 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX................................... 793 FINAL DRIVE PLANETARIES AND WHEEL HUBS.................................................... 795 FINAL DRIVE........................................................................... 795 Oil Level Check................................................................... 796 FINAL DRIVE CARRIER ASSEMBLY...................................................... 796 Removal....................................................................... 796 Installation.................................................................. 797 Disassembly................................................................... 797 Assembly...................................................................... 798 FINAL DRIVE ASSEMBLY.............................................................. 799 Disassembly................................................................... 799 Assembly...................................................................... 801 SECTION H - SUSPENSIONS - INDEX................................................................... 803 SECTION H2 - FRONT SUSPENSION - INDEX......................................................... 805 FRONT SUSPENSION.......................................................................... 807 FRONT SUSPENSION ASSEMBLY............................................................. 807 Suspension Operation.............................................................. 808 3-MODE SUSPENSION (Optional).......................................................... 809 Variable Damping Operation........................................................ 809 3-Mode Suspension System Components............................................... 810 Automatic Suspension Controller................................................... 810 Manifold Valve.................................................................... 810 Actuator.......................................................................... 811 Steering Sensor................................................................... 811 Suspension Removal................................................................ 812 Suspension Installation........................................................... 813 Disassembly....................................................................... 814 Inspection........................................................................ 814 Assembly.......................................................................... 814 DAMPING VALVE REPAIR.................................................................. 816 Damping Valve (Fixed Rate)........................................................ 816 Disassembly....................................................................... 816 Assembly.......................................................................... 816 Damping Valve/Actuator............................................................ 817 (3-Mode Damping Rate)............................................................. 817 Cleaning and Inspection........................................................... 817 Assembly.......................................................................... 817 SECTION H3 - REAR SUSPENSION - INDEX.......................................................... 819 REAR SUSPENSION........................................................................... 821 OPERATION............................................................................. 822 Removal........................................................................... 823 Installation...................................................................... 823 Disassembly....................................................................... 823 Assembly.......................................................................... 825 SPHERICAL BEARINGS.................................................................... 826 Removal........................................................................... 826 Inspection........................................................................ 826 Installation...................................................................... 826 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX.......................................... 827 SUSPENSION OILING AND CHARGING............................................................ 829 GENERAL INFORMATION................................................................... 829 Equipment List.................................................................... 829 FRONT SUSPENSION...................................................................... 831 Front Suspension Oiling........................................................... 831 Front Suspension Nitrogen Charging................................................ 834 REAR SUSPENSION....................................................................... 836 General Information............................................................... 836 Rear Suspension Oiling............................................................ 837 Rear Suspension Nitrogen Charging................................................. 840 Length Adjustment - Front And Rear Cylinders...................................... 841 SECTION J - BRAKE SYSTEM - INDEX.................................................................. 843 SECTION J2 - BRAKE CIRCUIT - INDEX............................................................ 845 BRAKE CIRCUIT............................................................................. 847 SERVICE BRAKE CIRCUIT................................................................. 847 SECONDARY BRAKING AND AUTOMATIC APPLY................................................. 849 PARKING BRAKE CIRCUIT................................................................. 849 Normal Operation.................................................................. 849 BRAKE LOCK CIRCUIT.................................................................... 850 AUXILIARY CIRCUIT..................................................................... 850 RETARDING CIRCUIT..................................................................... 850 WARNING CIRCUIT....................................................................... 850 BRAKE SYSTEM ELECTRICAL COMPONENTS.................................................... 851 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.......................................... 855 BRAKE CIRCUIT COMPONENT SERVICE........................................................... 857 BRAKE VALVE........................................................................... 857 Rebuild Criteria.................................................................. 857 Removal........................................................................... 858 Installation...................................................................... 858 Disassembly....................................................................... 859 Cleaning and Inspection........................................................... 860 Assembly.......................................................................... 862 Actuator Base Threaded Inserts.................................................... 862 Boot and Cap...................................................................... 862 Valve Body Seal Installation...................................................... 862 Regulator Sleeve O-Ring Installation.............................................. 862 Actuator Plunger O-ring Installation.............................................. 863 Assembly of Valve................................................................. 863 DIFFERENTIAL PRESSURE SWITCH.......................................................... 865 Disassembly....................................................................... 865 Cleaning and Inspection........................................................... 865 Assembly.......................................................................... 865 VALVE BENCH TEST AND ADJUSTMENT....................................................... 866 Test Bench Only................................................................... 867 Test Set Up Procedure............................................................. 867 Brake Valve Output Pressure Adjustment............................................ 867 Differential Pressure Switch Adjustment........................................... 868 Final Test and Adjustment......................................................... 868 Proximity Switch Installation and Adjustment...................................... 869 Installation Of Brake Pedal Actuator Assembly to Brake Valve...................... 870 RELAY VALVES.......................................................................... 871 Removal........................................................................... 871 Installation...................................................................... 871 Disassembly....................................................................... 872 Cleaning and Inspection........................................................... 873 Assembly.......................................................................... 873 VALVE TEST AND ADJUSTMENT............................................................. 874 Test Set Up Procedure............................................................. 875 Relay Valve........................................................................... 875 Output Pressure Adjustment........................................................ 875 HYDRAULIC BRAKE ACCUMULATORS.......................................................... 876 Brake Accumulator Bleed Down Procedure............................................ 876 BRAKE ACCUMULATOR CHARGING PROCEDURE.................................................. 877 BRAKE ACCUMULATOR REBUILD............................................................. 878 Removal........................................................................... 878 Installation...................................................................... 878 Disassembly....................................................................... 878 Cleaning and Inspection........................................................... 878 Assembly.......................................................................... 879 Testing........................................................................... 880 Storage........................................................................... 880 BRAKE COOLING VALVE (BCV)............................................................. 881 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED)...................................... 882 Lever Assembly Removal............................................................ 882 Lever Assembly Installation....................................................... 883 Disassembly and Adjustment........................................................ 883 Potentiometer Check............................................................... 883 Assembly.......................................................................... 883 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX................................................... 885 BRAKE CIRCUIT CHECK-OUT PROCEDURE......................................................... 887 EQUIPMENT REQUIRED.................................................................... 890 Preparation....................................................................... 890 BRAKE SYSTEM CHECKOUT................................................................. 892 Failure Modes Check-Out........................................................... 893 RCM Calibration Check............................................................. 895 RCM Calibration Procedure......................................................... 896 Preparation....................................................................... 896 How to Perform Calibration........................................................ 897 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................. 899 KOMATSU CHECK-OUT PROCEDURE............................................................... 903 HYDRAULIC BRAKE SYSTEM DATA SHEET......................................................... 903 KOMATSU CHECK-OUT PROCEDURE............................................................... 904 HYDRAULIC BRAKE SYSTEM DATA SHEET......................................................... 904 SECTION J5 - FRONT WET DISC BRAKES - INDEX.................................................... 913 FRONT WET DISC BRAKES..................................................................... 915 DESCRIPTION........................................................................... 915 FRONT DISC BRAKE ASSEMBLY............................................................. 916 Removal........................................................................... 916 Installation...................................................................... 917 BRAKE ASSEMBLY REBUILD................................................................ 917 DISC BRAKE MAINTENANCE................................................................ 917 Brake Disc Wear Indicator......................................................... 917 Checking Disc Wear................................................................ 918 WEAR INDICATOR SENSOR................................................................. 919 SPEED SENSOR.......................................................................... 919 WET DISC BRAKE BLEEDING PROCEDURE..................................................... 919 SECTION J6 - REAR WET DISC BRAKES - INDEX..................................................... 921 REAR WET DISC BRAKES...................................................................... 923 DESCRIPTION........................................................................... 923 Operation......................................................................... 923 MAINTENANCE........................................................................... 924 Brake Disc Wear Indicator......................................................... 924 Checking Disc Wear................................................................ 924 Wear Indicator Sensor............................................................. 925 Brake Assembly Removal............................................................ 926 Brake Assembly Installation....................................................... 927 BRAKE ASSEMBLY REBUILD................................................................ 928 Disassembly....................................................................... 928 Cleaning and Inspection........................................................... 929 Assembly.......................................................................... 930 Floating Ring Seal Assembly/Installation.......................................... 932 Alternate Procedure:.............................................................. 933 SECTION J7 - PARKING BRAKE - INDEX............................................................ 935 PARKING BRAKE............................................................................. 936 Description........................................................................... 937 Parking Brake Service Criteria........................................................ 937 Removal............................................................................... 938 Installation.......................................................................... 938 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................. 940 Removal........................................................................... 940 Installation...................................................................... 940 AUTOMATIC SLACK ADJUSTER.............................................................. 940 Adjustment Procedure.............................................................. 940 PARKING BRAKE CHECK-OUT............................................................... 941 SECTION L - HYDRAULIC SYSTEM - INDEX.............................................................. 943 SECTION L2 - HYDRAULIC SYSTEM - INDEX......................................................... 945 HYDRAULIC SYSTEM.......................................................................... 947 HYDRAULIC SYSTEM DESCRIPTION.......................................................... 947 Hydraulic Tank.................................................................... 947 Bleeddown Manifold................................................................ 948 Hoist Valve....................................................................... 948 Hoist Pump........................................................................ 949 Brake Cooling Pump................................................................ 949 Brake Control Valve (BCV)......................................................... 949 Filters........................................................................... 949 High Pressure Filter.............................................................. 949 Low pressure...................................................................... 949 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX........................................ 951 HYDRAULIC COMPONENT REPAIR................................................................ 953 HYDRAULIC TANK........................................................................ 953 FILLING INSTRUCTIONS.............................................................. 953 MAINTENANCE....................................................................... 953 Removal....................................................................... 954 Installation.................................................................. 956 Gap Measurement - Hydraulic Tank Mounting..................................... 956 STRAINERS AND DIFFUSERS........................................................... 957 Removal....................................................................... 957 Cleaning and Inspection....................................................... 957 Installation.................................................................. 958 HYDRAULIC TANK BREATHER............................................................... 958 Service........................................................................... 959 HYDRAULIC SYSTEM FLUSHING............................................................. 959 HYDRAULIC PUMPS....................................................................... 960 Removal........................................................................... 960 Installation...................................................................... 961 PUMP REBUILD...................................................................... 962 Disassembly................................................................... 962 Inspection Of Parts........................................................... 965 Assembly...................................................................... 965 Bearing Replacement........................................................... 968 Seal Replacement.............................................................. 968 TROUBLESHOOTING GUIDE............................................................. 971 SECTION L4 - STEERING CIRCUIT - INDEX......................................................... 973 STEERING CIRCUIT.......................................................................... 975 STEERING CIRCUIT OPERATION............................................................ 975 COMPONENT DESCRIPTION................................................................. 975 Steering Control Valve............................................................ 975 Bleeddown Manifold................................................................ 976 Bleeddown Solenoid................................................................ 976 Accumulators...................................................................... 976 High Pressure Filter.............................................................. 976 Warning Devices................................................................... 976 Flow Amplifier.................................................................... 976 Steering Left..................................................................... 980 STEERING/BRAKE PUMP................................................................... 986 Construction...................................................................... 986 Principle of Operation................................................................ 988 SECTION L5 - STEERING CONTROL UNIT - INDEX.................................................... 989 STEERING CONTROL UNIT..................................................................... 991 Removal............................................................................... 991 Installation.......................................................................... 991 REBUILD PROCEDURE..................................................................... 992 Disassembly....................................................................... 993 Cleaning and Inspection........................................................... 993 Assembly.......................................................................... 995 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX........................................ 999 STEERING CIRCUIT COMPONENT REPAIR.........................................................1001 BLEEDDOWN MANIFOLD....................................................................1001 Removal...........................................................................1001 Adjusting Relief Valve............................................................1001 Testing and Adjustment............................................................1002 FLOW AMPLIFIER........................................................................1003 Removal...........................................................................1003 Installation......................................................................1003 Disassembly.......................................................................1003 Assembly..........................................................................1006 ACCUMULATORS..........................................................................1007 Removal...........................................................................1007 Installation......................................................................1007 Disassembly.......................................................................1008 Cleaning and Inspection...........................................................1008 Assembly..........................................................................1009 Testing...........................................................................1009 STEERING ACCUMULATOR CHARGING PROCEDURE...............................................1010 STEERING CYLINDER.....................................................................1011 Removal...........................................................................1011 Installation......................................................................1011 STEERING CYLINDER REBUILD.............................................................1012 Disassembly.......................................................................1012 Cleaning and Inspection...........................................................1012 Assembly..........................................................................1013 STEERING/BRAKE PUMP...................................................................1014 Removal...........................................................................1014 Installation......................................................................1015 PUMP REBUILD..........................................................................1016 Disassembly.......................................................................1016 Control Group.....................................................................1017 Valve Plate Group.................................................................1018 Rotating Group....................................................................1018 Driveshaft Group..................................................................1019 Swashblock Group..................................................................1019 Inspection........................................................................1020 Control Group.....................................................................1020 Valve Plate Group.................................................................1020 Rotating Group....................................................................1020 Swashblock Group..................................................................1021 Driveshaft Group..................................................................1021 Assembly..........................................................................1021 Swashblock Group..................................................................1021 Driveshaft Group..................................................................1021 Rotating Group....................................................................1022 Valve Plate Group.................................................................1022 Control Group.....................................................................1023 TROUBLESHOOTING CHART.....................................................................1024 SECTION L7 - HOIST CIRCUIT - INDEX............................................................1027 HOIST CIRCUIT.............................................................................1029 HOIST CIRCUIT OPERATION...............................................................1029 COMPONENT DESCRIPTION.............................................................1030 Hydraulic Tank................................................................1030 Hoist Pump....................................................................1030 Hoist Valve...................................................................1030 Hoist Pilot Valve.............................................................1031 Power Up Limit Solenoid.......................................................1032 Pilot Operated Check Valve....................................................1032 Power Down Spool Limit Solenoid...............................................1032 HOIST CIRCUIT OPERATION...........................................................1032 POWER UP Operation............................................................1034 HOLD Operation................................................................1036 POWER DOWN Operation..........................................................1038 FLOAT Operation...............................................................1040 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...........................................1043 HOIST CIRCUIT COMPONENT REPAIR............................................................1045 HOIST VALVE...........................................................................1045 Removal...........................................................................1045 Installation......................................................................1045 O-Ring Replacement................................................................1046 INLET SECTION.....................................................................1047 Disassembly...................................................................1047 Cleaning and Inspection.......................................................1048 Assembly......................................................................1048 SPOOL SECTION.....................................................................1048 Disassembly...................................................................1048 Cleaning and Inspection.......................................................1049 Assembly......................................................................1051 HOIST PILOT VALVE.....................................................................1052 Removal...........................................................................1052 Installation......................................................................1052 Disassembly.......................................................................1053 Cleaning and Inspection...........................................................1054 Reassembly........................................................................1054 HOIST CYLINDERS.......................................................................1055 Removal...........................................................................1055 Installation......................................................................1057 Disassembly.......................................................................1057 Cleaning and Inspection...........................................................1059 Assembly - Quill And Cylinder.....................................................1060 Quill Installation................................................................1060 Installation Of Check Balls And Plugs In Quill....................................1061 Assembly of Cylinder..............................................................1062 POWER UP SPOOL LIMIT SOLENOID.........................................................1063 PILOT OPERATED CHECK VALVE............................................................1063 POWER DOWN HOIST LIMIT SOLENOID.......................................................1063 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.................................................1065 HYDRAULIC SYSTEM FILTERS..................................................................1067 HIGH PRESSURE FILTER..................................................................1067 Removal...........................................................................1067 Installation......................................................................1068 LOW PRESSURE FILTERS..................................................................1068 BRAKE COOLING & HOIST FILTERS.....................................................1068 TRANSMISSION FILTER...............................................................1068 Removal.......................................................................1069 Installation..................................................................1069 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...........................................1071 HYDRAULIC CHECK-OUT PROCEDURE.............................................................1073 GENERAL INFORMATION...................................................................1073 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.....................................1073 Equipment Requirements............................................................1074 Pump Pressure Control Adjustment..................................................1074 Steering Components Leakage Test..................................................1076 CHECKING HOIST SYSTEM PRESSURES.......................................................1077 Equipment Requirements............................................................1077 Power Down Relief Valve Adjustment................................................1078 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.....................................................1079 SPECIAL TOOLS.................................................................................1081 SECTION N - OPERATOR CAB - INDEX..................................................................1085 SECTION N2 - OPERATOR CAB - INDEX.............................................................1087 OPERATOR CAB..............................................................................1089 Removal...............................................................................1090 Installation..........................................................................1092 CAB DOORS.............................................................................1092 Removal...........................................................................1092 Installation......................................................................1093 Door Striker Adjustment...........................................................1093 Door Handle Plunger Adjustment....................................................1094 DOOR PANEL........................................................................1095 Removal.......................................................................1095 Installation..................................................................1095 DOOR WINDOW.......................................................................1096 Removal.......................................................................1096 Installation..................................................................1098 WINDOW REGULATOR..................................................................1100 Removal.......................................................................1100 Installation..................................................................1100 DOOR HANDLE AND DOOR LATCH........................................................1100 Removal.......................................................................1100 Installation..................................................................1100 DOOR SEALS............................................................................1101 Removal...........................................................................1101 Installation......................................................................1101 DOOR OPENING SEAL.....................................................................1101 Removal...........................................................................1101 Installation......................................................................1101 GLASS REPLACEMENT.....................................................................1102 Replacement.......................................................................1102 REAR GLASS........................................................................1104 Removal.......................................................................1104 Installation..................................................................1104 SECTION N3 - CAB COMPONENTS - INDEX...........................................................1105 CAB COMPONENTS............................................................................1107 WINDSHIELD WIPERS.....................................................................1107 Wiper Motor Replacement...........................................................1107 Removal...........................................................................1107 Installation......................................................................1107 Wiper Arm Replacement.............................................................1107 Removal...........................................................................1107 Installation......................................................................1108 Wiper Linkage Replacement.........................................................1108 Removal...........................................................................1108 Installation......................................................................1108 WINDSHIELD WASHER.....................................................................1109 Operation.........................................................................1109 Service...........................................................................1109 OPERATOR SEAT.........................................................................1110 Adjustment........................................................................1110 Removal...........................................................................1110 Installation......................................................................1110 SECTION N4 - OPERATOR COMFORT - INDEX.........................................................1111 OPERATOR COMFORT..........................................................................1113 HEATER/AIR CONDITIONER................................................................1113 Operation.........................................................................1113 HEATER/AIR CONDITIONER................................................................1114 Operation.........................................................................1114 HEATER COMPONENTS.....................................................................1114 Circuit Breaker...................................................................1114 D/C - D/C Converter...............................................................1115 Flapper Door Motors...............................................................1115 Temperature Control Potentiometer.................................................1115 Motorized Coolant Control Valve...................................................1115 Heater Coil.......................................................................1115 Fan Motor and Speed Control.......................................................1115 Test..............................................................................1115 FILTER................................................................................1115 Service...........................................................................1115 AIR CONDITIONING SYSTEM...................................................................1117 Environmental Impact..................................................................1117 OPERATOR CAB AIR CONDITIONING.........................................................1118 PRINCIPLES OF REFRIGERATION...........................................................1118 Air Conditioning..................................................................1118 Refrigeration - The Act Of Cooling................................................1119 The Refrigeration Cycle...........................................................1119 AIR CONDITIONER SYSTEM COMPONENTS.....................................................1120 Compressor (Refrigerant Pump).....................................................1120 Service Valves....................................................................1120 Condenser.........................................................................1120 Receiver-Drier....................................................................1120 Expansion Block Valve.............................................................1121 Evaporator........................................................................1121 ELECTRICAL CIRCUIT....................................................................1122 Thermostat........................................................................1122 Compressor Clutch.................................................................1122 Trinary™ Switch...................................................................1123 SYSTEM SERVICING......................................................................1124 SYSTEM OIL............................................................................1125 Handling and Reusing PAG Oil......................................................1125 Oil Quantity......................................................................1125 Replacing Oil After Servicing the System..........................................1125 Setting Up a New Compressor.......................................................1125 REFRIGERANT...........................................................................1126 Recycled Refrigerant..............................................................1126 Reclaimed Refrigerant.............................................................1126 Refrigerant Quantity..............................................................1126 R-134a Refrigerant Containers.....................................................1126 SERVICE TOOLS AND EQUIPMENT...........................................................1127 Recovery/Recycle Station..........................................................1127 Leak Detector.....................................................................1127 Service Valves....................................................................1128 Vacuum Pump.......................................................................1128 Manifold Gauge Set................................................................1129 Installing Manifold Gauge Set.....................................................1130 Purging Air From Service Hoses....................................................1131 Stabilizing the AC System.........................................................1132 SYSTEM PERFORMANCE TEST...............................................................1132 SYSTEM LEAK TESTING...................................................................1133 Electronic leak detector..........................................................1133 Tracer dyes.......................................................................1133 Soap and water....................................................................1133 A/C DRIVE BELT CHECKOUT PROCEDURE.....................................................1134 Pulley Alignment..................................................................1134 Belt Tension Check................................................................1134 SYSTEM REPAIR.........................................................................1136 System Cleaning...................................................................1136 Hoses and Fittings................................................................1136 Lines.............................................................................1136 Expansion Valve...................................................................1136 Receiver-Drier....................................................................1137 Thermostat........................................................................1137 Compressor........................................................................1137 Clutch............................................................................1137 Servicing the Compressor Clutch...................................................1138 Pulley Removal....................................................................1140 Clutch Coil Check.................................................................1140 Pulley Installation...............................................................1140 Clutch Assembly Installation......................................................1141 RECOVERING AND RECYCLING THE REFRIGERANT..............................................1142 Performing the Recovery Cycle.....................................................1142 Performing the Recycling Procedure................................................1142 Evacuating and Charging the AC System.............................................1142 EVACUATING THE SYSTEM.................................................................1143 CHARGING THE AC SYSTEM................................................................1144 TROUBLESHOOTING...........................................................................1145 Pre-Diagnosis Checks..................................................................1145 Preparing For Diagnosis...............................................................1145 Preliminary Steps.....................................................................1145 System Performance Test...............................................................1145 Diagnosis Of Gauge Readings And System Performance....................................1146 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS............................................1147 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM...........................................1153 SECTION N5 - OPERATOR CAB AND CONTROLS - INDEX................................................1155 OPERATOR CAB AND CONTROLS.................................................................1157 STEERING WHEEL AND CONTROLS...........................................................1158 Horn Button.......................................................................1158 Telescope Lock Ring...............................................................1158 Tilt Wheel Lever..................................................................1158 Turn Signal / Headlight Dimmer....................................................1158 Windshield Wiper / Washer Control.................................................1159 RETARDER CONTROL LEVER................................................................1159 STEERING WHEEL........................................................................1159 Removal...........................................................................1159 Installation......................................................................1160 SERVICE BRAKE PEDAL...................................................................1160 ACCELERATOR (THROTTLE) PEDAL..........................................................1160 INSTRUMENT PANEL......................................................................1161 RETARDING CAPACITY CHART..............................................................1161 Radio Speakers....................................................................1162 MOM Display Screen................................................................1162 MOM Dimmer Switch.................................................................1162 Warning Alarm Buzzer..............................................................1162 Cab Radio.........................................................................1162 PMC Interface Connector...........................................................1162 Air Cleaner Vacuum Gauges.........................................................1162 Payload Meter.....................................................................1162 Windshield Wipers.................................................................1162 CENTER CONSOLE........................................................................1163 Transmission Range Selector.......................................................1164 Control Switches..................................................................1165 Shift Limiter Switch..............................................................1165 F1 Start Switch...................................................................1165 Hoist Control Lever...............................................................1165 Parking Brake Switch..............................................................1165 Brake Lock Switch.................................................................1166 LH Window Control Switch..........................................................1166 RH Window Control Switch..........................................................1166 Ash Tray..........................................................................1166 Lighter...........................................................................1166 Passenger Seat w/Safety Belt......................................................1166 INSTRUMENT PANEL AND INDICATORS...........................................................1167 Keyswitch.............................................................................1168 Auxiliary Brake Switch................................................................1168 RH Control/Indicator Panel (Pod)......................................................1169 Center Display Panel..................................................................1169 LH Control/Indicator Panel (Pod)......................................................1169 Ladder Light Switch...................................................................1169 Head Light Switch.....................................................................1169 BackUp/Deck Lights Switch.............................................................1169 RH Control/Indicator Panel (Pod)......................................................1170 Cold Weather Starting Aid (Ether Injection) Switch....................................1170 Hazard Warning Lights Switch..........................................................1170 Automatic Idle Selector Switch (AISS).................................................1171 Air Conditioner & Heater Vent.........................................................1171 ASR Cut (Traction Control) Switch (Option)............................................1171 Center Display Panel..................................................................1172 Air Pressure Monitor (Not Used).......................................................1173 Air Pressure Gauge (Not Used).........................................................1173 Coolant Temperature Monitor...........................................................1173 Engine Cooling Water Temperature Gauge................................................1173 Torque Converter Oil Temperature Monitor..............................................1173 Torque Converter Oil Temperature Gauge................................................1173 Retarder Oil Temperature Monitor......................................................1173 Retarder Oil Temperature Gauge........................................................1173 Left Turn Signal Pilot Lamp...........................................................1174 High Beam Pilot Lamp..................................................................1174 Right Turn Signal Pilot Lamp..........................................................1174 Speedometer...........................................................................1174 Tachometer............................................................................1174 Lock-up Pilot Lamp....................................................................1174 Shift Limiter Pilot Lamp..............................................................1174 Shift Indicator.......................................................................1174 Transmission Shift Position Pilot Lamp................................................1174 Engine Controller Monitor.............................................................1174 Automatic Transmission Mechatronics Monitor...........................................1174 Other Mechatronics Monitor (Optional).................................................1175 Fuel Level Monitor....................................................................1175 Fuel Gauge............................................................................1175 Engine Power Derate Monitor...........................................................1175 F1 Start Monitor......................................................................1175 Auto Cruise Control (Not Used)........................................................1175 ASR Monitor (Optional)................................................................1175 ABS Monitor (Not Used)................................................................1175 Service Meter.........................................................................1175 Odometer..............................................................................1175 LH Control/Indicator Panel (Pod)......................................................1176 LH Panel/Pod Assembly.................................................................1176 Engine Oil Temperature................................................................1176 Engine Coolant Level..................................................................1176 Low Steering Pressure.................................................................1176 Accumulator Pre-Charge................................................................1176 Battery Charge Amps...................................................................1177 Check Engine..........................................................................1177 Parking Brake.........................................................................1177 Body Float............................................................................1177 Transmission Oil Temperature..........................................................1177 Service Brakes Applied................................................................1177 Maintenance Monitor...................................................................1177 Transmission Oil Filters..............................................................1177 Lamp Test.............................................................................1178 Low Brake Pressure....................................................................1178 Lateral Slope Warning.................................................................1178 Crankcase Pressure....................................................................1178 Panel Dimmer Switch...................................................................1178 Engine Oil Pressure...................................................................1178 Central Warning Lamp..................................................................1179 AC/Heater Vent........................................................................1179 REAR OF OPERATOR CAB..................................................................1179 QUANTUM™ FUEL SYSTEM DIAGNOSTICS......................................................1181 Determining Fault Codes...........................................................1181 Exiting The Diagnostics Mode......................................................1182 SECTION P - LUBRICATION AND SERVICE - INDEX.......................................................1183 SECTION P2 - LUBRICATION AND SERVICE - INDEX..................................................1185 LUBRICATION AND SERVICE...................................................................1187 TRANSMISSION OIL LEVEL CHECK..........................................................1187 10 HOUR (DAILY) INSPECTION............................................................1189 250 HOUR INSPECTION...................................................................1191 500 HOUR INSPECTION...................................................................1193 1000 HOUR INSPECTION..................................................................1194 2000 HOUR INSPECTION..................................................................1195 5000 HOUR INSPECTION..................................................................1196 HYDRAULIC TANK SERVICE................................................................1197 Filling Instructions..............................................................1197 Hydraulic Tank Service............................................................1197 STEERING CIRCUIT FILTER...............................................................1198 Removal...........................................................................1198 Installation......................................................................1198 HYDRAULIC TANK BREATHER...............................................................1199 Cleaning..........................................................................1199 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.............................................1201 LINCOLN AUTOMATIC LUBRICATION SYSTEM......................................................1203 SYSTEM COMPONENTS.....................................................................1203 System Operation..................................................................1206 System Priming....................................................................1207 System Checkout...................................................................1207 Pressure Reducer Adjustment.......................................................1207 24 VDC Solid State Timer Check....................................................1208 24 VDC Solid State Timer Adjustment...............................................1209 INJECTORS (SL-1 Series "H")...........................................................1210 Injector Specifications...........................................................1210 Injector Adjustment...............................................................1210 INJECTOR OPERATION....................................................................1211 PUMP CYCLE TIMER (FLASHER TIMER)......................................................1212 Pump Cycle Timer (Flasher Timer) Installation.....................................1212 Pump Cycle Timer (Flasher Timer) Adjustment:......................................1212 TROUBLESHOOTING CHART.....................................................................1214 RESERVOIR FILL PROCEDURE..............................................................1216 Lubricant Required for System.....................................................1216 Fill Procedure....................................................................1216 Preventive Maintenance Procedures.........................................................1217 Daily Lubrication System Inspection...................................................1217 250 Hour Inspection...................................................................1217 SECTION R - SYSTEM SCHEMATICS - INDEX.............................................................1219 HYDRAULIC SYSTEM SCHEMATIC ...................................................................1221 HYDRAULIC BRAKE SCHEMATIC ....................................................................1222 ELECTRICAL SCHEMATIC..........................................................................1223 ELECTRICAL HOOKUP SCHEMATIC...................................................................1247
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
