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Komatsu HD1500-5 Dump Truck Shop Manual SN A30072-A30076 – PDF DOWNLOAD
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Komatsu HD1500-5 Dump Truck Shop Manual
Book Code: CEBM013401
SERIAL NUMBERS A30072 – A30076
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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: A30072-A30076
Book Code: CEBM013401
Language: English
Pages: 1249
File Format: Portable Document Format (PDF)
KOMATSU HD1500-5 DUMP TRUCK SHOP MANUAL SN A30072-A30076 – 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 & OPERATING INSTRUCTIONS - INDEX.......................................... 15 SAFETY.................................................................................... 17 Safety Rules.......................................................................... 17 Safety Features....................................................................... 17 Clothing And Personal Items........................................................... 17 Unauthorized Modification............................................................. 17 Leaving The Operator’s Seat........................................................... 17 Mounting And Dismounting.............................................................. 18 Fire Prevention For Fuel And Oil...................................................... 18 Precautions With High Temperature Fluids.............................................. 18 Asbestos Dust Hazard Prevention....................................................... 19 Prevention Of Injury By Work Equipment................................................ 19 Fire Extinguisher And First Aid Kit................................................... 19 Precautions For ROPS.................................................................. 19 Precautions For Attachments........................................................... 19 PRECAUTIONS DURING OPERATION.............................................................. 20 Safety Is Thinking Ahead.............................................................. 20 BEFORE STARTING THE ENGINE............................................................ 20 Safety At The Work Site........................................................... 20 Fire Prevention................................................................... 20 Preparing For Operation........................................................... 20 Ventilation In Enclosed Areas..................................................... 20 In Operator’s Cab - Before Starting The Engine.................................... 21 Mirrors, Windows, And Lights...................................................... 21 OPERATING THE MACHINE................................................................. 21 When Starting The Engine.......................................................... 21 Precautions For Starting Machine.................................................. 21 Truck Operation - General......................................................... 21 Traveling......................................................................... 22 Traveling In Reverse.............................................................. 22 Traveling On Slopes............................................................... 23 Ensure Good Visibility............................................................ 23 Operate Carefully On Snow......................................................... 23 Avoid Damage To Dump Body......................................................... 23 Driving Near High Voltage Cables.................................................. 23 When Dumping...................................................................... 24 Working On Loose Ground........................................................... 24 Loading The Body.................................................................. 24 Parking The Machine............................................................... 24 TOWING................................................................................ 24 WORKING NEAR BATTERIES................................................................ 25 Battery Hazard Prevention......................................................... 25 Starting With Booster Cables...................................................... 25 PRECAUTIONS FOR MAINTENANCE............................................................... 26 BEFORE PERFORMING MAINTENANCE......................................................... 26 Warning Tag....................................................................... 26 Proper Tools...................................................................... 26 Stopping The Engine Before Service................................................ 26 Securing The Dump Body............................................................ 26 DURING MAINTENANCE.................................................................... 28 Personnel......................................................................... 28 Attachments....................................................................... 28 Working Under The Machine......................................................... 28 Keep The Machine Clean............................................................ 28 Rules To Follow When Adding Fuel Or Oil........................................... 28 Radiator Water Level.............................................................. 28 Use Of Lighting................................................................... 28 Precautions With The Battery...................................................... 29 Handling High Pressure Hoses...................................................... 29 Precautions With High Pressure Oil................................................ 29 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 29 Rotating Fan And Belts............................................................ 29 Waste Materials................................................................... 29 TIRES................................................................................. 30 Handling Tires.................................................................... 30 Tire Maintenance.................................................................. 30 Storing Tires After Removal....................................................... 30 WHEN REPAIRS ARE NECESSARY................................................................ 31 ADDITIONAL JOB SITE RULES................................................................. 32 OPERATING INSTRUCTIONS.................................................................... 33 PREPARING FOR OPERATION............................................................... 33 Safety Is Thinking Ahead.......................................................... 33 Walk Around Inspection............................................................ 33 ENGINE START-UP SAFETY PRACTICES...................................................... 36 Cold Weather Starting............................................................. 37 Jump Starting..................................................................... 37 EMERGENCY STEERING SYSTEM............................................................. 38 Operation......................................................................... 38 Pre-Operation Testing............................................................. 38 AFTER THE ENGINE HAS STARTED.......................................................... 39 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 41 LOADING............................................................................... 42 HAULING............................................................................... 43 RETARDER OPERATION.................................................................... 43 PASSING............................................................................... 44 DUMPING............................................................................... 44 Raising the Dump Body............................................................. 45 Lowering The Dump Body............................................................ 45 SAFE PARKING PROCEDURES............................................................... 46 SHUTTING THE ENGINE OFF............................................................... 46 SUDDEN LOSS OF ENGINE POWER........................................................... 46 Secondary Steering And Braking.................................................... 46 DISABLED TRUCK DUMPING PROCEDURE...................................................... 47 Hookup............................................................................ 47 Raising the Body.................................................................. 48 Lowering the Body................................................................. 48 DISABLED TRUCK STEERING AND BRAKING................................................... 49 TOWING................................................................................ 51 SECTION A4- WARNINGS AND CAUTIONS............................................................. 53 SECTION A5 - STANDARD TABLES.................................................................. 59 SECTION A7 - STORAGE PROCEDURES - INDEX....................................................... 67 STORAGE AND IDLE MACHINE PREPARATION...................................................... 69 SHORT TERM IDLE PERIODS............................................................... 69 PREPARATION FOR STORAGE............................................................... 69 REMOVAL FROM STORAGE.................................................................. 70 RECONDITIONING AN IDLE VEHICLE........................................................ 72 ENGINE OPERATION...................................................................... 75 AFTER THE ENGINE HAS STARTED.......................................................... 75 SHORT TERM ENGINE STORAGE............................................................. 76 Preparing the Engine.............................................................. 76 Removing the Engine from Long Term Storage........................................ 78 TRANSMISSION PRESERVATION AND STORAGE................................................. 78 Storage, New Transmission......................................................... 78 Storage, One Year- Without Oil.................................................... 78 Storage, One Year - With Oil - Normally Installed On The Truck.................... 79 Restoring The Transmission For Service............................................ 79 SECTION B - STRUCTURES - INDEX.................................................................... 81 SECTION B2 - STRUCTURAL COMPONENTS - INDEX.................................................... 83 STRUCTURAL COMPONENTS..................................................................... 85 PREPARATION........................................................................... 85 GRILLE, HOOD AND LADDERS.............................................................. 86 DECKS............................................................................. 87 CENTER DECK........................................................................... 87 Removal........................................................................... 87 Installation...................................................................... 87 RIGHT DECK AND COMPONENTS......................................................... 87 Removal....................................................................... 87 Installation.................................................................. 87 LEFT DECK AND CAB................................................................. 88 Installation.................................................................. 88 SECTION B3 - DUMP BODY - INDEX................................................................ 89 DUMP BODY................................................................................. 91 Removal............................................................................... 91 Installation.......................................................................... 93 BODY PADS............................................................................. 93 Body Pad Adjustment............................................................... 94 BODY GUIDE............................................................................ 94 BODY-UP RETENTION CABLE............................................................... 95 ROCK EJECTORS......................................................................... 95 Inspection........................................................................ 95 SECTION B4 - FUEL TANK - INDEX................................................................ 97 FUEL TANK................................................................................. 99 Removal............................................................................... 100 Cleaning.............................................................................. 100 Repair................................................................................ 100 Installation.......................................................................... 100 FUEL GAUGE AND SENDING UNIT........................................................... 101 Removal........................................................................... 101 Installation...................................................................... 101 WIGGINS QUICK FILL FUEL SYSTEM........................................................ 102 FUEL RECEIVER..................................................................... 102 FUEL TANK BREATHER................................................................ 102 Removal....................................................................... 102 Installation.................................................................. 102 Disassembly................................................................... 102 Assembly...................................................................... 102 LEFT SIDE FILL.................................................................... 103 SECTION C - ENGINE - INDEX........................................................................ 105 SECTION C3 - COOLING SYSTEM - INDEX........................................................... 107 COOLING SYSTEM............................................................................ 109 DESCRIPTION........................................................................... 109 LEAKS AND CONTAMINATION............................................................... 110 RADIATOR REMOVAL...................................................................... 110 RADIATOR REPAIR................................................................... 111 Internal Inspection........................................................... 111 External Cleaning............................................................. 112 Disassembly................................................................... 112 Cleaning and Inspection....................................................... 113 Assembly...................................................................... 114 Pressure Testing.............................................................. 115 Additional Service Information................................................ 115 RADIATOR INSTALLATION................................................................. 115 TRANSMISSION AND BRAKE COOLERS.................................................... 117 Removal....................................................................... 117 Disassembly................................................................... 117 Cleaning And Inspection....................................................... 118 Assembly...................................................................... 118 Inspection.................................................................... 120 Installation.................................................................. 121 SECTION C4 - ENGINE - INDEX................................................................... 123 ENGINE.................................................................................... 125 Removal............................................................................... 125 Inspection............................................................................ 128 DRIVE LINE ADAPTER AND DAMPER......................................................... 130 Removal........................................................................... 130 Disassembly....................................................................... 132 Assembly.......................................................................... 132 Installation...................................................................... 134 SECTION C5 - AIR FILTRATION SYSTEM - INDEX.................................................... 137 AIR FILTRATION SYSTEM..................................................................... 139 AIR CLEANER........................................................................... 139 Operation......................................................................... 139 General Maintenance............................................................... 139 FILTER SERVICE INDICATOR.......................................................... 141 MAIN FILTER ELEMENT............................................................... 141 Removal....................................................................... 141 Installation.................................................................. 141 SAFETY FILTER ELEMENT............................................................. 141 Removal....................................................................... 141 Installation.................................................................. 141 MAIN FILTER CLEANING.............................................................. 142 PRECLEANER CLEANING............................................................... 143 AIR INTAKE TROUBLESHOOTING............................................................ 144 SECTION C7 - FAN CLUTCH - INDEX............................................................... 145 FAN CLUTCH................................................................................ 147 REMOVAL & INSTALLATION TOOLING........................................................ 147 FAN CLUTCH - DISASSEMBLY.............................................................. 150 CLEANING AND INSPECTION............................................................... 160 ASSEMBLY - FAN CLUTCH................................................................. 164 TEST PROCEDURE........................................................................ 178 SECTION D - ELECTRICAL SYSTEM AND POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX.................... 179 SECTION D2 - STARTING SYSTEM - INDEX.......................................................... 181 STARTING SYSTEMS.......................................................................... 183 24 VDC REMOTE MOUNT PRELUB™ SYSTEM.................................................... 183 OPERATION......................................................................... 183 Oil Pressure Switch........................................................... 185 Check Valve................................................................... 185 Timer Solenoid................................................................ 185 MAINTENANCE....................................................................... 185 Prelub™ System Operation...................................................... 185 Prelub Pump................................................................... 185 Check Valve................................................................... 186 Timer Solenoid................................................................ 186 PRELUB CIRCUIT TROUBLESHOOTING.................................................... 187 24 VDC ELECTRIC START SYSTEM.......................................................... 189 OPERATION......................................................................... 189 CRANKING MOTORS................................................................... 189 Removal....................................................................... 189 Installation.................................................................. 189 Disassembly................................................................... 190 Cleaning and Inspection....................................................... 190 Armature Servicing............................................................ 190 Field Coil Checks............................................................. 191 Field Coil Removal............................................................ 191 Solenoid Checks............................................................... 194 Assembly...................................................................... 195 Pinion Clearance Adjustment................................................... 196 MAGNETIC SWITCH................................................................... 196 Removal....................................................................... 196 Installation.................................................................. 197 Coil Test..................................................................... 197 CRANKING MOTOR TROUBLESHOOTING........................................................ 198 PRELIMINARY INSPECTION............................................................ 198 NO-LOAD TEST...................................................................... 198 Load Test Diagnosis........................................................... 199 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX............................................. 201 ELECTRICAL SYSTEM COMPONENTS.............................................................. 203 GENERAL TROUBLESHOOTING............................................................... 203 CAB MOUNTED COMPONENTS................................................................ 204 Circuit Breakers.................................................................. 204 RELAY BOARDS.......................................................................... 207 Relay Boards (With Circuit Breakers).............................................. 207 Preliminary Checks................................................................ 207 Service........................................................................... 208 Relay Board Description........................................................... 210 Relay Board RB1................................................................... 210 Relay Board RB4................................................................... 210 Relay Board RB5................................................................... 210 Relay Boards (Without Circuit Breakers)........................................... 211 Truck Inclination Sensors......................................................... 213 Payload Meter Inclinometer Sensor................................................. 213 Lateral Inclination Sensor........................................................ 213 Lubrication System Timer.......................................................... 213 ACCELERATOR PEDAL..................................................................... 214 Operation......................................................................... 214 AISS Operation.................................................................... 215 Throttle Pedal Malfunction........................................................ 217 ACCELERATOR PEDAL CHECKS.............................................................. 217 Idle Validation Switch Continuity Check........................................... 217 24V COMPONENTS (Outside Cab).......................................................... 218 Battery Box....................................................................... 218 Battery Disconnect Switch......................................................... 218 Ground Level Shutdown Switch...................................................... 218 Control Power Relays.............................................................. 218 Circuit Breakers.................................................................. 218 Level Sensor...................................................................... 218 Battery Equalizer................................................................. 219 BODY POSITION SWITCHES................................................................ 219 Proximity Switch Operation........................................................ 219 Body-Up Switch Adjustment......................................................... 220 Hoist Limit Switch Adjustment..................................................... 222 Speed Sensors..................................................................... 223 Sensor Adjustment................................................................. 223 24V/240 AMP ALTERNATOR TEST AND REBUILD................................................... 224 BENCH TEST............................................................................ 224 TEST 1 - No Load Test............................................................. 224 STATIC TESTS.......................................................................... 225 Regulator Tests................................................................... 225 Control Box Tests................................................................. 226 ALTERNATOR DISASSEMBLY................................................................ 229 ASSEMBLY- ALTERNATOR.................................................................. 236 BF4822 STATOR SERVICE TOOL INSTRUCTIONS................................................... 245 Stator Removal And Replacement........................................................ 245 Stator Installation................................................................... 246 SECTION D22 - POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX.................................... 249 POWERTRAIN MANAGEMENT CONTROL™ SYSTEM..................................................... 251 System Description.................................................................... 251 Engine (Cummins QSK45)................................................................ 251 Transmission.......................................................................... 251 Transmission Controller............................................................... 251 Retard Control and Monitor............................................................ 251 Powertrain Management Controller...................................................... 251 Electronic Display Panel.............................................................. 251 Payload Meter......................................................................... 251 Message for Operator and Maintenance Display.......................................... 251 Suspension Controller................................................................. 251 Data Acquisition Device............................................................... 251 Cummins Quantum....................................................................... 252 Cummins CENSE......................................................................... 252 PMC SYSTEM TROUBLESHOOTING............................................................ 253 Preliminary Troubleshooting Procedures............................................ 253 Emergency Operation............................................................... 253 Indication Of A Fault Occurrence.................................................. 253 Action Codes...................................................................... 253 Fault History..................................................................... 253 System Troubleshooting............................................................ 253 EMERGENCY TRUCK OPERATION............................................................. 256 PMC SYSTEM FAULT CODES................................................................ 258 SECTION D23 - POWERTRAIN MANAGEMENT CONTROLLER - INDEX........................................ 275 POWERTRAIN MANAGEMENT CONTROLLER (PMC).................................................... 277 PMC CONTROLLER FEATURES............................................................... 277 LED Display....................................................................... 277 DIP Switch Settings............................................................... 277 NORMAL OPERATION - PMC................................................................ 278 Throttle Control.................................................................. 278 AISS Operation.................................................................... 278 Retarder Control.................................................................. 279 COMMUNICATION......................................................................... 279 S-NET............................................................................. 279 CENSE............................................................................. 279 RCM............................................................................... 279 PLM............................................................................... 279 “MOM” and “DAD”................................................................... 279 Additional Functions.............................................................. 280 PMC CONTROLLER TROUBLESHOOTING............................................................ 283 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 283 PMC FAULT CODE TROUBLESHOOTING............................................................ 284 PMC CONTROLLER LOGIC...................................................................... 292 Fault Recovery Classifications........................................................ 292 PMC FAULT CODE LOGIC DESCRIPTION.......................................................... 293 PMC WIRING HARNESS CONNECTORS......................................................... 317 SECTION D24 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX....................................... 323 AUTOMATIC TRANSMISSION CONTROLLER (ATC)................................................... 325 ATC CONTROLLER FEATURES............................................................... 325 LED Display....................................................................... 325 Rotary Switch Settings............................................................ 325 Shift Control..................................................................... 326 Range Selector Positions And Automatic Gear Shifting Ranges....................... 326 Transmission Operation Modes...................................................... 327 Braking Mode:..................................................................... 327 Normal Mode:...................................................................... 327 Automatic Gear Shifting........................................................... 327 Automatic Shifting Sequence....................................................... 328 Gearshifting time lag............................................................. 328 Shift Skip Logic.................................................................. 328 Safety Functions.................................................................. 329 TROUBLESHOOTING - ATC..................................................................... 330 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 330 ATC FAULT CODE TROUBLESHOOTING............................................................ 331 ATC FAULT CODE LOGIC DESCRIPTION.......................................................... 346 TRANSMISSION CONTROLLER HARNESS CONNECTORS............................................ 377 SECTION D25 - ELECTRONIC DISPLAY PANEL - INDEX................................................ 381 ELECTRONIC DISPLAY PANEL.................................................................. 383 Rotary Switch......................................................................... 383 Gauges and Indicators................................................................. 384 External Indicator Lamps.............................................................. 386 Display Self-Check Function........................................................... 388 Lamp Test............................................................................. 388 Action Code Display................................................................... 389 Cancellation of Action Code........................................................... 389 ELECTRONIC DISPLAY PANEL TROUBLESHOOTING.................................................. 390 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 390 Harness Circuit Tests............................................................. 390 Table 1: Continuity checks........................................................ 390 Table 2: Short Circuit to Ground Checks........................................... 391 Table 3: Circuit Isolation Checks................................................. 391 EDP WIRING HARNESS CONNECTORS......................................................... 409 SECTION D26 - RETARD CONTROL AND MONITOR (RCM) - INDEX........................................ 411 RETARD CONTROL AND MONITOR (RCM).......................................................... 413 Description........................................................................... 413 RCM Calibration....................................................................... 413 GENERAL TROUBLESHOOTING PROCEDURES........................................................ 414 RCM FAULT CODE TROUBLESHOOTING............................................................ 416 Description........................................................................... 416 RCM WIRING HARNESS CONNECTORS......................................................... 463 SECTION D27 - AUTOMATIC SUSPENSION SYSTEM - INDEX............................................. 465 AUTOMATIC SUSPENSION SYSTEM............................................................... 467 Automatic Suspension Controller....................................................... 467 Manifold Valve........................................................................ 467 Actuator.............................................................................. 467 Steering Sensor....................................................................... 467 AUTOMATIC MODE SELECTION CONTROL...................................................... 468 SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION........................................ 469 d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE................................... 469 d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE.................................... 469 d015:TRANSMISSION SPEED SIGNAL LOST................................................... 470 d016:STEERING SPEED SIGNAL LOST....................................................... 470 d021:SOLENOID OUTPUT 1 FAILURE........................................................ 471 d022:SOLENOID OUTPUT 2 FAILURE........................................................ 471 d023:SOLENOID OUTPUT 3 FAILURE........................................................ 471 SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING.............................................. 472 SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed....................... 472 SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed....................... 473 SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed..................... 474 SP-4: Fault Code d016: Fault in Steering Sensor System Displayed...................... 475 SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed......................... 476 SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed......................... 477 SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed......................... 478 SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS....................................... 479 SECTION D30 - MESSAGE FOR OPERATION AND MAINTENANCE - INDEX................................... 481 MOM - MESSAGE FOR OPERATION AND MAINTENANCE............................................... 483 INTRODUCTION.......................................................................... 483 SYSTEM CONFIGURATION.................................................................. 483 SOFTWARE.............................................................................. 484 Service Meters (SMR).............................................................. 485 FUNCTION.............................................................................. 486 Operator Information.............................................................. 486 Maintenance Information (Screen Hierarchy)........................................ 486 Display Able/Disable By Machine Status............................................ 488 Vehicle State..................................................................... 488 Display Able/Disable by Truck Model and Optional Equipment Status................. 489 SCREEN DATA........................................................................... 490 Realtime Data..................................................................... 490 Machine Trend Data................................................................ 490 Fault Condition Data.............................................................. 490 Machine Information............................................................... 491 Parameter Set..................................................................... 491 WARNING MESSAGE....................................................................... 492 HARDWARE TROUBLESHOOTING AND MAINTENANCE.................................................. 493 TROUBLESHOOTING THE MOM UNIT.......................................................... 493 PROBLEMS AND CORRECTIVE ACTIONS....................................................... 494 Program Errors.................................................................... 495 Warning & Communication Errors.................................................... 496 SELF-DIAGNOSIS........................................................................ 497 System Check...................................................................... 497 System Information................................................................ 497 Communication Port Check.......................................................... 497 Key Input Check................................................................... 498 MAINTENANCE........................................................................... 499 Battery Replacement............................................................... 499 Replacement of Protective Sheet................................................... 499 Back Light Replacement............................................................ 500 Setting Display OFF Time.......................................................... 501 SECTION D31 - MOM SCREEN DISPLAYS - INDEX..................................................... 503 MOM SCREEN DISPLAYS....................................................................... 505 i1 INITIAL MESSAGE.................................................................... 505 i2 INITIAL CHECK1..................................................................... 505 i3 INITIAL CHECK2..................................................................... 505 i4 NORMAL RUNNING..................................................................... 506 i7 BACKLIGHT OFF...................................................................... 507 To Access a Maintenance Information Screen:....................................... 508 i9 MENU SELECT........................................................................ 509 s1 SERVICE MENU....................................................................... 510 s2 COMPONENT CHECK MENU............................................................... 510 s21 ENGINE............................................................................ 511 s212 MACHINE TREND MENU (ENG.).................................................... 512 s213 FAULT CONDITION MENU (ENG.).................................................. 512 s2131 FAULT CONDITION (ENG.)...................................................... 513 s22 TRANSMISSION...................................................................... 514 s222 MACHINE TREND MENU (T/M)..................................................... 515 s2221 L/C ON/OFF COUNT............................................................ 515 s222E AB-USE COUNT................................................................ 516 s223 FAULT CONDITION MENU (T/M)................................................... 517 S2231 FAULT CONDITION (T/M)....................................................... 517 s23 BRAKE MENU........................................................................ 518 s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE).................................... 518 s233 FAULT CONDITION MENU (BRAKE)................................................. 519 s2331 FAULT CONDITION (BRAKE)..................................................... 519 s24 SUSPENSION MENU................................................................... 520 s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION)............................... 520 s242 FAULT CONDITION MENU (SUS)................................................... 521 s2421 FAULT CONDITION (SUS)....................................................... 521 s25 PMC MENU.......................................................................... 522 s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC)...................................... 522 s252 FAULT CONDITION MENU (PMC)................................................... 523 s2521 FAULT CONDITION (PMC)....................................................... 523 s26 ELECTRONIC DISPLAY PANEL MENU..................................................... 524 s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel)................. 524 s262 FAULT CONDITION MENU (ELE. DISPLAY PANEL).................................... 525 s2621 FAULT CONDITION (ELE. DISPLAY PANEL)........................................ 525 s27 PLM MENU.......................................................................... 526 s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM)...................................... 526 s272 CALIBRATION DATA............................................................. 527 s28 TMS MENU.......................................................................... 527 s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS)...................................... 528 s283 FAULT CONDITION MENU (TMS)................................................... 528 s2831 FAULT CONDITION (TMS)....................................................... 529 s3 MACHINE INFORMATION MENU........................................................... 529 s32-1/3 CONTROLLER INFORMATION.................................................... 531 SELECTOR SWITCH STATUS of the PMC................................................. 531 s32-2/3 CONTROLLER INFORMATION.................................................... 532 s32-3/3 CONTROLLER INFORMATION.................................................... 533 s33 OPTIONAL FUNCTION INFORMATION................................................. 533 s34 HISTORY OF USE.................................................................... 534 t1 PARAMETER SET MENU................................................................. 535 t2 TIME/DATE SET.................................................................. 535 t3 TRAVEL MODE MENU................................................................... 536 t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)................................ 536 t32 SPEED LIMITER................................................................. 537 t33 T/M MAX GEAR SELECT........................................................... 537 t34 T/M MAX GEAR SELECT (BODY UP)................................................. 538 t35 SUSPENSION MODE SET........................................................... 538 t4 PARAMETER UNIT SET............................................................. 539 t5 TMS SET MENU................................................................... 539 t51 TIRE PRESSURE LIMIT SET....................................................... 540 t52 TIRE TEMPERATURE LIMIT SET.................................................... 541 t53 CORRELATION CONSTANTS SET..................................................... 542 t54 TMS CLOCK SET................................................................. 543 t55 ID CODE SET................................................................... 544 SECTION D32 - DATA ACQUISITION DEVICE (DAD) - INDEX........................................... 545 DAD - DATA ACQUISITION DEVICE............................................................. 547 INTRODUCTION.......................................................................... 547 HARDWARE HOOKUP....................................................................... 547 SOFTWARE.............................................................................. 548 Installation Requirements......................................................... 548 Installing the Software........................................................... 548 Starting the Software Program..................................................... 548 Service Meters (SMR).............................................................. 548 Display Able/disable By Machine Status............................................ 549 Vehicle State..................................................................... 549 MAINTENANCE INFORMATION (SCREEN HIERARCHY)............................................ 549 Display Enable/Disable by Truck Model and Optional Equipment Status............... 553 SCREEN DATA........................................................................... 554 Real Time Data.................................................................... 554 Fault condition data.............................................................. 554 Snap-Shot Data.................................................................... 554 Transmission Snapshot Example..................................................... 555 Sample Snapshot Screens........................................................... 559 Machine Trend Data................................................................ 561 Machine Check..................................................................... 562 Machine Information............................................................... 562 Event Recorder.................................................................... 562 Parameter Set..................................................................... 562 SECTION D33 - DAD SCREEN DISPLAYS - INDEX..................................................... 563 DAD SCREEN DISPLAYS....................................................................... 565 PASSWORD INPUT........................................................................ 565 Changing the Password............................................................. 565 i3 MENU SELECT........................................................................ 565 s1 SERVICE MENU....................................................................... 566 s2 COMPONENT CHECK MENU............................................................... 566 s21 Engine........................................................................ 566 s21 CUMMINS ENG. MENU (for the CUMMINS engine).................................... 566 s21 KOMATSU ENG. MENU (for the KOMATSU engine).................................... 566 s22 TRANSMISSION.................................................................. 569 s23 BRAKE MENU.................................................................... 573 s24 SUSPENSION MENU............................................................... 576 s25 PMC MENU...................................................................... 578 s26 ELECTRONIC DISPLAY PANEL MENU................................................. 580 s27 PLM MENU...................................................................... 582 s28 TMS MENU...................................................................... 583 s3 MACHINE INFORMATION MENU........................................................... 586 s31 MACHINE INFORMATION MENU...................................................... 586 s32-1/3 CONTROLLER INFORMATION.................................................... 587 s32-2/3 CONTROLLER INFORMATION.................................................... 588 s32-3/3 CONTROLLER INFORMATION.................................................... 589 s33 OPTIONAL FUNCTION INFORMATION................................................. 589 s34 HISTORY OF USE................................................................ 590 t1 PARAMETER SET MENU................................................................. 591 t2 TIME/DATE SET...................................................................... 591 t3 TRAVEL MODE MENU................................................................... 592 t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)................................ 592 t32 SPEED LIMITER................................................................. 593 t33 T/M MAX GEAR SELECT........................................................... 593 t34 T/M MAX GEAR SELECT (BODY UP)................................................. 594 t35 SUSPENSION MODE SET........................................................... 594 t4 PARAMETER UNIT SET................................................................. 595 t5 TMS SET MENU....................................................................... 595 t51 TIRE PRESSURE LIMIT SET....................................................... 596 t52 TIRE TEMPERATURE LIMIT SET.................................................... 596 t53 CORRELATION CONSTANTS SET..................................................... 597 t54 TMS CLOCK SET................................................................. 597 t55 ID CODE SET................................................................... 598 SECTION D34 - REAL TIME DATA TABLES - INDEX................................................... 599 REAL TIME DATA TABLES..................................................................... 601 ACCESSING REAL TIME DATA SCREENS...................................................... 601 Real Time Data Screen Switches.................................................... 601 SECTION D35 - PAYLOAD METER II - INDEX........................................................ 611 GENERAL INFORMATION....................................................................... 613 Haul Cycles........................................................................... 613 LIGHTS, SWITCHES AND COMPONENTS........................................................... 614 TIPS FOR OPERATION........................................................................ 615 EXTERNAL DISPLAY LIGHTS................................................................... 615 THEORY OF OPERATION....................................................................... 616 Basic Description..................................................................... 616 Inclinometer.......................................................................... 616 Linkage Factor........................................................................ 616 Gain Factor........................................................................... 617 Brake Lock............................................................................ 617 Sources of Error...................................................................... 617 Typical Data From Service Check Mode.................................................. 617 Example Calculation of Payload........................................................ 618 Viewing Payload Calculation Inputs.................................................... 618 Checking the Gain..................................................................... 619 Adjusting the Gain.................................................................... 619 TYPES OF DATA STORED...................................................................... 620 Cycle Data............................................................................ 620 Engine ON/OFF Data.................................................................... 621 Fault Codes and Warning Data.......................................................... 621 Engine Operation...................................................................... 622 Total Payload and Total Number of Cycles.............................................. 622 Other Data............................................................................ 622 OPERATOR FUNCTIONS........................................................................ 623 Using the Operator Load Counter....................................................... 623 Viewing the Operator Load Counter..................................................... 623 Clearing the Operator Load Counter.................................................... 623 Dimming the Lights on the Display..................................................... 623 INITIAL SETUP OF PAYLOAD METER............................................................ 624 Switch Settings....................................................................... 624 Checking the Operator Check Mode...................................................... 625 Checking the Service Check Mode....................................................... 625 Checking the Gt setting:.............................................................. 626 Checking the Inclinometer Settings.................................................... 626 Calibrating a Truck................................................................... 626 DISPLAYS AT START-UP...................................................................... 627 Normal Operation...................................................................... 627 SETUP AND MAINTENANCE..................................................................... 628 Setting The Speed Limit............................................................... 628 Setting the Option Code............................................................... 628 Setting The Machine I.D. Code......................................................... 629 Setting The Operator I.D. Code........................................................ 629 Setting The Time and Date............................................................. 629 DOWNLOAD OF INFORMATION................................................................... 630 DISPLAY OF FAULT CODES.................................................................... 630 Monitoring Input Signals.............................................................. 634 Service Check Mode.................................................................... 634 UP FACTOR - PAYLOAD CALCULATION GAIN...................................................... 635 PL MODE -LOAD CALCULATION TIMING.......................................................... 635 FINAL GEAR RATIO SELECTION................................................................ 636 BATTERY REPLACEMENT PROCEDURE............................................................. 637 Replacing the Battery................................................................. 637 After Replacing the Battery........................................................... 638 SUSPENSION PRESSURE SENSOR................................................................ 638 Removal............................................................................... 638 Installation.......................................................................... 639 INCLINOMETER.............................................................................. 639 Removal............................................................................... 639 Installation.......................................................................... 639 Adjustment............................................................................ 639 PAYLOAD METER BACK PANEL.................................................................. 640 CONNECTIONS............................................................................... 641 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE............................................. 642 PAYLOAD CIRCUIT NUMBERS................................................................... 643 TROUBLESHOOTING........................................................................... 644 COMMON PROBLEMS....................................................................... 644 Suspension Charging............................................................... 644 Symptom Table..................................................................... 645 Missing Body-Up Signal............................................................ 645 Missing Speed Signal.............................................................. 646 F-18: Alternator R-Terminal, Oil Pressure Signals................................. 646 Shorted 18v Sensor Power Supply (930E)............................................ 646 FAULT TREE DIAGNOSIS.................................................................. 647 Payload Lights Won't Illuminate................................................... 647 Red, Amber or Green Payload Light Does Not Illuminate............................. 648 Cannot Download - PC Communications............................................... 649 PC Communications Configuration................................................... 650 F.CAL: Payload Meter Won't Calibrate.............................................. 651 F-20: Sensor Power Fault.......................................................... 652 F-21, F-25: Left Front Pressure Sensor............................................ 654 F-22, F-26: Right Front Pressure Sensor........................................... 654 F-23, F-27: Left Rear Pressure Sensor............................................. 654 F-24, F-28: Right Rear Pressure Sensor............................................ 654 F-31, F-32: Inclinometer.......................................................... 656 Body Up Input..................................................................... 658 Brake Lock Input.................................................................. 659 Speed Signal...................................................................... 660 Adjusting the Speed Sensor........................................................ 660 CONNECTORS AND PRESSURE SENSORS....................................................... 662 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM............................................... 665 Menu Functions........................................................................ 668 Using Scope........................................................................... 668 Log File Information.................................................................. 668 Connections to Payload Meter II™...................................................... 669 USING SCOPE............................................................................... 670 Monitoring Inputs Using Scope......................................................... 670 Monitoring Suspension Charging Using Scope............................................ 670 Pressure Sensor Dummy Loads........................................................... 673 GAIN ADJUSTMENT WORKSHEET................................................................. 674 SECTION F - TRANSMISSION / TORQUE CONVERTER - INDEX............................................... 675 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX........................................ 677 TORQUE CONVERTER AND TRANSMISSION......................................................... 679 TRANSMISSION.......................................................................... 679 TORQUE CONVERTER...................................................................... 680 MAIN RELIEF VALVE................................................................. 682 Function...................................................................... 682 Operation..................................................................... 682 TORQUE CONVERTER RELIEF VALVE..................................................... 682 Function...................................................................... 682 Operation..................................................................... 682 TORQUE CONVERTER REGULATOR VALVE.................................................. 684 Operation..................................................................... 684 LOCK-UP CLUTCH.................................................................... 685 Lock-up Clutch Accumulator.................................................... 685 HYDRAULIC PUMP.................................................................... 686 TORQUE CONVERTER STALL CHECK...................................................... 687 TRANSMISSION...................................................................... 688 LUBRICATION RELIEF VALVE.......................................................... 690 Function...................................................................... 690 TRANSMISSION CONTROL VALVE........................................................ 691 ELECTRONIC CONTROL MODULATION VALVE (ECMV)........................................ 693 Pressure Control Valve........................................................ 694 Flow Sensor Valve............................................................. 694 ECMV and Proportional Solenoid................................................ 694 ECMV and Fill Switch.......................................................... 694 ECMV Operation................................................................ 695 ECMV REPAIR PROCEDURE............................................................. 698 Filter Replacement Procedure.................................................. 698 ECMV Removal.................................................................. 699 Disassembly................................................................... 699 Assembly...................................................................... 700 TRANSMISSION FILTERS.............................................................. 702 Service....................................................................... 702 Installation.................................................................. 702 TRANSMISSION REMOVAL.............................................................. 703 TRANSMISSION INSTALLATION......................................................... 704 TRANSMISSION OIL LEVEL CHECK...................................................... 706 SECTION F3 - TRANSMISSION OIL COOLER AND STRAINERS - INDEX.................................... 707 TRANSMISSION OIL COOLER & STRAINERS....................................................... 709 TRANSMISSION OIL COOLER............................................................... 709 Removal and Installation.......................................................... 709 Repair............................................................................ 709 TRANSMISSION OIL STRAINER............................................................. 709 Removal........................................................................... 710 Inspection........................................................................ 710 Installation...................................................................... 710 SECTION F5 - DRIVE SHAFTS - INDEX............................................................. 711 DRIVE SHAFTS.............................................................................. 713 FRONT DRIVE SHAFT..................................................................... 713 Removal........................................................................... 713 Disassembly....................................................................... 713 Assembly.......................................................................... 714 Installation...................................................................... 714 FRONT DRIVE SHAFT ALIGNMENT....................................................... 715 REAR DRIVE SHAFT...................................................................... 718 Removal........................................................................... 718 Disassembly....................................................................... 718 Assembly.......................................................................... 719 Installation...................................................................... 719 SECTION F6 - TRANSMISSION ELECTRICAL - INDEX.................................................. 721 TRANSMISSION ELECTRICAL................................................................... 723 TRANSMISSION SHIFT CONTROLLER......................................................... 724 Event Memory...................................................................... 724 Fault History Data................................................................ 724 Snap-Shot Data.................................................................... 724 Trend Data........................................................................ 725 TRANSMISSION RANGE SELECTOR........................................................... 726 SENSORS AND SWITCHES.................................................................. 727 Transmission Speed Sensors........................................................ 727 Adjustment Procedure.............................................................. 727 Fill Switch....................................................................... 728 Shift Limit Switch................................................................ 728 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING..................................... 729 Preliminary Checks................................................................ 729 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX............................................... 733 SECTION G2 - TIRES AND RIMS - INDEX........................................................... 735 TIRES AND RIMS............................................................................ 737 GENERAL INFORMATION................................................................... 737 FRONT TIRES AND RIMS.................................................................. 738 Removal........................................................................... 738 Installation...................................................................... 739 REAR TIRE AND RIM..................................................................... 739 Removal........................................................................... 739 Installation...................................................................... 740 TIRE MATCHING......................................................................... 741 RIM................................................................................... 742 Tire Removal From Rim............................................................. 742 Tire Installation On Rim.......................................................... 742 FRONT WHEEL STUD INSTALLATION......................................................... 743 REAR WHEEL STUD INSTALLATION.......................................................... 744 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX.............................................. 745 FRONT WHEEL HUB AND SPINDLE............................................................... 747 OIL SAMPLE ANALYSIS................................................................... 747 Oil Sampling Guidelines........................................................... 747 Guidelines For Obtaining A Sample................................................. 747 FRONT WHEEL HUB....................................................................... 748 Removal........................................................................... 748 Disassembly....................................................................... 748 Inspection........................................................................ 748 Assembly and Installation......................................................... 749 Front Wheel Hub Bearing Adjustment................................................ 751 FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION.......................................... 751 SUSPENSION A-ARM...................................................................... 751 Removal........................................................................... 751 Inspection of Parts............................................................... 752 Installation...................................................................... 752 CENTER TIE ROD PIVOT.................................................................. 753 Removal........................................................................... 753 Inspection........................................................................ 753 Installation...................................................................... 753 TOE IN ADJUSTMENT..................................................................... 754 Adjustment Procedure.............................................................. 754 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX.................................................... 757 REAR AXLE ATTACHMENTS..................................................................... 759 CENTER LINK AND LOWER LINKS........................................................... 759 Removal........................................................................... 759 Inspection........................................................................ 760 Spherical Bearing Replacement..................................................... 760 Installation...................................................................... 760 PANHARD ROD (DIAGONAL LINK)........................................................... 761 Removal........................................................................... 761 Inspection........................................................................ 762 Installation...................................................................... 762 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX....................................... 763 REAR AXLE & FINAL DRIVE ASSEMBLY.......................................................... 765 DIFFERENTIAL OPERATION................................................................ 765 Straight-away-travel.............................................................. 765 Turning........................................................................... 765 REAR AXLE ASSEMBLY................................................................ 766 Removal....................................................................... 766 Installation.................................................................. 766 DIFFERENTIAL OIL LEVEL CHECK...................................................... 767 DIFFERENTIAL ASSEMBLY............................................................. 768 Removal....................................................................... 768 Installation.................................................................. 769 Disassembly................................................................... 769 Pinion Carrier Assembly....................................................... 772 Differential Gear Unit........................................................ 772 Differential Gear Unit........................................................ 773 Assembly...................................................................... 776 Differential Bearing.......................................................... 776 Assembly Of Differential Gear Assembly........................................ 776 Installation Of Differential Assembly......................................... 778 Input Pinion and Carrier Assembly............................................. 779 Adjusting Tooth Contact, Backlash............................................. 783 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX................................... 787 FINAL DRIVE PLANETARIES AND WHEEL HUBS.................................................... 789 FINAL DRIVE........................................................................... 789 Oil Level Check................................................................... 790 FINAL DRIVE CARRIER ASSEMBLY...................................................... 790 Removal....................................................................... 790 Installation.................................................................. 791 Disassembly................................................................... 791 Assembly...................................................................... 792 FINAL DRIVE ASSEMBLY.............................................................. 793 Disassembly................................................................... 793 Assembly...................................................................... 795 SECTION H - SUSPENSIONS - INDEX................................................................... 797 SECTION H2 - FRONT SUSPENSION - INDEX......................................................... 799 FRONT SUSPENSION.......................................................................... 801 FRONT SUSPENSION ASSEMBLY............................................................. 801 Suspension Operation.............................................................. 802 3-MODE SUSPENSION (Optional).......................................................... 803 Variable Damping Operation........................................................ 803 3-Mode Suspension System Components............................................... 804 Automatic Suspension Controller................................................... 804 Manifold Valve.................................................................... 804 Actuator.......................................................................... 805 Steering Sensor................................................................... 805 Suspension Removal................................................................ 806 Suspension Installation........................................................... 807 Disassembly....................................................................... 808 Inspection........................................................................ 808 Assembly.......................................................................... 808 DAMPING VALVE REPAIR.................................................................. 810 Damping Valve (Fixed Rate)........................................................ 810 Disassembly....................................................................... 810 Assembly.......................................................................... 810 Damping Valve/Actuator............................................................ 811 (3-Mode Damping Rate)............................................................. 811 Cleaning and Inspection........................................................... 811 Assembly.......................................................................... 811 SECTION H3 - REAR SUSPENSION - INDEX.......................................................... 813 REAR SUSPENSION........................................................................... 815 OPERATION............................................................................. 816 Removal........................................................................... 817 Installation...................................................................... 817 Disassembly....................................................................... 817 Assembly.......................................................................... 819 SPHERICAL BEARINGS.................................................................... 820 Removal........................................................................... 820 Inspection........................................................................ 820 Installation...................................................................... 820 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX........................................... 821 SUSPENSION OILING AND CHARGING............................................................ 823 GENERAL INFORMATION................................................................... 823 Equipment List.................................................................... 823 FRONT SUSPENSION...................................................................... 825 Front Suspension Oiling........................................................... 825 Front Suspension Nitrogen Charging................................................ 828 REAR SUSPENSION....................................................................... 830 General Information............................................................... 830 Rear Suspension Oiling............................................................ 831 Rear Suspension Nitrogen Charging................................................. 834 Length Adjustment - Front And Rear Cylinders...................................... 835 SECTION J - BRAKE SYSTEM - INDEX.................................................................. 837 SECTION J2 - BRAKE CIRCUIT - INDEX............................................................ 839 BRAKE CIRCUIT............................................................................. 841 SERVICE BRAKE CIRCUIT................................................................. 841 SECONDARY BRAKING AND AUTOMATIC APPLY................................................. 843 PARKING BRAKE CIRCUIT................................................................. 843 Normal Operation.................................................................. 843 BRAKE LOCK CIRCUIT.................................................................... 844 AUXILIARY CIRCUIT..................................................................... 844 RETARDING CIRCUIT..................................................................... 844 WARNING CIRCUIT....................................................................... 844 BRAKE SYSTEM ELECTRICAL COMPONENTS.................................................... 845 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX.......................................... 849 BRAKE CIRCUIT COMPONENT SERVICE........................................................... 851 BRAKE VALVE........................................................................... 851 Rebuild Criteria.................................................................. 851 Removal........................................................................... 852 Installation...................................................................... 852 Disassembly....................................................................... 853 Cleaning and Inspection........................................................... 854 Assembly.......................................................................... 856 Actuator Base Threaded Inserts.................................................... 856 Boot and Cap...................................................................... 856 Valve Body Seal Installation...................................................... 856 Regulator Sleeve O-Ring Installation.............................................. 856 Actuator Plunger O-ring Installation.............................................. 857 Assembly of Valve................................................................. 857 DIFFERENTIAL PRESSURE SWITCH.......................................................... 859 Disassembly....................................................................... 859 Cleaning and Inspection........................................................... 859 Assembly.......................................................................... 859 VALVE BENCH TEST AND ADJUSTMENT....................................................... 860 Test Bench Only................................................................... 861 Test Set Up Procedure............................................................. 861 Brake Valve Output Pressure Adjustment............................................ 861 Differential Pressure Switch Adjustment........................................... 862 Final Test and Adjustment......................................................... 862 Proximity Switch Installation and Adjustment...................................... 863 Installation Of Brake Pedal Actuator Assembly to Brake Valve...................... 864 RELAY VALVES.......................................................................... 865 Removal........................................................................... 865 Installation...................................................................... 865 Disassembly....................................................................... 866 Cleaning and Inspection........................................................... 867 Assembly.......................................................................... 867 VALVE TEST AND ADJUSTMENT............................................................. 868 Test Set Up Procedure............................................................. 869 Relay Valve........................................................................... 869 Output Pressure Adjustment........................................................ 869 HYDRAULIC BRAKE ACCUMULATORS.......................................................... 870 Brake Accumulator Bleed Down Procedure............................................ 870 BRAKE ACCUMULATOR CHARGING PROCEDURE.................................................. 871 BRAKE ACCUMULATOR REBUILD............................................................. 872 Removal........................................................................... 872 Installation...................................................................... 872 Disassembly....................................................................... 872 Cleaning and Inspection........................................................... 872 Assembly.......................................................................... 873 Testing........................................................................... 874 Storage........................................................................... 874 BRAKE COOLING VALVE (BCV)............................................................. 875 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................... 876 Removal............................................................................... 876 Installation.......................................................................... 876 Disassembly and Adjustment............................................................ 878 Potentiometer Check................................................................... 878 Assembly.............................................................................. 879 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX................................................... 881 BRAKE CIRCUIT CHECK-OUT PROCEDURE......................................................... 883 EQUIPMENT REQUIRED.................................................................... 886 Preparation....................................................................... 886 BRAKE SYSTEM CHECKOUT................................................................. 888 Failure Modes Check-Out........................................................... 889 RCM Calibration Check............................................................. 891 RCM Calibration Procedure......................................................... 892 Preparation....................................................................... 892 How to Perform Calibration........................................................ 893 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................. 895 KOMATSU CHECK-OUT PROCEDURE............................................................... 899 HYDRAULIC BRAKE SYSTEM DATA SHEET......................................................... 899 KOMATSU CHECK-OUT PROCEDURE............................................................... 900 HYDRAULIC BRAKE SYSTEM DATA SHEET......................................................... 900 SECTION J5 - FRONT WET DISC BRAKES - INDEX.................................................... 909 FRONT WET DISC BRAKES..................................................................... 911 DESCRIPTION........................................................................... 911 FRONT DISC BRAKE ASSEMBLY............................................................. 912 Removal........................................................................... 912 Installation...................................................................... 913 BRAKE ASSEMBLY REBUILD................................................................ 913 DISC BRAKE MAINTENANCE................................................................ 913 Brake Disc Wear Indicator......................................................... 913 Checking Disc Wear................................................................ 914 WEAR INDICATOR SENSOR................................................................. 915 SPEED SENSOR.......................................................................... 915 WET DISC BRAKE BLEEDING PROCEDURE..................................................... 915 SECTION J6 - REAR WET DISC BRAKES - INDEX..................................................... 917 REAR WET DISC BRAKES...................................................................... 919 DESCRIPTION........................................................................... 919 Operation......................................................................... 919 MAINTENANCE........................................................................... 920 Brake Disc Wear Indicator......................................................... 920 Checking Disc Wear................................................................ 920 Wear Indicator Sensor............................................................. 921 Brake Assembly Removal............................................................ 922 Brake Assembly Installation....................................................... 923 BRAKE ASSEMBLY REBUILD................................................................ 924 Disassembly....................................................................... 924 Cleaning and Inspection........................................................... 925 Assembly.......................................................................... 926 Floating Ring Seal Assembly/Installation.......................................... 928 Alternate Procedure:.............................................................. 929 SECTION J7 - PARKING BRAKE - INDEX............................................................ 931 PARKING BRAKE............................................................................. 932 Description........................................................................... 933 Parking Brake Service Criteria........................................................ 933 Removal............................................................................... 934 Installation.......................................................................... 934 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................. 936 Removal........................................................................... 936 Installation...................................................................... 936 AUTOMATIC SLACK ADJUSTER.............................................................. 936 Adjustment Procedure.............................................................. 936 PARKING BRAKE CHECK-OUT............................................................... 937 SECTION L - HYDRAULIC SYSTEM - INDEX.............................................................. 939 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX................................................ 941 HYDRAULIC SYSTEM OVERVIEW................................................................. 943 HYDRAULIC SYSTEM DESCRIPTION.......................................................... 943 Hydraulic Tank.................................................................... 943 Bleed-down Manifold............................................................... 944 Hoist Valve....................................................................... 945 Hoist Pump........................................................................ 945 Brake Cooling Pump................................................................ 945 Brake Control Valve (BCV)......................................................... 945 High Pressure Filter.............................................................. 946 Low pressure Filter............................................................... 946 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX........................................ 947 HYDRAULIC COMPONENT REPAIR................................................................ 949 HYDRAULIC TANK........................................................................ 949 FILLING INSTRUCTIONS.............................................................. 949 MAINTENANCE....................................................................... 949 Removal....................................................................... 950 Installation.................................................................. 952 Gap Measurement - Hydraulic Tank Mounting..................................... 952 STRAINERS AND DIFFUSERS........................................................... 953 Removal....................................................................... 953 Cleaning and Inspection....................................................... 953 Installation.................................................................. 954 HYDRAULIC TANK BREATHER............................................................... 954 Service........................................................................... 955 HYDRAULIC SYSTEM FLUSHING............................................................. 955 HYDRAULIC PUMPS....................................................................... 956 Removal........................................................................... 956 Installation...................................................................... 957 PUMP REBUILD...................................................................... 958 Disassembly................................................................... 958 Inspection Of Parts........................................................... 961 Assembly...................................................................... 961 Bearing Replacement........................................................... 964 Seal Replacement.............................................................. 964 TROUBLESHOOTING GUIDE............................................................. 967 SECTION L4 - STEERING CIRCUIT - INDEX......................................................... 969 STEERING CIRCUIT.......................................................................... 971 OPERATION............................................................................. 971 COMPONENT DESCRIPTION................................................................. 971 Steering Control Valve............................................................ 971 Bleed-down Manifold............................................................... 971 Bleed-down Solenoid............................................................... 972 Accumulators...................................................................... 972 Flow Amplifier.................................................................... 973 High Pressure Filter.............................................................. 973 Warning Devices................................................................... 973 FLOW AMPLIFIER OPERATION.............................................................. 975 STEERING/BRAKE PUMP................................................................... 983 COMPONENTS........................................................................ 983 OPERATION......................................................................... 985 SECTION L5 - STEERING CONTROL UNIT - INDEX.................................................... 987 STEERING CONTROL UNIT..................................................................... 989 Removal............................................................................... 989 Installation.......................................................................... 989 REBUILD PROCEDURE..................................................................... 990 Disassembly....................................................................... 991 Cleaning and Inspection........................................................... 992 Assembly.......................................................................... 994 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX........................................ 999 STEERING CIRCUIT COMPONENT REPAIR.........................................................1001 BLEED-DOWN MANIFOLD...................................................................1001 Removal...........................................................................1001 Adjusting Relief Valve............................................................1001 Testing and Adjustment............................................................1002 FLOW AMPLIFIER....................................................................1003 Removal.......................................................................1003 Installation..................................................................1003 Disassembly...................................................................1003 Assembly......................................................................1006 ACCUMULATORS......................................................................1007 Removal.......................................................................1007 Installation..................................................................1007 Disassembly...................................................................1008 Cleaning and Inspection.......................................................1009 Assembly......................................................................1009 Testing.......................................................................1010 STEERING ACCUMULATOR CHARGING PROCEDURE...........................................1010 STEERING CYLINDER.................................................................1011 Removal.......................................................................1011 Installation..................................................................1012 STEERING CYLINDER REBUILD.........................................................1013 Disassembly...................................................................1013 Cleaning and Inspection.......................................................1013 Assembly......................................................................1014 STEERING/BRAKE PUMP...............................................................1014 Removal.......................................................................1014 Installation..................................................................1015 PUMP REBUILD......................................................................1016 Disassembly...................................................................1016 Control Group.................................................................1017 Valve Plate Group.............................................................1018 Rotating Group................................................................1018 Drive Shaft Group.............................................................1019 Swashblock Group..............................................................1019 Inspection....................................................................1019 Control Group.................................................................1019 Valve Plate Group.............................................................1020 Rotating Group................................................................1020 Swashblock Group..............................................................1021 Drive Shaft Group.............................................................1021 Assembly......................................................................1021 Swashblock Group..............................................................1021 Drive Shaft Group.............................................................1022 Rotating Group................................................................1022 Valve Plate Group.............................................................1023 Control Group.................................................................1024 STEERING CIRCUIT FILTER...........................................................1025 Removal.......................................................................1025 Installation..................................................................1025 TROUBLESHOOTING CHART.....................................................................1026 SECTION L7 - HOIST CIRCUIT - INDEX............................................................1029 HOIST CIRCUIT.............................................................................1031 HOIST CIRCUIT OPERATION...............................................................1031 COMPONENT DESCRIPTION.............................................................1032 Hydraulic Tank................................................................1032 Hoist Pump....................................................................1032 Hoist Valve...................................................................1032 Hoist Pilot Valve.............................................................1033 Power Up Limit Solenoid.......................................................1034 Pilot Operated Check Valve....................................................1034 Power Down Spool Limit Solenoid...............................................1034 HOIST CIRCUIT OPERATION...........................................................1034 POWER UP Operation............................................................1036 HOLD Operation................................................................1038 POWER DOWN Operation..........................................................1040 FLOAT Operation...............................................................1042 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX...........................................1045 HOIST CIRCUIT COMPONENT REPAIR............................................................1047 HOIST VALVE...........................................................................1047 Removal...........................................................................1047 Installation......................................................................1047 O-Ring Replacement................................................................1048 INLET SECTION.....................................................................1049 Disassembly...................................................................1049 Cleaning and Inspection.......................................................1050 Assembly......................................................................1050 SPOOL SECTION.....................................................................1050 Disassembly...................................................................1050 Cleaning and Inspection.......................................................1051 Assembly......................................................................1053 HOIST PILOT VALVE.....................................................................1054 Removal...........................................................................1054 Installation......................................................................1054 Disassembly.......................................................................1055 Cleaning and Inspection...........................................................1056 Reassembly........................................................................1056 HOIST CYLINDERS.......................................................................1057 Removal...........................................................................1057 Installation......................................................................1059 Disassembly.......................................................................1059 Cleaning and Inspection...........................................................1061 Assembly - Quill And Cylinder.....................................................1062 Quill Installation................................................................1062 Installation Of Check Balls And Plugs In Quill....................................1063 Assembly of Cylinder..............................................................1064 POWER UP SPOOL LIMIT SOLENOID.........................................................1065 PILOT OPERATED CHECK VALVE............................................................1065 POWER DOWN HOIST LIMIT SOLENOID.......................................................1065 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX.................................................1067 HYDRAULIC SYSTEM FILTERS..................................................................1069 HIGH PRESSURE FILTER..................................................................1069 Removal...........................................................................1069 Installation......................................................................1070 LOW PRESSURE FILTERS..................................................................1070 BRAKE COOLING & HOIST FILTERS.....................................................1070 TRANSMISSION FILTER...............................................................1070 Removal.......................................................................1071 Installation..................................................................1071 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX...........................................1073 HYDRAULIC CHECK-OUT PROCEDURE.............................................................1075 GENERAL INFORMATION...................................................................1075 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.....................................1075 Equipment Requirements............................................................1076 Pump Pressure Control Adjustment..................................................1076 Steering Components Leakage Test..................................................1078 CHECKING HOIST SYSTEM PRESSURES.......................................................1079 Equipment Requirements............................................................1079 Power Down Relief Valve Adjustment................................................1080 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX.....................................................1081 SPECIAL TOOLS.................................................................................1083 SECTION N - OPERATOR CAB - INDEX..................................................................1087 SECTION N2 - OPERATOR CAB - INDEX.............................................................1089 OPERATOR CAB..............................................................................1091 Removal...............................................................................1092 Installation..........................................................................1094 CAB DOORS.............................................................................1094 Removal...........................................................................1094 Installation......................................................................1095 Door Striker Adjustment...........................................................1095 Door Handle Plunger Adjustment....................................................1096 DOOR PANEL........................................................................1097 Removal.......................................................................1097 Installation..................................................................1097 DOOR WINDOW.......................................................................1098 Removal.......................................................................1098 Installation..................................................................1100 WINDOW REGULATOR..................................................................1102 Removal.......................................................................1102 Installation..................................................................1102 DOOR HANDLE AND DOOR LATCH........................................................1102 Removal.......................................................................1102 Installation..................................................................1102 DOOR SEALS............................................................................1103 Removal...........................................................................1103 Installation......................................................................1103 DOOR OPENING SEAL.....................................................................1103 Removal...........................................................................1103 Installation......................................................................1103 GLASS REPLACEMENT.....................................................................1104 Replacement.......................................................................1104 REAR GLASS........................................................................1106 Removal.......................................................................1106 Installation..................................................................1106 SECTION N3 - CAB COMPONENTS - INDEX...........................................................1107 CAB COMPONENTS............................................................................1109 WINDSHIELD WIPERS.....................................................................1109 WIPER MOTOR.......................................................................1109 Removal.......................................................................1109 Installation..................................................................1109 WIPER ARM.........................................................................1109 Removal.......................................................................1109 Installation..................................................................1110 WIPER LINKAGE.....................................................................1110 Removal.......................................................................1110 Installation..................................................................1111 WINDSHIELD WASHER.................................................................1111 Operation.....................................................................1111 Service.......................................................................1111 OPERATOR SEAT.....................................................................1112 Adjustment....................................................................1112 Seat Removal..................................................................1113 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX.............................................1115 HEATING AND AIR CONDITIONING..............................................................1117 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.....................................1117 HEATER/AIR CONDITIONER................................................................1118 Operation.........................................................................1118 HEATER COMPONENTS.....................................................................1118 Circuit Breaker...................................................................1118 D/C - D/C Converter...............................................................1119 Flapper Door Motors...............................................................1119 Temperature Control Potentiometer.................................................1119 Motorized Coolant Control Valve...................................................1119 Heater Coil.......................................................................1119 Fan Motor and Speed Control.......................................................1119 Test..............................................................................1119 FILTER................................................................................1119 Service...........................................................................1119 AIR CONDITIONING SYSTEM...................................................................1122 Environmental Impact..................................................................1122 OPERATOR CAB AIR CONDITIONING.........................................................1123 PRINCIPLES OF REFRIGERATION...........................................................1123 Air Conditioning..................................................................1123 Refrigeration - The Act Of Cooling................................................1124 The Refrigeration Cycle...........................................................1124 AIR CONDITIONER SYSTEM COMPONENTS.....................................................1125 Compressor (Refrigerant Pump).....................................................1125 Service Valves....................................................................1125 Condenser.........................................................................1125 Receiver-Drier....................................................................1125 Expansion Block Valve.............................................................1126 Evaporator........................................................................1126 ELECTRICAL CIRCUIT....................................................................1127 Thermostat........................................................................1127 Compressor Clutch.................................................................1127 Trinary™ Switch...................................................................1128 SYSTEM SERVICING......................................................................1129 SYSTEM OIL............................................................................1130 Handling and Reusing PAG Oil......................................................1130 Oil Quantity......................................................................1130 Replacing Oil After Servicing the System..........................................1130 Setting Up a New Compressor.......................................................1130 REFRIGERANT...........................................................................1131 Recycled Refrigerant..............................................................1131 Reclaimed Refrigerant.............................................................1131 Refrigerant Quantity..............................................................1131 R-134a Refrigerant Containers.....................................................1131 SERVICE TOOLS AND EQUIPMENT...........................................................1132 Recovery/Recycle Station..........................................................1132 Leak Detector.....................................................................1132 Service Valves....................................................................1133 Vacuum Pump.......................................................................1133 Manifold Gauge Set................................................................1134 Installing Manifold Gauge Set.....................................................1135 Purging Air From Service Hoses....................................................1136 Stabilizing the AC System.........................................................1137 SYSTEM PERFORMANCE TEST...............................................................1137 SYSTEM LEAK TESTING...................................................................1138 Electronic leak detector..........................................................1138 Tracer dyes.......................................................................1138 Soap and water....................................................................1138 A/C DRIVE BELT CHECKOUT PROCEDURE.....................................................1139 Pulley Alignment..................................................................1139 Belt Tension Check................................................................1139 SYSTEM REPAIR.........................................................................1141 System Cleaning...................................................................1141 Hoses and Fittings................................................................1141 Lines.............................................................................1141 Expansion Valve...................................................................1141 Receiver-Drier....................................................................1142 Thermostat........................................................................1142 Compressor........................................................................1142 Clutch............................................................................1142 Servicing the Compressor Clutch...................................................1143 Pulley Removal....................................................................1145 Clutch Coil Check.................................................................1145 Pulley Installation...............................................................1145 Clutch Assembly Installation......................................................1146 RECOVERING AND RECYCLING THE REFRIGERANT..............................................1147 Performing the Recovery Cycle.....................................................1147 Performing the Recycling Procedure................................................1147 Evacuating and Charging the AC System.............................................1147 EVACUATING THE SYSTEM.................................................................1148 CHARGING THE AC SYSTEM................................................................1149 TROUBLESHOOTING...........................................................................1150 Pre-Diagnosis Checks..................................................................1150 Preparing For Diagnosis...............................................................1150 Preliminary Steps.....................................................................1150 System Performance Test...............................................................1150 Diagnosis Of Gauge Readings And System Performance....................................1151 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS............................................1152 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM...........................................1158 SECTION N5 - OPERATOR CAB & CONTROLS - INDEX..................................................1159 OPERATOR CAB AND CONTROLS.................................................................1161 STEERING WHEEL AND CONTROLS...........................................................1162 Horn Button.......................................................................1162 Telescope Lock Ring...............................................................1162 Tilt Wheel Lever..................................................................1162 Turn Signal / Headlight Dimmer....................................................1162 Windshield Wiper / Washer Control.................................................1163 RETARDER CONTROL LEVER................................................................1163 STEERING WHEEL........................................................................1163 Removal...........................................................................1163 Installation......................................................................1164 SERVICE BRAKE PEDAL...................................................................1164 ACCELERATOR PEDAL.....................................................................1164 INSTRUMENT PANEL......................................................................1165 RETARDING CAPACITY CHART..............................................................1165 Radio Speakers....................................................................1166 MOM Display Screen................................................................1166 MOM Dimmer Switch.................................................................1166 Warning Alarm Buzzer..............................................................1166 Cab Radio.........................................................................1166 PMC Interface Connector...........................................................1166 Air Cleaner Vacuum Gauges.........................................................1166 Payload Meter.....................................................................1166 Windshield Wipers.................................................................1166 CENTER CONSOLE........................................................................1167 Transmission Range Selector.......................................................1168 Control Switches..................................................................1169 Shift Limiter Switch..............................................................1169 F1 Start Switch...................................................................1169 Hoist Control Lever...............................................................1169 Parking Brake Switch..............................................................1169 Brake Lock Switch.................................................................1169 LH Window Control Switch..........................................................1170 RH Window Control Switch..........................................................1170 Ash Tray..........................................................................1170 Lighter...........................................................................1170 Passenger Seat w/Safety Belt......................................................1170 INSTRUMENT PANEL AND INDICATORS...........................................................1171 Keyswitch.............................................................................1172 Auxiliary Brake Switch................................................................1172 RH Control/Indicator Panel (Pod)......................................................1173 Center Display Panel..................................................................1173 LH Control/Indicator Panel (Pod)......................................................1173 Ladder Light Switch...................................................................1173 Head Light Switch.....................................................................1173 BackUp/Deck Lights Switch.............................................................1173 RH Control/Indicator Panel (Pod)......................................................1174 Cold Weather Starting Aid (Ether Injection) Switch....................................1174 Hazard Warning Lights Switch..........................................................1174 Automatic Idle Selector Switch (AISS).................................................1175 Air Conditioner & Heater Vent.........................................................1175 ASR Cut (Traction Control) Switch (Option)............................................1175 Center Display Panel..................................................................1176 Air Pressure Monitor (Not Used).......................................................1177 Air Pressure Gauge (Not Used).........................................................1177 Coolant Temperature Monitor...........................................................1177 Engine Cooling Water Temperature Gauge................................................1177 Torque Converter Oil Temperature Monitor..............................................1177 Torque Converter Oil Temperature Gauge................................................1177 Retarder Oil Temperature Monitor......................................................1177 Retarder Oil Temperature Gauge........................................................1177 Left Turn Signal Pilot Lamp...........................................................1178 High Beam Pilot Lamp..................................................................1178 Right Turn Signal Pilot Lamp..........................................................1178 Speedometer...........................................................................1178 Tachometer............................................................................1178 Lock-up Pilot Lamp....................................................................1178 Shift Limiter Pilot Lamp..............................................................1178 Shift Indicator.......................................................................1178 Transmission Shift Position Pilot Lamp................................................1178 Engine Controller Monitor.............................................................1178 Automatic Transmission Mechatronics Monitor...........................................1178 Other Mechatronics Monitor (Optional).................................................1179 Fuel Level Monitor....................................................................1179 Fuel Gauge............................................................................1179 Engine Power Derate Monitor...........................................................1179 F1 Start Monitor......................................................................1179 Auto Cruise Control (Not Used)........................................................1179 ASR Monitor (Optional)................................................................1179 ABS Monitor (Not Used)................................................................1179 Service Meter.........................................................................1179 Odometer..............................................................................1179 LH Control/Indicator Panel (Pod)......................................................1180 LH Panel/Pod Assembly.................................................................1180 Engine Oil Temperature................................................................1180 Engine Coolant Level..................................................................1180 Low Steering Pressure.................................................................1180 Accumulator Pre-Charge................................................................1180 Battery Charge Amps...................................................................1181 Check Engine..........................................................................1181 Parking Brake.........................................................................1181 Body Float............................................................................1181 Transmission Oil Temperature..........................................................1181 Service Brakes Applied................................................................1181 Maintenance Monitor...................................................................1181 Transmission Oil Filters..............................................................1181 Lamp Test.............................................................................1182 Low Brake Pressure....................................................................1182 Lateral Slope Warning.................................................................1182 Crankcase Pressure....................................................................1182 Panel Dimmer Switch...................................................................1182 Engine Oil Pressure...................................................................1182 Central Warning Lamp..................................................................1183 AC/Heater Vent........................................................................1183 REAR OF OPERATOR CAB..................................................................1183 QUANTUM™ FUEL SYSTEM DIAGNOSTICS......................................................1185 Determining Fault Codes...........................................................1185 Exiting The Diagnostics Mode......................................................1186 SECTION P - LUBRICATION AND SERVICE - INDEX.......................................................1187 SECTION P2 - LUBRICATION AND SERVICE - INDEX..................................................1189 LUBRICATION AND SERVICE...................................................................1191 10 HOUR (DAILY) INSPECTION............................................................1193 250 HOUR INSPECTION...................................................................1195 500 HOUR INSPECTION...................................................................1197 1000 HOUR INSPECTION..................................................................1198 2000 HOUR INSPECTION..................................................................1199 5000 HOUR INSPECTION..................................................................1200 SECTION P3 - AUTOMATIC LUBRICATION SYSTEM - INDEX.............................................1201 LINCOLN AUTOMATIC LUBRICATION SYSTEM......................................................1203 SYSTEM COMPONENTS.....................................................................1203 System Operation..................................................................1206 System Priming....................................................................1207 System Checkout...................................................................1207 Pressure Reducer Adjustment.......................................................1207 24 VDC Solid State Timer Check....................................................1208 24 VDC Solid State Timer Adjustment...............................................1209 INJECTORS (SL-1 Series "H")...........................................................1210 Injector Specifications...........................................................1210 Injector Adjustment...............................................................1210 INJECTOR OPERATION....................................................................1211 PUMP CYCLE TIMER (FLASHER TIMER)......................................................1212 Pump Cycle Timer (Flasher Timer) Installation.....................................1212 Pump Cycle Timer (Flasher Timer) Adjustment:......................................1212 TROUBLESHOOTING CHART.....................................................................1214 RESERVOIR FILL PROCEDURE..............................................................1216 Lubricant Required for System.....................................................1216 Fill Procedure....................................................................1216 Preventive Maintenance Procedures.........................................................1217 Daily Lubrication System Inspection...................................................1217 250 Hour Inspection...................................................................1217 SECTION R.............................................................................1219 SECTION R - SYSTEM SCHEMATICS - INDEX.............................................................1219 HYDRAULIC SYSTEM SCHEMATIC....................................................................1221 HYDRAULIC BRAKE SCHEMATIC ....................................................................1222 ELECTRICAL WIRING SCHEMATIC...................................................................1223
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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