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Komatsu HD1500-5 Dump Truck Shop Manual SN A30079 & UP – PDF DOWNLOAD
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Komatsu HD1500-5 Dump Truck Shop Manual
Book Code: CEBM014402
SERIAL NUMBERS A30079 & UP
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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: A30079 & UP
Language: English
Book Code: CEBM014402
Pages: 1219
File Format: Portable Document Format (PDF)
KOMATSU HD1500-5 DUMP TRUCK SHOP MANUAL SN A30079 & UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HD1500-5 Dump Truck Shop Manual
FOREWORD:
This manual is written for use by the operator and/or the service technician and is designed to help these persons to become fully knowledgeable of the truck and all its systems in order to keep it operating safely and efficiently. All operators and maintenance personnel must understand the content in this manual before maintaining or performing operational checks on the truck. All safety notices, warnings and cautions must be understood before repairing the truck.
- This manual shows dimensioning of metric and (U.S. standard) units throughout. All references to right, left, front, or rear are made with respect to the operator’s normal seated position, unless specifically stated otherwise.
- Standard torque requirements are shown in torque charts in the Introduction section and individual torques are provided in the text in bold face type, such as 135 N·m (100 ft lb). All torque specifications have ±10% tolerance unless otherwise specified.
- The illustrations used in this manual are typical of the component shown and may not be an exact reproduction of what is found on the truck. A product identification plate is located on the frame in front of the right side front wheel and designates the truck model number, product identification number (vehicle serial number), and maximum Gross Vehicle Weight (GVW) rating.
- The product identification number (vehicle serial number) contains information which will identify the original manufacturing bill of material for this unit. This complete number will be necessary for proper ordering of many service parts and/or warranty consideration.
TABLE OF CONTENTS:
Komatsu HD1500-5 Dump Truck Shop Manual
COVER ............................................................................................ 1 FOREWORD.......................................................................................... 4 TABLE OF CONTENTS................................................................................. 6 SECTION A GENERAL INFORMATION INDEX............................................................... 8 SECTION A2 - MAJOR COMPONENTS AND SPECIFICATIONS............................................. 10 SECTION A3 - SAFETY & OPERATING INSTRUCTIONS - INDEX ........................................ 14 SAFETY.................................................................................... 16 Safety Rules.......................................................................... 16 Safety Features....................................................................... 16 Clothing And Personal Items........................................................... 16 Unauthorized Modification............................................................. 16 Leaving The Operator’s Seat........................................................... 16 Mounting And Dismounting.............................................................. 17 Fire Prevention For Fuel And Oil...................................................... 17 Precautions With High Temperature Fluids.............................................. 17 Asbestos Dust Hazard Prevention....................................................... 18 Prevention Of Injury By Work Equipment................................................ 18 Fire Extinguisher And First Aid Kit................................................... 18 Precautions For ROPS.................................................................. 18 Precautions For Attachments........................................................... 18 PRECAUTIONS DURING OPERATION.............................................................. 19 Safety Is Thinking Ahead.............................................................. 19 BEFORE STARTING THE ENGINE............................................................ 19 Safety At The Work Site........................................................... 19 Fire Prevention................................................................... 19 Preparing For Operation........................................................... 19 Ventilation In Enclosed Areas..................................................... 19 In Operator’s Cab - Before Starting The Engine.................................... 20 Mirrors, Windows, And Lights...................................................... 20 OPERATING THE MACHINE................................................................. 20 When Starting The Engine.......................................................... 20 Precautions For Starting Machine.................................................. 20 Truck Operation - General......................................................... 20 Traveling......................................................................... 21 Traveling In Reverse.............................................................. 21 Traveling On Slopes............................................................... 22 Ensure Good Visibility............................................................ 22 Operate Carefully On Snow......................................................... 22 Avoid Damage To Dump Body......................................................... 22 Driving Near High Voltage Cables.................................................. 22 When Dumping...................................................................... 23 Working On Loose Ground........................................................... 23 Loading The Body.................................................................. 23 Parking The Machine............................................................... 23 TOWING................................................................................ 23 WORKING NEAR BATTERIES................................................................ 24 Battery Hazard Prevention......................................................... 24 Starting With Booster Cables...................................................... 24 PRECAUTIONS FOR MAINTENANCE............................................................... 25 BEFORE PERFORMING MAINTENANCE......................................................... 25 Warning Tag....................................................................... 25 Proper Tools...................................................................... 25 Stopping The Engine Before Service................................................ 25 Securing The Dump Body............................................................ 25 DURING MAINTENANCE.................................................................... 27 Personnel......................................................................... 27 Attachments....................................................................... 27 Working Under The Machine......................................................... 27 Keep The Machine Clean............................................................ 27 Rules To Follow When Adding Fuel Or Oil........................................... 27 Radiator Water Level.............................................................. 27 Use Of Lighting................................................................... 27 Precautions With The Battery...................................................... 28 Handling High Pressure Hoses...................................................... 28 Precautions With High Pressure Oil................................................ 28 Precautions When Performing Maintenance Near High Temperature Or High Pressure.... 28 Rotating Fan And Belts............................................................ 28 Waste Materials................................................................... 28 TIRES................................................................................. 29 Handling Tires.................................................................... 29 Tire Maintenance.................................................................. 29 Storing Tires After Removal....................................................... 29 WHEN REPAIRS ARE NECESSARY................................................................ 30 ADDITIONAL JOB SITE RULES................................................................. 31 OPERATING INSTRUCTIONS.................................................................... 32 PREPARING FOR OPERATION............................................................... 32 Safety Is Thinking Ahead.......................................................... 32 Walk Around Inspection............................................................ 32 ENGINE START-UP SAFETY PRACTICES...................................................... 35 Cold Weather Starting............................................................. 36 Jump Starting..................................................................... 36 EMERGENCY STEERING SYSTEM............................................................. 37 Operation......................................................................... 37 Pre-Operation Testing............................................................. 37 AFTER THE ENGINE HAS STARTED.......................................................... 38 MACHINE OPERATION SAFETY PRECAUTIONS.................................................. 40 LOADING............................................................................... 41 HAULING............................................................................... 42 RETARDER OPERATION.................................................................... 42 PASSING............................................................................... 43 DUMPING............................................................................... 43 Raising the Dump Body............................................................. 44 Lowering The Dump Body............................................................ 44 SAFE PARKING PROCEDURES............................................................... 45 SHUTTING THE ENGINE OFF............................................................... 45 SUDDEN LOSS OF ENGINE POWER........................................................... 45 Secondary Steering And Braking.................................................... 45 DISABLED TRUCK DUMPING PROCEDURE...................................................... 46 Hookup............................................................................ 46 Raising the Body.................................................................. 47 Lowering the Body................................................................. 47 DISABLED TRUCK STEERING AND BRAKING................................................... 48 TOWING................................................................................ 50 SECTION A4 - WARNINGS AND CAUTIONS........................................................... 52 SECTION A5 - TORQUE TABLES AND CONVERSION CHARTS............................................. 58 EFFECT OF SPECIAL LUBRICANTS On Fasteners and Standard Torque Values...................... 59 STANDARD TIGHTENING TORQUES For Class 10.9 Cap screws & Class 10 Nuts..................... 59 STANDARD TIGHTENING TORQUES For SAE Grade 5 and Grade 8 Cap screws........................ 60 STANDARD TIGHTENING TORQUES For SAE Grade 9 Cap screws.................................... 61 Hardware Tightening Method............................................................ 69 SECTION A7 - STORAGE PROCEDURES - INDEX ...................................................... 70 STORAGE AND IDLE MACHINE PREPARATION...................................................... 72 SHORT TERM IDLE PERIODS............................................................... 72 PREPARATION FOR STORAGE............................................................... 72 REMOVAL FROM STORAGE.................................................................. 73 RECONDITIONING AN IDLE VEHICLE........................................................ 75 ENGINE OPERATION...................................................................... 78 AFTER THE ENGINE HAS STARTED.......................................................... 78 SHORT TERM ENGINE STORAGE............................................................. 79 Preparing the Engine.............................................................. 79 Removing the Engine from Long Term Storage........................................ 81 TRANSMISSION PRESERVATION AND STORAGE................................................. 81 Storage, New Transmission......................................................... 81 Storage, One Year- Without Oil.................................................... 81 Storage, One Year - With Oil - Normally Installed On The Truck.................... 82 Restoring The Transmission For Service............................................ 82 SECTION B - STRUCTURES - INDEX ................................................................... 84 SECTION B2 - STRUCTURAL COMPONENTS - INDEX ................................................... 86 STRUCTURAL COMPONENTS..................................................................... 88 PREPARATION........................................................................... 88 GRILLE, HOOD AND LADDERS.............................................................. 89 DECKS............................................................................. 90 CENTER DECK........................................................................... 90 Removal........................................................................... 90 Installation...................................................................... 90 RIGHT DECK AND COMPONENTS......................................................... 90 Removal....................................................................... 90 Installation.................................................................. 90 LEFT DECK AND CAB................................................................. 91 Installation.................................................................. 91 SECTION B3 - DUMP BODY - INDEX ............................................................... 92 DUMP BODY................................................................................. 94 Removal............................................................................... 94 Installation.......................................................................... 96 BODY PADS............................................................................. 96 Body Pad Adjustment............................................................... 97 BODY GUIDE............................................................................ 97 BODY-UP RETENTION CABLE............................................................... 98 ROCK EJECTORS......................................................................... 98 Inspection........................................................................ 98 SECTION B4 - FUEL TANK - INDEX ............................................................... 100 FUEL TANK................................................................................. 102 Removal............................................................................... 103 Cleaning.............................................................................. 103 Repair................................................................................ 103 Installation.......................................................................... 103 FUEL GAUGE AND SENDING UNIT........................................................... 104 Removal........................................................................... 104 Installation...................................................................... 104 WIGGINS QUICK FILL FUEL SYSTEM........................................................ 105 FUEL RECEIVER..................................................................... 105 FUEL TANK BREATHER................................................................ 105 Removal....................................................................... 105 Installation.................................................................. 105 Disassembly................................................................... 105 Assembly...................................................................... 105 LEFT SIDE FILL.................................................................... 106 SECTION C - ENGINE - INDEX ....................................................................... 108 SECTION C3 - COOLING SYSTEM - INDEX ......................................................... 110 COOLING SYSTEM............................................................................ 112 DESCRIPTION........................................................................... 112 LEAKS AND CONTAMINATION............................................................... 113 RADIATOR REMOVAL...................................................................... 113 RADIATOR REPAIR................................................................... 114 Internal Inspection........................................................... 114 External Cleaning............................................................. 115 Disassembly................................................................... 115 Cleaning and Inspection....................................................... 116 Assembly...................................................................... 117 Pressure Testing.............................................................. 118 Additional Service Information................................................ 118 RADIATOR INSTALLATION................................................................. 118 TRANSMISSION AND BRAKE COOLERS.................................................... 120 Removal....................................................................... 120 Disassembly................................................................... 120 Cleaning And Inspection....................................................... 121 Assembly...................................................................... 121 Inspection.................................................................... 123 Installation.................................................................. 124 SECTION C4 - ENGINE - INDEX .................................................................. 126 ENGINE.................................................................................... 128 Removal............................................................................... 128 Inspection............................................................................ 131 DRIVE LINE ADAPTER AND DAMPER......................................................... 133 Removal........................................................................... 133 Disassembly....................................................................... 135 Assembly.......................................................................... 135 Installation...................................................................... 137 SECTION C5 - AIR FILTRATION SYSTEM - INDEX ................................................... 140 AIR FILTRATION SYSTEM..................................................................... 142 AIR CLEANER........................................................................... 142 Operation......................................................................... 142 General Maintenance............................................................... 142 FILTER SERVICE INDICATOR.......................................................... 144 MAIN FILTER ELEMENT............................................................... 144 Removal....................................................................... 144 Installation.................................................................. 144 SAFETY FILTER ELEMENT............................................................. 144 Removal....................................................................... 144 Installation.................................................................. 144 MAIN FILTER CLEANING.............................................................. 145 PRECLEANER CLEANING............................................................... 146 AIR INTAKE GUIDELINES............................................................. 147 Installation.................................................................. 147 AIR INTAKE TROUBLESHOOTING............................................................ 148 SECTION C7 - FAN CLUTCH - INDEX .............................................................. 150 FAN CLUTCH................................................................................ 152 REMOVAL & INSTALLATION TOOLING........................................................ 152 FAN CLUTCH - DISASSEMBLY.............................................................. 155 CLEANING AND INSPECTION............................................................... 165 ASSEMBLY - FAN CLUTCH................................................................. 169 TEST PROCEDURE........................................................................ 183 SECTION D - ELECTRICAL SYSTEM AND POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX ................... 184 SECTION D2 - STARTING SYSTEM - INDEX ......................................................... 186 STARTING SYSTEMS.......................................................................... 188 24 VDC REMOTE MOUNT PRELUB™ SYSTEM.................................................... 188 OPERATION......................................................................... 188 Oil Pressure Switch........................................................... 190 Check Valve................................................................... 190 Timer Solenoid................................................................ 190 MAINTENANCE....................................................................... 190 Prelub™ System Operation...................................................... 190 Prelub Pump................................................................... 190 Check Valve................................................................... 191 Timer Solenoid................................................................ 191 PRELUB CIRCUIT TROUBLESHOOTING.................................................... 192 24 VDC ELECTRIC START SYSTEM.......................................................... 194 OPERATION......................................................................... 194 CRANKING MOTORS................................................................... 194 Removal....................................................................... 194 Installation.................................................................. 194 Disassembly................................................................... 195 Cleaning and Inspection....................................................... 195 Armature Servicing............................................................ 195 Field Coil Checks............................................................. 196 Field Coil Removal............................................................ 196 Solenoid Checks............................................................... 199 Assembly...................................................................... 200 Pinion Clearance Adjustment................................................... 201 MAGNETIC SWITCH................................................................... 201 Removal....................................................................... 201 Installation.................................................................. 202 Coil Test..................................................................... 202 CRANKING MOTOR TROUBLESHOOTING........................................................ 203 PRELIMINARY INSPECTION............................................................ 203 NO-LOAD TEST...................................................................... 203 Load Test Diagnosis........................................................... 204 SECTION D3 - ELECTRICAL SYSTEM COMPONENTS - INDEX ............................................ 206 ELECTRICAL SYSTEM COMPONENTS.............................................................. 208 GENERAL TROUBLESHOOTING............................................................... 208 CAB MOUNTED COMPONENTS................................................................ 209 CIRCUIT BREAKERS.................................................................. 209 RELAY BOARDS...................................................................... 212 Relay Boards - With Circuit Breakers.......................................... 212 Preliminary Checks............................................................ 213 Service....................................................................... 213 Relay Board Description....................................................... 214 Relay Board RB1............................................................... 214 Relay Board RB4............................................................... 215 Relay Board RB5............................................................... 215 Relay Boards - Without Circuit Breakers....................................... 215 INCLINATION SENSORS............................................................... 218 Payload Meter Inclinometer Sensor............................................. 218 Lateral Inclination Sensor.................................................... 218 LUBRICATION SYSTEM TIMER.......................................................... 218 ACCELERATOR PEDAL................................................................. 219 AISS Operation................................................................ 220 Accelerator Pedal Malfunction................................................. 222 Accelerator Pedal Checks...................................................... 222 Idle Validation Switch Continuity Check....................................... 222 24V COMPONENTS - OUTSIDE CAB.......................................................... 223 BATTERY BOX....................................................................... 223 BATTERY DISCONNECT SWITCH......................................................... 223 GROUND LEVEL SHUTDOWN SWITCH...................................................... 223 CONTROL POWER RELAYS.............................................................. 223 CIRCUIT BREAKERS.................................................................. 223 BATTERY ELECTROLYTE LEVEL SENSOR.................................................. 223 BATTERY EQUALIZER................................................................. 224 BODY POSITION SWITCHES............................................................ 224 Proximity Switch Operation.................................................... 224 Body-Up Switch Adjustment..................................................... 225 Hoist Limit Switch Adjustment................................................. 227 WHEEL SPEED SENSORS............................................................... 228 Sensor Adjustment............................................................. 228 SECTION D22- POWERTRAIN MANAGEMENT CONTROL SYSTEM - INDEX .................................... 230 POWERTRAIN MANAGEMENT CONTROL™ SYSTEM..................................................... 232 System Description.................................................................... 232 Engine (Cummins QSK45)................................................................ 232 Transmission.......................................................................... 232 Transmission Controller............................................................... 232 Retard Control and Monitor............................................................ 232 Powertrain Management Controller...................................................... 232 Electronic Display Panel.............................................................. 232 Payload Meter......................................................................... 232 Message for Operator and Maintenance Display.......................................... 232 Suspension Controller................................................................. 232 Data Acquisition Device............................................................... 232 Cummins Quantum....................................................................... 233 Cummins CENSE......................................................................... 233 PMC SYSTEM TROUBLESHOOTING............................................................ 234 Preliminary Troubleshooting Procedures............................................ 234 Emergency Operation............................................................... 234 Indication Of A Fault Occurrence.................................................. 234 Action Codes...................................................................... 234 Fault History..................................................................... 234 System Troubleshooting............................................................ 234 EMERGENCY TRUCK OPERATION............................................................. 237 PMC SYSTEM FAULT CODES................................................................ 239 SECTION D23 - POWERTRAIN MANAGEMENT CONTROLLER - INDEX ....................................... 256 POWERTRAIN MANAGEMENT CONTROLLER (PMC).................................................... 258 PMC CONTROLLER FEATURES............................................................... 258 LED Display....................................................................... 258 DIP Switch Settings............................................................... 258 NORMAL OPERATION - PMC................................................................ 259 Throttle Control.................................................................. 259 AISS Operation.................................................................... 259 Retarder Control.................................................................. 260 COMMUNICATION......................................................................... 260 S-NET............................................................................. 260 CENSE............................................................................. 260 RCM............................................................................... 260 PLM............................................................................... 260 “MOM” and “DAD”................................................................... 260 Additional Functions.............................................................. 261 PMC CONTROLLER TROUBLESHOOTING............................................................ 264 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 264 PMC FAULT CODE TROUBLESHOOTING............................................................ 265 PMC CONTROLLER LOGIC...................................................................... 273 Fault Recovery Classifications........................................................ 273 PMC FAULT CODE LOGIC DESCRIPTION.......................................................... 274 PMC WIRING HARNESS CONNECTORS......................................................... 298 SECTION D24 - AUTOMATIC TRANSMISSION CONTROLLER - INDEX ...................................... 304 AUTOMATIC TRANSMISSION CONTROLLER (ATC)................................................... 306 ATC CONTROLLER FEATURES............................................................... 306 LED Display....................................................................... 306 Rotary Switch Settings............................................................ 306 Shift Control..................................................................... 307 Range Selector Positions And Automatic Gear Shifting Ranges....................... 307 Transmission Operation Modes...................................................... 308 Braking Mode:..................................................................... 308 Normal Mode:...................................................................... 308 Automatic Gear Shifting........................................................... 308 Automatic Shifting Sequence....................................................... 309 Gearshifting time lag............................................................. 309 Shift Skip Logic.................................................................. 309 Safety Functions.................................................................. 310 TROUBLESHOOTING – ATC..................................................................... 311 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 311 ATC FAULT CODE TROUBLESHOOTING............................................................ 312 ATC FAULT CODE LOGIC DESCRIPTION.......................................................... 327 TRANSMISSION CONTROLLER HARNESS CONNECTORS............................................ 358 SECTION D25 - ELECTRONIC DISPLAY PANEL - INDEX ............................................... 362 ELECTRONIC DISPLAY PANEL.................................................................. 364 Rotary Switch......................................................................... 364 Gauges and Indicators................................................................. 365 External Indicator Lamps.............................................................. 367 Display Self-Check Function........................................................... 369 Lamp Test............................................................................. 369 Action Code Display................................................................... 370 Cancellation of Action Code........................................................... 370 ELECTRONIC DISPLAY PANEL TROUBLESHOOTING.................................................. 371 GENERAL TROUBLESHOOTING PROCEDURES.................................................... 371 Harness Circuit Tests............................................................. 371 Table 1: Continuity checks........................................................ 371 Table 2: Short Circuit to Ground Checks........................................... 372 Table 3: Circuit Isolation Checks................................................. 372 EDP WIRING HARNESS CONNECTORS......................................................... 390 SECTION D26 - RETARD CONTROL AND MONITOR (RCM) - INDEX ....................................... 392 RETARD CONTROL AND MONITOR (RCM).......................................................... 394 Description........................................................................... 394 RCM Calibration....................................................................... 394 GENERAL TROUBLESHOOTING PROCEDURES........................................................ 395 RCM FAULT CODE TROUBLESHOOTING............................................................ 397 Description........................................................................... 397 RCM WIRING HARNESS CONNECTORS......................................................... 444 SECTION D27 - AUTOMATIC SUSPENSION SYSTEM - INDEX ............................................ 446 AUTOMATIC SUSPENSION SYSTEM............................................................... 448 Automatic Suspension Controller....................................................... 448 Manifold Valve........................................................................ 448 Actuator.............................................................................. 448 Steering Sensor....................................................................... 448 AUTOMATIC MODE SELECTION CONTROL...................................................... 449 SUSPENSION CONTROLLER FAULT CODE LOGIC DESCRIPTION........................................ 450 d011:RIGHT FRONT SUSPENSION PRESSURE SENSOR FAILURE................................... 450 d012:LEFT FRONT SUSPENSION PRESSURE SENSOR FAILURE.................................... 450 d015:TRANSMISSION SPEED SIGNAL LOST................................................... 451 d016:STEERING SPEED SIGNAL LOST....................................................... 451 d021:SOLENOID OUTPUT 1 FAILURE........................................................ 452 d022:SOLENOID OUTPUT 2 FAILURE........................................................ 452 d023:SOLENOID OUTPUT 3 FAILURE........................................................ 452 SUSPENSION CONTROLLER SYSTEM TROUBLESHOOTING.............................................. 453 SP-1: Fault Code d011: Faulty Pressure Sensor (Right) displayed....................... 453 SP-2: Fault Code d012: Faulty Pressure Sensor (Right) displayed....................... 454 SP-3: Fault Code d015: Faulty Truck Speed Sensor System Displayed..................... 455 SP-4: Fault Code d016: Fault in Steering Sensor System Displayed...................... 456 SP-5: Fault Code d021: Fault in Solenoid (1) System Displayed......................... 457 SP-6: Fault Code d022: Fault in Solenoid (2) System Displayed......................... 458 SP-7: Fault Code d023: Fault in Solenoid (3) System Displayed......................... 459 SUSPENSION CONTROLLER WIRING HARNESS CONNECTORS....................................... 460 SECTION D30 - MESSAGE FOR OPERATION AND MAINTENANCE (MOM) - INDEX ............................ 462 MOM — MESSAGE FOR OPERATION AND MAINTENANCE............................................... 464 INTRODUCTION.......................................................................... 464 SYSTEM CONFIGURATION.................................................................. 464 SOFTWARE.............................................................................. 465 Service Meters (SMR).............................................................. 466 FUNCTION.............................................................................. 467 Operator Information.............................................................. 467 Maintenance Information (Screen Hierarchy)........................................ 467 Display Able/Disable By Machine Status............................................ 469 Vehicle State..................................................................... 469 Display Able/Disable by Truck Model and Optional Equipment Status................. 470 SCREEN DATA........................................................................... 471 Realtime Data..................................................................... 471 Machine Trend Data................................................................ 471 Fault Condition Data.............................................................. 471 Machine Information............................................................... 472 Parameter Set..................................................................... 472 WARNING MESSAGE....................................................................... 473 HARDWARE TROUBLESHOOTING AND MAINTENANCE.................................................. 474 TROUBLESHOOTING THE MOM UNIT.......................................................... 474 PROBLEMS AND CORRECTIVE ACTIONS....................................................... 475 Program Errors.................................................................... 476 Warning & Communication Errors.................................................... 477 SELF-DIAGNOSIS........................................................................ 478 System Check...................................................................... 478 System Information................................................................ 478 Communication Port Check.......................................................... 478 Key Input Check................................................................... 479 MAINTENANCE........................................................................... 480 Battery Replacement............................................................... 480 Replacement of Protective Sheet................................................... 480 Back Light Replacement............................................................ 481 Setting Display OFF Time.......................................................... 482 SECTION D31 - MOM SCREEN DISPLAYS - INDEX .................................................... 484 MOM SCREEN DISPLAYS....................................................................... 486 i1 INITIAL MESSAGE.................................................................... 486 i2 INITIAL CHECK1..................................................................... 486 i3 INITIAL CHECK2..................................................................... 486 i4 NORMAL RUNNING..................................................................... 487 i7 BACKLIGHT OFF...................................................................... 488 To Access a Maintenance Information Screen:....................................... 489 i9 MENU SELECT........................................................................ 490 s1 SERVICE MENU....................................................................... 491 s2 COMPONENT CHECK MENU............................................................... 491 s21 ENGINE............................................................................ 492 s212 MACHINE TREND MENU (ENG.).................................................... 493 s213 FAULT CONDITION MENU (ENG.).................................................. 493 s2131 FAULT CONDITION (ENG.)...................................................... 494 s22 TRANSMISSION...................................................................... 495 s222 MACHINE TREND MENU (T/M)..................................................... 496 s2221 L/C ON/OFF COUNT............................................................ 496 s222E AB-USE COUNT................................................................ 497 s223 FAULT CONDITION MENU (T/M)................................................... 498 S2231 FAULT CONDITION (T/M)....................................................... 498 s23 BRAKE MENU........................................................................ 499 s231-1/4 to s231-4/4 REAL TIME MONITOR (BRAKE).................................... 499 s233 FAULT CONDITION MENU (BRAKE)................................................. 500 s2331 FAULT CONDITION (BRAKE)..................................................... 500 s24 SUSPENSION MENU................................................................... 501 s241-1/4 to s241-4/4 REAL TIME MONITOR (SUSPENSION)............................... 501 s242 FAULT CONDITION MENU (SUS)................................................... 502 s2421 FAULT CONDITION (SUS)....................................................... 502 s25 PMC MENU.......................................................................... 503 s251-1/9 to s251-9/9 REAL TIME MONITOR (PMC)...................................... 503 s252 FAULT CONDITION MENU (PMC)................................................... 504 s2521 FAULT CONDITION (PMC)....................................................... 504 s26 ELECTRONIC DISPLAY PANEL MENU..................................................... 505 s261-1/5 to s261-5/5 REAL TIME MONITOR (Electronic Display Panel)................. 505 s262 FAULT CONDITION MENU (ELE. DISPLAY PANEL).................................... 506 s2621 FAULT CONDITION (ELE. DISPLAY PANEL)........................................ 506 s27 PLM MENU.......................................................................... 507 s271-1/2 to s271-2/2 REAL TIME MONITOR (PLM)...................................... 507 s272 CALIBRATION DATA............................................................. 508 s28 TMS MENU.......................................................................... 508 s281-1/5 to s281-5/5 REAL TIME MONITOR (TMS)...................................... 509 s283 FAULT CONDITION MENU (TMS)................................................... 509 s2831 FAULT CONDITION (TMS)....................................................... 510 s3 MACHINE INFORMATION MENU........................................................... 510 s32-1/3 CONTROLLER INFORMATION.................................................... 512 SELECTOR SWITCH STATUS of the PMC................................................. 512 s32-2/3 CONTROLLER INFORMATION.................................................... 513 s32-3/3 CONTROLLER INFORMATION.................................................... 514 s33 OPTIONAL FUNCTION INFORMATION................................................. 514 s34 HISTORY OF USE.................................................................... 515 t1 PARAMETER SET MENU................................................................. 516 t2 TIME/DATE SET.................................................................. 516 t3 TRAVEL MODE MENU................................................................... 517 t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)................................ 517 t32 SPEED LIMITER................................................................. 518 t33 T/M MAX GEAR SELECT........................................................... 518 t34 T/M MAX GEAR SELECT (BODY UP)................................................. 519 t35 SUSPENSION MODE SET........................................................... 519 t4 PARAMETER UNIT SET............................................................. 520 t5 TMS SET MENU................................................................... 520 t51 TIRE PRESSURE LIMIT SET....................................................... 521 t52 TIRE TEMPERATURE LIMIT SET.................................................... 522 t53 CORRELATION CONSTANTS SET..................................................... 523 t54 TMS CLOCK SET................................................................. 524 t55 ID CODE SET................................................................... 525 SECTION D32 - DATA ACQUISITION DEVICE (DAD) - INDEX .......................................... 526 DAD – DATA ACQUISITION DEVICE............................................................. 528 INTRODUCTION.......................................................................... 528 HARDWARE HOOKUP....................................................................... 528 SOFTWARE.............................................................................. 529 Installation Requirements......................................................... 529 Installing the Software........................................................... 529 Starting the Software Program..................................................... 529 Service Meters (SMR).............................................................. 529 Display Able/disable By Machine Status............................................ 530 Vehicle State..................................................................... 530 MAINTENANCE INFORMATION (SCREEN HIERARCHY)............................................ 530 Display Enable/Disable by Truck Model and Optional Equipment Status............... 534 SCREEN DATA........................................................................... 535 Real Time Data.................................................................... 535 Fault condition data.............................................................. 535 Snap-Shot Data.................................................................... 535 Transmission Snapshot Example..................................................... 536 Sample Snapshot Screens........................................................... 540 Machine Trend Data................................................................ 542 Machine Check..................................................................... 543 Machine Information............................................................... 543 Event Recorder.................................................................... 543 Parameter Set..................................................................... 543 SECTION D33 - DAD SCREEN DISPLAYS - INDEX .................................................... 544 DAD SCREEN DISPLAYS....................................................................... 546 PASSWORD INPUT........................................................................ 546 Changing the Password............................................................. 546 i3 MENU SELECT........................................................................ 546 s1 SERVICE MENU....................................................................... 547 s2 COMPONENT CHECK MENU............................................................... 547 s21 Engine........................................................................ 547 s21 CUMMINS ENG. MENU (for the CUMMINS engine).................................... 547 s21 KOMATSU ENG. MENU (for the KOMATSU engine).................................... 547 s22 TRANSMISSION.................................................................. 550 s23 BRAKE MENU.................................................................... 554 s24 SUSPENSION MENU............................................................... 557 s25 PMC MENU...................................................................... 559 s26 ELECTRONIC DISPLAY PANEL MENU................................................. 561 s27 PLM MENU...................................................................... 563 s28 TMS MENU...................................................................... 564 s3 MACHINE INFORMATION MENU........................................................... 567 s31 MACHINE INFORMATION MENU...................................................... 567 s32-1/3 CONTROLLER INFORMATION.................................................... 568 s32-2/3 CONTROLLER INFORMATION.................................................... 569 s32-3/3 CONTROLLER INFORMATION.................................................... 570 s33 OPTIONAL FUNCTION INFORMATION................................................. 570 s34 HISTORY OF USE................................................................ 571 t1 PARAMETER SET MENU................................................................. 572 t2 TIME/DATE SET...................................................................... 572 t3 TRAVEL MODE MENU................................................................... 573 t31 ENG., T/M PATTERN SELECT (Komatsu Engine Only)................................ 573 t32 SPEED LIMITER................................................................. 574 t33 T/M MAX GEAR SELECT........................................................... 574 t34 T/M MAX GEAR SELECT (BODY UP)................................................. 575 t35 SUSPENSION MODE SET........................................................... 575 t4 PARAMETER UNIT SET................................................................. 576 t5 TMS SET MENU....................................................................... 576 t51 TIRE PRESSURE LIMIT SET....................................................... 577 t52 TIRE TEMPERATURE LIMIT SET.................................................... 577 t53 CORRELATION CONSTANTS SET..................................................... 578 t54 TMS CLOCK SET................................................................. 578 t55 ID CODE SET................................................................... 579 SECTION D34 - REAL TIME DATA TABLES - INDEX .................................................. 580 REAL TIME DATA TABLES..................................................................... 582 ACCESSING REAL TIME DATA SCREENS...................................................... 582 Real Time Data Screen Switches.................................................... 582 SECTION D35 - PAYLOAD METER II - ON BOARD WEIGHING SYSTEM - INDEX............................ 592 GENERAL INFORMATION....................................................................... 594 Haul Cycles........................................................................... 594 LIGHTS, SWITCHES AND COMPONENTS........................................................... 595 TIPS FOR OPERATION........................................................................ 596 EXTERNAL DISPLAY LIGHTS................................................................... 596 THEORY OF OPERATION....................................................................... 597 Basic Description..................................................................... 597 Inclinometer.......................................................................... 597 Linkage Factor........................................................................ 597 Gain Factor........................................................................... 598 Brake Lock............................................................................ 598 Sources of Error...................................................................... 598 Typical Data From Service Check Mode.................................................. 598 Example Calculation of Payload........................................................ 599 Viewing Payload Calculation Inputs.................................................... 599 Checking the Gain..................................................................... 600 Adjusting the Gain.................................................................... 600 TYPES OF DATA STORED...................................................................... 601 Cycle Data............................................................................ 601 Engine ON/OFF Data.................................................................... 602 Fault Codes and Warning Data.......................................................... 602 Engine Operation...................................................................... 603 Total Payload and Total Number of Cycles.............................................. 603 Other Data............................................................................ 603 OPERATOR FUNCTIONS........................................................................ 604 Using the Operator Load Counter....................................................... 604 Viewing the Operator Load Counter..................................................... 604 Clearing the Operator Load Counter.................................................... 604 Dimming the Lights on the Display..................................................... 604 INITIAL SETUP OF PAYLOAD METER............................................................ 605 Switch Settings....................................................................... 605 Checking the Operator Check Mode...................................................... 606 Checking the Service Check Mode....................................................... 606 Checking the Gt setting:.............................................................. 607 Checking the Inclinometer Settings.................................................... 607 Calibrating a Truck................................................................... 607 DISPLAYS AT START-UP...................................................................... 608 Normal Operation...................................................................... 608 SETUP AND MAINTENANCE..................................................................... 609 Setting The Speed Limit............................................................... 609 Setting the Option Code............................................................... 609 Setting The Machine I.D. Code......................................................... 610 Setting The Operator I.D. Code........................................................ 610 Setting The Time and Date............................................................. 610 DOWNLOAD OF INFORMATION................................................................... 611 DISPLAY OF FAULT CODES.................................................................... 611 Monitoring Input Signals.............................................................. 615 Service Check Mode.................................................................... 615 UP FACTOR - PAYLOAD CALCULATION GAIN...................................................... 616 PL MODE -LOAD CALCULATION TIMING.......................................................... 616 FINAL GEAR RATIO SELECTION................................................................ 617 BATTERY REPLACEMENT PROCEDURE............................................................. 618 Replacing the Battery................................................................. 618 After Replacing the Battery........................................................... 619 SUSPENSION PRESSURE SENSOR................................................................ 619 Removal............................................................................... 619 Installation.......................................................................... 620 INCLINOMETER.............................................................................. 620 Removal............................................................................... 620 Installation.......................................................................... 620 Adjustment............................................................................ 620 PAYLOAD METER BACK PANEL.................................................................. 621 CONNECTIONS............................................................................... 622 PAYLOAD METER II™ RE-INITIALIZATION PROCEDURE............................................. 623 PAYLOAD CIRCUIT NUMBERS................................................................... 624 TROUBLESHOOTING........................................................................... 625 COMMON PROBLEMS....................................................................... 625 Suspension Charging............................................................... 625 Symptom Table..................................................................... 626 Missing Body-Up Signal............................................................ 626 Missing Speed Signal.............................................................. 627 F-18: Alternator R-Terminal, Oil Pressure Signals................................. 627 Shorted 18v Sensor Power Supply (930E)............................................ 627 FAULT TREE DIAGNOSIS.................................................................. 628 Payload Lights Won't Illuminate................................................... 628 Red, Amber or Green Payload Light Does Not Illuminate............................. 629 Cannot Download - PC Communications............................................... 630 PC Communications Configuration................................................... 631 F.CAL: Payload Meter Won't Calibrate.............................................. 632 F-20: Sensor Power Fault.......................................................... 633 F-21, F-25: Left Front Pressure Sensor............................................ 635 F-22, F-26: Right Front Pressure Sensor........................................... 635 F-23, F-27: Left Rear Pressure Sensor............................................. 635 F-24, F-28: Right Rear Pressure Sensor............................................ 635 F-31, F-32: Inclinometer.......................................................... 637 Body Up Input..................................................................... 639 Brake Lock Input.................................................................. 640 Speed Signal...................................................................... 641 Adjusting the Speed Sensor........................................................ 641 CONNECTORS AND PRESSURE SENSORS....................................................... 643 REAL-TIME PAYLOAD METER II™ MONITOR PROGRAM............................................... 646 Menu Functions........................................................................ 649 Using Scope........................................................................... 649 Log File Information.................................................................. 649 Connections to Payload Meter II™...................................................... 650 USING SCOPE............................................................................... 651 Monitoring Inputs Using Scope......................................................... 651 Monitoring Suspension Charging Using Scope............................................ 651 Pressure Sensor Dummy Loads........................................................... 654 GAIN ADJUSTMENT WORKSHEET................................................................. 655 SECTION F - TRANSMISSION/TORQUE CONVERTER - INDEX ................................................ 656 SECTION F2 - TORQUE CONVERTER AND TRANSMISSION - INDEX ....................................... 658 TORQUE CONVERTER AND TRANSMISSION......................................................... 660 TRANSMISSION.......................................................................... 660 TORQUE CONVERTER...................................................................... 661 MAIN RELIEF VALVE................................................................. 663 Function...................................................................... 663 Operation..................................................................... 663 TORQUE CONVERTER RELIEF VALVE..................................................... 663 Function...................................................................... 663 Operation..................................................................... 663 TORQUE CONVERTER REGULATOR VALVE.................................................. 665 Operation..................................................................... 665 LOCK-UP CLUTCH.................................................................... 666 Lock-up Clutch Accumulator.................................................... 666 HYDRAULIC PUMP.................................................................... 667 TORQUE CONVERTER STALL CHECK...................................................... 668 TRANSMISSION...................................................................... 669 LUBRICATION RELIEF VALVE.......................................................... 671 Function...................................................................... 671 TRANSMISSION CONTROL VALVE........................................................ 672 ELECTRONIC CONTROL MODULATION VALVE (ECMV)........................................ 674 Pressure Control Valve........................................................ 675 Flow Sensor Valve............................................................. 675 ECMV and Proportional Solenoid................................................ 675 ECMV and Fill Switch.......................................................... 675 ECMV Operation................................................................ 676 ECMV REPAIR PROCEDURE............................................................. 679 Filter Replacement Procedure.................................................. 679 ECMV Removal.................................................................. 680 Disassembly................................................................... 680 Assembly...................................................................... 681 TRANSMISSION FILTERS.............................................................. 683 Service....................................................................... 683 Installation.................................................................. 683 TRANSMISSION REMOVAL.............................................................. 684 TRANSMISSION INSTALLATION......................................................... 685 TRANSMISSION OIL LEVEL CHECK...................................................... 687 SECTION F3 - TRANSMISSION OIL COOLER & STRAINERS - INDEX ..................................... 688 TRANSMISSION OIL COOLER & STRAINERS....................................................... 690 TRANSMISSION OIL COOLER............................................................... 690 Removal and Installation.......................................................... 690 Repair............................................................................ 690 TRANSMISSION OIL STRAINER............................................................. 690 Removal........................................................................... 691 Inspection........................................................................ 691 Installation...................................................................... 691 SECTION F5 - DRIVE SHAFTS - INDEX ............................................................ 692 DRIVE SHAFTS.............................................................................. 694 FRONT DRIVE SHAFT..................................................................... 694 Removal........................................................................... 694 Disassembly....................................................................... 694 Assembly.......................................................................... 695 Installation...................................................................... 695 FRONT DRIVE SHAFT ALIGNMENT....................................................... 696 REAR DRIVE SHAFT...................................................................... 699 Removal........................................................................... 699 Disassembly....................................................................... 699 Assembly.......................................................................... 700 Installation...................................................................... 700 SECTION F6 - TRANSMISSION ELECTRICAL - INDEX ................................................. 702 TRANSMISSION ELECTRICAL................................................................... 704 TRANSMISSION SHIFT CONTROLLER......................................................... 705 Event Memory...................................................................... 705 Fault History Data................................................................ 705 Snap-Shot Data.................................................................... 705 Trend Data........................................................................ 706 TRANSMISSION RANGE SELECTOR........................................................... 707 SENSORS AND SWITCHES.................................................................. 708 Transmission Speed Sensors........................................................ 708 Adjustment Procedure.............................................................. 708 Fill Switch....................................................................... 709 Shift Limit Switch................................................................ 709 TRANSMISSION AND TORQUE CONVERTER TROUBLESHOOTING..................................... 710 Preliminary Checks................................................................ 710 SECTION G - DRIVE AXLE, SPINDLES AND WHEELS - INDEX .............................................. 714 SECTION G2 - TIRES AND RIMS - INDEX .......................................................... 716 TIRES AND RIMS............................................................................ 718 GENERAL INFORMATION................................................................... 718 FRONT TIRES AND RIMS.................................................................. 719 Removal........................................................................... 719 Installation...................................................................... 720 REAR TIRE AND RIM..................................................................... 720 Removal........................................................................... 720 Installation...................................................................... 721 TIRE MATCHING......................................................................... 722 RIM................................................................................... 723 Tire Removal From Rim............................................................. 723 Tire Installation On Rim.......................................................... 723 FRONT WHEEL STUD INSTALLATION......................................................... 724 REAR WHEEL STUD INSTALLATION.......................................................... 725 SECTION G3 - FRONT WHEEL HUB AND SPINDLE - INDEX ............................................. 726 FRONT WHEEL HUB AND SPINDLE............................................................... 728 OIL SAMPLE ANALYSIS................................................................... 728 Oil Sampling Guidelines........................................................... 728 Guidelines For Obtaining A Sample................................................. 728 FRONT WHEEL HUB....................................................................... 729 Removal........................................................................... 729 Disassembly....................................................................... 729 Inspection........................................................................ 729 Assembly and Installation......................................................... 730 Front Wheel Hub Bearing Adjustment................................................ 732 FRONT WHEEL SPINDLE REMOVAL AND INSTALLATION.......................................... 732 SUSPENSION A-ARM...................................................................... 732 Removal........................................................................... 732 Inspection of Parts............................................................... 733 Installation...................................................................... 733 CENTER TIE ROD PIVOT.................................................................. 734 Removal........................................................................... 734 Inspection........................................................................ 734 Installation...................................................................... 734 TOE IN ADJUSTMENT..................................................................... 735 Adjustment Procedure.............................................................. 735 SECTION G4 - REAR AXLE ATTACHMENTS - INDEX ................................................... 738 REAR AXLE ATTACHMENTS..................................................................... 740 CENTER LINK AND LOWER LINKS........................................................... 740 Removal........................................................................... 740 Inspection........................................................................ 741 Spherical Bearing Replacement..................................................... 741 Installation...................................................................... 741 PANHARD ROD (DIAGONAL LINK)........................................................... 742 Removal........................................................................... 742 Inspection........................................................................ 743 Installation...................................................................... 743 SECTION G5 - REAR AXLE AND FINAL DRIVE ASSEMBLY - INDEX ...................................... 744 REAR AXLE & FINAL DRIVE ASSEMBLY.......................................................... 746 DIFFERENTIAL OPERATION................................................................ 746 Straight-away-travel.............................................................. 746 Turning........................................................................... 746 REAR AXLE ASSEMBLY................................................................ 747 Removal....................................................................... 747 Installation.................................................................. 747 DIFFERENTIAL OIL LEVEL CHECK...................................................... 748 DIFFERENTIAL ASSEMBLY............................................................. 749 Removal....................................................................... 749 Installation.................................................................. 750 Disassembly................................................................... 750 Pinion Carrier Assembly....................................................... 753 Differential Gear Unit........................................................ 753 Differential Gear Unit........................................................ 754 Assembly...................................................................... 757 Differential Bearing.......................................................... 757 Assembly Of Differential Gear Assembly........................................ 757 Installation Of Differential Assembly......................................... 759 Input Pinion and Carrier Assembly............................................. 760 Adjusting Tooth Contact, Backlash............................................. 764 SECTION G6 - FINAL DRIVE PLANETARIES AND WHEEL HUBS - INDEX .................................. 768 FINAL DRIVE PLANETARIES AND WHEEL HUBS.................................................... 770 FINAL DRIVE........................................................................... 770 Oil Level Check................................................................... 771 FINAL DRIVE CARRIER ASSEMBLY...................................................... 771 Removal....................................................................... 771 Installation.................................................................. 772 Disassembly................................................................... 772 Assembly...................................................................... 773 FINAL DRIVE ASSEMBLY.............................................................. 774 Disassembly................................................................... 774 Assembly...................................................................... 776 SECTION H - SUSPENSIONS - INDEX .................................................................. 778 SECTION H2 - FRONT SUSPENSION - INDEX ........................................................ 780 FRONT SUSPENSION.......................................................................... 782 DESCRIPTION........................................................................... 782 OPERATION............................................................................. 783 THREE-MODE SUSPENSION (OPTIONAL).................................................. 784 Variable Damping Operation.................................................... 784 Three-Mode Suspension System Components....................................... 785 Automatic Suspension Controller............................................... 785 Manifold Valve................................................................ 785 Actuator...................................................................... 786 Steering Sensor............................................................... 786 Removal....................................................................... 787 Installation.................................................................. 788 Disassembly................................................................... 788 Inspection.................................................................... 790 Assembly...................................................................... 790 DAMPING VALVE......................................................................... 791 DAMPING VALVE - FIXED RATE........................................................ 791 Disassembly................................................................... 791 Assembly...................................................................... 791 DAMPING VALVE & ACTUATOR - 3 MODE DAMPING RATE.................................... 792 Disassembly................................................................... 792 Cleaning and Inspection....................................................... 792 Assembly...................................................................... 793 SECTION H3 - REAR SUSPENSION - INDEX ......................................................... 796 REAR SUSPENSION........................................................................... 798 OPERATION............................................................................. 799 Removal........................................................................... 800 Installation...................................................................... 800 Disassembly....................................................................... 800 Assembly.......................................................................... 802 SPHERICAL BEARINGS.................................................................... 803 Removal........................................................................... 803 Inspection........................................................................ 803 Installation...................................................................... 803 SECTION H4 - SUSPENSION OILING AND CHARGING - INDEX .......................................... 804 SUSPENSION OILING AND CHARGING............................................................ 806 GENERAL INFORMATION................................................................... 806 Equipment List.................................................................... 806 FRONT SUSPENSION...................................................................... 808 Front Suspension Oiling........................................................... 808 Front Suspension Nitrogen Charging................................................ 811 REAR SUSPENSION....................................................................... 813 General Information............................................................... 813 Rear Suspension Oiling............................................................ 814 Rear Suspension Nitrogen Charging................................................. 817 Length Adjustment - Front And Rear Cylinders...................................... 818 SECTION J - BRAKE SYSTEM - INDEX ................................................................. 820 SECTION J2 - BRAKE CIRCUIT - INDEX ........................................................... 822 BRAKE CIRCUIT............................................................................. 824 SERVICE BRAKE CIRCUIT................................................................. 824 SECONDARY BRAKING AND AUTOMATIC APPLY............................................. 826 PARKING BRAKE CIRCUIT............................................................. 826 Normal Operation.............................................................. 826 BRAKE LOCK CIRCUIT................................................................ 827 AUXILIARY CIRCUIT................................................................. 827 RETARDING CIRCUIT................................................................. 827 WARNING CIRCUIT................................................................... 827 BRAKE SYSTEM ELECTRICAL COMPONENTS................................................ 828 SECTION J3 - BRAKE CIRCUIT COMPONENT SERVICE - INDEX ......................................... 832 BRAKE CIRCUIT COMPONENT SERVICE........................................................... 834 BRAKE VALVE........................................................................... 834 Rebuild Criteria.................................................................. 834 Removal........................................................................... 835 Installation...................................................................... 835 Disassembly....................................................................... 836 Cleaning and Inspection........................................................... 837 Assembly.......................................................................... 839 Actuator Base Threaded Inserts.................................................... 839 Boot and Cap...................................................................... 839 Valve Body Seal Installation...................................................... 839 Regulator Sleeve O-Ring Installation.............................................. 839 Actuator Plunger O-ring Installation.............................................. 840 Assembly of Valve................................................................. 840 VALVE BENCH TEST AND ADJUSTMENT....................................................... 842 Test Bench Only................................................................... 843 Test Set Up Procedure............................................................. 843 Brake Valve Output Pressure Adjustment............................................ 843 Final Test and Adjustment......................................................... 844 Proximity Switch Installation and Adjustment...................................... 845 Installation Of Brake Pedal Actuator Assembly to Brake Valve...................... 845 RELAY VALVES.......................................................................... 846 Removal........................................................................... 846 Installation...................................................................... 847 Disassembly....................................................................... 848 Cleaning and Inspection........................................................... 848 Assembly.......................................................................... 848 VALVE TEST AND ADJUSTMENT............................................................. 850 Test Set Up Procedure............................................................. 851 Relay Valve........................................................................... 851 Output Pressure Adjustment........................................................ 851 HYDRAULIC BRAKE ACCUMULATORS.......................................................... 852 Brake Accumulator Bleed Down Procedure............................................ 852 BRAKE ACCUMULATOR CHARGING PROCEDURE.................................................. 853 BRAKE ACCUMULATOR REBUILD............................................................. 854 Removal........................................................................... 854 Installation...................................................................... 854 Disassembly....................................................................... 854 Cleaning and Inspection........................................................... 854 Assembly.......................................................................... 855 Testing........................................................................... 856 Storage........................................................................... 856 BRAKE COOLING VALVE (BCV)............................................................. 857 RETARDER CONTROL LEVER (STEERING COLUMN-MOUNTED).......................................... 858 Removal............................................................................... 858 Installation.......................................................................... 858 Disassembly and Adjustment............................................................ 860 Potentiometer Check................................................................... 860 Assembly.............................................................................. 861 SECTION J4 - BRAKE CIRCUIT CHECKOUT - INDEX .................................................. 862 BRAKE CIRCUIT CHECK-OUT PROCEDURE......................................................... 864 Required Equipment.................................................................... 867 Preparation........................................................................... 867 Initial System Setup.................................................................. 867 Parking Brake......................................................................... 868 Brake Lock............................................................................ 869 Low-Brake Pressure and Auto-Apply..................................................... 869 Reapplications........................................................................ 869 RCM Calibration....................................................................... 870 How to Perform Calibration............................................................ 870 HD1500 HYDRAULIC BRAKE SYSTEM CHECKOUT DATA SHEET......................................... 872 BRAKE CIRCUIT AND BRAKE VALVE TROUBLESHOOTING............................................. 875 SECTION J5 - FRONT WET DISC BRAKES - INDEX ................................................... 880 FRONT WET DISC BRAKES..................................................................... 882 DESCRIPTION........................................................................... 882 FRONT DISC BRAKE ASSEMBLY............................................................. 883 Removal........................................................................... 883 Installation...................................................................... 884 BRAKE ASSEMBLY REBUILD................................................................ 884 DISC BRAKE MAINTENANCE................................................................ 884 Brake Disc Wear Indicator......................................................... 884 Checking Disc Wear................................................................ 885 WEAR INDICATOR SENSOR................................................................. 886 SPEED SENSOR.......................................................................... 886 WET DISC BRAKE BLEEDING PROCEDURE..................................................... 886 SECTION J6 - REAR WET DISC BRAKES - INDEX .................................................... 888 REAR WET DISC BRAKES...................................................................... 890 DESCRIPTION........................................................................... 890 Operation......................................................................... 890 MAINTENANCE........................................................................... 891 Brake Disc Wear Indicator......................................................... 891 Checking Disc Wear................................................................ 891 Wear Indicator Sensor............................................................. 892 Brake Assembly Removal............................................................ 893 Brake Assembly Installation....................................................... 894 BRAKE ASSEMBLY REBUILD................................................................ 895 Disassembly....................................................................... 895 Cleaning and Inspection........................................................... 896 Assembly.......................................................................... 897 Floating Ring Seal Assembly/Installation.......................................... 899 Alternate Procedure:.............................................................. 900 SECTION J7 - PARKING BRAKE - INDEX ........................................................... 902 PARKING BRAKE............................................................................. 904 Description........................................................................... 904 Parking Brake Service Criteria........................................................ 904 Removal............................................................................... 905 Installation.......................................................................... 905 PARKING BRAKE SPRING CYLINDER REPLACEMENT............................................. 907 Removal........................................................................... 907 Installation...................................................................... 907 AUTOMATIC SLACK ADJUSTER.............................................................. 907 Adjustment Procedure.............................................................. 907 PARKING BRAKE CHECK-OUT............................................................... 908 SECTION L - HYDRAULIC SYSTEM - INDEX............................................................. 910 SECTION L2 - HYDRAULIC SYSTEM OVERVIEW - INDEX ............................................... 912 HYDRAULIC SYSTEM OVERVIEW................................................................. 914 HYDRAULIC SYSTEM DESCRIPTION.......................................................... 914 Hydraulic Tank.................................................................... 914 Bleed-down Manifold............................................................... 915 Hoist Valve....................................................................... 916 Hoist Pump........................................................................ 916 Brake Cooling Pump................................................................ 916 Brake Control Valve (BCV)......................................................... 916 High Pressure Filter.............................................................. 917 Low pressure Filter............................................................... 917 SECTION L3 - HYDRAULIC SYSTEM COMPONENT REPAIR - INDEX ....................................... 918 HYDRAULIC COMPONENT REPAIR................................................................ 920 HYDRAULIC TANK........................................................................ 920 FILLING INSTRUCTIONS.............................................................. 920 MAINTENANCE....................................................................... 920 Removal....................................................................... 921 Installation.................................................................. 923 Gap Measurement - Hydraulic Tank Mounting..................................... 923 STRAINERS AND DIFFUSERS........................................................... 924 Removal....................................................................... 924 Cleaning and Inspection....................................................... 924 Installation.................................................................. 925 HYDRAULIC TANK BREATHER............................................................... 925 Service........................................................................... 926 HYDRAULIC SYSTEM FLUSHING............................................................. 926 HYDRAULIC PUMPS....................................................................... 927 Removal........................................................................... 927 Installation...................................................................... 928 PUMP REBUILD...................................................................... 929 Disassembly................................................................... 929 Inspection Of Parts........................................................... 932 Assembly...................................................................... 932 Bearing Replacement........................................................... 935 Seal Replacement.............................................................. 935 TROUBLESHOOTING GUIDE............................................................. 938 SECTION L4 - STEERING CIRCUIT - INDEX ........................................................ 940 STEERING CIRCUIT.......................................................................... 942 OPERATION............................................................................. 942 COMPONENT DESCRIPTION................................................................. 942 Steering Control Valve............................................................ 942 Bleed-down Manifold............................................................... 942 Bleed-down Solenoid............................................................... 943 Accumulators...................................................................... 943 Flow Amplifier.................................................................... 944 High Pressure Filter.............................................................. 944 Warning Devices................................................................... 944 FLOW AMPLIFIER OPERATION.............................................................. 946 STEERING/BRAKE PUMP................................................................... 954 COMPONENTS........................................................................ 954 OPERATION......................................................................... 956 SECTION L5 - STEERING CONTROL UNIT - INDEX ................................................... 958 STEERING CONTROL UNIT..................................................................... 960 Removal............................................................................... 960 Installation.......................................................................... 960 REBUILD PROCEDURE..................................................................... 961 Disassembly....................................................................... 962 Cleaning and Inspection........................................................... 963 Assembly.......................................................................... 965 SECTION L6 - STEERING CIRCUIT COMPONENT REPAIR - INDEX ....................................... 970 STEERING CIRCUIT COMPONENT REPAIR......................................................... 972 BLEED-DOWN MANIFOLD................................................................... 972 Removal........................................................................... 972 Adjusting Relief Valve............................................................ 972 Testing and Adjustment............................................................ 973 FLOW AMPLIFIER.................................................................... 974 Removal....................................................................... 974 Installation.................................................................. 974 Disassembly................................................................... 974 Assembly...................................................................... 977 ACCUMULATORS...................................................................... 978 Removal....................................................................... 978 Installation.................................................................. 978 Disassembly................................................................... 979 Cleaning and Inspection....................................................... 980 Assembly...................................................................... 980 Testing....................................................................... 981 STEERING ACCUMULATOR CHARGING PROCEDURE........................................... 981 STEERING CYLINDER................................................................. 982 Removal....................................................................... 982 Installation.................................................................. 983 STEERING CYLINDER REBUILD......................................................... 984 Disassembly................................................................... 984 Cleaning and Inspection....................................................... 984 Assembly...................................................................... 985 STEERING/BRAKE PUMP............................................................... 985 Removal....................................................................... 985 Installation.................................................................. 986 PUMP REBUILD...................................................................... 987 Disassembly................................................................... 987 Control Group................................................................. 988 Valve Plate Group............................................................. 989 Rotating Group................................................................ 989 Drive Shaft Group............................................................. 990 Swashblock Group.............................................................. 990 Inspection.................................................................... 990 Control Group................................................................. 990 Valve Plate Group............................................................. 991 Rotating Group................................................................ 991 Swashblock Group.............................................................. 992 Drive Shaft Group............................................................. 992 Assembly...................................................................... 992 Swashblock Group.............................................................. 992 Drive Shaft Group............................................................. 993 Rotating Group................................................................ 993 Valve Plate Group............................................................. 994 Control Group................................................................. 995 STEERING CIRCUIT FILTER........................................................... 996 Removal....................................................................... 996 Installation.................................................................. 996 TROUBLESHOOTING CHART..................................................................... 997 SECTION L7 - HOIST CIRCUIT - INDEX ...........................................................1000 HOIST CIRCUIT.............................................................................1002 HOIST CIRCUIT OPERATION...............................................................1002 COMPONENT DESCRIPTION.............................................................1003 Hydraulic Tank................................................................1003 Hoist Pump....................................................................1003 Hoist Valve...................................................................1003 Hoist Pilot Valve.............................................................1004 Power Up Limit Solenoid.......................................................1005 Pilot Operated Check Valve....................................................1005 Power Down Spool Limit Solenoid...............................................1005 HOIST CIRCUIT OPERATION...........................................................1005 POWER UP Operation............................................................1007 HOLD Operation................................................................1009 POWER DOWN Operation..........................................................1011 FLOAT Operation...............................................................1013 SECTION L8 - HOIST CIRCUIT COMPONENT REPAIR - INDEX ..........................................1016 HOIST CIRCUIT COMPONENT REPAIR............................................................1018 HOIST VALVE...........................................................................1018 Removal...........................................................................1018 Installation......................................................................1018 O-Ring Replacement................................................................1019 INLET SECTION.....................................................................1020 Disassembly...................................................................1020 Cleaning and Inspection.......................................................1021 Assembly......................................................................1021 SPOOL SECTION.....................................................................1021 Disassembly...................................................................1021 Cleaning and Inspection.......................................................1022 Assembly......................................................................1024 HOIST PILOT VALVE.....................................................................1025 Removal...........................................................................1025 Installation......................................................................1025 Disassembly.......................................................................1026 Cleaning and Inspection...........................................................1027 Reassembly........................................................................1027 HOIST CYLINDERS.......................................................................1028 Removal...........................................................................1028 Installation......................................................................1030 Disassembly.......................................................................1030 Cleaning and Inspection...........................................................1032 Assembly - Quill And Cylinder.....................................................1033 Quill Installation................................................................1033 Installation Of Check Balls And Plugs In Quill....................................1034 Assembly of Cylinder..............................................................1035 Pressure Testing..................................................................1035 POWER UP SPOOL LIMIT SOLENOID.........................................................1036 PILOT OPERATED CHECK VALVE............................................................1036 POWER DOWN HOIST LIMIT SOLENOID.......................................................1036 SECTION L9 - HYDRAULIC SYSTEM FILTERS - INDEX ................................................1038 HYDRAULIC SYSTEM FILTERS..................................................................1040 HIGH PRESSURE FILTER..................................................................1040 Removal...........................................................................1040 Installation......................................................................1041 LOW PRESSURE FILTERS..................................................................1041 BRAKE COOLING & HOIST FILTERS.....................................................1041 TRANSMISSION FILTER...............................................................1041 Removal.......................................................................1042 Installation..................................................................1042 SECTION L10 - HYDRAULIC CHECK-OUT PROCEDURE - INDEX ..........................................1044 HYDRAULIC CHECK-OUT PROCEDURE.............................................................1046 GENERAL INFORMATION...................................................................1046 STEERING CIRCUIT CHECK-OUT & ADJUSTMENT PROCEDURE.....................................1046 Equipment Requirements............................................................1047 Pump Pressure Control Adjustment..................................................1047 Steering Components Leakage Test..................................................1049 CHECKING HOIST SYSTEM PRESSURES.......................................................1050 Equipment Requirements............................................................1050 Power Down Relief Valve Adjustment................................................1051 SECTION M - OPTIONS AND SPECIAL TOOLS - INDEX ....................................................1052 SECTION M8 - SPECIAL TOOLS...................................................................1054 SECTION N - OPERATOR CAB - INDEX .................................................................1058 SECTION N2 - OPERATOR CAB - INDEX ............................................................1060 OPERATOR CAB..............................................................................1062 Removal...............................................................................1063 Installation..........................................................................1065 CAB DOORS.............................................................................1065 Removal...........................................................................1065 Installation......................................................................1066 Door Striker Adjustment...........................................................1066 Door Handle Plunger Adjustment....................................................1067 DOOR PANEL........................................................................1068 Removal.......................................................................1068 Installation..................................................................1068 DOOR WINDOW.......................................................................1069 Removal.......................................................................1069 Installation..................................................................1071 WINDOW REGULATOR..................................................................1073 Removal.......................................................................1073 Installation..................................................................1073 DOOR HANDLE AND DOOR LATCH........................................................1073 Removal.......................................................................1073 Installation..................................................................1073 DOOR SEALS............................................................................1074 Removal...........................................................................1074 Installation......................................................................1074 DOOR OPENING SEAL.....................................................................1074 Removal...........................................................................1074 Installation......................................................................1074 GLASS REPLACEMENT.....................................................................1075 Replacement.......................................................................1075 REAR GLASS........................................................................1077 Removal.......................................................................1077 Installation..................................................................1077 SECTION N3 - CAB COMPONENTS - INDEX ..........................................................1078 CAB COMPONENTS............................................................................1080 WINDSHIELD WIPERS.....................................................................1080 WIPER MOTOR.......................................................................1080 Removal.......................................................................1080 Installation..................................................................1080 WIPER ARM.........................................................................1080 Removal.......................................................................1080 Installation..................................................................1081 WIPER LINKAGE.....................................................................1081 Removal.......................................................................1081 Installation..................................................................1082 WINDSHIELD WASHER.................................................................1082 Operation.....................................................................1082 Service.......................................................................1082 OPERATOR SEAT.....................................................................1083 Seat Belts....................................................................1083 Adjustment....................................................................1083 Seat Removal..................................................................1084 SECTION N4 - HEATING AND AIR CONDITIONING - INDEX ............................................1086 HEATING AND AIR CONDITIONING..............................................................1088 HEATER / AIR CONDITIONER COMPARTMENT AND CONTROLS.....................................1088 HEATER/AIR CONDITIONER................................................................1089 Operation.........................................................................1089 HEATER COMPONENTS.....................................................................1089 Circuit Breaker...................................................................1089 D/C - D/C Converter...............................................................1090 Flapper Door Motors...............................................................1090 Temperature Control Potentiometer.................................................1090 Motorized Coolant Control Valve...................................................1090 Heater Coil.......................................................................1090 Fan Motor and Speed Control.......................................................1090 Test..............................................................................1090 FILTER................................................................................1090 Service...........................................................................1090 AIR CONDITIONING SYSTEM...................................................................1093 Environmental Impact..................................................................1093 OPERATOR CAB AIR CONDITIONING.........................................................1094 PRINCIPLES OF REFRIGERATION...........................................................1094 Air Conditioning..................................................................1094 Refrigeration - The Act Of Cooling................................................1095 The Refrigeration Cycle...........................................................1095 AIR CONDITIONER SYSTEM COMPONENTS.....................................................1096 Compressor (Refrigerant Pump).....................................................1096 Service Valves....................................................................1096 Condenser.........................................................................1096 Receiver-Drier....................................................................1096 Expansion Block Valve.............................................................1097 Evaporator........................................................................1097 ELECTRICAL CIRCUIT....................................................................1098 Thermostat........................................................................1098 Compressor Clutch.................................................................1098 Trinary™ Switch...................................................................1099 SYSTEM SERVICING......................................................................1100 SYSTEM OIL............................................................................1101 Handling and Reusing PAG Oil......................................................1101 Oil Quantity......................................................................1101 Replacing Oil After Servicing the System..........................................1101 Setting Up a New Compressor.......................................................1101 REFRIGERANT...........................................................................1102 Recycled Refrigerant..............................................................1102 Reclaimed Refrigerant.............................................................1102 Refrigerant Quantity..............................................................1102 R-134a Refrigerant Containers.....................................................1102 SERVICE TOOLS AND EQUIPMENT...........................................................1103 Recovery/Recycle Station..........................................................1103 Leak Detector.....................................................................1103 Service Valves....................................................................1104 Vacuum Pump.......................................................................1104 Manifold Gauge Set................................................................1105 Installing Manifold Gauge Set.....................................................1106 Purging Air From Service Hoses....................................................1107 Stabilizing the AC System.........................................................1108 SYSTEM PERFORMANCE TEST...............................................................1108 SYSTEM LEAK TESTING...................................................................1109 Electronic leak detector..........................................................1109 Tracer dyes.......................................................................1109 Soap and water....................................................................1109 A/C DRIVE BELT CHECKOUT PROCEDURE.....................................................1110 Pulley Alignment..................................................................1110 Belt Tension Check................................................................1110 SYSTEM REPAIR.........................................................................1112 System Cleaning...................................................................1112 Hoses and Fittings................................................................1112 Lines.............................................................................1112 Expansion Valve...................................................................1112 Receiver-Drier....................................................................1113 Thermostat........................................................................1113 Compressor........................................................................1113 Clutch............................................................................1113 Servicing the Compressor Clutch...................................................1114 Pulley Removal....................................................................1116 Clutch Coil Check.................................................................1116 Pulley Installation...............................................................1116 Clutch Assembly Installation......................................................1117 RECOVERING AND RECYCLING THE REFRIGERANT..............................................1118 Performing the Recovery Cycle.....................................................1118 Performing the Recycling Procedure................................................1118 Evacuating and Charging the AC System.............................................1118 EVACUATING THE SYSTEM.................................................................1119 CHARGING THE AC SYSTEM................................................................1120 TROUBLESHOOTING...........................................................................1121 Pre-Diagnosis Checks..................................................................1121 Preparing For Diagnosis...............................................................1121 Preliminary Steps.....................................................................1121 System Performance Test...............................................................1121 Diagnosis Of Gauge Readings And System Performance....................................1122 TROUBLESHOOTING BY MANIFOLD GAUGE SET READINGS............................................1123 PREVENTATIVE MAINTENANCE SCHEDULE FOR AC SYSTEM...........................................1129 SECTION N5 - OPERATOR CAB & CONTROLS - INDEX .................................................1130 OPERATOR CAB AND CONTROLS.................................................................1132 STEERING WHEEL AND CONTROLS...........................................................1133 Horn Button.......................................................................1133 Telescope Lock Ring...............................................................1133 Tilt Wheel Lever..................................................................1133 Turn Signal / Headlight Dimmer....................................................1133 Windshield Wiper / Washer Control.................................................1134 RETARDER CONTROL LEVER................................................................1134 STEERING WHEEL........................................................................1134 Removal...........................................................................1134 Installation......................................................................1135 SERVICE BRAKE PEDAL...................................................................1135 ACCELERATOR PEDAL.....................................................................1135 INSTRUMENT PANEL......................................................................1136 RETARDING CAPACITY CHART..............................................................1136 Radio Speakers....................................................................1137 MOM Display Screen................................................................1137 MOM Dimmer Switch.................................................................1137 Warning Alarm Buzzer..............................................................1137 Cab Radio.........................................................................1137 PMC Interface Connector...........................................................1137 Air Cleaner Vacuum Gauges.........................................................1137 Payload Meter.....................................................................1137 Windshield Wipers.................................................................1137 CENTER CONSOLE........................................................................1138 Transmission Range Selector.......................................................1139 Control Switches..................................................................1140 Shift Limiter Switch..............................................................1140 F1 Start Switch...................................................................1140 Hoist Control Lever...............................................................1140 Parking Brake Switch..............................................................1140 Brake Lock Switch.................................................................1140 LH Window Control Switch..........................................................1141 RH Window Control Switch..........................................................1141 Ash Tray..........................................................................1141 Lighter...........................................................................1141 Passenger Seat w/Safety Belt......................................................1141 INSTRUMENT PANEL AND INDICATORS...........................................................1142 Keyswitch.............................................................................1143 Auxiliary Brake Switch................................................................1143 RH Control/Indicator Panel (Pod)......................................................1144 Center Display Panel..................................................................1144 LH Control/Indicator Panel (Pod)......................................................1144 Ladder Light Switch...................................................................1144 Head Light Switch.....................................................................1144 BackUp/Deck Lights Switch.............................................................1144 RH Control/Indicator Panel (Pod)......................................................1145 Cold Weather Starting Aid (Ether Injection) Switch....................................1145 Hazard Warning Lights Switch..........................................................1145 Automatic Idle Selector Switch (AISS).................................................1146 Air Conditioner & Heater Vent.........................................................1146 ASR Cut (Traction Control) Switch (Option)............................................1146 Center Display Panel..................................................................1147 Air Pressure Monitor (Not Used).......................................................1148 Air Pressure Gauge (Not Used).........................................................1148 Coolant Temperature Monitor...........................................................1148 Engine Cooling Water Temperature Gauge................................................1148 Torque Converter Oil Temperature Monitor..............................................1148 Torque Converter Oil Temperature Gauge................................................1148 Retarder Oil Temperature Monitor......................................................1148 Retarder Oil Temperature Gauge........................................................1148 Left Turn Signal Pilot Lamp...........................................................1149 High Beam Pilot Lamp..................................................................1149 Right Turn Signal Pilot Lamp..........................................................1149 Speedometer...........................................................................1149 Tachometer............................................................................1149 Lock-up Pilot Lamp....................................................................1149 Shift Limiter Pilot Lamp..............................................................1149 Shift Indicator.......................................................................1149 Transmission Shift Position Pilot Lamp................................................1149 Engine Controller Monitor.............................................................1149 Automatic Transmission Mechatronics Monitor...........................................1149 Other Mechatronics Monitor (Optional).................................................1150 Fuel Level Monitor....................................................................1150 Fuel Gauge............................................................................1150 Engine Power Derate Monitor...........................................................1150 F1 Start Monitor......................................................................1150 Auto Cruise Control (Not Used)........................................................1150 ASR Monitor (Optional)................................................................1150 ABS Monitor (Not Used)................................................................1150 Service Meter.........................................................................1150 Odometer..............................................................................1150 LH Control/Indicator Panel (Pod)......................................................1151 LH Panel/Pod Assembly.................................................................1151 Engine Oil Temperature................................................................1151 Engine Coolant Level..................................................................1151 Low Steering Pressure.................................................................1151 Accumulator Pre-Charge................................................................1151 Battery Charge Amps...................................................................1152 Check Engine..........................................................................1152 Parking Brake.........................................................................1152 Body Float............................................................................1152 Transmission Oil Temperature..........................................................1152 Service Brakes Applied................................................................1152 Maintenance Monitor...................................................................1152 Transmission Oil Filters..............................................................1152 Lamp Test.............................................................................1153 Low Brake Pressure....................................................................1153 Lateral Slope Warning.................................................................1153 Crankcase Pressure....................................................................1153 Panel Dimmer Switch...................................................................1153 Engine Oil Pressure...................................................................1153 Central Warning Lamp..................................................................1154 AC/Heater Vent........................................................................1154 REAR OF OPERATOR CAB..................................................................1154 QUANTUM™ FUEL SYSTEM DIAGNOSTICS......................................................1156 Determining Fault Codes...........................................................1156 Exiting The Diagnostics Mode......................................................1157 SECTION P - LUBRICATION AND SERVICE - INDEX ......................................................1158 SECTION P2 - LUBRICATION AND SERVICE - INDEX .................................................1160 LUBRICATION AND SERVICE...................................................................1162 COOLANT SPECIFICATIONS................................................................1162 Unacceptable Practices............................................................1162 QUICK FILL SERVICE CENTER.............................................................1162 10 HOUR (DAILY) INSPECTION............................................................1164 250 HOUR INSPECTION...................................................................1166 500 HOUR INSPECTION...................................................................1168 1000 HOUR INSPECTION..................................................................1169 2000 HOUR INSPECTION..................................................................1170 5000 HOUR INSPECTION..................................................................1171 SECTION P3 - LINCOLN AUTOMATIC LUBRICATION SYSTEM - INDEX ....................................1172 LINCOLN AUTOMATIC LUBRICATION SYSTEM......................................................1174 SYSTEM COMPONENTS.....................................................................1174 System Operation..................................................................1177 System Priming....................................................................1178 System Checkout...................................................................1178 Pressure Reducer Adjustment.......................................................1178 24 VDC Solid State Timer Check....................................................1179 24 VDC Solid State Timer Adjustment...............................................1180 INJECTORS (SL-1 Series "H")...........................................................1181 Injector Specifications...........................................................1181 Injector Adjustment...............................................................1181 INJECTOR OPERATION....................................................................1182 PUMP CYCLE TIMER (FLASHER TIMER)......................................................1183 Pump Cycle Timer (Flasher Timer) Installation.....................................1183 Pump Cycle Timer (Flasher Timer) Adjustment:......................................1183 TROUBLESHOOTING CHART.....................................................................1185 RESERVOIR FILL PROCEDURE..............................................................1187 Lubricant Required for System.....................................................1187 Fill Procedure....................................................................1187 Preventive Maintenance Procedures.........................................................1188 Daily Lubrication System Inspection...................................................1188 250 Hour Inspection...................................................................1188 SECTION R - SYSTEM SCHEMATICS - INDEX ............................................................1190 HYDRAULIC SYSTEM SCHEMATIC ..................................................................1192 BRAKE SCHEMATIC ..............................................................................1193 ELECTRICAL WIRING SCHEMATIC ..................................................................1194
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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